Toyota Prius: Fuel Sender Gauge Assembly

• Removal
• Inspection
• Installation

Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during fuel sender gauge assembly removal/installation are shown below.

NOTICE:

After the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) auxiliary battery terminal.

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HINT:

When the cable is disconnected / reconnected to the auxiliary battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

Learning completes when Toyota Prius vehicle is driven

Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
Front Camera System	Drive the Toyota Prius vehicle straight ahead at 35 km/h (22 mph) or more for 5 seconds or more.

Learning completes when vehicle is operated normally

Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
*1: w/o Power Back Door System *2: w/ Power Back Door System
Power Door Lock Control System*1 Back door opener	Perform door unlock operation with door control switch or electrical key transmitter sub-assembly switch.
Power Back Door System*2	Reset back door close position
Air Conditioning System	After the ignition switch is turned to ON, the servo motor standard position is recognized.	-

CAUTION / NOTICE / HINT

COMPONENTS (REMOVAL)

Procedure		Part Name Code
1	FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY	77020A	-	-	-
2	FUEL SENDER GAUGE ASSEMBLY	83320		-	-

PROCEDURE

1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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2. REMOVE FUEL SENDER GAUGE ASSEMBLY

(1) Disconnect the fuel sender gauge assembly connector.

(2) Disengage the 3 clamps to disconnect the wire harness from the fuel suction tube with pump and gauge assembly.

(3) Disengage the 2 claws to remove the fuel sender gauge assembly from the fuel suction tube with pump and gauge assembly.

NOTICE:

Be careful not to bend the arm of the fuel sender gauge assembly.

Inspection

INSPECTION

PROCEDURE

1. INSPECT FUEL SENDER GAUGE ASSEMBLY

CAUTION:

Perform the inspection in a well-ventilated area.

Do not perform the inspection near an open flame.

(a) Check that the float moves smoothly between F and E.

(b) Check the fuel sender gauge assembly voltage.

(1) Apply 5 V between terminals 2 and 3. NOTICE: Be careful when connecting the leads, as the fuel sender gauge assembly may be damaged if the leads are connected to the wrong terminals. Do not apply more than 6 V to terminals 2 or 3. HINT: If a stable power supply is not available, connect 4 nickel-metal hydride batteries (1.2 V each) or equivalent in series.

*a Component without harness connected (Fuel Sender Gauge Assembly) *b Voltage Applied between Terminals

(2) Measure the voltage according to the value(s) in the table below. Standard Voltage: Tester Connection Float Level Specified Condition Result 1 - 2 F 4.255 to 4.605 V V 1 - 2 Between F and E 0.345 to 4.605 V V 1 - 2 E 0.345 to 0.695 V V HINT: The output voltage changes depending on the voltage applied to the terminals. Output voltage (F) = (0.851 x Voltage applied to terminals) to (0.921 x Voltage applied to terminals) Output voltage (E) = (0.069 x Voltage applied to terminals) to (0.139 x Voltage applied to terminals) If the result is not as specified, replace the fuel sender gauge assembly.

*a Component without harness connected (Fuel Sender Gauge Assembly)

Installation

INSTALLATION

CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)

Procedure		Part Name Code
1	FUEL SENDER GAUGE ASSEMBLY	83320		-	-
2	FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY	77020A	-	-	-

PROCEDURE

1. INSTALL FUEL SENDER GAUGE ASSEMBLY

(1) Engage the 2 claws to install the fuel sender gauge assembly to the fuel suction tube with pump and gauge assembly.

NOTICE:

Be careful not to bend the arm of the fuel sender gauge assembly.

(2) Engage the 3 clamps to connect the wire harness.

(3) Connect the fuel sender gauge assembly connector.

2. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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