4l V6 Petrol Pump replacement

[Philly]

Hi Guys.

Not sure if anybody has had a problem or will have a problem regarding their petrol pump. This is what I have done, maybe some useless reading but if you are in the same boat as I was and is not scared of working on you own vehicle, you could save yourself more than R10000.00

Just a quick background of what and why.

A few months ago I started noticing that my bakkie felt sluggish and when driving it felt like it was surging very slightly. With my last service I asked Toyota to check petrol pump, they told me it was busy going and would need to be replaced at a cost of R10500!!

1st of all I don't have that amount of money lying around and 2nd I'm not paying for something that I will be over charged more than 200%.
So the research started and looking for prices and solutions, there was basically 2 options from Toyota for the fuel pumps, 1 was R1500odd with housing and all and the other R5250odd no housing just pump and filter... obviously Toyota picked up on this and discounted the R1500 product.

Long story short, after plenty of reading on this forum and 4x4 community and asking around I managed to find a replacement, new pump with the filter at Midas Randburg for R296.40.

Bought it and replaced the fuel pump Friday.. as can be read underneath..........



I found a replacement petrol pump for R296.40. This is a replacement part from Midas just the pump and filter. (I recall that on another thread in 4x4 community there is somebody that found the exact same thing, Bosch replacement part). The one I found is however not Bosch. Anyways, much better than paying R5250 from Toyota or R10500 for them to replace the pump.

Any ways I bought the pump and Friday replaced the pump. Was a whole day job, and it was more difficult taking the extended tank out and putting it back in than the normal tank. The reason that I had to take the extended tank out was, I just could not get to the clamps of the main inlet pipe. Was not double jointed enough..

Replacing the pump was very easy, only thing that had to be done on the pump was to swop the pipes from the old one to the new as the new pipes was to short. Oh and loosening the pump retainer is a bit of a mission as well.. We ended up using the ends of a shelving rack with 2 nuts and bolts, they fit between the ribs, both of us sat on tank. 1 positioned the "tool" and pushed down on the both the tool and retainer, while the other slowly loosened the retainer.
We managed to break a few ribs on the retainer while tightening again. It has to be seriously tightened again.

After all was back in and bolted down etc.. my bakkie is 100% sorted!!
I do have a full service manual, that helps a heap lot.. takes bit of time to look for whatever you need. But when you use it, it really is worth the time to go through it step by step.

Unfortunately I did not take any pictures, but the manual is more than efficient to follow.
Really happy with end result. It is more than possible to do this job by yourself and a buddy. With the help of the manual. And there is a huge difference between R296.40 and R10500!!

Hope this helps somebody somewhere save some money..

Cheers
Phillip

[Dadz Toy]

Well done Phillip, it's immensely satisfying to work on your own vehicle hey!
Shame you didn't take photos!

Rich

[Dirka]

Thanx for a valuable article Phillip!
Some good pointers there and certainly a huge cut in cost.
Just some questions I have:

In your opinion - will the Midas pump have same life expectancy as the Toy/Bosch pump?
The pump and filter - is the filter part of the pump assembly that goes into the tank?
I don't get the (R5250odd no housing just pump and filter) option from Toy. Why have it if they sell the
(R1500odd with housing and all) as an alternative option?

Thanks again for a great post.

[Philly]

Hi Dirka.

According to the guy that I received the pump from, it is the replacement part used in Toyotas. Whether it is or not can't tell you. I still have the box. Will look at the part number and see I can find out a bit more.

The pump and filter part is the parts that goes into the tank. The whole petrol pump assembly goes into the tank.

Regarding the 2 options from Toyota, only option is the one for R5250. The other option Toyota doesn't stock anymore as they realized that people can get the whole assembly with petrol pump and filter for more than half the price than just the pump and filter. Sorry for not actually mentioning it better.

I must also mention that the service manual helps a lot.

Hope that helps.

Hi Rich! Thank you very much! Yes, very satisfying to get all this done.


Sent from my iPhone using Tapatalk

[ChrisF]

Phillip excellent post. Thanks for sharing.


real pity you did not take photos. But in the stress of a new project the camera is often neglected.



Do you think the job would have been much easier without the long range tank ?

Thinking back, any way to make it easier to get the old pump out of the tank ?

If you had to do it again, what would you do differently ?

[Dirka]

Thanx for the reply on my questions Phillip.
It really sheds some good light for future reference.

I tried to search for various manufactures on the fuel pump.
I could only find one global distributor. So it might be possible
for one manufacturer but placed in different box for the various dealers and stealers?

Anyways..
I've seen the pump retainer is in fact a mission to accomplish.
Toyota has specialised tool for that.
But I guess the pieces of shelving rack did it's part also..
Nice work there!

[Ali3n]

I went through this exersise a few months ago on Cleaners truck. Not a fun exersise if you are alone. When I pulled the pump out it was black with a grease like buildup. Cleaned it and tested the pump. Worked perfect with the correct pressure. The power was drastically increased when I put everything back together again.

[Mars]

Good post thanks

[Knuppel]

I have found that measuring the pressure may not give you the correct info. A buggered pump can give the right pressure but it may not be possible to maintain that pressure under flow. Meaning if you close the pump off then pressure within spec but as soon as you put your foot down and demand the same pressure at 50% throttle then the pressure fades away.

[Ali3n]

I have found that measuring the pressure may not give you the correct info. A buggered pump can give the right pressure but it may not be possible to maintain that pressure under flow. Meaning if you close the pump off then pressure within spec but as soon as you put your foot down and demand the same pressure at 50% throttle then the pressure fades away.

Yes, I agree with you on that. However with the amount of build up on the filter at the bottom of the pump (it was a thick black greasy build up) i thought that it was not getting enough pressure through in any case so if anything it would help. the filter was completely black, once cleaned it was white again. It has made a difference. If we get to the point that it needs replacement we will just go through the process again.

[dewet4linde]

Hi Philly, when you say the bakkie was sluggish was it througout the rev range that you experienced this?

Reason for asking, my dad owns a 2006 4.0 V6 with about 160k km (and a long range tank aswell) and between 1000rpm to 2200 rpm it feels dead and then suddenly it has lots of power... Think it might also be the fuel pump? Just checking if your symptoms was the same then I know i'm on the right track.

Sorry for the thread hijack. And great post wil definitely save some fellow luxers a great amount of money

[Philly]

Hello De Wet

Thank you.. You are not Hi-jacking the thread. I just find it ridiculous that we get over charged for almost everything and everything, so the more we can help each other save a few rands the better for us..

To answer your question..
It almost felt like you were driving with the hand brake up. And if you start driving and kept your foot steady it felt like surging forward slighty... I never had the sluggish and then it pulls all of a sudden.
It could very well be the fuel pump. or maybe a dirty injector or a dirty fuel filter.. If I was you I would start with the easy-ish stuff like checking the feul filters etc..

If they all look good and clean. Take the vehicle to Toyota and ask them to do a fuel pump test.

Hope you come right..

Thanks
Phillip

[Philly]

I have found that measuring the pressure may not give you the correct info. A buggered pump can give the right pressure but it may not be possible to maintain that pressure under flow. Meaning if you close the pump off then pressure within spec but as soon as you put your foot down and demand the same pressure at 50% throttle then the pressure fades away.

I think that is exactly the scenario I had, hence the surging effect..

[Philly]

Phillip excellent post. Thanks for sharing.


real pity you did not take photos. But in the stress of a new project the camera is often neglected.



Do you think the job would have been much easier without the long range tank ?

Thinking back, any way to make it easier to get the old pump out of the tank ?

If you had to do it again, what would you do differently ?

Hi Chris.

Yes for sure it would be easier, the extended tank prevents you from getting to the main inlet pipes. In my case I couldn't get to the hose clamps and get them loose... not sure about others. My friend has a 4l V6 as well, and by the looks of it his extended would need to come out as well to get to the inlet pipes and clamps.

There is basically only one way getting the tank out and in again.. only thing that I would do to make my life easier is get a trolley with wheels or a car lift (which is not something you just have for in case you want to work on you car). i am not sure how many time i was under the car and out again. All I know is my back was feeling it the night and next day from scuffing it getting under and out again.

Or maybe a tool app to give me the tools.. and a cold beer...

Cheers
Phillip

[dewet4linde]

Hello De Wet

Thank you.. You are not Hi-jacking the thread. I just find it ridiculous that we get over charged for almost everything and everything, so the more we can help each other save a few rands the better for us..

To answer your question..
It almost felt like you were driving with the hand brake up. And if you start driving and kept your foot steady it felt like surging forward slighty... I never had the sluggish and then it pulls all of a sudden.
It could very well be the fuel pump. or maybe a dirty injector or a dirty fuel filter.. If I was you I would start with the easy-ish stuff like checking the feul filters etc..

If they all look good and clean. Take the vehicle to Toyota and ask them to do a fuel pump test.

Hope you come right..

Thanks
Phillip

Agreed! Its just sad to see you pay such a premium and can do a better job yourself for not even a 10th of the money and know it is done right!

Thanks for the reply, I think I will do as you suggested and start with the easy and cheaper stuff on the list and create a thread if I find the fix.

Regards De Wet

[Obelix and Dogmatix]

If you download the manual there us a section under the tank removal section that says special tool. it gives you a picture and if you are tackling this job you should have the ability to make it yourself out of a bit of scrap metal. Hope this helps those that still need to do this.

Alien did Cleaner mention anything about improved fuel consumption? or is that just wishful thinking on my part.

[Ali3n]

Alien did Cleaner mention anything about improved fuel consumption? or is that just wishful thinking on my part.

Improved fuel consumption on his truck??? If he gets 0.2km/l more he will be over the moon.

Not that I am aware of, His truck is standing by me as he has a company car so does not get to use it much but I will ask him and report back.

[Obelix and Dogmatix]

Alien did Cleaner mention anything about improved fuel consumption? or is that just wishful thinking on my part.

Improved fuel consumption on his truck??? If he gets 0.2km/l more he will be over the moon.

Not that I am aware of, His truck is standing by me as he has a company car so does not get to use it much but I will ask him and report back.

Was waiting for that laugh. But would be interesting to see if that sludge had an effect.

Thanks Alien, and did you enjoy the beer?

[Ali3n]

Alien did Cleaner mention anything about improved fuel consumption? or is that just wishful thinking on my part.

Improved fuel consumption on his truck??? If he gets 0.2km/l more he will be over the moon.

Not that I am aware of, His truck is standing by me as he has a company car so does not get to use it much but I will ask him and report back.

Was waiting for that laugh. But would be interesting to see if that sludge had an effect.

Thanks Alien, and did you enjoy the beer?

This is what it looked like. Only have the 1 pic. I will need to find the others.

And yes, It was awesome. Went to get my jacket and when I got back you were gone.

[Philly]

WOW!! That is dirty!!! Mine didn't look that bad at all!! It did a few metal shavings and was dirty. But not as bad as that!

I must also add, I put in only R500 when I finished. And after driving around I noticed that fuel economy looked better. But its not possible to make any comprehensive conclusions by just that amount of fuel. I ended up with 13.8l/100km or 7.24km/l economy when I filled up this morning after doing 238km mix of town and once going to Wadeville from Honeydew. Not getting to excited yet..
I filled up this morning, so will keep a eye and give feed back after I filled up again.

[Knuppel]

That is terribly dirty, beyond the norm of where it should get to so I presume there will not be many that look like that. Could you in any way determine what the gunk was?

[Ali3n]

That is terribly dirty, beyond the norm of where it should get to so I presume there will not be many that look like that. Could you in any way determine what the gunk was?

Jip, never seen one like that before.

I have no idea what it was but it was similar to grease in texture. I managed to clean it with sunlight after a few washes and a bit of scrubbing with a soft brush it was clean but I was shocked to see the condition it was in. Possibly contaminated fuel at some stage in its life?

[Scooter]

I can tell you that after recently replacing my pump, that strainer filter on the end of the pump was as dirty as yours.
Since I was replacing the whole unit I didn't need to clean it but I gave it a shake in some clean fuel and we'll the fuel was more like chocolate milk afterwards.

I'm sure that is one of the main causes of the surging as the fuel is being restricted by the strainer. I wasn't going to just replace the strainer to test though as I didn't feel like taking the tank out twice

For those of you looking to do the job yourself......I made up a quick tool for aiding in loosening the fuel assembly retainer. I used a piece of 40 x 5mm thick flat bar and welded a nut in the centre to take a 24mm socket.

Then I used two pieces of a sliding gate rack, two teeth per piece, and cut out between the teeth more to be able to fit it over the fins on the retainer. And of course welded them to the other side of the flat bar at the right points.

It worked for me but if I had to do it again I would make another piece to form a cross thus giving the tool four points to hold instead of two.

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[justaguy]

Hi Philly is your fuel pump still working ?