Fuel tank empty but still 20L inside the tank

[Fabrieg]

Hello,

my name is Fabian, and I’m from Germany. I’ve joined this forum because my 2012 3.0D automatic Hilux is driving me crazy.

The issue is that my Hilux’s engine always shuts off as soon as the fuel gauge reaches about 1/4. Sometimes it has also happened when the gauge was just slightly above 1/4.
The problem is that when I go to refuel afterward, I can only fill up 50 liters (I usually add about 5-10 liters with a jerrycan before refueling). According to my research, this means there are still around 20-25 liters missing.
What’s strange is that shortly after I bought the car about six months ago, I was able to fill up almost 70 liters.

Here’s what I’ve done or checked so far:

- I replaced the fuel sender unit because I initially thought it was defective. However, it’s not an original part but a replacement from "Hitachi".
- The instrument cluster was checked multiple times, and all resistors were resoldered.
- I removed the tank breather valve on top of the tank to check for blockages. I can blow through it with my mouth in both directions, although one direction is harder than the other.
- I inspected the tank for deformations but couldn’t find any.
- I checked the connector under the seat for moisture.

I have also read other posts, but I have not found a real solution.
I’m really at a loss and am close to buying a new tank and a new fuel sender unit.
Maybe someone has had the exact same issue and can tell me what the problem was.

[Rob_Wood]

Has there been any repairs to holes in the tank? The reason for asking is to discover if a silicone product has ever been used to patch, repair or reseal any part of the tank?
Petroleum products (like petrol & diesel) don't go well with silicone products, like silastic gasket or other silastic products. The petroleum products make the silicone products expand exponentially, taking up a large percentage of a fuel tank for example.

[Fabrieg]

Hey Rob,

no when I replaced the fuel sender unit I could not see any silicone or sealant. As it looked to me, the tank had never been dropped before.

[ptommo59]

Hi Fabian,

When you checked the sender unit and tank did you look at the white plastic slosh baffle at the bottom of the pick up?

It has holes at the bottom with a rubber flap to allow fuel to enter but not exit after the tank empties past the top of it.
There have been cases of these holes becoming blocked with debris or the flap pushing through and reversing its function. In both of these cases you lose access to the fuel in the bottom 1/3 - 1/4 of the tank and as a result the engine will get fuel starvation from about 1/3-1/4 tank on the gauge.

Worth a check.

[dave g]

There is a post same where on here off the dashboard having dry joints on the fuel gauge
Do a search on fuel gauge its in there same where.