Gas tank building excessive pressure & fuel smell. Dangerous for sure! Why does this happen? (8 Viewers)

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What constitutes a good number for fuel trim? And which fuel trim numbers do you use on torque pro?

When cleaning the radiator, do you just blast a jet of water at the fins? Or is there some special method?

I'm getting fuel smells and long venting (60 sec +) after a big steep slow climb OAT 97F, 1/2 tank of ethanol free 88octane, 7-9k elevation

196K miles 2003
ECT reached 215F
Running new fan clutch at 195K
coolant flush, new water pump and timing belt at 179K

orig radiator, cap and t-stat I believe.
Images of stats.

Screenshot_20200725-115230.jpg
Screenshot_20200725-121852.jpg
 
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At 196k miles, I’d forget about cleaning the radiator and instead replace it with new ASAP.
I was considering that, though I have read from more than a few members that age/mileage isn't a direct correlation to condition/health. Rather the maintenance history and coolant used reflects the longevity of the radiator.

Any one else have input on this?
 
Within the last 2 months I've done:

O2 sensors (pre cat)
Fuel Pump (OEM)
Fan Clutch (OEM)
Built heat shield and wrapped fuel lines
Radiator is less than a year old (OEM)
Coolant is fresh and correct

Truck runs cool. Never see it get above 190.

I leave for Silverton on Sunday to run trails all next week. So I'll be testing with and without Ethanol free fuel. I will also be recording engine temp the whole time.

I was going to swap out EVAP system parts too before I leave but I want to do some testing and see what works. If I replace everything at once we won't get a lot data. Parts I have on hand with me to swap out during the trip are all the vacuum lines under the hood, VCS (2586050100) under hood, fuel pressure regulator (2328050050) and CC. All OEM parts. I'll keep everyone posted!

UPDATE: Today we ran Mineral Creek (slow rocky uphill that seemed a lot rougher that last year, lots of spotting) to Engineer Pass (12,800ft) then later to California Pass (12,960ft) all with normal ethanol gas. Zero issues. Engine temp never got above 190. I kept the engine on at all passes. Zero gas smell. Night and day difference from last year! Last year in colder weather I had boiling fuel on half dollar which is nothing. Tomorrow is Ophir and Imogene and I’ll keep everyone posted. At this point I’m not even going to try non ethanol fuel.
 
Looking at the system diagram in the FSM, I'm focusing hard on the purge VSV. I'd love to know if any vehicle experiencing excess pressure has a functional purge VSV and line and whether or not it's activating when needed. If the valve works and is just not activating the problem could be one of the many input parameters to the ECM or there could be an input sensor with a potential failure at high altitude.

I imagine a manual trigger switch for the VSV could solve the issue by forcing it open, allowing vent into the intake manifold (as is factory plumbed).

Step one would be for someone experiencing this reliably to run the Techstream utility that activates the purge VSV. If you can run the utility while the venting is occurring out the gas cap you should hear the engine respond when the utility is run and pressure is vented suddenly. If you run the utility on and off with no change in engine sound, my guess would be the purge VSV is not working and that's the culprit.

@2001LC I wonder if you ran this utility on your troublesome car before the issue was fixed.

How do you trigger this in Tech Stream?
 
Something I noticed last week was that my LX has ZERO pressure in the tank, at any time I've ever noticed. Every time I fill up, there's zero pressure. Not a little, completely zero. Low elevation, high elevation, hot temp, doesn't matter. My 99 always has some pressure. The 99 has had the gas vent problem on multiple occasions, the LX has not (to date, granted it's still new to me this year). I suspect the 99 is not managing tank pressures properly and the LX is.
Same with my LX. I've posted about it a ton also but alas here we are. That is #2 behind heat IMO. Without pressure in the tank the fuel can boil that much easier.

In the charcoal canister thread I posted about my experience pressurizing the fuel tank with compressed air. The filler neck leaks on my truck around the outside where a plastic collar is molded on. I believe this is a check valve or overpressure valve that has failed. I think having the fuel tank vented to the atmosphere is also contributing to my horrendous fuel mileage that doesn't change no matter what fuel or driving habits I use.
 
Same with my LX. I've posted about it a ton also but alas here we are. That is #2 behind heat IMO. Without pressure in the tank the fuel can boil that much easier.

In the charcoal canister thread I posted about my experience pressurizing the fuel tank with compressed air. The filler neck leaks on my truck around the outside where a plastic collar is molded on. I believe this is a check valve or overpressure valve that has failed. I think having the fuel tank vented to the atmosphere is also contributing to my horrendous fuel mileage that doesn't change no matter what fuel or driving habits I use.

To be clear, I think pressure is important in that the tank should disallow high pressure (pressure should remain very low). Higher pressures keep the hydrocarbons in liquid form at higher temps, but I think the OEM system is only designed to hold a very small internal tank pressure roughly equal to the vapor pressure of typical fuels - far less than people are experiencing when they start to get prolonged, violent venting out of the gas filler area.

If the tank allows high pressures, then the last resort safety valves will vent (gas cap and the filler vent thing). I believe the OEM purge system is a part of what is meant to prevent the pressure from ever building high enough to trigger the last resort safety valves.

I thought about this more and I think common temps on the highway in hot climates are 160F+. The fuel system should work flawlessly with fuel temps at a minimum at 160F. Ambient temps 10" above the road surface in rush hour traffic in Phoenix in summer are probably 130-140F+. Unless folks have fuel temps in excess of 200F, I just can't see temp being the culprit here. A contributor that likely highlights the problem, yes, but not the root cause. That pressure should be managed by something other than the safety vents.
 
UPDATE: Today we ran Mineral Creek (slow rocky uphill that seemed a lot rougher that last year, lots of spotting) to Engineer Pass (12,800ft) then later to California Pass (12,960ft) all with normal ethanol gas. Zero issues. Engine temp never got above 190. I kept the engine on at all passes. Zero gas smell. Night and day difference from last year! Last year in colder weather I had boiling fuel on half dollar which is nothing. Tomorrow is Ophir and Imogene and I’ll keep everyone posted. At this point I’m not even going to try non ethanol fuel.

I ran all the same trails last week, most of them with full tank or nearly full tank every day vs half tank last year. I was using 87 or 88 octane fuel with stated 10% ethanol content. I never had any boiling issues, didn't have any staining on the side of the truck but I did have an occasional wiff of fuel vapor and some marginal pressure at the gas cap; but it was quite random. I don't have any heat shielding, or fuel line wrap, still have original canister. Some 12,000+ trails were fine and others even at lower elevation produced some vapor smell. In previous years I left my engine running constantly at elevation, this year I shut my engine off on several high passes as a test and didn't have an issue to report. I think it might be due to how quickly you ascend altitude. Corkscrew rises pretty quickly and I noticed some vapor smell at the 1/2 way stop 10,000ft +/- before you climb up to the pass. Full tank of 88octane 10% ethanol blend ascending Black Bear and no vapor smell or pressure indication. I will say that the ambient temps were cooler this year than last year- avg 50's-60's at higher elevations last week and rainy vs 70's + and sunny last year. Engine temps climbing passes were 186-190 and trans temps never exceeded 132F. On down hill slopes of trail decnends, lowest recored engine temp was 179 and lowest trans temp was 107! I do have fan clutch mod in place which moves a fair bit more air at low speeds and rpms up to 3,000rpm +/-.

Hwy driving through Salida (7,000 ft +/-) 80's ambient temps ( had been driving for several hours, I noticed some vapor smell and my gas cap self-venting. Removing the gas cap very warm moist vapor escaped, it condensed on my hand quickly, while not overly pressurized but I could feel it lightly outgassing warm vapor for several minutes. Engine load, heat soak from road has some impact. Turn up your volume and if you listen closely to the video you can hear my fuel cap venting:

 
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To be clear, I think pressure is important in that the tank should disallow high pressure (pressure should remain very low). Higher pressures keep the hydrocarbons in liquid form at higher temps, but I think the OEM system is only designed to hold a very small internal tank pressure roughly equal to the vapor pressure of typical fuels - far less than people are experiencing when they start to get prolonged, violent venting out of the gas filler area.

If the tank allows high pressures, then the last resort safety valves will vent (gas cap and the filler vent thing). I believe the OEM purge system is a part of what is meant to prevent the pressure from ever building high enough to trigger the last resort safety valves.

I thought about this more and I think common temps on the highway in hot climates are 160F+. The fuel system should work flawlessly with fuel temps at a minimum at 160F. Ambient temps 10" above the road surface in rush hour traffic in Phoenix in summer are probably 130-140F+. Unless folks have fuel temps in excess of 200F, I just can't see temp being the culprit here. A contributor that likely highlights the problem, yes, but not the root cause. That pressure should be managed by something other than the safety vents.
Again, I think you are just talking past me. I tried to pressurize my tank. It won't even hold .5 psi. Is that "high pressure?" Have you done similar tests or is this just written based on theory?

Secondly, we have a member in this forum in Vegas saying his truck dies and can't be restarted until it cools down. What should happen is clearly not what is happening.
 
I had a really scary incident yesterday with my 100's fuel system. I started my 100 series and instantly got a strong fuel smell in the cabin. I remembered this thread so I went over to the tank and listened for boiling fuel, I didn't hear anything but when I opened the cap a huge amount of pressure released. The truck had been sitting so I figured maybe bad gas and went for a drive around the block....big mistake.

After a couple minutes I went back home to take another look and noticed fuel gushing out the front of the vehicle. The plastic hardline that runs between the fuel filter and the engine cracked open when I started my vehicle. It was shooting high pressure fuel into hood insulation. The cause of this looks like a loose hose bracket which caused the evap/vacuum lines to slowly rub away at the fuel line over 250k miles. I am really lucky this happened when the engine was cold.
 
I had a really scary incident yesterday with my 100's fuel system. I started my 100 series and instantly got a strong fuel smell in the cabin. I remembered this thread so I went over to the tank and listened for boiling fuel, I didn't hear anything but when I opened the cap a huge amount of pressure released. The car had been sitting so I figured maybe bad gas and went for a drive around the block....big mistake.

After a couple minutes I went back home to take another look and noticed fuel gushing out the front of the vehicle. The plastic hardline that runs between the fuel filter and the engine cracked open when I started my vehicle. It was shooting high pressure fuel into hood insulation. The cause of this looks like a loose hose bracket which caused the evap/vacuum lines to slowly rub away at the fuel line over 250k miles. I am really lucky this happened when the engine was cold.
I think when these occurrences happen- its important to file a NTSB Vehicle Safety complaint to record the concern.

 
I ran all the same trails last week, most of them with full tank or nearly full tank every day vs half tank last year. I was using 87 or 88 octane fuel with stated 10% ethanol content. I never had any boiling issues, didn't have any staining on the side of the truck but I did have an occasional wiff of fuel vapor and some marginal pressure at the gas cap; but it was quite random. I don't have any heat shielding, or fuel line wrap, still have original canister. Some 12,000+ trails were fine and others even at lower elevation produced some vapor smell. In previous years I left my engine running constantly at elevation, this year I shut my engine off on several high passes as a test and didn't have an issue to report. I think it might be due to how quickly you ascend altitude. Corkscrew rises pretty quickly and I noticed some vapor smell at the 1/2 way stop 10,000ft +/- before you climb up to the pass. Full tank of 88octane 10% ethanol blend ascending Black Bear and no vapor smell or pressure indication. I will say that the ambient temps were cooler this year than last year- avg 50's-60's at higher elevations last week and rainy vs 70's + and sunny last year. Engine temps climbing passes were 186-190 and trans temps never exceeded 132F. On down hill slopes of trail decnends, lowest recored engine temp was 179 and lowest trans temp was 107! I do have fan clutch mod in place which moves a fair bit more air at low speeds and rpms up to 3,000rpm +/-.

Hwy driving through Salida (7,000 ft +/-) 80's ambient temps ( had been driving for several hours, I noticed some vapor smell and my gas cap self-venting. Removing the gas cap very warm moist vapor escaped, it condensed on my hand quickly, while not overly pressurized but I could feel it lightly outgassing warm vapor for several minutes. Engine load, heat soak from road has some impact. Turn up your volume and if you listen closely to the video you can hear my fuel cap venting:


What fan clutch mod do you have installed? Did you replace your fluid with higher viscosity?
 
I had a really scary incident yesterday with my 100's fuel system. I started my 100 series and instantly got a strong fuel smell in the cabin. I remembered this thread so I went over to the tank and listened for boiling fuel, I didn't hear anything but when I opened the cap a huge amount of pressure released. The truck had been sitting so I figured maybe bad gas and went for a drive around the block....big mistake.

After a couple minutes I went back home to take another look and noticed fuel gushing out the front of the vehicle. The plastic hardline that runs between the fuel filter and the engine cracked open when I started my vehicle. It was shooting high pressure fuel into hood insulation. The cause of this looks like a loose hose bracket which caused the evap/vacuum lines to slowly rub away at the fuel line over 250k miles. I am really lucky this happened when the engine was cold.
Yikes! That's a good reminder to change out our fuel system soft lines at preventative maintenance on these older rigs. I'm glad it didn't turn into a really bad scenario for you!
 
Again, I think you are just talking past me. I tried to pressurize my tank. It won't even hold .5 psi. Is that "high pressure?" Have you done similar tests or is this just written based on theory?

Secondly, we have a member in this forum in Vegas saying his truck dies and can't be restarted until it cools down. What should happen is clearly not what is happening.

Don't mean to talk past you, sorry.

.5 psi would not be what I consider high pressure, no. When people experience this gas vent phenomenon I'm assuming it is far greater than .5 psi of pressure in the tank. I estimate (wild ass guess) it would take upwards of 10 psi (the vapor pressure limit of gasoline in the US) to cause the blowout vent scenarios. A component or series of components is failing which allow unsafe pressures to build in the tank. Given everyone's intermittent occurrences with this phenomenon, I'm guessing the failures come and go (perhaps with heat or vibration or the phase of the moon). If you've experienced the venting, perhaps the components were cooperating when you manually pressurized and were in a filed state when the venting occurred.

I have not measured tank pressure on a vehicle that is currently violently venting (or on a 100 in any circumstance). I don't think anyone here has, but it would be an extremely valuable data point.

There is a leak detection pump within the EVAP system with a pressure sensor that feeds back the ECM. I wonder if something related to that pump might tell the ECM to not open the purge VSV.
 
What fan clutch mod do you have installed? Did you replace your fluid with higher viscosity?
Yeah I experimented with a new fan clutch- draining the little bit (20ml +/-) of stock fluid and replacing with 1 bottle (59ml) 20kcst silicone fluid. I also double checked to make sure what temperature the valves fully opened. I did this last fall, but this was the first cross country test and mountain off road conditions. I need to play with the adjustment- the clutch stays hooked up and releases slower at higher rpm's than I would like it to.
 
We live at 500 ft in NY.

We are in Grand Junction till late August.

But this started happening to the truck roughly in Kansas.

New gas cap installed last week. All vacuum lines have been replaced. FF is new.

CC hasn’t been replaced and is original. Could be the CC but truck would have thrown codes.

Funny thing is my Prius is fine out here. :lol:

Another +1 for the best toaster ever made. :lol:
We missed you in Silverton-......
 
What constitutes a good number for fuel trim? And which fuel trim numbers do you use on torque pro?

When cleaning the radiator, do you just blast a jet of water at the fins? Or is there some special method?

I'm getting fuel smells and long venting (60 sec +) after a big steep slow climb OAT 97F, 1/2 tank of ethanol free 88octane, 7-9k elevation

196K miles 2003
ECT reached 215F
Running new fan clutch at 195K
coolant flush, new water pump and timing belt at 179K

orig radiator, cap and t-stat I believe.
Images of stats.

View attachment 2386866View attachment 2386865
So this is a prime example of engine (ECT) running to hot and fuel boiling. This is great anecdotal evidence and data. Thanks for posting! ;)

Whereas it not a bad idea to replace radiator. I'd be inclined to first clean the fins of radiator, see what outcome is. I'd also replace radiator cap and thermostat with new OEM.

You may also want to reflush using BG Flush & Cool kit. Make sure you drain block drains and examine flush distilled water for color and practicals. This will yield clues of health of radiator. Use compressed at ~10 PSI ,to blow out system before filling with Toyota coolant. That way you'll get most distilled water out. IIRC 03 is Toyota SLL "Pink". Personally I prefer "Red" LL at 50/50 distilled water. But I stick with whatever Toyota OEM recommends for the year.

I've a 90 degree wand for my HP washer. I blast water from inside out, from between fan blades. I pull #1 skid and wash between all radiators. I blow water in from front also. I repeat and repeat and repeat as many times as it take.

LTFT are what engine is doing to correct STFT. Yours are okay. We see LTFT 2.5 to 5.5 often. Closest to zero is goal of ECU. The 5.5 indicates bank 2 running a little lean (hot). ECU is correcting the baseline of STFT to richen the mixture, in your screen shot.

UPDATE: Today we ran Mineral Creek (slow rocky uphill that seemed a lot rougher that last year, lots of spotting) to Engineer Pass (12,800ft) then later to California Pass (12,960ft) all with normal ethanol gas. Zero issues. Engine temp never got above 190. I kept the engine on at all passes. Zero gas smell. Night and day difference from last year! Last year in colder weather I had boiling fuel on half dollar which is nothing. Tomorrow is Ophir and Imogene and I’ll keep everyone posted. At this point I’m not even going to try non ethanol fuel.
Now that too is great anecdotal evidence and data. Thanks for posting!:cheers:
This is what I'd expect to see ECT at. It speaks volumes, as to health of your engine and it's cooling system. Nice JOB! It also show this is not a systemic problem with all 100 and 200 series. Even a heavy aromed like yours. Which is what I'm seeing time and time again with my anecdotal evidence of manly stock rigs.

BTW. Do you have Slee bell pan armor or any brand?

To be clear, I think pressure is important in that the tank should disallow high pressure (pressure should remain very low). Higher pressures keep the hydrocarbons in liquid form at higher temps, but I think the OEM system is only designed to hold a very small internal tank pressure roughly equal to the vapor pressure of typical fuels - far less than people are experiencing when they start to get prolonged, violent venting out of the gas filler area.

If the tank allows high pressures, then the last resort safety valves will vent (gas cap and the filler vent thing). I believe the OEM purge system is a part of what is meant to prevent the pressure from ever building high enough to trigger the last resort safety valves.

I thought about this more and I think common temps on the highway in hot climates are 160F+. The fuel system should work flawlessly with fuel temps at a minimum at 160F. Ambient temps 10" above the road surface in rush hour traffic in Phoenix in summer are probably 130-140F+. Unless folks have fuel temps in excess of 200F, I just can't see temp being the culprit here. A contributor that likely highlights the problem, yes, but not the root cause. That pressure should be managed by something other than the safety vents.
Pressure in tank and atmospheric pressure, is reason I replaced the FPR. But it still just a hunch on my part. Thinking was: FPR may be one more factor in high fuel tank pressure. That to much returning fuel to fast, may overwhelm increasing pressure..

I do agree with you on OAT and blacktop radiant temps. These rigs can handle it, when basic are inline as they should be. Or we see this in every 100 & 200 series and many fires. DOT would have had a field-day! But for sure, OAT and radiant heat does contribute to fuel, cabin and drivetrain temps. But should not ever cause fuel boiling to point of overwhelming EVAP or causes a dangerous condition. At least not on this planet as we know it today!

One only needs to keep up PM as spelled out in OM & FSM. Which also included washing radiator fins, remove dirty & debris. Than this should only be issue if a failure occurs. Which is rare if OM followed, like "do not fill gas tank past auto shut off of pump handle". That was clearly spelled out in the 2003-up OM from Toyota. I'd add, that fuel boil building creating excessive pressure, may damage EVAP components.

My question has always been. Does off road modifying vehicle cause issue with EVAP. By reducing air flow, retaining heat and heavy weights work drivetrain harder.???

But We're seeing rigs like @abuck99 and @guardcompany built. The ECT are just fine. They do not have fuel boiling issues of any concern. One of the most off-road built rig I've ever had the pleasure of working on, belongs to @gungriffin. Yet he has no fuel issue. Interesting, His TRD package, has a 160F thermostat and he run what I'd call too cool for a stock engine.

Whereas @J1000 is indicating he at least had fuel boiling issue, before installing many heatshield in the system, even a fuel cooler. Some cool stuff...;) But that is a modified fuel system engine and not the norm in most built rigs. His data is valuable, but for very different reason. He points to the many in mud with this issue and engine stalls. In places like LV NV. But the key in all cases: Is the vehicle up to spec with PM. My anecdotal evidence says 90%, of all 100 series are not up to spec. 100 series are so over engineered, they'll keep running under very poor maintenance condition, that would kill most vehicles. But just because it gets down the road, does not mean it's fit. I can assure you, my anecdotal evidence of more 100 series than I can remember inspecting and working on. Most need a lot of work. But then it's the sick ones that come to me the most. Yet even so, most do not have the fuel boiling issue. BTW, all I see are running blended fuels.

I ran all the same trails last week, most of them with full tank or nearly full tank every day vs half tank last year. I was using 87 or 88 octane fuel with stated 10% ethanol content. I never had any boiling issues, didn't have any staining on the side of the truck but I did have an occasional wiff of fuel vapor and some marginal pressure at the gas cap; but it was quite random. I don't have any heat shielding, or fuel line wrap, still have original canister. Some 12,000+ trails were fine and others even at lower elevation produced some vapor smell. In previous years I left my engine running constantly at elevation, this year I shut my engine off on several high passes as a test and didn't have an issue to report. I think it might be due to how quickly you ascend altitude. Corkscrew rises pretty quickly and I noticed some vapor smell at the 1/2 way stop 10,000ft +/- before you climb up to the pass. Full tank of 88octane 10% ethanol blend ascending Black Bear and no vapor smell or pressure indication. I will say that the ambient temps were cooler this year than last year- avg 50's-60's at higher elevations last week and rainy vs 70's + and sunny last year. Engine temps climbing passes were 186-190 and trans temps never exceeded 132F. On down hill slopes of trail decnends, lowest recored engine temp was 179 and lowest trans temp was 107! I do have fan clutch mod in place which moves a fair bit more air at low speeds and rpms up to 3,000rpm +/-.

Hwy driving through Salida (7,000 ft +/-) 80's ambient temps ( had been driving for several hours, I noticed some vapor smell and my gas cap self-venting. Removing the gas cap very warm moist vapor escaped, it condensed on my hand quickly, while not overly pressurized but I could feel it lightly outgassing warm vapor for several minutes. Engine load, heat soak from road has some impact. Turn up your volume and if you listen closely to the video you can hear my fuel cap venting:

Great data, THX!
See there you go; 186 -190f ECT in a heavy climbing passes. A well tuned and maintained heavy built 100 series. No unusual temps issues climbing off road passes at high altitude... Nice job my friend!

So it seems built is not big issue, even with full belly pan. May be adding 3f to ECT. I do recall you did the fan clutch mod. That may be helping you keep ECT in line.

Undoubtedly normal US fuel blend is a factor. But still in properly maintained rig, it should not really be factor, that's of high concern.

You should be able to keep those temps w/both AC running, IMHO. Which is hotter ECT, than I'd expect in a stock rig. But not so much as to overwhelm the EVAP.

Will be interesting to see you swap out FPR. See if that minor tank pressure "Removing the gas cap very warm moist vapor escaped" reduces/improves.
I think when these occurrences happen- its important to file a NTSB Vehicle Safety complaint to record the concern.

I think it's import he tune this puppy. Tune includes inspecting all lines and coolant system service. I bet I'd find a ton of work to do on this one.
 
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I had a really scary incident yesterday with my 100's fuel system. I started my 100 series and instantly got a strong fuel smell in the cabin. I remembered this thread so I went over to the tank and listened for boiling fuel, I didn't hear anything but when I opened the cap a huge amount of pressure released. The truck had been sitting so I figured maybe bad gas and went for a drive around the block....big mistake.

After a couple minutes I went back home to take another look and noticed fuel gushing out the front of the vehicle. The plastic hardline that runs between the fuel filter and the engine cracked open when I started my vehicle. It was shooting high pressure fuel into hood insulation. The cause of this looks like a loose hose bracket which caused the evap/vacuum lines to slowly rub away at the fuel line over 250k miles. I am really lucky this happened when the engine was cold.
To bad you're not in Denver. I'd love to have a look at this one. Do you work on these/this one yourself?
Can you post a pic of this "plastic hardline" crack. Only hard plastic, is part of the retainer, IIRC!
 
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Ton of work? Eh not really. I've done new all OEM steering rack/ radiator/ clutch fan/ shocks/ thermostat /CV's all DIY in the last year. Maybe a few hose brackets were loose but its maintained well. I'm not sure if a fuel line inspection is part of a normal service. Cooling system never goes above 193F.

I normally would DIY this job but I have a LS 80 series now that needs all my time so this one got towed to a LC specialist. It was a pinhole crack in the plastic inner line. I could see where the rubber outer part had warn down but it wasn't exactly clear what was rubbing on it. Also, I can't tell if the damaged rubber outer portion is due to friction wear or when the line ruptured it blew the rubber outer part off since 60psi fuel would probably do that. I've only had this for 20k miles so its very possible it was damaged by a VC gasket job done by the prior owner. I'll ask for the old line when it gets replaced.

The fuel line is rubber on the outside but has a hard plastic inner I believe. I'll double check when it gets back but I'm 90% sure it has a plastic core.

Also, to reiterate, I do not think it was caused by any increase in fuel tank/line pressure. It was definitely caused due to wear on the line itself. But I should probably stop speculating until I get the line back...:)
 
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