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Old 05-10-2012, 07:47 PM #1
Zonly1 Zonly1 is offline
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URGENT! Need help with Fuel Pump/Tank removal

Hello,

Well, this morning at 5am I get a call from my wife and she tells me the 4Runner (2003 SR5) shut off while she was driving stuck on the side of the road. Im Military and I work from 12am-0800am. She had only gotten a few blocks from the house luckily.

Symptoms:
Turns over but wont crank. Checked all the fuses and relays. Good to go there. I wait till O'reliys opens and check google, youtube and this site for some quick fault isolation. Tried to bang on the tank while she cranked it..nothing. Swapped some relays...nothing. Then I bought starter fluid and sprayed it in the intake. Bang! it starts. So its not getting fuel. I work on Aircraft and im deaf. Wife says she doesnt hear the pump prime just before start. So My thought is to get a new fuel pump.

Oh! we have never had a problem with the truck since we got her. Bought brand new and paid off since Jan 2006.

Result:

I decied to pull the tank. While taking the tank apart and out..I manage to break a connector (just pulled the wires out). Now im not sure where the plug back in. I will have to resolder them in place. They seem to be for the fuel gauge. If anyone can help here this would be awesome.


Bigger problem:

After taking the tank apart and pulling the fuel sending unit out to get at the fuel pump I notice that the connector I striped has a burn wire, connection. Very bad one and it made the plastic crumble it was burnt so badly. I have a new sending unit on the way from Toyota. Has anyone ever had this problem? Any helpful tips would be great. I have a Chiltons but the wire diagram doesnt break down this connector.

My guess would be red to red and black to yellow as for the ground? these two look like they work the fuel gauge and the other two are for the pump. Thanks






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Old 05-10-2012, 08:35 PM #2
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Desert Fox Desert Fox is offline
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Ouch
Try this link, I have not used these so I can not say how good they are.
Service Manual Download Links.

Any idea what caused the short? That is something Toyota may want to know about before they start frying owners.

Good luck with repair
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Old 05-11-2012, 01:22 AM #3
Zonly1 Zonly1 is offline
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Thanks alot this will do wonders I hope. Not sure how this would have happend but now i have the assym on order $900. gotta do some wiring fix.
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Old 05-11-2012, 08:10 PM #4
settytb settytb is offline
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Dang a burnt connector next to the fuel tank is definitely scary. Good luck with the fix.
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Old 05-12-2012, 12:15 AM #5
Zonly1 Zonly1 is offline
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Quote:
Originally Posted by settytb View Post
Dang a burnt connector next to the fuel tank is definitely scary. Good luck with the fix.
yea after i told the wife she freaked. It was actually inside the fuel tank in the fuel sending unit too. Luckily it was only a quarter tank full.
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