T4R_Canuck
Member
** UPDATE #2....Solution Found ** So I finally gave up and brought this into a local dealer for diagnosis and they found the issue, which was quite unique. It appears that when my fuel pump recall was performed, approximately 2 months prior to me buying this vehicle, the fuel pump was disassembled and then reassembled incorrectly. It looks like the tech who did my recall rotated the bottom of the pump 180 degrees before reassembling the unit which then wedged the fuel pump float up against the drivers side of the fuel tank, instead of allowing it to float while pointing towards the middle of the tank.
The tech at the dealer came out to explain what he found and I showed him pictures of when I had the pump out to change the fuel sending unit. He confirmed that what he saw in the picture was the pump assembled incorrectly and that he disassembled it, rotated the top plate and fixed the problem. As an average Joe, I had no idea it was assembled wrong when I changed the fuel sending unit so it didn't occur to me that it could be the problem.
Needless to say, I have all the original service records from the vehicle, which show that the only time in its history that the fuel pump was touched was during the recall, pictures of the pump assembled incorrectly after being removed again to diagnose and the dealer who found the problem stated on my invoice that the problem was the incorrect assembly of the fuel pump. So, I'm going to contact the dealer who performed the recall on the fuel pump, speak to the service manager and plead my case to have some or all of my out of pocket expenses for this repair reimbursed, as it was specifically caused by the tech who performed the fuel pump recall. If that doesn't accomplish much, I will contact Toyota Canada Customer Service and file a complaint. I should have enough documentation to show that this was negligence. Here's hoping I recoup some of my out of pocket costs.
**UPDATE #1** I accessed the fuel pump connection through the rear seat to verify the exterior electrical connection was sound. The connection from the vehicle returned 1.28volts in the circuit that leads to the fuel pump sending unit while the connection from the vehicle to the fuel pump itself returns 10volts. The fuel pump sending unit shows no resistance when tested using the leads on the connection outside the tank. It looks like I have to drop my tank again to verify that I properly connected the electrical connector to the pump housing, as its reading like an open circuit currently. Alternatively, less likely thought, the new sending unit is also dead.
Original Post:
Gentlemen and Ladies, I seek your input.
Picked up a used T4R Trail Premium and noticed the fuel gauge only worked between full and 3/4 tank, then was stuck. Diagnosed it, with help from this forum, as a faulty fuel gauge sending unit so after a long wait for the part I pulled the tank and replaced it yesterday.
Upon startup I noticed that the fuel gauge now sits on Empty with the fuel light on and does not move when fuel is added. I've paid to access TIS and bench tested the old unit as it suggests. Resistance tests shows no reading between the 3/4 tank mark down to empty, so the unit itself was bad as far as I can tell.
My only thought is that a wire on the electrical plug on top of the tank was pulled out, pinched, etc and is now not sending any info to the fuel gauge. I'm about to pull the rear seats and try to access this plug to test my theory.
Any other thoughts on what the problem could be?? I'm assuming the fuel gauge is working fine as it was working prior to the job being performed.
the 4Runner starts and drives perfectly normal after the "repair".
Appreciate any feedback anyone can provide!
The tech at the dealer came out to explain what he found and I showed him pictures of when I had the pump out to change the fuel sending unit. He confirmed that what he saw in the picture was the pump assembled incorrectly and that he disassembled it, rotated the top plate and fixed the problem. As an average Joe, I had no idea it was assembled wrong when I changed the fuel sending unit so it didn't occur to me that it could be the problem.
Needless to say, I have all the original service records from the vehicle, which show that the only time in its history that the fuel pump was touched was during the recall, pictures of the pump assembled incorrectly after being removed again to diagnose and the dealer who found the problem stated on my invoice that the problem was the incorrect assembly of the fuel pump. So, I'm going to contact the dealer who performed the recall on the fuel pump, speak to the service manager and plead my case to have some or all of my out of pocket expenses for this repair reimbursed, as it was specifically caused by the tech who performed the fuel pump recall. If that doesn't accomplish much, I will contact Toyota Canada Customer Service and file a complaint. I should have enough documentation to show that this was negligence. Here's hoping I recoup some of my out of pocket costs.
**UPDATE #1** I accessed the fuel pump connection through the rear seat to verify the exterior electrical connection was sound. The connection from the vehicle returned 1.28volts in the circuit that leads to the fuel pump sending unit while the connection from the vehicle to the fuel pump itself returns 10volts. The fuel pump sending unit shows no resistance when tested using the leads on the connection outside the tank. It looks like I have to drop my tank again to verify that I properly connected the electrical connector to the pump housing, as its reading like an open circuit currently. Alternatively, less likely thought, the new sending unit is also dead.
Original Post:
Gentlemen and Ladies, I seek your input.
Picked up a used T4R Trail Premium and noticed the fuel gauge only worked between full and 3/4 tank, then was stuck. Diagnosed it, with help from this forum, as a faulty fuel gauge sending unit so after a long wait for the part I pulled the tank and replaced it yesterday.
Upon startup I noticed that the fuel gauge now sits on Empty with the fuel light on and does not move when fuel is added. I've paid to access TIS and bench tested the old unit as it suggests. Resistance tests shows no reading between the 3/4 tank mark down to empty, so the unit itself was bad as far as I can tell.
My only thought is that a wire on the electrical plug on top of the tank was pulled out, pinched, etc and is now not sending any info to the fuel gauge. I'm about to pull the rear seats and try to access this plug to test my theory.
Any other thoughts on what the problem could be?? I'm assuming the fuel gauge is working fine as it was working prior to the job being performed.
the 4Runner starts and drives perfectly normal after the "repair".
Appreciate any feedback anyone can provide!
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