Fuel Tank and Fuel Gauge Diagnostic Tips: TSB-0163-08

[galaxee]

T-SB-0163-08 August 5, 2008
Fuel Tank and Fuel Gauge Diagnostic Tips

Section Meter/Gauge/Display Market USA

2004 – 2008 Prius


Introduction
This TSB explains the design and operational characteristics of the bladder tank and fuel gauge
system. Diagnostic tips for the following customer concerns are also included.
• Fuel tank capacity and/or fuel gauge accuracy (Procedure A)
• Difficulty adding fuel (Procedure B)

Warranty Information
N/A Not Applicable to Warranty

[dogfriend]

Cool. Thanks for posting.

The note on the very last page is interesting:

DO NOT suggest refueling using the lowest setting on the fuel nozzle. This can cause overfilling and possible damage to the EVAP system.

Several people here have suggested using the slowest setting, but that seems to be contrary to the suggestion here.

My own experience with this is that I had the BGS (barfing gas syndrome) twice in the first few months, and both times it was with a pump that had a very low setting and the pump did not shut off.

[9G-man]

I had the "burp" once when I first bought the car, almost two years ago.
Mine has had no issues since, I get at least 600 miles out of every tank, and 10-10.8 gallons go in every fill-up.
I take it to the low fuel warning every time, and beyond, because I run the numbers and know what my anticipated range is for every tank.
I simply note how much fuel I pump into the tank. Then divide the mileage I drive by the average MPG I'm getting. When the result approaches the fuel amount I originally pumped, it's time to get gas.
Or even easier......I know at least 10 gallons are in there, so I just multiply my average MPG by 10, (easy mental math) and when the number reaches the miles I've driven since fill-up, BINGO......time for gas.
It's so simple, I don't see what the issue is. And it's basically the same method I've used for every car before the Prius.

The most important direction in that TSB is this........"

start the pump nozzle on a lower flow
setting then increase the pump speed to its maximum. Allow the fuel tank to fill until the fuel
nozzle shuts off by itself. And don't do partial fill-ups. Fill the tank up everytime!

I think some folks are jamming the nozzle in there, and giving it full blast. I've had some pumps that simple pump fuel with too much force, no matter what you do. I complain and never go back to that station. And that can be a issue with non-Prius cars too.
Ever had a pump that auto-shutoff as soon as you pulled the trigger? The pump is not set right and pumps too forcefully.

[[H]ackerK]

Interesting.... Maybe I will print off a copy and bring it to dealership. Procedure B: Refueling Issues does sounds like what I have. only works well if I fill it slowly and only insert the gun a almost 3/4 way out!

"It is recommended to add a minimum of 3 gallons when refueling." I guess I must fall asleep while RTFM. For once, I only filled up ~11L when the gun just keep tripping and I looks like an idiot there...

[thepolarcrew]

After my first couple of 11.5+ tanks and 2 pips showing haven't had a 11gal fill since.

[krousdb]

Procedure A: Fuel Gauge Accuracy

Confirm the current fuel tank level and fuel gauge value.
1. Park the vehicle on a level surface.
2. Record the current fuel gauge value on the combination meter.
3. Access the F14 connector on the top of the fuel tank
Refer to the Technical Information System (TIS), applicable model year Prius Repair Manual:

2004 or 2005 Prius, Vehicle

Can anyone tell me where I can find the F14 connector???????

[alex7227997]

Originally Posted by galaxee

T-SB-0163-08 August 5, 2008
Fuel Tank and Fuel Gauge Diagnostic Tips

Section Meter/Gauge/Display Market USA

2004 – 2008 Prius


Introduction
This TSB explains the design and operational characteristics of the bladder tank and fuel gauge
system. Diagnostic tips for the following customer concerns are also included.
• Fuel tank capacity and/or fuel gauge accuracy (Procedure A)
• Difficulty adding fuel (Procedure

Warranty Information
N/A Not Applicable to Warranty

Hi,
I have a problem with the fuel gauge on my Prius 2008. The guage stayes fixed on 3/4 tank and does not change witrh refueling or usage. I disconnected the plug from the tank and the guage changed to the minimum worning signal and the whole system behaved as no fuel is present.
In older cars I would suspect thta the float inside the fuel tank is stucked. However, I could not find any document shwoing the inside of the fuel tank or giving details how to diagnos e the problem. I read the T-SB-0163-08 document that you gave but it refers to a document: 2008 Prius, Vehicle interior-Meter/Guage/Display etc... Is this document also availabel somewhere on the net?
Do you have any suggestiion for me how to solve this problem?
I would not like any local Toyota garage to paly with my car as usually they are working based on trial and error.

Thanks

[firepa63]

Originally Posted by alex7227997

Hi,
I have a problem with the fuel gauge on my Prius 2008. The guage stayes fixed on 3/4 tank and does not change witrh refueling or usage. I disconnected the plug from the tank and the guage changed to the minimum worning signal and the whole system behaved as no fuel is present.
In older cars I would suspect thta the float inside the fuel tank is stucked. However, I could not find any document shwoing the inside of the fuel tank or giving details how to diagnos e the problem. I read the T-SB-0163-08 document that you gave but it refers to a document: 2008 Prius, Vehicle interior-Meter/Guage/Display etc... Is this document also availabel somewhere on the net?
Do you have any suggestiion for me how to solve this problem?
I would not like any local Toyota garage to paly with my car as usually they are working based on trial and error.

Thanks

You have a 2008 Prius. It should be under warranty. Let Toyota fix the problem.