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Hi all,
I just got back from a trip to NT doing 12000km. I wasn't a member but referred to this thread for some info as my 120 series 2008 d4d had this fuel problem. Basically, I first noticed in cobar when trying to fill up, kept gurgling and fuel kept coming up through the breather as if the tanks were full but I knew they weren't. It took me about 45mins to put in 60 litres of fuel, i had to fill up like this all the way to Katherine! The problem is the jet pump (fuel pump) in main tank (front tank) wasn't working. This pump transfers fuel from subtank into main from where the fuel pick up is. The fuel gauge on the dash was still working as usual (the gauge reading is an average between the two tanks and because the main tank is slightly larger than subtank it transfers over to second tank on gauge before the main was empty). After reading this thread, I needed actually see if what I suspected and read was true and sure enough 20k north of mataranka I run out of fuel when the gauge read just above 3/4 with green 90l light on.
In the meantime on the way up I checked all fuses which were fine, fuel tank breather and changed the filter between the two tanks. All this made no difference. So definitely related to jet pump in main tank.
I got under the car again...... and found the drain on the sub tank which I could reach with a socket (located on back rhs of tank). Using the mrs wee bucket and a cut off plastic bottle as a funnel, i managed to drain 5 litres at a time from sub tank and poured into main tank. The fuel went into main tank as it fills first and because the level of subtank was going down as I was draining it, the tank breather was clear of fuel therefore didn't gurgle and take forever. I managed to get 30l into main tank, primed the fuel pump (in engine bay on top of fuel filter) until hard and drove onto Katherine. The subtank is supposedly 87 litres so if this happens to you you can get this fuel out if desperate like I was.
When I got to Katherine I decided to drop the main tank out to try finding the problem. I phoned a few toyota service centres and they had no idea. There is no fuel drain on the main tank so if you have do this, do it when you know tank is nearly empty as it is too heavy to handle and manoeuvre. You need to discount all fuel lines to the main tank, filler pipe, tank bash plate and disconnect an electrical cable on top of the tank that you can only do through the floor of the car by taking out passenger side rear seat, lifting carpet and unscrewing a plastic cover.
Once this is done you can lower the tank. On top of the tank is a large white round screw on cap with fuel pipes. You need to un clip 1 or 2 of these to unscrew the cap. I had to use a hammer and large screw driver to undo as very tight. Once undone pull out a large white canister looking thing. Be careful removing as float, pick up, sender etc are all part of this. Once out, you need to un clip to access the jet pump. There are a two wires attached to a clip on either end ( one to jet pump itself and other to the cap on canister (I don't know what this canister is actually called- fuel assembly unit??)
I tested the pump by using a battery and a couple of wires and and was working. I plugged it all back together in the canister and tried to power power it using the battery and nothing. I then discovered that the plug into the cap (top of canister) was all burnt and melted and not connecting with the connection pin on the cap. I phoned Toyota to try purchasing the cable and plugs and they would not sell me it separately, stating I must buy the whole fuel unit at $1300! You pay $65000 for a car with a reputation and that is the service you get! It is literally two pieces of wire 6 inches long that plug into a single plug each end. I tried every car parts shop and auto electrician but could not source one or have one made to suit. Without melting the insulation on the wire I soldered pin into plug and insulated with electrical tape and put it all back together. When you put canister back into tank ensure the cap is in the position it was before removing and as you screw up the large locking screw it will lock into position.
Once back together I nervously went to the servo and filled up. Fuel went in properly and fast like it should. I filled up to max capacity. When I started it, the 90l light came on and showed empty but after I turned off and on again it reprogrammed as usual. Obviously there is no relay or fuse associated with the jet pump as i would of expected it to blow given the burnt out plug. I did another 8000k including on heavy corrugation and didn't have any further issues with the fuel tanks or transfer of fuel. If you have this problem I hope this information is of help to you. I certainly know how it feels. It seems to becoming an issue with the 120s as they age and I have heard it happening to a couple of 150s. Good luck
I just got back from a trip to NT doing 12000km. I wasn't a member but referred to this thread for some info as my 120 series 2008 d4d had this fuel problem. Basically, I first noticed in cobar when trying to fill up, kept gurgling and fuel kept coming up through the breather as if the tanks were full but I knew they weren't. It took me about 45mins to put in 60 litres of fuel, i had to fill up like this all the way to Katherine! The problem is the jet pump (fuel pump) in main tank (front tank) wasn't working. This pump transfers fuel from subtank into main from where the fuel pick up is. The fuel gauge on the dash was still working as usual (the gauge reading is an average between the two tanks and because the main tank is slightly larger than subtank it transfers over to second tank on gauge before the main was empty). After reading this thread, I needed actually see if what I suspected and read was true and sure enough 20k north of mataranka I run out of fuel when the gauge read just above 3/4 with green 90l light on.
In the meantime on the way up I checked all fuses which were fine, fuel tank breather and changed the filter between the two tanks. All this made no difference. So definitely related to jet pump in main tank.
I got under the car again...... and found the drain on the sub tank which I could reach with a socket (located on back rhs of tank). Using the mrs wee bucket and a cut off plastic bottle as a funnel, i managed to drain 5 litres at a time from sub tank and poured into main tank. The fuel went into main tank as it fills first and because the level of subtank was going down as I was draining it, the tank breather was clear of fuel therefore didn't gurgle and take forever. I managed to get 30l into main tank, primed the fuel pump (in engine bay on top of fuel filter) until hard and drove onto Katherine. The subtank is supposedly 87 litres so if this happens to you you can get this fuel out if desperate like I was.
When I got to Katherine I decided to drop the main tank out to try finding the problem. I phoned a few toyota service centres and they had no idea. There is no fuel drain on the main tank so if you have do this, do it when you know tank is nearly empty as it is too heavy to handle and manoeuvre. You need to discount all fuel lines to the main tank, filler pipe, tank bash plate and disconnect an electrical cable on top of the tank that you can only do through the floor of the car by taking out passenger side rear seat, lifting carpet and unscrewing a plastic cover.
Once this is done you can lower the tank. On top of the tank is a large white round screw on cap with fuel pipes. You need to un clip 1 or 2 of these to unscrew the cap. I had to use a hammer and large screw driver to undo as very tight. Once undone pull out a large white canister looking thing. Be careful removing as float, pick up, sender etc are all part of this. Once out, you need to un clip to access the jet pump. There are a two wires attached to a clip on either end ( one to jet pump itself and other to the cap on canister (I don't know what this canister is actually called- fuel assembly unit??)
I tested the pump by using a battery and a couple of wires and and was working. I plugged it all back together in the canister and tried to power power it using the battery and nothing. I then discovered that the plug into the cap (top of canister) was all burnt and melted and not connecting with the connection pin on the cap. I phoned Toyota to try purchasing the cable and plugs and they would not sell me it separately, stating I must buy the whole fuel unit at $1300! You pay $65000 for a car with a reputation and that is the service you get! It is literally two pieces of wire 6 inches long that plug into a single plug each end. I tried every car parts shop and auto electrician but could not source one or have one made to suit. Without melting the insulation on the wire I soldered pin into plug and insulated with electrical tape and put it all back together. When you put canister back into tank ensure the cap is in the position it was before removing and as you screw up the large locking screw it will lock into position.
Once back together I nervously went to the servo and filled up. Fuel went in properly and fast like it should. I filled up to max capacity. When I started it, the 90l light came on and showed empty but after I turned off and on again it reprogrammed as usual. Obviously there is no relay or fuse associated with the jet pump as i would of expected it to blow given the burnt out plug. I did another 8000k including on heavy corrugation and didn't have any further issues with the fuel tanks or transfer of fuel. If you have this problem I hope this information is of help to you. I certainly know how it feels. It seems to becoming an issue with the 120s as they age and I have heard it happening to a couple of 150s. Good luck
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