Canada - Instruments/Fuel - Fuel Gauge is Inaccurate

Bulletin
TSB2095R

Issue Date
07 September, 2004

Market
Canada

Title
FUEL GAUGE INACCURACY

Component
BODY ELECTRICAL

Models
'04 Prius

TSB REVISION NOTICE:
- October 31, 2006: The OFP in Warranty Information has been updated. Applicable Warranty has been changed to Toyota Emissions Warranty. The note in Parts Information has been expanded. Illustrations have been added near the beginning of Repair Procedure 2 to clarify installation of the refueling check valve and the rollover check valve. A note has been added and the illustration has been updated in step 7 of Repair Procedure 2.
Previous versions of this TSB should be discarded.

INTRODUCTION:

Some 2004 Prius customers may complain of the following:
- Fuel gauge is not accurate and/or
- Fuel tank volume is not close to the stated capacity

An updated Combination Meter Computer and Fuel Filler Pipe have been created to improve this condition.

APPLICABLE VEHICLES:

- 2004 model year Prius vehicles produced WITHIN the VINs shown.

WARRANTY INFORMATION:

PARTS INFORMATION:

REPAIR PROCEDURE 1: COMBINATION METER COMPUTER

Replace Combination Meter Computer.

1. Verify that the vehicle is on a level surface.
2. Remove the Combination Meter as per "overhaul" instructions in the ETAS, 2004 model year Prius Repair Manual: Instrument Panel/meter; Combination Meter Assy.

CAUTION:
- Before performing each step of the disassembly/reassembly procedure below, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.
- Upon removing the combination meter computer from the static free packaging, be sure to hold it by the edges as shown in the illustration.

3. Remove Combination Meter Cover RH.
A. Remove the screw, then remove the combination meter cover RH.

4. Remove Combination Meter Cover No. 3.
A. Remove the 4 screws.
B. Widen the 2 claws along the outside to disengage them.
C. Raise the cover from the bottom and remove the combination meter reflector No. 1.

5. Remove Meter Circuit Plate No. 3.
A. Pull the connector locks in the direction indicated by the arrows in the illustration, and remove the meter circuit plate No. 3.

6. Remove Meter Circuit Plate No. 4.
A. Pull the connector locks in the direction indicated by the arrows in the illustration, and remove the meter circuit plate No. 4.

7. Remove Combination Meter Computer.
A. Disconnect the connector and remove the combination meter computer.

HINT:
There is no locking mechanism on this connector.

8. Install Combination Meter Computer.
A. Install the new combination meter computer.
B. Connect the connector.

9. Install Meter Circuit Plate No. 4.
A. Pull the connector locks in the direction indicated by the arrows in the illustration, and install the meter circuit plate No. 4.
B. Lock the connector lock.

10. Install Meter Circuit Plate No. 3.
A. Pull the connector locks in the direction indicated by the arrows in the illustration, and install the meter circuit plate No. 3.
B. Lock the connector locks.

11. Install Combination Meter Cover No. 3.
A. Install the combination meter reflector No. 1 with the 4 screws.

12. Install Combination Meter Cover RH.
A. Install the combination meter cover RH with the screw.

13. Install Combination Meter in Reverse of Disassembly.
14. Reset Inclination Sensor.

HINT:
After replacement of the combination meter computer, reset the standard horizontal angle of the inclination sensor.

A. Keep the vehicle stationary in both longitudinally and laterally horizontal position (within +/-- 0.3°).

HINT:
Place the vehicle on a level surface such as an alignment rack, if available.

B. Switch to the "Trip A" mode of the odometer display.
C. Turn the power switch OFF.
D. Make sure your foot is off of the brake pedal.
E. Push in and hold the "ODO/TRIP" button.
F. Turn the power switch ON (push the "POWER" button twice).
G. Turn the "ODO/TRIP" button OFF, then ON 3 times within 5 seconds.
H. Continue to hold the "ODO/TRIP" button until the "ODO" indicator in the display turns off and a 6-digit code (######) is displayed.
I. Release the "ODO/TRIP" button.

J. Push and hold the "ODO/TRIP" button for 5 seconds or more again. The 6-digit code (######) will then change to a 5--digit code (#####).
K. After "1" is displayed at the 3rd digit of the 5-digit code, release the "ODO/TRIP" button.
L. Approximately 5 seconds after "1" is displayed at the 3rd digit, the "TRIP A" indicators are displayed, and the odometer returns to the normal operation.

NOTE:
- The "TRIP A" kilometers will revert to 0.0 kilometers in this procedure.
- Do not drive the vehicle before the reset procedure has been completed.

HINT:
If a write error occurs, start the procedure again from the beginning.

REPAIR PROCEDURE 2: FUEL FILLER PIPE

Replace Fuel Filler Pipe

PRECAUTIONS:
- Verify that the fuel level is 3/4 tank or below (to prevent fuel spillage).
- Verify that there will be no flames or sparks in the area in which the procedure will take place.
- Do not smoke during this operation.

1. Disconnect Engine Wire No. 3 (battery negative terminal).
2. Remove Left Rear Tire.
3. Remove Fuel Tank Cap Assembly.

4. Remove Floor Under Cover No. 1.
A. Remove the 2 clips and 2 bolts, then remove the floor under cover No. 1.

5. Remove Fuel Tank Filler Pipe Protector.
A. Remove the nut, then remove the fuel tank filler pipe protector.

FUEL PIPE CONNECTOR CAUTIONS:
- Remove any dirt or foreign objects from the connectors before proceeding.
- Be careful not to scratch the O-ring on the connector or the connector may not seal properly upon reconnection.
- Disconnect the fuel pipe connector by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- After disconnection, protect the connector end by covering it with a vinyl bag.
- If the connector is stuck, gently push and pull it to release.

6. Remove Fuel Tank Filler Pipe Sub-assembly.
A. Disconnect the fuel tank vent hose (fuel tank inlet pipe side).

a. Pinch the retainer and pull out the fuel tank vent connector No. 2 with the connector pushed to the pipe side.

B. Disconnect the fuel tank vent hose (fuel tank side) from the clamp.

C. Disconnect the fuel suction tube.
a. Pinch the retainer and pull out the quick connector with the connector pushed to the pipe side.

D. Disconnect the charcoal canister tube No. 1.
a. Pinch the retainer and pull out the quick connector with the connector pushed to the pipe side.

E. Remove the fuel filler pipe clamp and fuel tube connector from the fuel tank inlet pipe.

F. Remove the 2 bolts, then remove the fuel tank filler pipe sub-assembly.

7. Transfer the following parts to the NEW filler pipe:
- Fuel inlet box rings
- Fuel tank filler pipe shield assembly
- Filler pipe clamps 1 and 2
- Fuel inlet pipe plate
- Fuel hose joint
- Fuel tank gasket
- Fuel tube connector seal
- Fuel suction tube set gasket
- Fuel tank tube
- Fuel filler pipe clamp

NOTE:
- Make sure that the fuel inlet seal with retainer are transferred to the NEW fuel filler pipe.
- Improper installation of the refuelling check valve and/or the rollover check valve may result in slow refueling. Refer to the illustrations at the beginning of Repair Procedure 2 for proper installation.

8. Install the NEW Fuel Tank Filler Pipe Sub-assembly.

A. Install the NEW fuel tank filler pipe sub-assembly.
B. Tighten the 2 bolts.

Torque A: 34 N-m (347 kgf-cm, 25 ft-lbf)

Torque B: 18 N-m (185 kg-cm, 13 ft-lbf)

C. Install the fuel tube connector and fuel filler pipe clamp to the fuel tank inlet pipe.

NOTE:
- Securely lock the fuel filler pipe clamp.
- After locking the fuel filler pipe clamp, check that the fuel tube connector is securely installed by pulling the fuel tube in the removal direction.

NOTE:
Before reconnecting each quick connector:
- Check that there are no scratches or foreign objects in or around the contact area of the quick connector and pipe.
- After reconnection, check that the connector is tight by pulling the quick connector in the removal direction.

D. Connect the charcoal canister tube No. 1.
a. Align the quick connector with the pipe, then push in the connector until the retainer makes a "click" sound.

E. Connect the fuel suction tube.
a. Align the quick connector with the pipe, then push in the connector until the retainer makes a "click" sound.

F. Install the fuel tank vent hose (fuel tank side) to the clamp.

G. Connect the fuel tank vent hose (fuel tank inlet pipe side).
a. Align the fuel tank vent connector No. 2 with the pipe, then push in the connector until the retainer makes a "click" sound.

9. Install Fuel Tank Filler Pipe Protector.
a. Install the fuel tank filler pipe protector with the nut.

10. Install Floor Undercover No. 1.
a. Install the floor under cover No. 1 with the 2 clips and 2 bolts.

11. Install Fuel Tank Cap Assembly.
12. Install Left Rear Tire.