Fuel Supply Problem -diesel

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[JOMATA Lurker Find all posts View Profile Close JOMATA]

Hi all

I don't know if it is correct to post this here or if I should start a new thread.

I own a 2009 D4D Auto diesel Prado. It is an Australian import so it has two tanks. Right now it shows 155.000Km.

Last year it started dripping diesel from the tank area and I had both tanks removed for inspection. Sure enough, the main tank had a few very small holes caused by friction of sand or small stones that got in between the tank and the protection and the constant rubbing.

After the holes been welded and no more dripping the tanks were reassembled and all was good. Some six months after, I started getting wrong readings of fuel level, when below 50% (green 90L light came on). After some 100Km the gauge would indicate near empty.

As I live in East Timor and genuine parts and maintenance is a problem, and I know that full tanks last me around 1,200Km, I started using my trip meter to calculate range.

Last week the motor stopped and the orange engine light came on indicating fuel blockage. I knew the fuel/water separator filter under the bonet had been replaced one month before so it couldn't be from there. So the next most probable culprit would be the filter on the main tank under the passenger back seat. It was removed and sure enough it was full of a black gunk. Filter cleaned, manual pump primed and all was good.

I decided to let the tanks almost empty and have them removed to be properly cleaned and the sender cleaned and checked for any bad contact or whatever.

Everything was badly contaminated with this black gunk and properly cleaned.

I filled with 20 litres to check the gauge behavior and it seemed to indicate correct amount of fuel. The next day i went to the fuel station to fill the tanks, and as I opened the fuel cap it made a sound like sucking air and I heard something inside fall to bottom.

Filled with 100 litres and the gauge shows green 90L light on and needle on empty with reserve light on.

Is the sender trashed or wrongly mounted/connected?

Any suggestions before I fork out for a new sender?

Thank you

[nateees Lurker Find all posts View Profile Close nateees]

Hi all
not sure if this is the correct place to reply although having what sounds like very similar issues although slightly different.

i have a 2009 kdj150 kakadu diesel D4D

i was recently towing my caravan, and found after the car got to operating temp it completely lost power and would not want to go up any incline whatsoever!

I got to our destination after slow driving and using the tip tonic to put back in gears and slowly get up any incline until we arrived.

Unhitched the caravan and car drove fine for rest of weekend, did not tow though. I also went to a local mechanic to see if any error codes came up on the diagnostic and was nothing. No lights came up on the dash either when the issues occcurres. So was led to believe maybe bad fuel, put in another 60L to top up and mix in what was left in the tank hoping it would fix the issue.

although again on way home, after approx 30mins of driving which included hills, it started to do the same thing.

Managed to get the car home and haven’t towed since, have car booked in to get both fuel filters changed (not done for 40,000kms) although wondering if it is the fuel tank issue written about and discussed here or the connector rusted as per pg 2 photo.

so my question is, when people have had this fuel issue, have their cars completely stopped or have they too lost power on any inclines? Which to me seems like the car wants more diesel under load and can’t get it meaning lack of power and a fuel issue.

Is hard too as issue doesn’t happen all the time and want to try avoid replacing this that and everything until issue is fixed.

any help / advice would be appreciated.

i must say this community is great. Have learnt a lot from previous thread although this is one of my first posts asking for help

I love this car, has done 255,000 and believe has plenty more in here but this issue has really affected my confidence with the old girl, too date has no issues other than electrical things like batteries and alternator replacement so this is really troubling me and good to fix it and drive it for many more years if I can!!

thanks in advance