METER / GAUGE SYSTEM Fuel Receiver Gauge Malfunction

WIRING DIAGRAM

B007OSSE02

INSPECTION PROCEDURE

Note

Be careful of flames.

PROCEDURE


  1. PERFORM ACTIVE TEST USING GTS (FUEL METER OPERATION)


    1. Use the Active Test to check the operation of the fuel receiver gauge Click here.

      Combination Meter
      Tester Display Test Part Control Range Diagnostic Note
      Fuel Meter Operation Fuel receiver gauge OFF, Sender E, Empty, Warning, 1/4, 1/2, 3/4, Full or Sender F -
      OK
      Fuel receiver gauge is normal.

    NG

    REPLACE COMBINATION METER ASSEMBLY Click here

    OK

  2. READ VALUE USING GTS (FUEL INPUT)


    1. Use the Data List to check if the fuel receiver gauge is operating properly Click here.

      Combination Meter
      Tester Display Measurement Item/Range Normal Condition Diagnostic Note
      Fuel Input Fuel input signal/Min.: 0, Max. 127.5 Current fuel level displayed Unit: Liters
      OK
      Fuel amount value displayed on the GTS is almost the same as needle indication.
      Result
      Result Proceed to
      NG A
      OK (Engine Type Diesel) B
      OK (Engine Type Gasoline) C

    B

    CHECK HARNESS AND CONNECTOR (COMBINATION METER ASSEMBLY - FRONT FUEL MAIN AND RETURN TUBE SUB-ASSEMBLY) Click here

    C

    CHECK HARNESS AND CONNECTOR (COMBINATION METER ASSEMBLY - FRONT FUEL MAIN AND RETURN TUBE SUB-ASSEMBLY) Click here

    A

    REPLACE COMBINATION METER ASSEMBLY Click here

  3. CHECK HARNESS AND CONNECTOR (COMBINATION METER ASSEMBLY - FRONT FUEL MAIN AND RETURN TUBE SUB-ASSEMBLY)


    1. Disconnect the H20 combination meter assembly connector.

    2. Disconnect the h1 front fuel main and return tube sub-assembly connector.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      H20-33 (FUEL) - h1-2 Always Below 1 Ω
      H20-34 (E2) - h1-3
      H20-33 (FUEL) or h1-2 - Body ground Always 10 kΩ or higher
      H20-34 (E2) or h1-3 - Body ground

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  4. INSPECT FRONT FUEL MAIN AND RETURN TUBE SUB-ASSEMBLY


    1. B007P1GE11

      Remove the front fuel main and return tube sub-assembly.


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

      Standard Resistance
      Tester Connection Condition Specified Condition
      A-2 - B-2 Always Below 1 Ω
      A-3 - B-1
      Result
      Result Proceed to
      OK A
      NG (for 1KD-FTV) B
      NG (for 2KD-FTV) C
      NG (for 5L-E) D
      NG (for 1GD-FTV) E

    B

    REPLACE FRONT FUEL MAIN AND RETURN TUBE SUB-ASSEMBLY Click here

    C

    REPLACE FRONT FUEL MAIN AND RETURN TUBE SUB-ASSEMBLY Click here

    D

    REPLACE FRONT FUEL MAIN AND RETURN TUBE SUB-ASSEMBLY Click here

    E

    REPLACE FRONT FUEL MAIN AND RETURN TUBE SUB-ASSEMBLY Click here

    A

  5. INSPECT FUEL SENDER GAUGE ASSEMBLY


    1. B007V6KE01
      Text in Illustration
      *a F (Upper)
      *b E (Lower)

      Remove the fuel sender gauge assembly.


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

      Standard Resistance
      Tester Connection Condition Specified Condition
      1 - 2 Float level is F (upper) 13.5 to 16.5 Ω
      Float level is E (lower) 405.5 to 414.5 Ω
      Result
      Result Proceed to
      OK A
      NG (for 1KD-FTV) B
      NG (for 2KD-FTV) C
      NG (for 5L-E) D
      NG (for 1GD-FTV) E

    B

    REPLACE FUEL SENDER GAUGE ASSEMBLY Click here

    C

    REPLACE FUEL SENDER GAUGE ASSEMBLY Click here

    D

    REPLACE FUEL SENDER GAUGE ASSEMBLY Click here

    E

    REPLACE FUEL SENDER GAUGE ASSEMBLY Click here

    A

    REPLACE COMBINATION METER ASSEMBLY Click here

  6. CHECK HARNESS AND CONNECTOR (COMBINATION METER ASSEMBLY - FRONT FUEL MAIN AND RETURN TUBE SUB-ASSEMBLY)


    1. Disconnect the H20 combination meter assembly connector.

    2. Disconnect the h2 front fuel main and return tube sub-assembly connector.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      H20-33 (FUEL) - h2-2 Always Below 1 Ω
      H20-34 (E2) - h2-3
      H20-33 (FUEL) or h2-2 - Body ground Always 10 kΩ or higher
      H20-34 (E2) or h2-3 - Body ground

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  7. INSPECT FRONT FUEL MAIN AND RETURN TUBE SUB-ASSEMBLY


    1. B007P1GE11

      Remove the front fuel main and return tube sub-assembly.


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

      Standard Resistance
      Tester Connection Condition Specified Condition
      A-2 - B-2 Always Below 1 Ω
      A-3 - B-1
      Result
      Result Proceed to
      OK A
      NG (for 1TR-FE) B
      NG (for 2TR-FE) C

    B

    REPLACE FRONT FUEL MAIN AND RETURN TUBE SUB-ASSEMBLY Click here

    C

    REPLACE FRONT FUEL MAIN AND RETURN TUBE SUB-ASSEMBLY Click here

    A

  8. INSPECT FUEL SENDER GAUGE ASSEMBLY


    1. B007V6KE01
      Text in Illustration
      *a F (Upper)
      *b E (Lower)

      Remove the fuel sender gauge assembly.


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

      Standard Resistance
      Tester Connection Condition Specified Condition
      1 - 2 Float level is F (upper) 13.5 to 16.5 Ω
      Float level is E (lower) 405.5 to 414.5 Ω
      Result
      Result Proceed to
      OK A
      NG (for 1TR-FE) B
      NG (for 2TR-FE) C

    B

    REPLACE FUEL SENDER GAUGE ASSEMBLY Click here

    C

    REPLACE FUEL SENDER GAUGE ASSEMBLY Click here

    A

    REPLACE COMBINATION METER ASSEMBLY Click here