FCM Problem ::FIXED::

[fplucid]

Just pinged all capacitors' ends - linkes are ok everywhere. Ok, it will try to re-solder these, but this will be really difficult.
BTW, 2 left capacitors have 310 (or something like this) marker, right one is brown without markers - is this ok (see photo)?
Can you please provide information for voltages on bottom ends of left and right capacitors in both modes, if it is not difficult. I will try to check this as well - maybe problem is somewhere deeper.

[Richard L]

The unmarked parts are capacitors, the rest are resistor. They are not too important.

The next step. Put jumper on as below:

MPS = unlinked
IDC = linked
PRK = unlinked
TST = linked
INJ = unlinked (disable the FCM)

Please measure the voltages 1, 2,and 3. The voltage should all be over 5V. If they are, the pump relay should turn on.

[fplucid]

Voltage there is twice higher than on left leg of transistor: ~2,50-2,58 in "TST"
Voltage halves on legs of left capacitor twice to 1,25-1,29.

Funny thing is that when I shorten lower legs of left and middle capacitor (equals shortening left capacitor), voltage of 2,58 is coming directly to left leg of transistor and pump begis to work! Unlinking "TST" drops voltage to 0,8 and pump is not working. This means system begins to function properly.

So what will you advice? Does constant shortening of legs of left capacitor makes sense?

[Richard L]

I don't want to go into another direction. Is it possible for you to give me the voltages on location 1,2 and 3 as requested?

[fplucid]

1 - 2,60
2 - 2,60
3 - 3,10

[Richard L]

This is interesting, Those voltages are too low to turn the transistor on. It should be in the region of 5-7 volts. We have some how lost some voltage somewhere on the "TST" link.

There are three possibilities this voltage can be interfered with, I can rule out two of them by:

1. Removing the gauge harness
2. Removing the Pump harness.

Please now measure location 3...

[fplucid]

1 - 3,10
2 - 3,10

[Richard L]

Can you tell me if all the leds on the controller are still lit?

[Richard L]

Please remove this transistor. This transistor does nothing useful. It is intended for a handheld tester but never put into production.

[fplucid]

It worked! Finally. After removing the transistor voltage jumped to 7+V and everything is functioning properly. Thank you very much, Richard, problem is resolved at last.
So is it ok to run system w/o this transistor?
Tomorrow I will try to make a test run to be sure everything is fine.
Thanks again!