Last Modified: 05-13-2024 6.11:8.1.0 Doc ID: RM10000000255WQ
Model Year Start: 2023 Model: GR Corolla Prod Date Range: [09/2022 -           ]
Title: G16E-GTS (ENGINE CONTROL): SFI SYSTEM: P04602A; Fuel Level Sensor "A" Signal Stuck In Range; 2023 - 2025 MY GR Corolla [09/2022 -        ]

DTC

P04602A

Fuel Level Sensor "A" Signal Stuck In Range

DESCRIPTION

Refer to DTC P046012.

Click here 2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (ENGINE CONTROL): SFI SYSTEM: P046012,P046014; Fuel Level Sensor "A" Circuit Short to Battery+

Refer to DTC P206512.

Click here 2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (ENGINE CONTROL): SFI SYSTEM: P206512,P206514; Fuel Level Sensor "B" Circuit Short to Battery+

DTC No.

Detection Item

DTC Detection Condition

Trouble Area

MIL

Note

P04602A

Fuel Level Sensor "A" Signal Stuck In Range

The change in the fuel sender gauge or No. 2 fuel sender gauge value is below the threshold when a certain amount of fuel is calculated to have been consumed. (1 trip detection logic).

  • Fuel sender gauge assembly
  • No. 2 fuel sender gauge assembly
  • ECM

Comes on

SAE Code: P0461

MONITOR DESCRIPTION

When the fuel sender gauge assembly or No. 2 fuel sender gauge assembly output value changes less than a specified amount, when compared to the fuel consumption calculated from the fuel injection volume, the ECM will detect a malfunction, illuminate the MIL and store a DTC.

MONITOR STRATEGY

Related DTCs

P0461: Fuel level sensor stuck

Required Sensors/Components (Main)

Fuel level sensor

Required Sensors/Components (Related)

-

Frequency of Operation

Continuous

Duration

Less than 10 seconds

MIL Operation

1 driving cycles

Sequence of Operation

None

TYPICAL ENABLING CONDITIONS

Lost communication with instrument panel cluster control module (U0155)

Not detected

Fuel level sensor circuit malfunction (P0462, P0463, P2067, P2068)

Not detected

Either of the following conditions is met

Condition A or B

A. Battery voltage

8.5 V or higher

B. Check mode

On

Fuel level sensor output via CAN

Received

Ignition switch

ON

TYPICAL MALFUNCTION THRESHOLDS

One of the following conditions is met

A, B or C

A. Accumulated volume of injected fuel during (a) is met at high fuel level

43.7 L or more

B. Accumulated volume of injected fuel during (a) is met at middle fuel level

13.2 L or more

C. Accumulated volume of injected fuel during (a) is met at low fuel level

33.5 L or more

(a) Smoothed fuel level sensor output (Maximum - Minimum)

Less than 2.7 L

CONFIRMATION DRIVING PATTERN

HINT:

  • After repair has been completed, clear the DTC and then check that the vehicle has returned to normal by performing the following All Readiness check procedure.

    Click here 2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (ENGINE CONTROL): SFI SYSTEM: DTC CHECK / CLEAR

  • When clearing the permanent DTCs, refer to the "CLEAR PERMANENT DTC" procedure.

    Click here 2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (ENGINE CONTROL): SFI SYSTEM: DTC CHECK / CLEAR

  1. Connect the GTS to the DLC3.
  2. Turn the ignition switch to ON.
  3. Turn the GTS on.
  4. Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).
  5. Turn the ignition switch off and wait for at least 30 seconds.
  6. Turn the ignition switch to ON [A].
  7. Turn the GTS on.
  8. Start the engine [B].
  9. Drive the vehicle at 80 km/h (50 mph) or more for 30 minutes [C].
  10. Enter the following menus: Powertrain / Engine / Trouble Codes [D].
  11. Read the pending DTCs.

    HINT:

    • If a pending DTC is output, the system is malfunctioning.
    • If a pending DTC is not output, perform the following procedure.
  12. Enter the following menus: Powertrain / Engine / Utility / All Readiness.
  13. Input the DTC: P04602A.
  14. Check the DTC judgment result.

    GTS Display

    Description

    NORMAL

    • DTC judgment completed
    • System normal

    ABNORMAL

    • DTC judgment completed
    • System abnormal

    INCOMPLETE

    • DTC judgment not completed
    • Perform driving pattern after confirming DTC enabling conditions

    HINT:

    • If the judgment result shows NORMAL, the system is normal.
    • If the judgment result shows ABNORMAL, the system has a malfunction.
    • If the judgment result is INCOMPLETE, perform steps [E] through [F] again.
    • [A] to [D]: Normal judgment procedure.

      The normal judgment procedure is used to complete DTC judgment and also used when clearing permanent DTCs.

    • When clearing the permanent DTCs, do not disconnect the cable from the battery terminal or attempt to clear the DTCs during this procedure, as doing so will clear the universal trip and normal judgment histories.
  15. Drive the vehicle at 80 km/h (50 mph) or more for 30 minutes [E].
  16. Enter the following menus: Powertrain / Engine / Trouble Codes [F].
  17. Read the pending DTCs.

    HINT:

    • If a pending DTC is output, the system is malfunctioning.
    • If a pending DTC is not output, perform the following procedure.
  18. Enter the following menus: Powertrain / Engine / Utility / All Readiness.
  19. Input the DTC: P04602A.
  20. Check the DTC judgment result.

    GTS Display

    Description

    NORMAL

    • DTC judgment completed
    • System normal

    ABNORMAL

    • DTC judgment completed
    • System abnormal

    INCOMPLETE

    • DTC judgment not completed
    • Perform driving pattern after confirming DTC enabling conditions

    HINT:

    • If the judgment result shows NORMAL, the system is normal.
    • If the judgment result shows ABNORMAL, the system has a malfunction.
    • [A] to [F]: Normal judgment procedure.

      The normal judgment procedure is used to complete DTC judgment and also used when clearing permanent DTCs.

    • When clearing the permanent DTCs, do not disconnect the cable from the battery terminal or attempt to clear the DTCs during this procedure, as doing so will clear the universal trip and normal judgment histories.

CAUTION / NOTICE / HINT

HINT:

Read Freeze Frame Data using the GTS. The ECM records vehicle and driving condition information as Freeze Frame Data the moment a DTC is stored. When troubleshooting, Freeze Frame Data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred.

PROCEDURE

1.

INTERVIEW THE CUSTOMER

(a) Interview the customer for details about when the they refuel the vehicle.

HINT:

When the fuel tank is full, if the vehicle is repeatedly driven a short distance and then refueled, the fuel sender gauge or No. 2 fuel sender gauge* output value will not change. In this case, the ECM may judge that the fuel sender gauge is stuck and store DTC P04602A. If the vehicle was driven in this manner, as the DTC was stored due to a user action, clear the DTCs without performing troubleshooting and return the vehicle to the customer.

*: for AWD models

NEXT

2.

INSPECT FUEL SENDER GAUGE ASSEMBLY

(a) Remove the fuel sender gauge assembly.

Click here 2023 MY GR Corolla [09/2022 - 11/2022]; G16E-GTS (FUEL): FUEL SENDER GAUGE ASSEMBLY: REMOVAL 2023 - 2025 MY GR Corolla [11/2022 -        ]; G16E-GTS (FUEL): FUEL SENDER GAUGE ASSEMBLY: REMOVAL

(b) Inspect the fuel sender gauge assembly.

Click here 2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (FUEL): FUEL SENDER GAUGE ASSEMBLY: INSPECTION

NG

REPLACE FUEL SENDER GAUGE ASSEMBLY 2023 MY GR Corolla [09/2022 - 11/2022]; G16E-GTS (FUEL): FUEL SENDER GAUGE ASSEMBLY: REMOVAL 2023 - 2025 MY GR Corolla [11/2022 -        ]; G16E-GTS (FUEL): FUEL SENDER GAUGE ASSEMBLY: REMOVAL

OK

3.

INSPECT NO. 2 FUEL SENDER GAUGE ASSEMBLY

(a) Remove the No. 2 fuel sender gauge assembly.

Click here 2023 MY GR Corolla [09/2022 - 11/2022]; G16E-GTS (FUEL): FUEL SENDER GAUGE ASSEMBLY: REMOVAL 2023 - 2025 MY GR Corolla [11/2022 -        ]; G16E-GTS (FUEL): FUEL SENDER GAUGE ASSEMBLY: REMOVAL

(b) Inspect the No. 2 fuel sender gauge assembly.

Click here 2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (FUEL): FUEL SENDER GAUGE ASSEMBLY: INSPECTION

OK

CHECK FOR INTERMITTENT PROBLEMS

NG

REPLACE NO. 2 FUEL SENDER GAUGE ASSEMBLY 2023 MY GR Corolla [09/2022 - 11/2022]; G16E-GTS (FUEL): FUEL SENDER GAUGE ASSEMBLY: REMOVAL 2023 - 2025 MY GR Corolla [11/2022 -        ]; G16E-GTS (FUEL): FUEL SENDER GAUGE ASSEMBLY: REMOVAL