Fuel Pump Replacement Advice

[FD7683]

Hello all, the fuel pump for my truck is dead at 267k i'm getting crank no start and verified no fuel is coming in the engine. I'm getting 11V on the male connector for the fuel pump but its not working or humming like it should I'm going to need to replace it are there any tricks on replacing it on a rustbelt truck? Looking at the condition of my sending unit I already know I need new screws but how about the tank/shield? Any tips appreciated thanks.

 

[brillo_76]

Get ready.. You may need a new tank depending on how bad this is... I changed 3 tanks so far. you have to unplug everything on top before you drop the tank. The early years up to 00 have the evap canister in the front so those are simplier. 01 and 02 had it near the tank and that one breather is so easy to snap off. Dont ask me how I know this ...AS i own both early and late models i replaced and fixed both.,

How rusty is everything?

 

[96RedRunner]

Fixed my P0440 Evap code too! 2002 SR5 4x4 - COMPLETE FUEL AND EVAP PARTS LISTS

Though for 01-02 this thread maybe useful.

 

[phattyduck]

you have to unplug everything on top before you drop the tank. The early years up to 00 have the evap canister in the front so those are simplier. 01 and 02 had it near the tank and that one breather is so easy to snap off.

Along those lines...

For '96-'00, need to remove:
- Main fill on the back of the tank
- Fill vent on the top of the tank (not behind the crossmember, above the rear 1/3 of the tank)
- Front 3 hoses - take a picture to get orientation right later. One pressure, one return, one vent to evap.
- Wiring to the pump/sender (top, under seat)

Once you start to drop the tank a bit, there is 1 wiring clip (for the non-in-tank part of the harness there) that needs to be released from the tank.

Here's a reference for what's on the top of the tank (again, '96-'00). The plastic clip for the harness is next to the clip on the tank:

-Charlie

 

[FD7683]

Thank you all for the replies. The gas tank is quite rusty but not in terrible shape what is bad is the shield underneath. Main concern is the bolts breaking off but I took a good look and they're not too bad I sprayed Kroil. I cannot find a new sending unit for the truck I will either have to buy a used one off another 4Runner and replace the pump with Denso or replace pump only but reuse the sending unit which is in awful shape let me get some pics real quick.

 

[FD7683]

Yikes... thoughts on reusing? Also don't know how to upload pictures its been a while since I used this site but the PDF are at the bottom.

 

[brillo_76]

I really hate to give bad news. But that is looking like that tank and sending unit maybe toast. You know for sure until you get it out. Just be prepared to replace it.

 

[FD7683]

Thank you Brillo my truck is pretty rusty so I’m prepared for the worst. Already ordered induction heater, new hardware and new Toyota sending unit bracket and will transfer lever sensor and new Denso pump. I will only know if the tank is save-able by actually doing the job I will be extremely cautious when removing sending unit. Now you scared me! But it’s ok lol I will keep this thread updated Runner in good shape otherwise

 

[toverturf]

I'd look at this attached TSB and see if your VIN is listed. I have a 2000 Limited and mine was. There is updated parts for the Fuel Sender Gauge and Fuel Suction Tube assemblies. I just ordered these and will be replacing them along with Denso pump when I get them.

 

[FD7683]

I'd look at this attached TSB and see if your VIN is listed. I have a 2000 Limited and mine was.

I have known this TSB for a while but I did some digging with my VIN and it does fall for the sender replacement category. With the fixed ground on my pump wires it does read accurately but now i'm second guessing if I should update the sender with the updated part even though (i'm assuming) my original 99 sender is reading accurate... I will see.

 

[brillo_76]

Thank you Brillo my truck is pretty rusty so I’m prepared for the worst. Already ordered induction heater, new hardware and new Toyota sending unit bracket and will transfer lever sensor and new Denso pump. I will only know if the tank is save-able by actually doing the job I will be extremely cautious when removing sending unit. Now you scared me! But it’s ok lol I will keep this thread updated Runner in good shape otherwise

Not trying to scare you. Just the last 1 that looked like that I had to replace. Hole on top of the tank after all the scale was off.. Was all, Denso pump is excellence choice. I just didn't have the luck. Maybe you will.

They make replacements tanks so its not a major deal if you have to go that route. Sadly, just adds to the repair bill cost...

 

[FD7683]

Oh yes absolutely, I was looking online and they are pricey I hope I don't have to go that route. I'm already prepared if the tank needs replacement thanks Brillo i'll update how it goes in the end.

 

[rickoliver]

FWIW I would replace the whole tank including the pump. I went through this on another car and it was a cascade of problems, one after the other, that would have been resolved if I had installed a complete unit.

 

[FD7683]

Tomorrows the day. Just for shits and giggles I hit the tank underneath with the soft blow hammer and it fires up but chokes out and dies seconds later. Pump must be super dead but i'm not mad since it made it 26 years plus 268k miles its finally time to replace. I will update how it goes later.

 

[FD7683]

To end the thread it was the fuel pump I got it running with a new unit thanks for the advice everyone!

 

[jgue467]

OEM fuel pumps do last a long while - mine gave out last summer at 24yrs and 365k - cannot ask for better. Enjoy those Runners.