3rd gen fuel gauge problem: I think I figured out the problem (pics)

rimpainter.com · 06-01-2005, 09:05 AM

Many of us suffer from the dreaded fuel gauge problem; up, down, fast, slow…it seems that the symptoms can vary from one vehicle to another. On my rig, the tank shows full for 20 miles or so, then drops like a rock to just above halfway, where it remains until 100 miles. Then it does a normal “descent” to E, or about 230 – 250 miles.

Well, as I dropped my tank to install my Walbro 190 fuel pump the other day (in anticipation of my supercharger install), I figured it would be a perfect time to look at the sending unit and see if I could spot the problem.

This first picture is the fuel pick-up unit in its entirety (with the Walbro 190 installed already). It is obviously upside down. The sending unit is that gray open “box” bolted to that arm. In addition, you can see that little metal arm with a small bend going out of the picture to the float. The sending unit is what we will be concentrating on. Because the unit is upside down in this picture, the sending unit is maxed out on “full.” So keep that in mind.

Now, here is the money shot. Sorry it’s blurry. You can see how the contact piece travels up and down the points in relation to the float level in the tank. Again, this is upside down, so it is on full. Do you see the black on the points between full and just above halfway? Well, that is exactly where my problem is on the gauge itself. Coincidental? I think not.

I am no electrical engineer, but I know a thing or two about how things work. I am pretty sure this is our problem. Unfortunately, I don’t have a solution, nor did I have time to mess with mine. My gauge does not bother me much, so I didn’t want to make it worse. I can see why the dealer just replaces the unit as a whole. It is possible that it cannot be fixed anyway. So there you have it, my theory as to why the fuel gauge problem exists.

This ad is not displayed to registered members.
Register your free account today and become a member on Yotatech!

ugadawg95 · 06-01-2005, 09:32 AM

Good work Christian!!! btw...I hope that's not blood on those towels?

I don't have this problem now, thank god...but my 99 Tacoma did.

rimpainter.com · 06-01-2005, 09:46 AM

Quote:

Originally Posted by ugadawg95

Good work Christian!!! btw...I hope that's not blood on those towels?

Thanks!

actually, it's K&N oil (from the cone filter on our Accord).

HOJU · 06-01-2005, 10:02 AM

it may just be the angle, but couldn't you use some cleaner, maybe acetone or something and clean the connection points?

rimpainter.com · 06-01-2005, 10:24 AM

I don't know, but I sure as heck aint pulling that tank again if I can help it!

Maybe an eraser to a pencil would work

MTL_4runner · 06-01-2005, 11:02 AM

Quote:

Originally Posted by <96 Runner>

I don't know, but I sure as heck aint pulling that tank again if I can help it!

Maybe an eraser to a pencil would work

Yes, an old pencil eraser would be the best way to clean those contacts (use a new pencil, erasers get crusty after time and don't work as well). You might also have the pull the contact arm off and clean it too to make it work 100% again. It is just a big potentiometer (variable resistor), no worries there.

data · 06-01-2005, 11:24 AM

was the tank difficult to pull out?

rimpainter.com · 06-01-2005, 11:39 AM

With air tools it took me about 4 hours from start to finish. And that's with the FP install in between.

Unhappy99 · 06-01-2005, 11:58 AM

There are two independent issues:
1) Low fuel light comes on with 4-5 gallons left, instead of the 2 or so where it should. Caused by the sending unit being miscalibrated. Fixed by replacing sending unit.

2) Fuel gauge reads erradic. Caused by a faulty levelling circuit on the #3 dash panel PCB. Fixed by replacing this PCB. Somewhere I've read that the levelling circuit can be hacked and the gauge work properly, although the details of what precisely got hacked are vague. If you remove the dash panel, the levelling sensor itself is the white plastic thingy mounted on the back side with 3 small wires connecting to the gauge PCB.

It could be that if the sensor were disconnected, and the gauge recalibrated via TSB EL010-99, then the gauge might work ok. I didn't try this when I replaced mine, but since I still have my old PCB, I might.

rimpainter.com · 06-01-2005, 12:14 PM

Quote:

Originally Posted by Unhappy99

There are two independent issues:
1) Low fuel light comes on with 4-5 gallons left, instead of the 2 or so where it should. Caused by the sending unit being miscalibrated. Fixed by replacing sending unit.

Good point about the light coming on. I don't have that problem, so I didn't look into that further. I only have the screwy fuel gauge problem. It would be interesting to see if someone with both problems could fix or possibly alleviate the issues.

Anyone know how much a properly functioning sending unit costs? I guess if you have the dang thing pulled then you might as well replace the whole darn thing if the cost is within reason.

dragr1 · 06-01-2005, 12:55 PM

I have the fuel ligh coming on with 4-5 gallons left problem. I think the sending units are pretty expensive, I guess I'll just live with mine.

Unhappy99 · 06-01-2005, 01:22 PM

<96 Runner> if you are discussing your 96, I don't think these things apply. TSB EL010 applies to 99 and 00 4Runners. Your 96 may very likely just have a sending unit problem, not a levelling sensor circuit problem.

Anyways:

The sending units are about $80 or so I think, so they are cheap enough. It just takes the time to R&R the tank.

The pick-up tube assembly is another $80, but you don't need it. The difference between the old pick-up assembly and new one is that the new one has a shorter vent pipe, allowing the tank to fill a little more quickly as it approaches being full. No reason why you can't hacksaw your pipe an inch or so, using the photo below as reference.

See this thread and photo of pick-up tubes

MTL_4runner · 06-01-2005, 06:34 PM

Too bad you didn't take a multi meter to the sending unit output and measure resistance as you move the float arm up and down. All you would need to do to correct the guage reading (assuming the potentiometer is working.....ie varies linearly) is to add the proper value of resistor inline on the sender (this could also be done at the PCB where the sender input comes in). Then it would read correctly. If you were unsure which value of resistor to put in, you could solder a pot in line, vary the resistance to make the sender read correctly for the amount of fuel in the tank and then remove the pot, measure the resistance and then solder in the proper resistor value.

norflaballer · 06-16-2006, 02:44 PM

i didn't read every post exactly

but walking through advanced auto parts one day to get some fuel injector cleaner.... I saw a bottle in w/ the cleaners that was called fuel sensor cleaner. You pour it in ur tank like fueld injector cleaner and fill the tank and it's suppose dto clean up the sensor.. I forget who made it but i know it has a picture of a fuel sensor on it (like the little array of lines.

I am gonna go back to advanced next week and check it out... maybe pick up a bottle, b/c i am having some fuel guage problems.

--Jared

Ringmaster · 06-24-2006, 12:26 AM

Heres a TSB I found on Alldata,

Electrical EL010-99 99 & 00 4Runner

Vehicle has to be sitting on a level surface with an inclination of +/- 0.5 degrees.

1.With the ignition switch in the Off position, press and hold the trip speedometer reset button.
2. Continue pressing the reset button while turning the ignition switch to the On position.
3. Within 5 seconds of turning the ignition switch On, release the trip switch, press trip switch 3 times and on the 3rd press, hold the switch for 5 seconds. The buzzer will sound for 1 second at 800HZ.
4. After the buzzer stops, release the trip switch.
5.Press the trip switch one more time and hold for 5 seconds. Once more the buzzer will sound for 1 second at 800HZ.

Worked like a charm on mine, hopefully it will work on yours too!

HOJU · 06-24-2006, 07:24 AM

Seriously though, I wish there was something like that for 96-98 4runners.

dragr1 · 06-25-2006, 02:42 PM

Quote:

Originally Posted by Ringmaster

Heres a TSB I found on Alldata,

Electrical EL010-99 99 & 00 4Runner

Vehicle has to be sitting on a level surface with an inclination of +/- 0.5 degrees.

1.With the ignition switch in the Off position, press and hold the trip speedometer reset button.
2. Continue pressing the reset button while turning the ignition switch to the On position.
3. Within 5 seconds of turning the ignition switch On, release the trip switch, press trip switch 3 times and on the 3rd press, hold the switch for 5 seconds. The buzzer will sound for 1 second at 800HZ.
4. After the buzzer stops, release the trip switch.
5.Press the trip switch one more time and hold for 5 seconds. Once more the buzzer will sound for 1 second at 800HZ.

Worked like a charm on mine, hopefully it will work on yours too!

Is this for real? I've never heard of anything like that?

Ringmaster · 06-26-2006, 08:08 AM

Call your dealer and ask about TSB [ Technical Service Bulletin ]

EL 010-99

It is about the fuel gauge problem.

Worked great on my drop like a rock gauge.

ScubaDuck · 06-26-2006, 09:54 AM

Ringmaster-

Do you have the replacement circuit board mentioned in the TSB? I thought the code only worked with the replacement, not the original (defective) circuit board. If it works with the defective one, I am trying the code tonight!

Thanks-
Scubaduck

Ringmaster · 06-26-2006, 02:27 PM

Scubaduck, nope same old board. I thought I'd try it and see, and it works.

2000t4r · 06-27-2006, 08:53 PM

Ringmaster what did it do for you exactly? Did the gas gauge start to read correctly? How many gallons were left when the gas light came on?

I just did it tonight, I'll update in a few days.

Ringmaster · 06-28-2006, 12:51 AM

My gas gauge dropped like a rock from full to 1/2 tank, then it stabilized and dropped slowly to the empty side.

After I did the dealio with the trip meter button, the gauge acts entirely normal now, 172 miles from full to 1/2, and seem's to drop normally.

kmchby76 · 06-28-2006, 03:22 AM

Quote:

Originally Posted by norflaballer

i didn't read every post exactly

but walking through advanced auto parts one day to get some fuel injector cleaner.... I saw a bottle in w/ the cleaners that was called fuel sensor cleaner. You pour it in ur tank like fueld injector cleaner and fill the tank and it's suppose dto clean up the sensor.. I forget who made it but i know it has a picture of a fuel sensor on it (like the little array of lines.

I am gonna go back to advanced next week and check it out... maybe pick up a bottle, b/c i am having some fuel guage problems.

--Jared

norflaballer,

did you get a chance to use the fuel sensor cleaner yet? if so, does it work?

2000t4r · 06-28-2006, 07:24 AM

Quote:

Originally Posted by Ringmaster

My gas gauge dropped like a rock from full to 1/2 tank, then it stabilized and dropped slowly to the empty side.

After I did the dealio with the trip meter button, the gauge acts entirely normal now, 172 miles from full to 1/2, and seem's to drop normally.

Thank you, I did notice on the drive in to work this morning that my gas gauge is still on 3/4 of a tank. My drive in is about 52 miles, so time will tell if the reset fixed my problem.

MTL_4runner · 06-28-2006, 07:28 AM

Quote:

Originally Posted by 2000t4r

Thank you, I did notice on the drive in to work this morning that my gas gauge is still on 3/4 of a tank. My drive in is about 52 miles, so time will tell if the reset fixed my problem.

Keep us updated because it had people baffled before and it would be great if the fix were as simple as that.
.....still makes you wonder what was the true cause of the issue the fix hopefully solves.

06-01-2005, 09:32 AM	#2 (permalink)
ugadawg95 Contributing Member Join Date: Jun 2003 Location: Bethlehem, GA Posts: 1,072	Good work Christian!!! btw...I hope that's not blood on those towels? I don't have this problem now, thank god...but my 99 Tacoma did. __________________ Stephen SOLD! 99 4Runner Limited, Jade Mica. 08 4Runner Urban Runner Edition 4wd. Blizzard Pearl White...Let the mods begin!

06-01-2005, 10:02 AM	#4 (permalink)
HOJU Contributing Member Join Date: Feb 2004 Location: UTAH Posts: 1,278	it may just be the angle, but couldn't you use some cleaner, maybe acetone or something and clean the connection points? __________________ Allen- "You'll have to speak up, I'm wearing a towel..." Return With Honor

06-01-2005, 10:24 AM	#5 (permalink)
rimpainter.com Contributing Member Join Date: Jan 2003 Posts: 10,797	I don't know, but I sure as heck aint pulling that tank again if I can help it! Maybe an eraser to a pencil would work __________________ www.rimpainter.com Get your O Gasket Mod Here! My SC'd 4Runner's Profile My YouTube vids

06-01-2005, 11:24 AM	#7 (permalink)
data Senior Member Join Date: Jun 2002 Location: Arkansas Posts: 1,915	was the tank difficult to pull out? __________________ 98 Limited 4x4, Rockstomper skid, Rockware Front bumper, Warn HS9500i, 1" RB BL, Tundra coils front & OME HD rear, Nuke quick discos, diff drop'd, 305/70/16 Baja Claws, Electric Locker, couple of battle scars, but nothing major :)

06-01-2005, 11:39 AM	#8 (permalink)
rimpainter.com Contributing Member Join Date: Jan 2003 Posts: 10,797	With air tools it took me about 4 hours from start to finish. And that's with the FP install in between. __________________ www.rimpainter.com Get your O Gasket Mod Here! My SC'd 4Runner's Profile My YouTube vids Last edited by rimpainter.com; 06-01-2005 at 11:46 AM.

06-01-2005, 11:58 AM	#9 (permalink)
Unhappy99 Registered User Join Date: Sep 2003 Location: Albuquerque, NM Posts: 381	There are two independent issues: 1) Low fuel light comes on with 4-5 gallons left, instead of the 2 or so where it should. Caused by the sending unit being miscalibrated. Fixed by replacing sending unit. 2) Fuel gauge reads erradic. Caused by a faulty levelling circuit on the #3 dash panel PCB. Fixed by replacing this PCB. Somewhere I've read that the levelling circuit can be hacked and the gauge work properly, although the details of what precisely got hacked are vague. If you remove the dash panel, the levelling sensor itself is the white plastic thingy mounted on the back side with 3 small wires connecting to the gauge PCB. It could be that if the sensor were disconnected, and the gauge recalibrated via TSB EL010-99, then the gauge might work ok. I didn't try this when I replaced mine, but since I still have my old PCB, I might. __________________ 03 Dodge Ram 2500 CTD...its amazing Ex: 1999 4Runner JT3HN86R1X0199261...Now somebody elses Karl Malone Toyota 'Certified' POS Legendary Toyota quality is exactly that: A thing of legend. Defective fuel gauge - 'Certified' Defective brake rotors - 'Certified' Defective axle seals - 'Certified' Defective heater diverter - 'Certified' etc. etc. etc. Last edited by Unhappy99; 06-01-2005 at 12:02 PM.

06-01-2005, 12:55 PM	#11 (permalink)
dragr1 Contributing Member Join Date: Sep 2002 Location: Auburn, AL Posts: 3,627	I have the fuel ligh coming on with 4-5 gallons left problem. I think the sending units are pretty expensive, I guess I'll just live with mine. __________________ 1985 4Runner Dual e-lockers, dual cases, yada yada 1996 4runner, lifted, 2 lockers, 315 KM2's, IFS and more '00 Suburban 2500 4x4 '07 Tacoma Double Cab 4wd TRD '02 Lexus IS300 1991 Tiffin Allegro 31' Class A

06-01-2005, 01:22 PM	#12 (permalink)
Unhappy99 Registered User Join Date: Sep 2003 Location: Albuquerque, NM Posts: 381	<96 Runner> if you are discussing your 96, I don't think these things apply. TSB EL010 applies to 99 and 00 4Runners. Your 96 may very likely just have a sending unit problem, not a levelling sensor circuit problem. Anyways: The sending units are about $80 or so I think, so they are cheap enough. It just takes the time to R&R the tank. The pick-up tube assembly is another $80, but you don't need it. The difference between the old pick-up assembly and new one is that the new one has a shorter vent pipe, allowing the tank to fill a little more quickly as it approaches being full. No reason why you can't hacksaw your pipe an inch or so, using the photo below as reference. See this thread and photo of pick-up tubes __________________ 03 Dodge Ram 2500 CTD...its amazing Ex: 1999 4Runner JT3HN86R1X0199261...Now somebody elses Karl Malone Toyota 'Certified' POS Legendary Toyota quality is exactly that: A thing of legend. Defective fuel gauge - 'Certified' Defective brake rotors - 'Certified' Defective axle seals - 'Certified' Defective heater diverter - 'Certified' etc. etc. etc. Last edited by Unhappy99; 06-01-2005 at 01:31 PM.

06-01-2005, 06:34 PM	#13 (permalink)
MTL_4runner Contributing Member Join Date: Jul 2003 Location: Montreal, QC Canada Posts: 8,807	Too bad you didn't take a multi meter to the sending unit output and measure resistance as you move the float arm up and down. All you would need to do to correct the guage reading (assuming the potentiometer is working.....ie varies linearly) is to add the proper value of resistor inline on the sender (this could also be done at the PCB where the sender input comes in). Then it would read correctly. If you were unsure which value of resistor to put in, you could solder a pot in line, vary the resistance to make the sender read correctly for the amount of fuel in the tank and then remove the pot, measure the resistance and then solder in the proper resistor value. __________________ - Jamie 1996 4Runner SR5 4X4 Auto Deckplate Mod, Hayden Tranny Cooler, Amsoil Air Filter, OME 881/906 N86C/N91SC Lift Best OBD II scan tool I have used!. .....and I am AMERICAN!

06-16-2006, 02:44 PM	#14 (permalink)
norflaballer Registered User Join Date: Mar 2006 Location: Jacksonville, FL Posts: 72	i didn't read every post exactly but walking through advanced auto parts one day to get some fuel injector cleaner.... I saw a bottle in w/ the cleaners that was called fuel sensor cleaner. You pour it in ur tank like fueld injector cleaner and fill the tank and it's suppose dto clean up the sensor.. I forget who made it but i know it has a picture of a fuel sensor on it (like the little array of lines. I am gonna go back to advanced next week and check it out... maybe pick up a bottle, b/c i am having some fuel guage problems. --Jared __________________ 98' SR5 4x4 #65

06-24-2006, 12:26 AM	#15 (permalink)
Ringmaster Registered User Join Date: Jun 2006 Location: Spokane Valley Washington Posts: 814	Heres a TSB I found on Alldata, Electrical EL010-99 99 & 00 4Runner Vehicle has to be sitting on a level surface with an inclination of +/- 0.5 degrees. 1.With the ignition switch in the Off position, press and hold the trip speedometer reset button. 2. Continue pressing the reset button while turning the ignition switch to the On position. 3. Within 5 seconds of turning the ignition switch On, release the trip switch, press trip switch 3 times and on the 3rd press, hold the switch for 5 seconds. The buzzer will sound for 1 second at 800HZ. 4. After the buzzer stops, release the trip switch. 5.Press the trip switch one more time and hold for 5 seconds. Once more the buzzer will sound for 1 second at 800HZ. Worked like a charm on mine, hopefully it will work on yours too! Last edited by Ringmaster; 06-24-2006 at 12:30 AM.

06-24-2006, 07:24 AM	#16 (permalink)
HOJU Contributing Member Join Date: Feb 2004 Location: UTAH Posts: 1,278	Seriously though, I wish there was something like that for 96-98 4runners. __________________ Allen- "You'll have to speak up, I'm wearing a towel..." Return With Honor

06-26-2006, 08:08 AM	#18 (permalink)
Ringmaster Registered User Join Date: Jun 2006 Location: Spokane Valley Washington Posts: 814	Call your dealer and ask about TSB [ Technical Service Bulletin ] EL 010-99 It is about the fuel gauge problem. Worked great on my drop like a rock gauge.

06-26-2006, 09:54 AM	#19 (permalink)
ScubaDuck Registered User Join Date: Feb 2005 Location: Clyde, CA Posts: 107	Ringmaster- Do you have the replacement circuit board mentioned in the TSB? I thought the code only worked with the replacement, not the original (defective) circuit board. If it works with the defective one, I am trying the code tonight! Thanks- Scubaduck

06-26-2006, 02:27 PM	#20 (permalink)
Ringmaster Registered User Join Date: Jun 2006 Location: Spokane Valley Washington Posts: 814	Scubaduck, nope same old board. I thought I'd try it and see, and it works.

06-27-2006, 08:53 PM	#21 (permalink)
2000t4r Registered User Join Date: Nov 2004 Location: Norcal Posts: 373	Ringmaster what did it do for you exactly? Did the gas gauge start to read correctly? How many gallons were left when the gas light came on? I just did it tonight, I'll update in a few days.

06-28-2006, 12:51 AM	#22 (permalink)
Ringmaster Registered User Join Date: Jun 2006 Location: Spokane Valley Washington Posts: 814	My gas gauge dropped like a rock from full to 1/2 tank, then it stabilized and dropped slowly to the empty side. After I did the dealio with the trip meter button, the gauge acts entirely normal now, 172 miles from full to 1/2, and seem's to drop normally.

Thread Tools	Search this Thread
Show Printable Version Email this Page	Search this Thread: Advanced Search

Similar Threads
Thread	Thread Starter	Forum	Replies	Last Post
Fuel Gauge Problem	4runamok	95.5-2004 Tacomas & 96-2002 4Runners	3	07-04-2007 05:59 AM
'99 With Dreaded Fuel Gauge Problem....	99whiteSR5	95.5-2004 Tacomas & 96-2002 4Runners	31	09-14-2005 12:36 PM
Fuel gauge problem solved(?)	cracker_1	95.5-2004 Tacomas & 96-2002 4Runners	6	09-07-2005 08:55 AM
3rd Generation Fuel Gauge Problem	k_r_o_w	Maintenance & Repair Archives	14	05-19-2005 04:28 PM
3rd gen Fuel gauge	JDeMello	95.5-2004 Tacomas & 96-2002 4Runners	8	12-10-2003 06:54 AM