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fuel gauge broken - new gas tank?

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by zeeman, Jan 18, 2012.

  1. zeeman

    zeeman Member

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    as of recently, my 2008 Prius fuel gauge shows only 1 flashing bar unless the fuel level is more than half-full.

    I just got a quote from the dealer; they said it will cost me $ 900 + to replace the whole fuel tank, as fuel gauge is not a replaceable part. Yap, the whole gas tank needs to be replaced for fuel sender!
    how nice, how logical, how great for the environment!

    well, i find this hard to believe, but i guess it is possible that they have built everything together as one big replaceable unit.

    BTW, if this is true then Toyota is not making environmentally friendly vehicles, when we have to throw away perfectly good gas tank and other parts within in order to replace a moving part that is most likely to fail.

    I used to work on cars for many years and it really used to tick me off when a whole assembly needed to be replaced for a small part that has failed.
    But, this 'replace the whole gas tank' for fuel sending unit scenario is even worse, this is insane and this MUST change as this is waste of natural resources, this eliminates the jobs in auto repair industry and this creates lots of extra toxic waste.
    I mean, the car is less than 4 years old and i have to throw away perfectly good gas tank so that i can replace a small moving part?! What rocket scientist has designed Prius fuel sending unit/gas tank assembly?

    anyways, does anyone know can fuel sending unit be replaced separately?
    There must be some aftermarket replacement that someone is making.

    TIA
     
    #1 zeeman, Jan 18, 2012
  2. GuamKelly

    GuamKelly Member

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    I don't know if this is correct, or if there is a workaround, but it occurs to me you can do quite nicely without a working fuel gauge in these cars. Plenty of info on the MFD, as long as you don't wait for the last couple liters (bad idea anyhow) to fill up . . .
     
    #2 GuamKelly, Jan 18, 2012
  3. xs650

    xs650 Senior Member

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    Check the aftermarket, this place list a pump and sender combo for $65.

    Fuel Pump - Auto Parts Warehouse

    I have no idea how hard it is to replace on your bladdered fuel tank. An independent Prius shop might be able to help.

    Changing the sender may be difficult and iffy enough of a job that it isn't worth doing.

    Edit: Based on the post linked to by Cwerdna, it doesn't sound like a practical job to do (That was an understatement)
     
    #3 xs650, Jan 18, 2012
  4. zeeman

    zeeman Member

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    thanks for the feedback
    yes, i can use daily trip counter to estimate the fuel level and i could also use my scan gauge for additional information.

    i have no idea if this bladder type gas tank is serviceable or not, but i imagine that there must be some kind of way to service the gas tank as there was most definitely a way to install the fuel sending unit in the tank. but with modern cars you never know, maybe some genius engineer at Toyota have figured out how to make the whole gas tank disposable?!

    if i remeber correctly, the bladder is inside the gas tank, and this is contrary what a service manager at toyota has told me today. he said that prius does not have a gas tank, but it only has a bladder?!
     
    #4 zeeman, Jan 18, 2012
  5. cwerdna

    cwerdna Senior Member

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    #5 cwerdna, Jan 18, 2012
  6. northwichita

    northwichita .

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    Just in case the link is missed...
    The inclinometer must be reset if the customer complains that they can
    only pump a few gallons of gas into their tank or that they run out of
    gas with three or four bars left on the fuel meter. The inclinometer
    must also be reset if the Prius is refilled on an excessive slope or if the
    fuel gauge becomes inaccurate. Please refer to the Prius Repair
    Manual for the inclinometer calibration procedure. "
    -----------------------------------------------------------------------------------
    AUTOMOTIVE TECHNICAL ARTICLES



    -----------------------------------------------------------------------------------

    Bear68
    Senior Member

    Easter Egg Time.... Anybody wanna reset the fuel gauge inclination
    sensor? Make sure your fuel level is somewhere between 1/4 and 3/4, and
    temp should be about 70-90 F.

    Step 1: PARK ON A LEVEL SURFACE!!!! If you are on a slope you will reset
    the sensor to an incorrect level!!
    Step 2: Press the ODO/trip button to turn the odometer to trip A
    Step 3: Turn off the ignition and set the parking brake.
    Step 4: DO NOT STEP ON THE BRAKE PEDAL! AT ALL! IT ISN"T NEEDED FOR
    THIS PROCEDURE!!
    Step 5: Press and hold the ODO/trip button and press the Power button
    twice.
    Step 6: Release and press the ODO/trip button three times
    Release-Press-Release-Press-Release-Press and HOLD.

    The Odometer on the combo meter should now be showing the normal
    mileage, as you hold the ODO/trip button down, the reading should change.
    Something along the lines of 650D0 or similar. The actual figures don't really
    matter.

    Step 7: Release and press the ODO/trip botton once more and HOLD it in.
    The figure will change again. This time, only ONE digit will change.
    650D0>65010 as an example.

    Don't be afraid to try it. Even if it doesn't work, you won't goof anything up.
    Try, try again. It sometimes takes a half dozen attempts before you get it
    work right the first couple of times you do it. This only needs to be done
    once in a while. I would recommend once every ten tanks or so. I usually
    only do it when a customer has a fuel gauge issue. [Emphasis added.]

    Takes a bit of practice but it resets the ECU to try to be more accurate in
    it's estimation of your actual fuel level.

    GOOD LUCK!!
     
    #6 northwichita, Jan 18, 2012
    SFO and TheSnowSnake like this.
  7. cwerdna

    cwerdna Senior Member

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    Also, http://www.autoshop101.com/forms/Hybrid13.pdf gives more details about the tank, bladder, fuel system, etc. and refers to the above procedure.

    I've never personally done the procedure as I've never seen the need. My car was bought new and I'm past 60K miles now.
     
    #7 cwerdna, Jan 18, 2012
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