My 93 4runner 3.0 has a fuel smell upon start up. This is a new engine just installed 2K miles ago. The smell has been there the whole time. When I start the engine it fires right up but there is a faint fuel smell in the cabin. I don't smell it in the engine compartment. I have boreascoped the injectors and all the fuel rail connections. I have checked the fuel canister and it seems OK, yet I haven't found the proper test yet. There seems to be no trace of fuel leakage. I boreascoped the cylinders and there is some wetting of the valves, but I would think that would burn off as soon as the engine fires. I have also had some issues with the Total Seal Rings sealing, but I believe they are seated now, since the smoking has stopped and it's getting 22 mpg.

Any suggestions? I am leaning toward the canister or a internally



leaking injector.

 

Is your vacuum line from the evap cannister through the TVV (Thermal Vacuum Valve) to the throttle body all connected correctly? Have you tested the evap cannister? http://web.archive.org/web/201003261...76evaporat.pdf

The FPD (Fuel Pressure Damper) at the back end of the RH Fuel rail can leak. I recommend running the fuel pump with the jumper, then putting a brown paper towel back under the damper (gasoline is so clear that it is hard to see on a white paper towel).

 

TVV is connected with new lines. I will still have to test the canister when I get a chance. The damper is also new, with a new sealing ring and torqued to factory spec and there is no visible leakage when using a bore a scope. I have put my fingers on the damper and it comes up dry. Does the fuel supply hose on these ever get saturated with fuel over time? Is that ever a problem on the Toyota?
Funny thing is it smells right through the firewall into the cab, yet all openings in the fire wall are sealed except for the steering column. I am talking as soon as the key is turned it smells and there is no smell on the engine side of the firewall. It's almost like it is inside the cab.
Once the engine fires the smell quickly dissipates.
I will test the canister and get back with the result.

 

The TVV lower line goes to the Throttle body and the upper goes to the canister, correct. I have had the one to the throttle body pull out before. I will also check that as well. It is not easy to see since mine has a two piece line there that connects behind the heater hose. Don't ask why, it was always like that. It is the one with the large loop connected to the throttle body. I will have to see that the bigger canister line is routed to the proper connection as well. And don't laugh at my quick disconnect for the canister strap. It works well.

 

Are your fuel lines actual "fuel" line or just rubber hose?

 

The fuel lines are the original OEM.
I have not been able to get to this issue because my wife is in the hospital, But I was able to scope the rail fittings and injectors and none are leaking. I did notice the drain line on the fuel canister hit the header and burned off so it is no longer draining below the firewall. The drain line now ends right at the area where the ac lines go through the firewall. I will replace that line when I have the chance and see if that fixes it.

 

If by "fuel canister" you mean Evap Canister, and by "drain line" you mean the rubber line at the bottom of the canister, that line is where air is pulled into the canister (then out to the throttle body). http://web.archive.org/web/201003261...76evaporat.pdf If it is blocked, the Canister can't be emptied into the intake, and I'm pretty sure that would cause a fuel smell.

 

I have also noticed I don't get the fuel smell when starting if when I shut down the engine I rev the engine slightly and turn the switch off at the top of the rev cutting the fuel injectors off to clear the cylinders.
I will also replace the hose on the evap fuel canister as well.