2009 LX570 Fuel Problem

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Joined
Jul 10, 2004
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Location
Knoxville TN
I could really use some ideas on a problem I’m having with my 09’ LX570 w/ 166k miles.

Short version: fuel sending unit was giving false readings at the bottom of the tank but the truck was running fine. The sending unit was replaced along with the fuel pump. ~30 miles later it throws a P0171 and P0174 code. 50 miles later it loses fuel pressure and dies. The fuel pump is re-replaced and it does the same thing again. Fuel ECU replaced: same problem, pump reinstalled: same problem, relays replaced: same problem. All parts were OEM Toyota.

Any ideas on what might be going on?


Long Version: The LX was running and driving totally fine but I ran it out of gas a couple of times while the gauge showed between 1/8 and 1/4 tank of fuel. It’s a semi common problem that the sending units go bad in these trucks so I ordered a new one along with the fuel pump (“while I’m in there”) and seals from Toyota. All the parts were OEM Toyota/Lexus parts.

I was going to do the work myself but once I looked into it a little further and realized it called for dropping the tank and a couple of SST’s I decided to just let a friend that owns a certified Toyota shop do the work.

They do the work in a few hours and I get it back. Everything seems fine at first but about 30 miles after the repair I get a P0171 and a P0174 CEL. The LX was running fine so I figured I’d check it out once I got home. Well 50 miles later I notice it starts hesitating and then I’m dead in the water....10 miles outside cell coverage, offroad in a National Forrest with my family and no supplies.

9 hours later, some hitchhiking, a drunk Bigfoot hunter, some luck and a helpful friend...I drag it back to the shop on a trailer.

The next day they check it out and it only has about 10 psi of fuel pressure and they think the new OEM Toyota fuel pump is bad. They replace the pump, the LX runs fine again and the exact same thing happens at the same mileage. P0171/P0174 and eventual death around 50 miles. This time I deliberately stayed close to home so it got a rollback ride from by driveway back to the shop.

Now...what the heck is going on? It’s losing fuel pressure somehow but the pump is properly installed (allegedly) but they’ve had it in and out several times now. They’ve replaced the fuel pump ECU, fuel pump, sending unit, relay, and really everything else that might cause this. The LX is still not getting fuel and the shop is out of ideas. If any of you cruiser guru’s out there have any advice, I’d love to hear it. We’re kind of grasping at straws at this point.

Thanks in advance and sorry for the long read if anyone actually read it all.
 
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Wow. That's a really interesting set of repeat events.
Since you've already swapped all the stuff that isn't a fuel hardline or supply hose, that's kind of what I think. How it gets thru 2 or 3 gallons first is pretty confounding though. A leak at the fuel rail should be really obvious . . .
 
Did you order the complete replacement fuel sender / pump / plate / tank package or just the sender and pump and the shop rebuilt the existing assembly?
 
Yeah, it makes no sense. The fuel filter hasn’t been replaced so I’m curious about that but it’s almost like there is a pressure leak inside the tank. There is no fuel smell anywhere.
 
Did you order the complete replacement fuel sender / pump / plate / tank package or just the sender and pump and the shop rebuilt the existing assembly?
Just the sender and pump which might lend itself to an improperly seated pump and pressure leak inside the tank...maybe?
 
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I've had the pump out recently and I doubt it is incorrectly installed, it only goes in one way and the orientation and keyway are obvious.
 
Maybe some of the bits were not assembled perfectly in the package. I have my old one sitting here if you need pictures. I haven't taken it apart yet. I installed the factory assembly (all the parts pre-assembled).
 
Maybe some of the bits were not assembled perfectly in the package. I have my old one sitting here if you need pictures. I haven't taken it apart yet. I installed the factory assembly (all the parts pre-assembled).
The shop said the same thing about the pump only going one way. They are confident it is installed correctly. I appreciate the offer of pictures. I’m not sure if they’ll help but they couldn’t hurt. I’ll pass them on if you get a chance to snap a few.
 
Maybe there is an issue with the vent valve. If it is stuck open, then the car will go lean . . .

Around min 18

 
Well, I paid a visit to the shop yesterday and looked at the pump assembly on the bench with the techs. I figured out what they did wrong.

They didn’t transfer the spacer for the o-ring from the old pump. This allowed the o-ring to slide down the discharge nipple eventually unseating from the receptacle and losing fuel pressure. Gas was spraying back into the tank just as suspected. When the tech said the new pump didn’t look the same as the old one it all made sense. It didn’t look the same because they installed it without the spacer, which they thought was part of the old pump. I pulled up the parts fiche and showed them the missing piece.

It should be here Monday but I’m 99.9% sure this is the problem.

09267D96-7CBA-4774-847C-E92DE2AA4375.png
 
Well, I paid a visit to the shop yesterday and looked at the pump assembly on the bench with the techs. I figured out what they did wrong.

They didn’t transfer the spacer for the o-ring from the old pump. This allowed the o-ring to slide down the discharge nipple eventually unseating from the receptacle and losing fuel pressure. Gas was spraying back into the tank just as suspected. When the tech said the new pump didn’t look the same as the old one it all made sense. It didn’t look the same because they installed it without the spacer, which they thought was part of the old pump. I pulled up the parts fiche and showed them the missing piece.

It should be here Monday but I’m 99.9% sure this is the problem.

View attachment 2627115
Sorry I didn't get the pics up for you to reference while at the shop. Glad you got it figured.
 

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