1kd stalled and won't restart

[solidute Junior Member Find all posts View Profile Close solidute]

Replaced a pair of spotlights and added a lightbar to the 120 2 weeks ago.

On that afternoon I picked the wife up from work (5 minutes away) and on the way home it stalled, coughed a couple of times then stalled. Took forever to restart but got it going and no issues until today.

Today it stalled 550km from home so no tools, or anything to help diagnose/replace/fix did all the same things as last time but no go. Called RAA they tried to no avail, well a few sprays of start ya bastard helped fire it up but wouldn't keep going without it.

Today's symptoms were we were sitting on 110kmh on cruise control when we lost speed then cruise dropped a gear and revved up to get to speed again this happened a few times over maybe 3km before it stalled.

So it's on the flatbed and on the way to the nearest garage (thankfully their Facebook page makes them look like they have a good idea of what they're doing) stuck in a cabin 2 towns away with 3 kids isnt doing my mood any favours either....

Anyway throwing it out there


anyone have ideas for a cause?

Cheers

[Guest Close Guest]

Possibly fuel related. Air leak, Is it getting fuel after filter? Does primer feel really soft and pump up hard after a while of pressing it?

[krypto Avid PP Poster! Find all posts View Profile Close krypto]

Problems like this are often, not always, related to the most recent change so it is worth looking at the spotlight install. Definitely look at everything that they might have touched.

I picked up my Prado from a crash repairer a while ago for a minor repair and one of the back seat belts stopped working. Crash repairer swore black and blue nothing to do with him. When I insisted that they look at it one of the guys in the shop said that he'd accidentally removed the plastic seat belt cover, they found something jammed in the belt.

Moral of the story, look deeply at anything that they might have touched. Also did they go near any ECU looms? How did they get the cable into the cabin?

[solidute Junior Member Find all posts View Profile Close solidute]

Problems like this are often, not always, related to the most recent change so it is worth looking at the spotlight install. Definitely look at everything that they might have touched.

I picked up my Prado from a crash repairer a while ago for a minor repair and one of the back seat belts stopped working. Crash repairer swore black and blue nothing to do with him. When I insisted that they look at it one of the guys in the shop said that he'd accidentally removed the plastic seat belt cover, they found something jammed in the belt.

Moral of the story, look deeply at anything that they might have touched. Also did they go near any ECU looms? How did they get the cable into the cabin?

Yep definitely not related to spotlight install, I did that and have already gone over everything I did, about 15 times so far not exaggerating....

99.9% sure it's the electric fuel pump in the main tank. Part arriving in morning and should be doing job on Sunday.

Will keep updated on how it goes.

[solidute Junior Member Find all posts View Profile Close solidute]

Well well well!

So wasn't just a fuel pump, well technically it wasn't a fuel pump at all but it would've been at some point judging by the condition it was in.

Turned out to be loose terminals in a plug within the fuel tank module - where the fuel pump, jet pump and sender unit are housed.

Had to remove the wires from a plug and push the contacts out so they actually made contact with the pins on the other end of the plug.

Now no idea how this became a problem, this is a part that does not move so shouldn't be "wear and tear". Technically, the module does move and has a big travel range, but it bottoms out in the tank before being done up therefore it only really moves a mm or 2 with fuel tank expansion/contraction.

Anyway, removed the fuel tank to replace the pump. Reinstalled and then got message from Toyota master technician mate (know most people's thoughts on dealership technicians, but he is a guru and I trust him beyond any other mechanic I've ever known. I was/am a mechanic so I know quite a few). Anyway, he said to check the flow. Nope no flow. Removed fuel tank again and double checked everything I did - no issues.

Reinstalled no different.

Removed again....

Pulled out multimeter. Everything tested ok on its own, but when all connected there was an issue.

Ended up being a lead between the module body and the pump. One of the plugs on this lead had loose connections. As above had to remove both wires for the plug to fix.

I'll follow up with individual posts with pictures describing each step/issue

[solidute Junior Member Find all posts View Profile Close solidute]

Entire fuel tank module. Parts highlighted

[solidute Junior Member Find all posts View Profile Close solidute]

Plugs labelled inside the fuel tank module

[solidute Junior Member Find all posts View Profile Close solidute]

Specific parts highlighted. It was the terminals in the grey fuel pump plug that needed the repair.

Hope this helps someone in the future

[krypto Avid PP Poster! Find all posts View Profile Close krypto]

The most annoying problems! Sometimes things just wear and move, it's an old car. Thanks for sharing!