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  • Fuel Supply Problem -diesel

    Hope someone can help. The Prado stalled whilst driving at about 60kph. The fuel guage indicated about half full on the second tank(but the green light went out??). Trying to start - it would result in about 30 seconds of life and then dying. Fuel filter not the problem. Turned out it appeared to have run out of fuel. However, when filling up it would now only take a total of about 90 litres. When trying to fill, it has significant blow back and not accept more fuel. It seems like one of the tanks is full , but not transferring to the other tank. Not sure whether the problem may be the pump which cycles fuel from one tank to the other, or the primary fuel pump or the fuel guage as well as one of the pumps. The guage seems to operate OK, except that I have no confidence in what it telling me? Any recommendations - before I have to rip out both tanks to find out what is going on? Thanks

  • #2
    Re: Fuel Supply Problem -diesel

    Havnt heard of it in the prado but my holden used to get some sort of airlock thing going on and you could only fill the tank half way. I used to have to rock the car when it did this then i could put more fuel in, just a thought??

    Is it a 90 or 120 series as i think the fuel between the tanks is managed differently between the models
    Dont list all ya mods, you will only be more upset when i get further

    Comment


    • #3
      Re: Fuel Supply Problem -diesel

      Thanks - it is a 2007 120 D4D model, auto. Currently it will not accept fuel into the filler from a bowser - just froths up. I suspect that one of the tanks is full and the fuel is not transferring from tank to tank. Do you know where I can view a diagram of the fuel tanks, pumps and fuel lines?

      Comment


      • #4
        Re: Fuel Supply Problem -diesel

        try here and go through the information

        http://www.toyodiy.com/parts/q_G_2007_T ... DJ120.html
        Manata 3" Exhaust, Blisten shocks, King Springs 50 mm lift, Poly Air Bags, Roof Rack, Iron Man Bull Bar, HID 50W LightForce XGT spotties, Daul Batteries, GME TX3440 & AE4705 ant, Upgraded window washer, Bonnet Scoop, Tunit chip, bonnet protector, headlight protector, Cooper STT's, ScangaugeII, Dash Mat, Endless Air, Stebel Nautilus, Diff Breathers, Water Sedimentor. ([b]Camprite TL8s [/b] Arrived ALIVE~!)

        Comment


        • #5
          Re: Fuel Supply Problem -diesel

          Hi Rob

          From what I can gather there are 2 filters in the D4D, 1 in the engine bay, and 1 between the 2 tanks, more info here How many fuel filters

          Maybe the 1 between the tanks is blocked causing transfer issues.

          Matt
          2003 Prado Grande TD Auto Pearl White

          Comment


          • #6
            Re: Fuel Supply Problem -diesel

            Hello all
            I have resolved the problem, so here are the symptoms and solution for anyone to learn from.
            The problem was the fuel pump which is in the main tank(central underbody one). This pump does nothing except pump fuel out, through another fuel filter (underbody, next to main tank - small black one)and back into the same main tank, passing through a venturi valve at the same time. This pump and venturi valve are all in the same pump housing inside the tank.The assembly/housing also has a fuel level switch attached as well.This pump runs all the time your motor is on. Its only function is to pass fuel through the venturi valve, which creates a suction, sucking fuel from the back tank to the front tank. It does not pump fuel to the front filter or the injector pump. The motor sucks fuel only from the front/main tank. If the pump in the main tank stops working (or the inline fuel filter that it runs through is blocked - as another writer suggested) then there will be no fuel supplied from the rear tank and sooner or later the front tank will run dry. When that happens, the motor stops. There must be two fuel gauge senders, one which shows when the rear tank has no fuel. When you finally figure out that you have run out of fuel, despite your gauge showing that you may have say half a tank - the first thing you do is fill up - probably both tanks. When you do this, the back tank remains full and the motor drains only the front tank. 90 litres or so later you will run out again, despite there being 90l in the back tank. To make things worse, when you go to the garage to fill up, the bowser will not take any fuel - just goes into blowback mode. The reason is that the main fuel vent relief runs between tanks and with the back tank at peak level , the airflow is blocked(fuel blocks it). Thus you can't put fuel in, because you can't get any air out. You can trickle fuel in with a jerry can to get by and get you moving. Apparently you can get a replacement pump $700-800 or you replace the whole unit - about $1200-1300(all plus labor).I decided to replace the whole assembly. The smart thing for Toyota to do would have been to have the pump as an inline pump mounted externally. So if it failed it could easily be replaced , particularly if you were in a remote location. It is probably possible to trace the lines and install an inline pump externally, but I did not have time or incentive to do this. If you were taking a Prado into the outback I suggest you do this - or take a spare pump(as well as spare fuel filters). It would not be an easy job to get the small pump out of the whole assembly, just because it is fiddly. It is not much good going to Toyota as after three of the main dealers in Perth, they did not know how the fuel system works, that the vehicle actually had two fuel filters or why the symptoms were happening. It is not hard to replace the fuel pump assembly - just drop the main tank, making sure you don't get the lines confused, remove the pump from the tank and put the new one in, hook it all up again and all should be good.

            Don't get stuck - and thanks to all the suggestions.

            Comment


            • #7
              Re: Fuel Supply Problem -diesel

              Thank you...not a bad write up and I am sure it will help one and all in the future. Was there any crap in the tank that casued the failure or did the part just fail?
              Manata 3" Exhaust, Blisten shocks, King Springs 50 mm lift, Poly Air Bags, Roof Rack, Iron Man Bull Bar, HID 50W LightForce XGT spotties, Daul Batteries, GME TX3440 & AE4705 ant, Upgraded window washer, Bonnet Scoop, Tunit chip, bonnet protector, headlight protector, Cooper STT's, ScangaugeII, Dash Mat, Endless Air, Stebel Nautilus, Diff Breathers, Water Sedimentor. ([b]Camprite TL8s [/b] Arrived ALIVE~!)

              Comment


              • #8
                Re: Fuel Supply Problem -diesel

                [quote="robktm"]
                An excellent description "robktm", I hope members read this.
                07 Upgrade GXL D4D, Manual, Dune,Sov Bar, BFG's, SG11, Redark dual Batts, Extensive Aux wiring, Stebel, LED stop tails, IPF HID's (my mod), 240V Inv, ARB Comp, GME UHF,TPMS, Safari snorkel, GPS,Hilux washers, 40l Engel in 30% pas pos,homemade A/C cond protection plate, polyairs.

                Comment


                • #9
                  Re: Fuel Supply Problem -diesel

                  Brilliant that I came across this.

                  Two weeks ago, I broke down with my 08 VX D4D and I had to get a tow to a well established Diesel Expert in the Southern Highlands of NSW. Anyhow, they reckoned it was fuel contamination. Not having pradopoint handy at the time, I had to go with it. $500 later for just a fuel dump and replace, plus labour - just yesterday the same thing happened. Fortunately I was not too far away from a computer to check up and I came across this post - well I ducked down and got 2 jerry cans full of diesel and gave it a go. Wella - we ran well. AND when I tried to fill up completely I had the same frothing issue.

                  So - if you konk out with about 45 - 60 litres left it may well be this issue so try and fill up first - prime the fuel pump and give it another go. Saves $500 for a mechanics labour.

                  Thanks robktm - this post was a life and money saver for me.... a little later than I would have hoped but anyhow. Will see about the replacement cost of the pump though :cry: .
                  Burger
                  2008 D4D VX, Burnt Ash... Sovereign Bar, Light Force 140's, Rear Kaymar Work/Camplight, ORS Drawers, Cargo Barrier, Entertainment for the Kids, Entertainment for me and the Missus - Polaris NextGen, Sheepskin Covers, Snorkel... can't think what else! To come - Sliders, Under body protection, Diff breathers, Winch.

                  Comment


                  • #10
                    Re: Fuel Supply Problem -diesel

                    If amyome is intrestd in the outcome of this for me - never know it may happen to you. Yes, bad diesel. Anyhow, my mechanic dropeed the fuel tank and pulled the puymp out. It was squealing like crazy and the gauze filters were blocked with black gunk. Anyhow, he could not source a new pump quickly so he pulled it apart and put it back together and after that, all is good! I've now done about 10,000k's ater and had no problems since.

                    Just in case you come across it!
                    Burger
                    2008 D4D VX, Burnt Ash... Sovereign Bar, Light Force 140's, Rear Kaymar Work/Camplight, ORS Drawers, Cargo Barrier, Entertainment for the Kids, Entertainment for me and the Missus - Polaris NextGen, Sheepskin Covers, Snorkel... can't think what else! To come - Sliders, Under body protection, Diff breathers, Winch.

                    Comment


                    • #11
                      I am another one caught out by my dealership not replacing the underbody fuel filter during servicing. Car slowly died at the side of the road 140k south of Blackall, requiring a tow truck to carry the Prado and tow the van to the RACQ contractor's workshop. (Fortunately we have Ultimate cover with RACQ which allows for up to 200k towing to the contractor's premises).

                      The next day they managed to prime the fuel pump and then fill the tank, so we could get on our way. The only problem is that we could not get the car in to the 2 nearest Toyota dealers for 2 weeks to have the problem rectified. (Maybe I should book services at Toyota dealers in the country in advance for my ETA at their location just in case I have any problems). Managed to get a booking back in Brisbane in a week's time, so home we came. I had left my jerry cans at home and did not want to risk any further problems in the outback.

                      Armed with the info from these posts (including part numbers) got the service guys to look firstly at the underbody fuel filter before they did anything else - filter was blocked as it had never been replaced. Service advisor at this branch knew that the sedimenter filter was normally replaced when the filter light came on, but could not explain why the other servicing area had replaced this filter instead of the underbody filter.

                      Now have to test it out in the suburbs by running the tanks down to about 30 litres before heading out again in a month to make sure that there is no other problem.

                      Nev
                      2008 GXL D4D Auto
                      nevandcher
                      Lurker
                      Last edited by nevandcher; 19-05-2011, 06:54 PM.

                      Comment


                      • #12
                        Originally posted by robktm View Post
                        Thanks - it is a 2007 120 D4D model, auto. Currently it will not accept fuel into the filler from a bowser - just froths up. I suspect that one of the tanks is full and the fuel is not transferring from tank to tank. Do you know where I can view a diagram of the fuel tanks, pumps and fuel lines?
                        I have a diagram in PDF format (thanks to PeteS some years ago) , however unable to post copy. If anyone can assist with directions will post it on this thread
                        Pedro

                        2007 D4D Auto

                        Comment


                        • #13
                          Folks,

                          I have a prado with only 1 tank but need the 2nd one. So I am building the second/sub tank into my Prado, buying all the bits and peaces from Toyota and and building it in. i have been studying all the posts and the diagrams and have a question regarding the second filter mention in the post. if i look at http://auto-kat.com/index.php?route=...up=7751&page=3 then i do not see the filter between the two tanks. does anyone have a diagram showing it's location or a part number for it?

                          Thanks,
                          DS

                          Comment


                          • #14
                            http://www.ebay.com.au/itm/FUEL-FILT...-/271289872087 is the filter in question.
                            [FONT=Century Gothic][B][SIZE=4][URL="http://www.pradopoint.com.au/showthread.php?36057-Ryback-s-Flinders-Red-120"][COLOR="#B22222"]'04 120 Petrol Flinders Red GXL[/URL][/COLOR][/B][/FONT][/SIZE]
                            with ARB Catalog, with TJM add ons!

                            [CENTER][SIGPIC][/SIGPIC][/CENTER]

                            Comment


                            • #15
                              I have replaced the main tank filter on my 08 120 D4D a couple of times. My vehicle having the two 90 litre tanks. I use the cheaper filter brands like Wesfil as I change this every 20,000K as this filter does some real work.
                              Here are a couple of points if you DIY this job.
                              Easier to change underneath a low ramp but can be done without it.
                              No pressure in these lines but you will have diesel drips onto the ground, hands and forearms.
                              Loosen off the two 6mm bolts for easier hand access to the top of the black/orange fuel line clips.
                              WEAR EYE PROTECTION
                              You have to squeeze together the top of clip while gently prying the small slot to make the orange clip pop out almost completely from the black clip housing.
                              When fitting new filter make sure the fuel line is pushed on hard, do it twice and you may hear a click. Then press the orange clip back into place. If it is very hard to push or will not click flush then there is a small amount of dirt in the clip. This is between the little flange on the filter pipe and inside the black/orange clip.
                              Use RP7 or similar will the small tube to go inside the fitting to flush out , face it down as you do this so the dirt drips out of the fitting and not into the fuel line.
                              Make sure all tight and clips flush.

                              Thong, Tas

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