Toyota Hilux 1KD Fuel Gauge Malfunction

Toyota Hilux KUN26, 1KD engine, Fuel Gauge does not drop below approximately a quarter full and vehicle has run out of fuel. I test the fuel sender at the combination meter and confirm fuel gauge is faulty and combination meter requires repair.
CAUTION: This video depicts engine running while the bonnet is open, this is performed by trained personnel aware of the dangers of reciprocating engine parts. To avoid serious injury or death, we strongly advise to carry out engine bay inspection with engine turned OFF.

[@patrickburton6130]

Same issue with my 2015 model, will be reflowing the solder joints.

[@randyh5465]

Thank you for the post. It has help me out. The issue was in the instrument cluster. Reflowed some solder on resisters located on the instrument cluster circuit board and that repaired the fuel gauge issue. Keep posting videos on Toyota's repairs. You are helping a lot of DIY out there.

[@nunawadingtoyota8134]

Great feedback. Thank you.😀

[@kalindambozi2356]

Very common problem with Toyota Hilux. Test procedure is correct. I have repaired 5 cluster's so far. Takes about 20 minutes.

[@maxgermasi3302]

Awesome process of fault finding!
Toyota is the best when it come to processes methodology.
Thanks for sharing it Darrek.

[@nunawadingtoyota8134]

Thank you Max. 🙂

[@jenkodiesel5768]

Good to see a dealership not manned by apprentices . Real shame that we’ve come to a point where we have to warn people that you need to be trained to open the bonnet when the engine is running.

[@nunawadingtoyota8134]

Thanks for the comment🙂
That is unfortunately the sad state of affairs.

[@timkeen619]

I have a 15 and 16 plate invincible with the same problem, you run out of diesel on quarter of a tank , A guy who works for me has a 13 plate hi lux that does the same. A very common issue

[@jozefszoke2547]

I have no power to the pump at all, nor can I measure the circumference of the pump cables.Then I found out that there is no pump in the tank of the car, even though the cables run there.

[@dodoymonde4664]

hard starting

[@sburtoffski]

Great video, very informative. I have this problem with mine. How long does it take to send away the gauge cluster to get it repaired? I figure the vehicle is not drivable in the meantime? Cheers

[@nunawadingtoyota8134]

Thanks so much for visiting our channel and subscribing😀
Turnaround time for this repair is normally 2 days. We drop it off with the repairer and pick it up. You can continue to drive the vehicle until you remove the combination meter to get it repaired, provided you keep track of the fuel you use.

[@garyn1360]

I have this problem ( wouldn’t go below 1/4) I disconnected the plug from the top of the tank and the gauge dropped to empty with light on. Does this mean it’s the sender unit ?

[@radeshcheyanand2147]

Awesome video, excellent detail. Can you show how to fix the gauge please... thanks

[@nunawadingtoyota8134]

Hi
Thanks for the kind comment. 🙂

[@TheMirrorify]

Great video, I think mine has this issue, although it seems better since I disconnected the battery to replace it, maybe it reset?
What is the rough cost of the gauge repair?
Cheers.

[@nunawadingtoyota8134]

Hi,
Thanks so much for the comments. Last time we sent one away for repairs it was $250.

[@TheMirrorify]

@@nunawadingtoyota8134 awesome, thanks for responding so quickly, great info in this video too.
Cheers.

[@godiraonemoaro6114]

After reconnecting the cluster, the rev count and fuel gauge pointers go below 0 and Empty and not moving but the speedometer is working well.. help

[@nunawadingtoyota8134]

Have you had it repaired?

[@godiraonemoaro6114]

@@nunawadingtoyota8134 no luck … what’s the process calibrating it so tht the rpm pointer starts at zero n fuel gauge starts at E