Took our first long trip in our 94 FZJ (we bought it over the summer and have driven it close to home to see how it does). Got down to a half tank of fuel and the low fuel light came on. Thought it may be due to grade changes on the freeway but the light never went away. About 15 minutes later the engine started sputtering as if it was running out of gas and then it would run fine for a few moments before doing it again getting more frequent. Of course, we were 20 plus miles from gas. With white knuckles we pulled into a station and filled up, it only needed 18 gallons, and the problem went away. We haven't let the tank get that low again to see if it repeats. History: two weeks after we bought the cruiser we had to replace the gas tank with a used one due to a crack in the upper part of the tank that leaked fuel when completely full. That was six months ago. This is new to me so any advice is much appreciated and we're still on our trip. Cheers
Low fuel warning light on a 1/2 tank of gas
- Thread starter Seppe
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Sounds like someone opened the tank access port to pull the pump and maybe replace the fuel stock and bent the metal arm that holds the flat to give fuel readings. You could open the tank up and try and bend it back.
ppc
M Go Blue
I remember a post a few months ago with something similar. I would look for wiring issues on the pump support, inside the tank that was not properly routed/secured causing the insulation to be worn through by sharp edges on the support bracket.
What they said. Sometime back I removed my pump to replace the sock filter and since then my fuel gauge reads full and never moves. I have taken the pump out a few more times to free the float and it appears to work until I fill up and then the arm gets stuck again at the top. The low fuel lights works on its own wiring and does not use the float...
So yes, it could be the float getting stuck or an electrical issue with the connections but, believe in the low fuel light since its circuit is separate...
So yes, it could be the float getting stuck or an electrical issue with the connections but, believe in the low fuel light since its circuit is separate...
- Thread starter
- #6
@jwilber: Although I was amped on adrenaline I'm pretty sure there was pressure in the tank. I know for a fact there has been pressure from the last two fill ups.
One thing I didn't mention was the accelerated rate the needle dropped from 1/2 to 1/4(ish) tank once the sputtering started.
One thing I didn't mention was the accelerated rate the needle dropped from 1/2 to 1/4(ish) tank once the sputtering started.
Bent tank causing baffle to hang up with float or someone messed up the float arm installing the sender. I lightly massaged my tank which caused the first problem. Pulled the sender three times slightly tweaking the float to the front, back and slightly more til it worked smoothly inside the tank once again without rubbing.
The low fuel light uses its own wiring and sensor so its seperate from the level sending unit. Electrical problem would most likely cause it to read low(open circuit/high resistance) or read over full (shorted).
Internal tank pressure would be extremely unlikely to cause this sort of problem.
The low fuel light uses its own wiring and sensor so its seperate from the level sending unit. Electrical problem would most likely cause it to read low(open circuit/high resistance) or read over full (shorted).
Internal tank pressure would be extremely unlikely to cause this sort of problem.
lrowe_csp
Too many cruisers, not enough time
It is really easy to get into the tank port by unbolting and removing the middle row seat. The carpet seam between front and rear is under the rear of the front seats, pull the carpet back. You will see the panel that covers the tank, unbolt it and open the tank, pull out the sender, check the wiring and the sender float, replace the sock filter while you are in there and inspect the interior of the tank (call Cdan or Beno to order this sock filter and possibly a new gasket before you start work). This is all easily done in a couple of hours, and is best done with an almost empty tank so you can see the interior of the tank better. HTH
- Thread starter
- #9
Thanks to all the replies. Y'all have painted a good picture to help guide me along. Since the new tank is used I can't attest to its condition and can only hope it isn't causing the problem. Funny how the problem surfaced when on a long trip with the family. We are currently on our vacation and trying to run the fuel level down around civilization to see if the problem repeats before heading up to the mountains to play in the snow. Cheers!
I'm messing with my tank now, going diesel. The fuel pump attaches to the fuel line by a short piece of hose and its about 1/2 tank height, if there's a leak there it could loose pressure and cause the sputtering. I can grab pics tomorrow if you want.
