Fuel cap/fuel neck vapor leak 2021

I have a 2021 TRD sport I recently took in to the dealership to investigate a sucking sound coming from the gas cap area, and the fact that every time I tried to fuel up the pump would constantly kick off as if the tank was full. They determined it was an evap cannister leak and replaced it under warranty. After some discussion we figured out that my buddy who fuels up the truck for me sometimes was filling the tank to the brim of the neck and overfilling it (especially when using jerrycans)

After the cannister replacement both problems were fixed and truck was good as new... but a day later after the repair the truck threw a Check Gas Cap warning and the check engine light came on (this was the first time - it never came on prior to this) so I took it back a couple of times and they reset the codes and the problem persisted. They did a smoke test and said the gas cap gasket was damaged, and seemed to fit abnormally when they checked it. $80 later for a new gas cap, problem still persisting. They did a second smoke test and now have determined the smoke is leaking from the fuel neck, and it requires replacing (another 500 bucks not covered under warranty)

When I questioned them if this was a known problem on this model they said it was very rare an unusual, and it was probably caused from being overfilled as the secondary tubes near the upper part of the neck are not meant to have fuel in them and corrode, and that the difficulty fuelling up is a symptom of a faulty fuel neck as well. I told them when they replaced the evap cannister the problem was totally corrected, though, and the truck's engine light never came on until they worked on it.

If anyone wants to chime in and let me known if this sounds legit I'd appreciate it. My enthusiasm for the truck only extends to driving it, I'm afraid I'm not mechanically inclined enough to know whether I'm getting the runaround here. If it's something I genuinely did or caused I would love to know so I don't repeat it. Needless to say nobody is filling the truck up other than me from now on. Thanks.

 

Ask if they had to drop the gas tank to replace Evap Canister if so most likely they damaged your filler neck.

 

Pretty sure they don't drop the gas tank, the cannister just slides out from on top of it.

If its truly something I caused I'll eat the cost of it and call it a lesson learned. I just fail to understand why the truck is only throwing codes now, if the problem that caused it was the same problem that caused the evap cannister to fail. Frustrated, this is not the first "highly unusual" (their words) thing to go on this truck and I haven't even owned it for 4 years.

 

You're getting the runaround. Your friend did bork the original canister by topping off the tank, but since then after canister was replaced? That's on the dealer, sorry not sorry. The song & dance from them about the EVAP lines not being meant for exposure to fuel is laughable. It's exactly what they were designed to be exposed to.

Step #1 in the FSM for R&Ring the EVAP canister is, "1. Remove fuel tank assembly" so there's that. Whether or not the canister can be removed without tank dropping, or bed lifting? I do not know. Either way, there are hoses/connections between the tank, filler neck and canister itself that would've been disturbed during the canister R&R. The tech probably caused the issue with the filler neck, trying to make time and his shortcut bit him in the ass with a comeback. What's deplorable is them trying to pass the buck and make you pay for it.

 

Thanks. I had a good chat with them this afternoon, the smoke test revealed it's leaking from the very upper part of the filler pipe itself, which they fist assumed to be a gas cap leak, but after sealing the opening with a rubber glove they can see the smoke coming out from a little farther back.

When it was acting up and not letting me fill the tank properly prior to replacing the evap cannister, I found that backing the nozzle out and trickling the gas in was the only real way to get gas in the thing. They said these parts near the opening are not meant to have exposure to fuel... im still scratching my head at that part because you would think the entire pipe would be designed to handle exposure to fuel to some degree and not corrode like that. If that's really case then it seems like a design oversight.

In the end, what can I do. They gave me a break to cover for the extra gas cap I bought that I didn't end up needing. It needs replacing I guess I gotta just suck it and pick my battles.

 

Ask them if it's part of the emissions system and covered under the extended warranty for them. They are also full of crap that it shouldn't be exposed to gasoline. It's ALWAYS exposed to gas vapors.

 

I had an incident where I drilled a hole into my fill filler neck, ( yea, my own fault, ) any way I figured it out as it was leaking fuel while I was filling up at the gas station. I had read that dropping the gas tank was necessary, so that’s kind of more than I wanted to take on and probably more than I’m capeable of. Anyway, took to shop I trust, (not a dealer) and it turns out he didn’t have to drop the tank, If remember correctly the whole thing was somewhere in the $300-$350 range.

 

Yeah I questioned the warranty thing as I assumed I had extended warranty, but I only have "gold" extended warranty not platinum, which would have covered it. Frustrating. I can understand the charcoal cannister being pooched, but it boggles my mind that the head of the filler pipe can't take a bit of fuel being splashed on it. Apparently the pile itself has two components, and it's between the join of the main pipe and the head where the smoke his leaking out, hence why they thought it was leaking from the gas cap. I don't have much other option than just get it done.

 

That honestly sounds like a manufacturer defect, not something you, the customer did. There is a reason so many people absolutely hate dealers nowadays. They KNOW there is a manufacturer defect issue with them and yet, refuse repairs under warranty. Bypass them and call Toyota directly, politely tell them the issue, the incorrect parts the dealer replaced [this is likely why it's not covered, the dealer failed to diagnose properly and toyota already ate bills for incorrect repairs] the warranty you have, and see what they will do. I wonder if the dealer has even gotten with toyota after the last two misdiagnoses.

 

Just a thought. I do not know the actual lengths of time and milage, but isn't the evaporative system on a very extended emissions warrantee for all vehicles? I thought post #6 touched upon this.

 

8 years or 80,000 miles.

 

Thanks @fxntime for the clarification. It seems the OP did not pick up on this. It would not matter just what warrantee he has as we all have the same. If gas fumes have the ability to leak out into the atmosphere it is emissions as I understand it. So, if the OP has less than 80,000 miles, he should be good.