Thursday, Nov 30, 2006 at 18:09
John,
Our petrol FJ75 did that once upon a time. It was very expensive.
Mine has 2 solenoid operated valves in the lines between
tank and pump. One selects which
tank to draw fuel from, the other selects which
tank to return excess fuel to. One of my valves failed so that fuel was sourced from one
tank and the excess returned to the other
tank (just as you have described.) When the receiving
tank is already full of fuel, something has to give. In my case, after the engine was turned off, fuel was forced through into the carby, (maybe through the fuel pump, maybe through the vent line, carbon filter etc). From there it overflowed to the inlet manifold and into the cylinder/s. Hit the starter, piston slams up and tries to compress the incompressible fuel, (a hydraulic lock) bends the con rod, very lucky not to break it (and the crank shaft). Cost - thousands.
How does it happen? There are no filters between the tanks and the valves so any rubbish, rust, etc in the tanks can reach the valves. If either one gets jambed in one position, there's a 50% chance excess fuel will be returned to the wrong
tank. Toyoto doesn't deserve top marks for this design effort. There should be a filter in each line drawing from the
tank. There should be one double changeover valve, rather than 2 independent valves. My troopy now has filters, though I had fitted 2 independent valves before realising the importance of using a double (multiport) unit. Suggest check out your valves - attached in my case to the main chassis member under floor below the driver's
seat.
Hope you find something better than I did!
John
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