ELECTRICAL

Title:

EL010-04
FUEL GAUGE INACCURACY
Technical Service Models:

BULLETIN ’04 Prius

August 24, 2004

TSB REVISION
September 23, 2004: PANT Bulletin search clarified in Note in Parts Information;
new Repair Procedure step 7 inserted on page 11.
Previous versions of this TSB should be discarded.

Introduction Some 2004 Prius customers may complain of the following:

S Fuel gauge is not accurate
and/or
S 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 S 2004 model year Prius vehicles produced WITHIN the VINs shown below.
Vehicles
APPLICABLE VEHICLE VIN RANGE PARTS NEEDED REPAIR PROCEDURE

JTDKB2#U#40000001 -- JTDKB2#U#40057579 Meter and Filler Pipe 1 and 2

JTDKB2#U#40057580 -- JTDKB2#U#40078361 Filler Pipe Only 2 Only

Parts PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME QTY
Information
77201--47080 77201--47090 Pipe, Fuel Filler 1
83291--47100 83291--47101--RP* Computer, Combination Meter 1

* NOTE:
The combination meter computer contains the vehicle odometer memory.
This component should be ordered directly from the vendor (Yazaki) with the correct
mileage programmed. (Please refer to PANT Bulletin No. 01--17, “GI01- 17: Digital
Odometer Replacement Program Launch,” using Keyword search “01--17” on the
Technical Information System [TIS], for additional information.)

Warranty PROCEDURE OP CODE DESCRIPTION TIME OFP T1 T2

Information
R & R Fuel Filler Pipe and
1 EL4006 2.0 83291--47100 73 74
Combination Meter Cluster
2 EL4007 R & R Fuel Filler Pipe 1.0 77201--47080 87 50

Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in
effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s
in-service date.
* Warranty application is limited to correction of a problem based upon a customer’s specific complaint.

Toyota Supports ASE Certification Page 1 of 14

FUEL GAUGE INACCURACY -- EL010-04 Revised August 24, 2004

Repair Replace Combination Meter Computer.

Procedure 1:
Combination 1. Verify that the Parts Department has received the new combination meter computer
Meter with the vehicle’s correct mileage.
Computer
2. Verify that the vehicle is on a level surface.

3. Remove the Combination Meter per “overhaul” instructions in the Technical

Information System (TIS), 2004 model year Prius Repair Manual: Instrument
Panel/meter: Combination Meter Assy.

CAUTION:
S 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.
S Upon removing the combination
meter computer from the static free
packaging, be sure to hold it by the
edges as shown in the illustration.

4. Remove Combination Meter

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

5. 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.

: 2 Claws

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FUEL GAUGE INACCURACY -- EL010-04 Revised August 24, 2004

Repair 6. Remove Meter Circuit Plate No. 3.

Procedure 1:
Combination A. Pull the connector locks in the
Meter direction indicated by the arrows
Computer in the illustration, and remove the
(Continued) meter circuit plate No. 3.

7. 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.

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

HINT:
There is no locking mechanism on
this connector.

Page 3 of 14
FUEL GAUGE INACCURACY -- EL010-04 Revised August 24, 2004

Repair 9. Install Combination Meter Computer.

Procedure 1:
Combination A. Install the new combination
Meter meter computer.
Computer B. Connect the connector.
(Continued)

10. 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.

11. 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.

Page 4 of 14
FUEL GAUGE INACCURACY -- EL010-04 Revised August 24, 2004

Repair 12. Install Combination Meter

Procedure 1: Cover No. 3.
Combination
Meter A. Install the combination meter
Computer reflector No. 1 with the 4 screws.
(Continued)

: 2 Claws

13. Install Combination Meter Cover RH.

A. Install the combination meter
cover RH with the screw.

14. Install Combination Meter in Reverse

of Disassembly.

15. 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_).
Power Switch
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. “ODO/TRIP Meter Switching and
C. Turn the power switch OFF. TRIP Meter Reset” Switch

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FUEL GAUGE INACCURACY -- EL010-04 Revised August 24, 2004

Repair D. Make sure your foot is off of the

Procedure 1: brake pedal.
Combination
Meter E. Push in and hold the
Computer “ODO/TRIP” button.
(Continued)
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:
S The “TRIP A” mileage will revert to
0.0 miles in this procedure.
S Do not drive the vehicle before the
reset procedure has been completed.
X Y Z

HINT:
X: Values Written Into Meter
If a write error occurs, start the (Longitudinal Direction)
procedure again from the beginning. Y: Write Status and Result
Z: Values Written Into Meter
(Lateral Direction)

Write Status and Result:

0: Writing
1: Write Completetd
2: Write Error
3: Write Canceled

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FUEL GAUGE INACCURACY -- EL010-04 Revised August 24, 2004

Repair Replace Fuel Filler Pipe.

Procedure 2:
Fuel Filler
Fuel Filler Pipe Components Fuel Tank Cap Assembly
Pipe

Fuel Tank Filler

Pipe Sub-- Assembly

Charcoal Canister
Filter Assembly

PRECAUTIONS:
S Verify that the fuel level is 3/4 tank or below (to prevent fuel spillage).
S Verify that there will be no flames or sparks in the area in which the procedure will
take place.
S 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.

Page 7 of 14
FUEL GAUGE INACCURACY -- EL010-04 Revised August 24, 2004

Repair 5. Remove Fuel Tank Filler

Procedure 2: Pipe Protector.
Fuel Filler
Pipe A. Remove the nut, then remove the
(Continued) fuel tank filler pipe protector.

FUEL PIPE CONNECTOR CAUTIONS:

S Remove any dirt or foreign objects from the connectors before proceeding.
S Be careful not to scratch the O--ring on the connector or the connector may not
seal properly upon reconnection.
S Disconnect the fuel pipe connector by hand. Do not use any tools.
S Do not forcibly bend, twist or turn the nylon tube.
S After disconnection, protect the connector end by covering it with a vinyl bag.
S 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
Pinch
hose (fuel tank inlet pipe side). Pull

a. Pinch the retainer and pull out

the fuel tank vent connector
No. 2 with the connector Pinch
pushed to the pipe side.

Fuel Tank Vent Retainer

Connector No. 2

Pipe
Nylon O-- Ring
Tube

Page 8 of 14
FUEL GAUGE INACCURACY -- EL010-04 Revised August 24, 2004

Repair
Procedure 2: Fuel Tank Vent Hose
Fuel Filler
Pipe
(Continued)

Charcoal Canister
Fuel Suction Tube Tube No. 1

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
Pinch
out the quick connector with
the connector pushed to the Pull
pipe side.

Pinch

Retainer
Quick Connector

Nylon
Tube Pipe
O-- Ring

Page 9 of 14
FUEL GAUGE INACCURACY -- EL010-04 Revised August 24, 2004

Repair D. Disconnect the charcoal canister

Procedure 2: tube No. 1.
Fuel Filler Pinch
Pipe a. Pinch the retainer and pull out
(Continued) the quick connector with the
connector pushed to the
pipe side. Pull

Pinch

Retainer
Quick Connector

Nylon
Tube Pipe
O-- Ring

E. Remove the fuel filler pipe clamp

and fuel tube connector from the
fuel tank inlet pipe.

Fuel Tube Connector

Fuel Tube Connector

Fuel Filler Pipe Clamp

Page 10 of 14
FUEL GAUGE INACCURACY -- EL010-04 Revised August 24, 2004

Repair F. Remove the 2 bolts, then remove

Procedure 2: the fuel tank filler pipe
Fuel Filler sub--assembly.
Pipe
(Continued)

7. Transfer the following parts to the new

Filler Pipe Assembly:
S Fuel inlet box rings
S Fuel tank filler pipe
shield assembly
S Filler pipe clamps 1 and 2
S Fuel inlet pipe plate
S Fuel hose joint
S Fuel tank gasket
S Fuel tube connector seal
S Fuel suction tube set gasket
S Fuel tank tube
S Fuel filler pipe clamp

8. Install Fuel Tank Filler Pipe

Sub--assembly.
A. Install new fuel tank filler pipe
sub--assembly.
B. Tighten the 2 bolts. A
Torque A:
34 NSm (347 kgfScm, 25 ftSlbf) B
Torque B:
18 NSm (185 kgScm, 13 ftSlbf)

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FUEL GAUGE INACCURACY -- EL010-04 Revised August 24, 2004

Repair C. Install the fuel tube connector and

Procedure 2: fuel filler pipe clamp to the fuel
Fuel Filler tank inlet pipe.
Pipe
(Continued)
NOTE:
S Securely lock the fuel filler pipe clamp.
S 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.

Fuel Filler Pipe Clamp

Fuel Filler Pipe Clamp

Locked Unlocked

NOTE:
Before reconnecting each quick connector:
S Check that there are no scratches or foreign objects in or around the contact area of
the quick connector and pipe.
S 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.
Push

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FUEL GAUGE INACCURACY -- EL010-04 Revised August 24, 2004

Repair E. Connect the fuel suction tube.

Procedure 2:
Fuel Filler a. Align the quick connector with
Pipe the pipe, then push in the
(Continued) connector until the retainer
makes a “click” sound. Push

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 Push
until the retainer makes a
“click” sound.

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FUEL GAUGE INACCURACY -- EL010-04 Revised August 24, 2004

Repair 9. Install Fuel Tank Filler Pipe Protector.

Procedure 2:
Fuel Filler A. Install the fuel tank filler pipe
Pipe protector with the nut.
(Continued)

10. Install Floor Under Cover 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.

Page 14 of 14