1997 4WD 2.7L - Fuel leaking from air drain of charcoal canister

I was smelling gas passing by the truck and noticed the truck was having a hard time getting fuel on initial start. Ended up finding that the fuel pressure gauge I had hooked up to the fuel filter had a snapped banjo bolt, reinstalled the original bolt and no more issues.

Next day I walk outside and smell even more gas and see a puddle under the driver's side frame under the door. The charcoal canister has an air drain that connects to the frame and it's leaking fuel. Also of note when I unscrew the fuel cap a lot of pressure comes out like a long sigh of trapped vapor.

While running the truck trying to figure out how fuel is getting into the charcoal canister I noticed the VSV for Vapor Pressure Sensor was really hot? I can't find a part number for that and I'm not sure how to test it. I would like for the truck to not be pissing fuel on the driveway.

 

Replaced the charcoal canister, seems to have fixed the leaking fuel maybe. Hard to tell because I've not been able to fill it with a full tank, I'm thinking the fuel assembly unit I got off Amazon is no good. I had replaced the old one because it was very rusty. When installing it felt like it was sitting high I'm thinking the float is stuck as the fuel gauge doesn't seem to change when I add fuel from the can.

When I open the gas cap I still hear a lot of pressure come out, and at the fuel pump the hand pump clicks off because of that same pressure. I've ordered a new pump off RockAuto I'll swap it out when that arrives.

 

I was wrong, drove it for a couple days but after it sits it starts to leak fuel out of the same air drain hose. I'm going to try replacing the fuel pump hopefully tomorrow not really sure what would be causing the pressure buildup in the tank.

 

There is a purge valve that should be opening to allow vapors from the charcoal canister to enter the intake manifold during certain operating conditions... really easy to check, it sounds like yours is stuck closed. Pressure when taking the fuel cap off is normal. As a secondary "thing" when it is warm outside you should hear a ticking from the canister, that is the pressure valve relifing pressure and that is normal. I have only heard this ticking on Tacomas that have the cannister on the D/S fender.

 

How do I go about checking if the purge valve is stuck? I had replaced the entire charcoal canister with valves is there something upstream that controls that I need to check?

This is the pressure relieved when taking off the fuel cap.
https://streamable.com/404urt

I found new spots of fuel leak on the front drivers and passengers side, passenger seems to be coming from the hose connecting the air box to the charcoal canister, drivers I'm not sure but it may be from the fuel injectors on cylinder 1 not being seated properly to the fuel rail. The gasket looks warped and it's giving cyl 1 misfire code with fuel leaking.

 

I have taken the valve off and put a hose on one side and my finger on the other hose connector, powered the valve with tiny jumper wires and drawn a vacuum with my mouth then disconnect and connect the jumper cables multiple times. If the internal seal leaks hopefully it will do this durring one of the power cycles. Yeah, it sounds silly but you do what you have to do with what you have.

Yeah, That seal doesnt look right.

 

Looks like it was the o-ring that failed... on all of them? Only the first one was noticably leaking. Admittedly I kind of jacked these from the Amazon special injectors I had issues with so... my bad

I ordered this seal kit:

$32 UREMCO 44301 15-4 Fuel Injector Seal Kit, 1 Pack

https://www.amazon.com/dp/B01GWWJ03C
Just got the filter baskets out gonna hit the store to get a few things to try to clean the injectors.

Got thefl fuel pump swapped out, the new one felt like it set in better hopefully that's a good omen. Did have issues with fuel leaking from the flare connector, saw a post where someone cleaned the gunk from the female end, did the same all better! Will see if that solves the evap canister leak too?

 

Got everything buttoned up new seals on injectors, doesn't seem to be leaking fuel like it was before. Gas tank doesn't have so much pressure when I open the cap anymore so I'm hopeful!

 

Bad news, fuel gushing out. Was driving fine then suddenly stalled while stopped at a light. Pulled into parking lot and died again and smelled gas.

Pulled codes and have a pending code P0401 exhaust gas recirculation flow insufficient. I don't believe this is related, I think that code is from EGR delete.

I could hear the charcoal canister ticking.

https://streamable.com/gjh7xj

Starting to think EGR delete was a horrible idea, wondering if that's what's causing the purge valve to remain open

 

I have a question I need help with. How do I know which of the 2 rubber lines that connect to the fuel assembly unit go to which port? I wonder if I got them mixed up.

 

I'm thinking I may have the evap vent tube and the return line mixed up...
Diagram showing the fuel return hose

when I follow this to the fuel tank it's connected to... fuel evaporation vent tube

 

Got those lines swapped, I'm like 99% sure that was the issue and that I'm an idiot. Cheers all and thank you!

Attached image of the lines after I swapped them to the correct spots