120 Series Prado Deisel Fuel wont pump from sub tank & blows F/Pump fuse

[Adrian&JenHotz Lurker Find all posts View Profile Close Adrian&JenHotz]

Hi all. We are new to this page so please let us know if we need to post this to another area.
We are really hoping someone out here might be able to help.
We have a 2008 Turbo Diesel 120 Series Prado, which we purchased approximately 2 years ago. Ever since we purchased the car we have had fuel problems.
The car will read it has fuel still in the tank and then cut out - like it is has run out of fuel.
My husband is quite mechanically minded and so far has totally replaced the sub tank, the white plastic piece which attaches to the main tank

Despite all of the troubleshooting the car still runs out of fuel at around 1/4 a tank (with the 90 light on). We drained the tank yesterday and the main tank was empty and the sub tank still had approximately 60l remaining. In addition it continues to blow the f/pump fuse (under the bonnet). (only when the white connection on the main tank is plugged in)

So far we have had mixed answers from various 'professionals' about how the fuel system works on this model.
Can anyone here tell us how the dual fuel system works?
Also has any one else had this problem? do you have any advice?

thanks in advance for any advice / help
Adrian n Jen

[Razorback81 Advanced Member Find all posts View Profile Close Razorback81]

Hey guys
where are located?

have you had the pump out of the tank?

has the rear filter above the tailshaft been replaced?

have you checked the breather above the diff

is there a burnt wire in the plug on the top of the pump ?

[Adrian&JenHotz Lurker Find all posts View Profile Close Adrian&JenHotz]

Thanks for your reply...
We are in Bundaberg QLD 4670

*We have replaced the pump assembly in the main tank with the fuel level float attached to it.

*We have replaced the fuel filter next to the tailshaft.

*We have replaced the breather above the diff.

*There is a couple of darkish wires on top of the pump yes'

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

If you have replaced the pump I would disconnect the pump and see if the fuse still blows, as this is probably not easy to do if you have the tank back in I would suggest you need to look at the wiring to the pump and see if it has been damaged, also make sure the correct fuse is in position.

[Adrian&JenHotz Lurker Find all posts View Profile Close Adrian&JenHotz]

Thanks for your reply

Im going to take it to the auto electrician in the morning to check the wiring out *

Ive disconnected the pump from underneath the rear passenger seat & started the car & it dosent blow the fuse at all.
Once i start the car i plugged it in & pop it blows straight away.

[Razorback81 Advanced Member Find all posts View Profile Close Razorback81]

show us what you find , as there has been a few with different problems and it would be good to hopefully get to the bottom of it

[Pedro Advanced Member Find all posts View Profile Close Pedro]

Check out how it works from attachment

[Rob64981 Lurker Find all posts View Profile Close Rob64981]

Check out how it works from attachment

Pedro can you please send me this image as when i open it its too small to read?
Thanks Rob