Been a reader of the forum for a couple of months now, but this is first post. Its a great site
Had an issue with my '07 D4D this week, which I thought might be of interest, and perhaps help others to avoid the problem. (I'll try to keep it short)
My fuel gauge was showing just under half, with 90L green light on, so I was thinking I had about 40 litres of diesel in the tank, when the engine died on me. Had RACV come along, mucked around with fuel lines for a while, primed things up, eventually put 10 litres of diesel in it and got it going again.
I went to servo to see how much I could get into it, figuring maybe gauge was playing up, but could only force about 80 litres into it. So something funny going on.
Had it at Toyota yesterday, who, after much investigation, discovered there was a fuse which powers a pump on the sub-tank that had not been installed.
The service guy told me there is a pump which runs for about 10-20 minutes after start up which pumps some fuel from the sub-tank to the main tank, then a gravity feed system takes over to provide a slow transfer as the car is driving. Apparently without the pump in operation the sub-tank was filling more each time I put fuel in, until it was completely full. Without some area of air pocket in the sub-tank, the gravity feed system does not work. Eventually, despite the gauge showing just under half (as there was fuel in the sub-tank), the main tank got to empty point and the engine died.
Not being majorly mechanically or understanding exactly how the fuel transfer system works, I have to believe this explanation. Havent got the gauge back to where it was when the problem happened, so will have to burn up some fuel to test the theory....and maybe carry a full gerry tank around with me for a while!
He said the vehicle comes from factory without this fuse fitted, so it is up the pre-delivery team to ensure it is done (which was apparently news to them...great).
So I wanted to share the story with everyone to possibly help others avoid being stranded on the road-side. Maybe get your Toyota dealer to check for this fuse. Unfortunately I did not find out where it is located so cannot let you know in order to check yourselves. Sorry about that.