Last Modified: 04-05-2023 6.11:8.1.0 Doc ID: RM100000000VJOE
Model Year Start: 2016 Model: Sienna Prod Date Range: [12/2015 - 08/2016]
Title: METER / GAUGE / DISPLAY: METER / GAUGE SYSTEM: Fuel Receiver Gauge Malfunction; 2016 MY Sienna [12/2015 - 08/2016]

Fuel Receiver Gauge Malfunction

DESCRIPTION

The meter CPU uses the fuel sender gauge assembly to determine the level of the fuel in the fuel tank. The resistance of the fuel sender gauge will vary between approximately 13.5 Ω with the float at the full position, and 414.5 Ω with the float at the empty position. The meter outputs battery voltage through two 820 Ω resistors that are mounted in parallel inside the meter CPU. The meter CPU measures the voltage between the variable resistor in the fuel sender gauge and the two resistors mounted in parallel in the meter. Voltage measured at this point will vary as the float of the fuel sender gauge is moved. The highest voltage observed should be approximately half of the battery voltage.

WIRING DIAGRAM

PROCEDURE

1.

CHECK CAN COMMUNICATION SYSTEM

(a) Check if a CAN communication DTC is output (See page 2016 MY Sienna [12/2015 - 08/2016]; NETWORKING: CAN COMMUNICATION SYSTEM: DIAGNOSIS SYSTEM ).

Result

Result

Proceed to

CAN communication DTC is not output

A

CAN communication DTC is output

B

B

GO TO CAN COMMUNICATION SYSTEM

A

2.

PERFORM ACTIVE TEST USING TECHSTREAM (FUEL METER OPERATION)

(a) Connect the Techstream to the DLC3.

(b) Turn the ignition switch to ON.

(c) Turn the Techstream on.

(d) Enter the following menus: Body Electrical / Combination Meter / Active Test.

(e) According to the display on the Techstream, perform the Active Test.

Combination Meter

Tester Display

Test part

Control Range

Diagnostic Note

Fuel Meter Operation

Fuel receiver gauge

OFF, Sender E, Empty, Warning, 1/4, 1/2, 3/4, Full, Sender F

Operate with IG ON and the vehicle is stopped.

OK:

Fuel receiver gauge indication is normal.

NG

REPLACE COMBINATION METER ASSEMBLY

OK

3.

READ VALUE USING TECHSTREAM (FUEL INPUT)

(a) Connect the Techstream to the DLC3.

(b) Turn the ignition switch to ON.

(c) Turn the Techstream on.

(d) Enter the following menus: Body Electrical / Combination Meter / Data List.

(e) According to the display on the Techstream, read the Data List.

Combination Meter

Tester Display

Measurement Item/Range

Normal Condition

Diagnostic Note

Fuel Input

Fuel input signal/

Min.: 0, Max.: 127.5

Current fuel level displayed

Unit: Liter

OK:

Fuel level signal displayed on the Techstream is almost the same as fuel receiver gauge indication.

NG

REPLACE COMBINATION METER ASSEMBLY

OK

4.

CHECK HARNESS AND CONNECTOR (COMBINATION METER ASSEMBLY - FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY)

(a) Disconnect the D145 combination meter assembly connector.

(b) Disconnect the g2 fuel suction with pump and gauge tube assembly connector.

(c) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Tester Connection

Condition

Specified Condition

D145-14 (FR) - g2-2

Always

Below 1 Ω

D145-14 (FR) or g2-2 - Body ground

Always

10 kΩ or higher

D145-15 (FE) - g2-3

Always

Below 1 Ω

D145-15 (FE) or g2-3 - Body ground

Always

10 kΩ or higher

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

5.

INSPECT FUEL SENDER GAUGE ASSEMBLY

(a) Remove the fuel sender gauge assembly (See page 2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE FUEL: FUEL SENDER GAUGE ASSEMBLY: REMOVAL ).

(b) Inspect the fuel sender gauge assembly (See page 2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE FUEL: FUEL SENDER GAUGE ASSEMBLY: INSPECTION ).

NG

REPLACE FUEL SENDER GAUGE ASSEMBLY

OK

6.

INSPECT FUEL SUCTION PUMP AND GAUGE TUBE ASSEMBLY

(a) Remove the fuel suction pump and gauge tube assembly (See page 2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE FUEL: FUEL PUMP: REMOVAL ).

(b) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Tester Connection

Condition

Specified Condition

A-2 - B-2

Always

Below 1 Ω

A-3 - B-1

Text in Illustration

*a

Upper Side

*b

Lower Side (to Fuel Sender Gauge Assembly)

*c

Connector A

*d

Connector B

OK

REPLACE COMBINATION METER ASSEMBLY

NG

REPLACE FUEL SUCTION PUMP AND GAUGE TUBE ASSEMBLY