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  • Fuel gauge registering half when Full

    Hi All,
    I have had a look through the search and may have missed a post that may explain my problem, at this stage trying to figure out where the fault is and if it is the actual sender.
    I have a 120 series petrol on VSI gas. The fuel gauge has been working properly for four months and now all of a sudden it only goes to halfway when i fill the primary tank up. i do go offroad and not sure whether something has dislodged somewhere, I am unsure to when it actually happen as i generally run gas and petrol is seldom used other than once a month and when starting.

    Any thoughts on what it may be would be appreciated. i didnt want to pull the sender unit out just yet if it could possibly be something else.

    Thanks Alan

  • #2
    Re: Fuel gauge registering half when Full

    Hi Alan,

    Did you ever get this sorted out? I've got a friend who has the same problem after replacing the battery in his gas converted Prado. If you know what the problem was please share ...

    Comment


    • #3
      Re: Fuel gauge registering half when Full

      Had the same problem with my 9/04 GXL.. Got out the electrical drawings and found that the senders are wired in series.. When the gas guys replaced the sub tank (rear) with the Gas tank they cut off the wiring to the sender and inserted a 510 ohm resister to simulate an empty sub tank.. With the battery reset not sure what happened but it was reading half full with no 90L light (as before).. Fixed it by setting it up as a main tank only (No sub -- as per drawings) and replaced the resister with a short circuit . Is ok now.. Rod

      Comment


      • #4
        Re: Fuel gauge registering half when Full

        I have a customer with same problem,,,thought no worries,, and then when i disconnected battery to charge and reconnected, the fuel gauge and speedo have gone crazy. They work perfectly till the ign is swithched off for half hour, then fluctuate when turned back on and both needles jitter and slowly drop to point straight down,, as in way past the E on fuel gauge and 0 on speedo. BIZARRE. I think its a capacitor that starts the fuel gauge problem reading half,(hence a complete instrument cluster needed) and when powewr is taken away, like battery disconnected or cluster unplugged, the capacitor shits itself and wont fire up again when given power. Even leaving a door open so the light is on in the cluster and it works perfect. As soon as you black it out,,,half hour later, the mystery kicks in.
        ANYONE come across this or have advice?? HELP!!
        Originally posted by ac
        Hi All,
        I have had a look through the search and may have missed a post that may explain my problem, at this stage trying to figure out where the fault is and if it is the actual sender.
        I have a 120 series petrol on VSI gas. The fuel gauge has been working properly for four months and now all of a sudden it only goes to halfway when i fill the primary tank up. i do go offroad and not sure whether something has dislodged somewhere, I am unsure to when it actually happen as i generally run gas and petrol is seldom used other than once a month and when starting.

        Any thoughts on what it may be would be appreciated. i didnt want to pull the sender unit out just yet if it could possibly be something else.

        Thanks Alan

        Comment


        • #5
          Re: Fuel gauge registering half when Full

          Interesting about leaving the door open. The instrument panel has two power sources,
          when the ignition is on it is supplied from the ignition power. When the ignition is off backup
          power is supplied from the interior light power source. If you disconnect the interior
          light power source when the ignition is of the dash instruments will loose their calibration
          settings. When you turn on the ignition all the gauges will step and then be reset to 0.

          Might be worth checking the interior light power source?

          Cheers

          LeighW
          HKB Electronics, manufacturer of the Alternator Voltage Booster, Silver 2008 D4D,Lifted,Underbody protection, Alternator Voltage Booster, Tiger Z winch, Lightforce DL, Air Horns, Tanami Drawers, Drop down fridge slide, Outback cargo barriers, Rotronics dual Battery system, Polaris GPS, HF/UHF/VHF, Radio speaker combiner, Long ranger water tank, Diff breathers, Inverter, Snorkel and others

          Comment


          • #6
            Re: Fuel gauge registering half when Full

            First positive help ive had.Now to sort it ARGH!! You are correct,, that is exactly what is happening, the gauges are re-calibrating, and the stepper motors stop after about 15 secs and all is good except the needles are not pointing in the right spot. Move them by hand and they are perfect again until power is cut. Any hint as to where i can start to test??? Interior light works fine off all doors and the light on instrument cluster works to. I think that any power to the cluster starts it up, as in if i turn on hazard lights etc, or anything to illuminate a light on the cluster. Your idea that the door light keeps it calibrated definitely sounds on the right track.The toyota dealers are no help at all and have never heard of it before. They suggest i start with a new cluster at $1400.00 and go from there. Please offer any help and advice you can. Thanks
            Originally posted by LeighW
            Interesting about leaving the door open. The instrument panel has two power sources,
            when the ignition is on it is supplied from the ignition power. When the ignition is off backup
            power is supplied from the interior light power source. If you disconnect the interior
            light power source when the ignition is of the dash instruments will loose their calibration
            settings. When you turn on the ignition all the gauges will step and then be reset to 0.

            Might be worth checking the interior light power source?

            Cheers

            LeighW

            Comment


            • #7
              Re: Fuel gauge registering half when Full

              Hi mcleod,

              Without the service manual your going to find it hard. The backup power is feed from connector IM1 pin 4.
              This plug is located behind the drivers side kick panel. There is a bunch of plugs there, at the very top are two horizontal plugs
              and a vertical plug (inner most side) the wire colour is red.

              This wire runs to the instrument cluster plug C9 pin 20. Ign power feeds in on pin 19. C9 is the right most plug of the instrument cluster
              looking at the instrument cluster rear.

              Looking at the wiring form plug with the locking mech at the top pins 19 & 20 are the right most two on the lower row of pins.

              Generally if the dome power is missing when you turn on the ignition all the gauges will step up a few steps then return gradually to the
              zero position.

              If yours are driving past zero then you may still have a fault in the instrument panel itself.

              You maybe able to get the cluster repaired by a speedo repairer, do a search on speedo and rev counter repairs as this has
              been discussed before in other threads. Also, there a specialist repairers around who can repair the ECU modules and most likely the cluster
              too. From what I have read most faults in the cluster seem to be caused by faulty soldering on the PCB board (know in the electronics industry as dry joints)
              any good electronics technician should be able to have a look at it and see if this is the case.

              Good luck with your fault finding.

              Cheers
              LeighW
              HKB Electronics, manufacturer of the Alternator Voltage Booster, Silver 2008 D4D,Lifted,Underbody protection, Alternator Voltage Booster, Tiger Z winch, Lightforce DL, Air Horns, Tanami Drawers, Drop down fridge slide, Outback cargo barriers, Rotronics dual Battery system, Polaris GPS, HF/UHF/VHF, Radio speaker combiner, Long ranger water tank, Diff breathers, Inverter, Snorkel and others

              Comment


              • #8
                Re: Fuel gauge registering half when Full

                Hi mcleod,

                Without the service manual your going to find it hard. The backup power is feed from connector IM1 pin 4.
                This plug is located behind the drivers side kick panel. There is a bunch of plugs there, at the very top are two horizontal plugs
                and a vertical plug (inner most side) this is the connector you want and could be worth checking if you have been working around there, the wire colour is red,
                can't tell you how the plug pins go as form some reason they haven't shown a diagram of this plug.

                This wire runs to the instrument cluster plug C9 pin 20. Ign power feeds in on pin 19. C9 is the right most plug of the instrument cluster
                looking at the instrument cluster rear.

                Looking at the wiring form plug with the locking mech at the top, pins 19 & 20 are the right most two on the lower row of pins.

                Generally if the dome power is missing when you turn on the ignition all the gauges will step up a few steps then return gradually to the
                zero position.

                If yours are driving past zero then you may still have a fault in the instrument panel itself.

                You maybe able to get the cluster repaired by a speedo repairer, do a search on speedo and rev counter repairs as this has
                been discussed before in other threads. Also, there a specialist repairers around who can repair the ECU modules and most likely the cluster
                too. From what I have read most faults in the cluster seem to be caused by faulty soldering on the PCB board (know in the electronics industry as dry joints)
                any good electronics technician should be able to have a look at it and see if this is the case.

                Good luck with your fault finding.

                Cheers
                LeighW
                HKB Electronics, manufacturer of the Alternator Voltage Booster, Silver 2008 D4D,Lifted,Underbody protection, Alternator Voltage Booster, Tiger Z winch, Lightforce DL, Air Horns, Tanami Drawers, Drop down fridge slide, Outback cargo barriers, Rotronics dual Battery system, Polaris GPS, HF/UHF/VHF, Radio speaker combiner, Long ranger water tank, Diff breathers, Inverter, Snorkel and others

                Comment

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