Toyota Avalon (XX50): Fuel Level Sensor "A" Signal Stuck In Range (P04602A). Brake Switch "A"/"B" Signal Cross Coupled (P05042B). Actuator Supply Voltage "A" Stuck On (P06579E)

Toyota Avalon (XX50) 2019-2022 Service & Repair Manual / Engine / 2gr-fks Engine Control / Sfi System / Fuel Level Sensor "A" Signal Stuck In Range (P04602A). Brake Switch "A"/"B" Signal Cross Coupled (P05042B). Actuator Supply Voltage "A" Stuck On (P06579E)

Fuel Level Sensor "A" Signal Stuck In Range (P04602A)

DESCRIPTION

Refer to DTC P046012.

Click here

DTC No.	Detection Item	DTC Detection Condition	Trouble Area	MIL	Memory	Note
P04602A	Fuel Level Sensor "A" Signal Stuck In Range	The change in the fuel sender gauge value is below the threshold when a certain amount of fuel is calculated to have been consumed. (1 trip detection logic).	Fuel sender gauge assembly ECM	Comes on	DTC stored	SAE Code: P0461

MONITOR DESCRIPTION

When the fuel sender gauge assembly output value changes less than a specified amount, when compared to the fuel consumption calculated from the fuel injection volume, the ECM will detect a malfunction, illuminate the MIL and store a DTC.

MONITOR STRATEGY

Related DTCs	P0461: Fuel level sensor stuck
Required Sensors/Components (Main)	Fuel level sensor
Required Sensors/Components (Related)	-
Frequency of Operation	Continuous
Duration	Less than 10 seconds
MIL Operation	1 driving cycles
Sequence of Operation	None

TYPICAL ENABLING CONDITIONS

Lost communication with instrument panel cluster control module (U0155)	Not detected
Fuel level sensor circuit malfunction (P0462, P0463)	Not detected
Either of the following conditions is met	Condition A or B
A. Battery voltage	8 V or higher
B. Check mode	On
Fuel level sensor output via CAN	Received
Engine switch	On (IG)

TYPICAL MALFUNCTION THRESHOLDS

One of the following conditions is met	A, B or C
A. Accumulated volume of injected fuel during (a) is met at high fuel level	36.9 L or more
B. Accumulated volume of injected fuel during (a) is met at middle fuel level	10.7 L or more
C. Accumulated volume of injected fuel during (a) is met at low fuel level	22.2 L or more
(a) Smoothed fuel level sensor output (Maximum - Minimum)	Less than 3 L

CONFIRMATION DRIVING PATTERN

HINT:

After repair has been completed, clear the DTC and then check that the vehicle has returned to normal by performing the following All Readiness check procedure.
Click here
When clearing the permanent DTCs, refer to the "CLEAR PERMANENT DTC" procedure.
Click here

Connect the Techstream to the DLC3.
Turn the engine switch on (IG).
Turn the Techstream on.
Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).
Turn the engine switch off and wait for at least 30 seconds.
Turn the engine switch on (IG) [A].
Turn the Techstream on.
Start the engine [B].
Drive the vehicle at 80 km/h (50 mph) or more for 30 minutes [C].
Enter the following menus: Powertrain / Engine / Trouble Codes [D].
Read the pending DTCs.
HINT:
- If a pending DTC is output, the system is malfunctioning.
- If a pending DTC is not output, perform the following procedure.
Enter the following menus: Powertrain / Engine / Utility / All Readiness.
Input the DTC: P04602A.

Check the DTC judgment result.

Techstream Display	Description
NORMAL	DTC judgment completed System normal
ABNORMAL	DTC judgment completed System abnormal
INCOMPLETE	DTC judgment not completed Perform driving pattern after confirming DTC enabling conditions

HINT:

If the judgment result shows NORMAL, the system is normal.
If the judgment result shows ABNORMAL, the system has a malfunction.
If the judgment result is INCOMPLETE, perform steps [E] through [F] again.
[A] to [D]: Normal judgment procedure.
The normal judgment procedure is used to complete DTC judgment and also used when clearing permanent DTCs.
When clearing the permanent DTCs, do not disconnect the cable from the battery terminal or attempt to clear the DTCs during this procedure, as doing so will clear the universal trip and normal judgment histories.

Drive the vehicle at 80 km/h (50 mph) or more for 30 minutes [E].
Enter the following menus: Powertrain / Engine / Trouble Codes [F].
Read the pending DTCs.
HINT:
- If a pending DTC is output, the system is malfunctioning.
- If a pending DTC is not output, perform the following procedure.
Enter the following menus: Powertrain / Engine / Utility / All Readiness.
Input the DTC: P04602A.

Check the DTC judgment result.

Techstream Display	Description
NORMAL	DTC judgment completed System normal
ABNORMAL	DTC judgment completed System abnormal
INCOMPLETE	DTC judgment not completed Perform driving pattern after confirming DTC enabling conditions

HINT:

If the judgment result shows NORMAL, the system is normal.
If the judgment result shows ABNORMAL, the system has a malfunction.
[A] to [F]: Normal judgment procedure.
The normal judgment procedure is used to complete DTC judgment and also used when clearing permanent DTCs.
When clearing the permanent DTCs, do not disconnect the cable from the battery terminal or attempt to clear the DTCs during this procedure, as doing so will clear the universal trip and normal judgment histories.

CAUTION / NOTICE / HINT

HINT:

Read freeze frame data using the Techstream. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred.

PROCEDURE

1.	INTERVIEW THE CUSTOMER

(a) Interview the customer for details about when the they refuel the vehicle.

HINT:

When the fuel tank is full, if the vehicle is repeatedly driven a short distance and then refueled, the fuel sender gauge output value will not change. In this case, the ECM may judge that the fuel sender gauge is stuck and store DTC P04602A. If the vehicle was driven in this manner, as the DTC was stored due to a user action, clear the DTCs without performing troubleshooting and return the vehicle to the customer.

2.	INSPECT FUEL SENDER GAUGE ASSEMBLY

(a) Remove the fuel sender gauge assembly.

Click here

(b) Inspect the fuel sender gauge assembly.

Click here

CHECK FOR INTERMITTENT PROBLEMS

REPLACE FUEL SENDER GAUGE ASSEMBLY

Brake Switch "A"/"B" Signal Cross Coupled (P05042B)

DESCRIPTION

The stop light switch assembly is a duplex system that transmits two signals: STP and ST1-. These two signals are used by the ECM to monitor whether or not the brake system is working properly. If the signals, which indicate the brake pedal is being depressed and released, are detected simultaneously, the ECM interprets this as a malfunction in the stop light switch assembly and stores this DTC.

HINT:

The normal signal conditions are as shown in the table below.

Signal (ECM Terminal)	Brake Pedal Released	In Transition	Brake Pedal Depressed
STP	OFF	ON	ON
ST1-	ON	ON	OFF

[OFF] denotes ground potential.
[ON] denotes battery potential (+B).

On the Techstream, Data List item Stop Light SW is ON when the brake pedal is depressed.

DTC No.	Detection Item	DTC Detection Condition	Trouble Area	MIL	Memory	Note
P05042B	Brake Switch "A"/"B" Signal Cross Coupled	Conditions (a) and (b) are met for 0.5 seconds or more (1 trip detection logic): (a) Engine switch on (IG) (b) STP signal OFF when ST1- signal OFF	Open or short in stop light switch signal circuit Stop light switch assembly Instrument panel junction block assembly ECM	Does not come on	DTC stored	SAE Code: P0504

DTC No.

Detection Item

DTC Detection Condition

Trouble Area

MIL

Memory

Note

P05042B

Brake Switch "A"/"B" Signal Cross Coupled

Conditions (a) and (b) are met for 0.5 seconds or more (1 trip detection logic):

(a) Engine switch on (IG)

(b) STP signal OFF when ST1- signal OFF

Open or short in stop light switch signal circuit
Stop light switch assembly
Instrument panel junction block assembly
ECM

Does not come on

DTC stored

SAE Code: P0504

WIRING DIAGRAM

CAUTION / NOTICE / HINT

NOTICE:

Inspect the fuses for circuits related to this system before performing the following procedure.

HINT:

Stop light switch assembly conditions can be checked using the Techstream.
1. Connect the Techstream to the DLC3.
2. Turn the engine switch on (IG).
3. Turn the Techstream on.
4. Enter the following menus: Powertrain / Engine / Data List / Stop Light SW.
5. Check the Data List indication when the brake pedal is depressed and released.
  
  Brake Pedal Operation
  
  Stop Light SW
  
  Depressed
  
  ON
  
  Released
  
  OFF
Read freeze frame data using the Techstream. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred.

Brake Pedal Operation	Stop Light SW
Depressed	ON
Released	OFF

PROCEDURE

1.	CHECK TERMINAL VOLTAGE (POWER SOURCE OF STOP LIGHT SWITCH ASSEMBLY)

*a	Front view of wire harness connector (to Stop Light Switch Assembly)

(a) Disconnect the stop light switch assembly connector.

(b) Measure the voltage according to the value(s) in the table below.

Standard Voltage:

Tester Connection	Condition	Specified Condition
A33-7 (B) - Body ground	Always	11 to 14 V

GO TO STEP 11

2.	CHECK TERMINAL VOLTAGE (POWER SOURCE OF STOP LIGHT SWITCH ASSEMBLY)

*a	Front view of wire harness connector (to Stop Light Switch Assembly)

(a) Disconnect the stop light switch assembly connector.

(b) Turn the engine switch on (IG).

Standard Voltage:

Tester Connection	Condition	Specified Condition
A33-6 (B) - Body ground	Engine switch on (IG)	11 to 14 V

GO TO STEP 6

3.	CHECK HARNESS AND CONNECTOR (STOP LIGHT SWITCH ASSEMBLY - BODY GROUND)

(a) Disconnect the stop light switch assembly connector.

(b) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Tester Connection	Condition	Specified Condition
A33-2 (GND) - Body ground	Always	Below 1 Ω

REPAIR OR REPLACE HARNESS OR CONNECTOR

4.	CHECK TERMINAL VOLTAGE (STP AND ST1- VOLTAGE)

Brake Pedal Depressed

Brake Pedal Released

Front view of wire harness connector

(to ECM)

(a) Disconnect the ECM connector.

(b) Turn the engine switch on (IG).

Standard Voltage:

Tester Connection	Brake Pedal Operation	Specified Condition
A18-42 (ST1-) - Body ground	Released	7.5 to 14 V
A18-42 (ST1-) - Body ground	Depressed	Below 1.5 V
A18-27 (STP) - Body ground	Released	Below 1.5 V
A18-27 (STP) - Body ground	Depressed	7.5 to 14 V

REPLACE ECM

5.	CHECK HARNESS AND CONNECTOR (STOP LIGHT SWITCH ASSEMBLY - ECM)

(a) Disconnect the stop light switch assembly connector.

(b) Disconnect the ECM connector.

Standard Resistance:

Tester Connection	Condition	Specified Condition
A33-5 (L) - A18-42 (ST1-)	Always	Below 1 Ω
A33-3 (L) - A18-27 (STP)	Always	Below 1 Ω
A33-5 (L) or A18-42 (ST1-) - Body ground and other terminals	Always	10 kΩ or higher
A33-3 (L) or A18-27 (STP) - Body ground and other terminals	Always	10 kΩ or higher

REPLACE STOP LIGHT SWITCH ASSEMBLY

REPAIR OR REPLACE HARNESS OR CONNECTOR

6.	CHECK HARNESS AND CONNECTOR (INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY - STOP LIGHT SWITCH ASSEMBLY)

(a) Disconnect the instrument panel junction block assembly connector.

(b) Disconnect the stop light switch assembly connector.

Standard Resistance:

Tester Connection	Condition	Specified Condition
4F-15 - A33-6 (B)	Always	Below 1 Ω
4F-15 or A33-6 (B) - Body ground and other terminals	Always	10 kΩ or higher

REPAIR OR REPLACE HARNESS OR CONNECTOR

7.	CHECK HARNESS AND CONNECTOR (INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY - BODY GROUND)

(a) Disconnect the instrument panel junction block assembly connector.

(b) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Tester Connection	Condition	Specified Condition
4D-3 - Body ground	Always	Below 1 Ω

REPAIR OR REPLACE HARNESS OR CONNECTOR

8.	CHECK INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY (POWER SOURCE)

*a	Front view of wire harness connector (to Instrument Panel Junction Block Assembly)

(a) Disconnect the instrument panel junction block assembly connector.

(b) Measure the voltage according to the value(s) in the table below.

Standard Voltage:

Tester Connection	Condition	Specified Condition
4L-1 - Body ground	Always	11 to 14 V

REPAIR OR REPLACE HARNESS OR CONNECTOR (BATTERY - INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY)

9.	CHECK HARNESS AND CONNECTOR (INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY - CERTIFICATION ECU (SMART KEY ECU ASSEMBLY))

(a) Disconnect the instrument panel junction block assembly connector.

(b) Disconnect the certification ECU (smart key ECU assembly) connector.

Standard Resistance:

Tester Connection	Condition	Specified Condition
4A-17 - G40-17 (IG1D)	Always	Below 1 Ω
4A-17 or G40-17 (IG1D) - Body ground and other terminals	Always	10 kΩ or higher

REPAIR OR REPLACE HARNESS OR CONNECTOR

10.	CHECK SMART KEY SYSTEM

(a) Check the smart key system.

Click here

REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY

REPAIR SMART KEY SYSTEM

11.	CHECK HARNESS AND CONNECTOR (INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY - STOP LIGHT SWITCH ASSEMBLY)

(a) Disconnect the instrument panel junction block assembly connector.

(b) Disconnect the stop light switch assembly connector.

Standard Resistance:

Tester Connection	Condition	Specified Condition
4F-3 - A33-7 (B)	Always	Below 1 Ω
4F-3 or A33-7 (B) - Body ground and other terminals	Always	10 kΩ or higher

REPAIR OR REPLACE HARNESS OR CONNECTOR

12.	CHECK INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY (POWER SOURCE)

*a	Front view of wire harness connector (to Instrument Panel Junction Block Assembly)

(a) Disconnect the instrument panel junction block assembly connector.

(b) Measure the voltage according to the value(s) in the table below.

Standard Voltage:

Tester Connection	Condition	Specified Condition
4L-1 - Body ground	Always	11 to 14 V

REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY

REPAIR OR REPLACE HARNESS OR CONNECTOR (BATTERY - INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY)

Actuator Supply Voltage "A" Stuck On (P06579E)

MONITOR DESCRIPTION

The ECM monitors the output voltage to the throttle actuator. This self-check ensures that the ECM is functioning properly. The output voltage is usually 0 V when the engine switch is turned off. If the output voltage is 7 V or higher when the engine switch is turned off, the ECM illuminates the MIL and stores this DTC when the engine switch is turned on (IG).

DTC No.	Detection Item	DTC Detection Condition	Trouble Area	MIL	Memory	Note
P06579E	Actuator Supply Voltage "A" Stuck On	A throttle actuator power supply error (1 trip detection logic).	ECM	Comes on	DTC stored	SAE Code: P0657

MONITOR STRATEGY

Related DTCs	P0657: Electronic throttle actuator supply voltage circuit performance
Required Sensors/Components (Main)	ECM
Required Sensors/Components (Related)	Throttle actuator
Frequency of Operation	Once per driving cycle
Duration	1 second
MIL Operation	Immediate
Sequence of Operation	None

TYPICAL ENABLING CONDITIONS

Monitor runs whenever the following DTCs are not stored	None
Both of the following conditions are met	-
Battery voltage	8 V or higher
Command to electronic throttle actuator power	Off

TYPICAL MALFUNCTION THRESHOLDS

Electronic throttle actuator power supply voltage

7 V or higher

CONFIRMATION DRIVING PATTERN

HINT:

After repair has been completed, clear the DTC and then check that the vehicle has returned to normal by performing the following All Readiness check procedure.
Click here
When clearing the permanent DTCs, refer to the "CLEAR PERMANENT DTC" procedure.
Click here

Connect the Techstream to the DLC3.
Turn the engine switch on (IG).
Turn the Techstream on.
Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).
Turn the Techstream off.
Turn the engine switch off.
Disconnect the Techstream.
Disconnect the cable from the negative (-) battery terminal and wait for 1 minute.
Connect the cable to the negative (-) battery terminal.
Turn the engine switch on (IG) [A].
Wait 10 seconds or more.
Turn the engine switch off [B].
Wait 15 seconds or more.
Connect the Techstream to the DLC3.
Turn the engine switch on (IG).
Turn the Techstream on.
Wait 5 seconds or more [C].
Enter the following menus: Powertrain / Engine / Trouble Codes [D].
Read the pending DTCs.
HINT:
- If a pending DTC is output, the system is malfunctioning.
- If a pending DTC is not output, perform the following procedure.
Enter the following menus: Powertrain / Engine / Utility / All Readiness.
Input the DTC: P06579E.

Check the DTC judgment result.

Techstream Display	Description
NORMAL	DTC judgment completed System normal
ABNORMAL	DTC judgment completed System abnormal
INCOMPLETE	DTC judgment not completed Perform driving pattern after confirming DTC enabling conditions

HINT:

If the judgment result is NORMAL, the system is normal.
If the judgment result is ABNORMAL, the system is malfunctioning.
If the judgment result is INCOMPLETE, perform steps [B] through [D] again.
[A] to [D]: Normal judgment procedure.
The normal judgment procedure is used to complete DTC judgment and also used when clearing permanent DTCs.
When clearing the permanent DTCs, do not disconnect the cable from the battery terminal or attempt to clear the DTCs during this procedure, as doing so will clear the universal trip and normal judgment histories.

CAUTION / NOTICE / HINT

NOTICE:

After turning engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

Click here

HINT:

PROCEDURE

CLEAR DTC

(a) Connect the Techstream to the DLC3.

(b) Turn the engine switch on (IG).

(d) Clear the DTC.

Powertrain > Engine > Clear DTCs

(e) Turn the engine switch off.

2.	READ OUTPUT DTC (DTC P06579E)

(a) Disconnect the cable from the negative (-) battery terminal and wait for 1 minute.

(b) Connect the cable to the negative (-) battery terminal.

(d) Wait 10 seconds or more.

(e) Turn the engine switch off.

(f) Wait 15 seconds or more.

(g) Connect the Techstream to the DLC3.

(h) Turn the engine switch on (IG).

(i) Wait 5 seconds or more.

(j) Turn the Techstream on.

(k) Enter the following menus: Powertrain / Engine / Trouble Codes.

(l) Read the DTCs.

Powertrain > Engine > Trouble Codes

Result	Proceed to
DTCs are not output	A
DTC P06579E is output	B

CHECK FOR INTERMITTENT PROBLEMS

REPLACE ECM

Evaporative Emission System Incorrect Purge Flow Actuator Stuck On (P04417E,P04417F,P04419C)

Fuel Rail / System Pressure - Too Low (P008700)

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