But you also don't tow or go off-road or drive across country so how would you know?
J1000, we've never meet, yet you presume to know me!
Regardless, now your implying not all boil fuel. Just one driven certain ways.
Just because it came that way from the factory doesn't mean it's best. There are so many other considerations that manufacturers have to juggle. Taking a wiring diagram as gospel and disregarding the physics of electricity is probably the wrong way to go about fixing problems.
I would agree with this. There are a few things IMHO need correcting.
But if hot wiring (bypass resistor) fuel pump, corrects fuel pump issue we see in 06-07. Then replacing fuel pump, would not correct. But it does, and does long term. It also keeps design as intended. Without any other mods or parts need replacing.
You've not really said why you hot wire FP, or did I miss that. If it's a case, of design flaw resulting in to little voltage. Wouldn't correcting output, be the best way to go!
Hot wiring fuel pump, I don't see as one cure. Sure it can be done, but at what expense. Seems your going down a rabbit hole on it already. In that you replaced the fuel damping device (FDD) with new OEM. Now, adjusting it pop up screw on FDD, which is a factory preset. You're the first I every heard of, need this replaced or adjusted. Is this in the same one you've 12 holes fuel injector. Is that causing some resonation in fuel rails. Or did the FDD, fail (screw not pop up). Is it the same pure ethanol 100s, that you insulated every fuel line. I've know idea which rabbit hole you've gone down!
FYI, mine has had the boiling/vapor lock issue. I'm sure it will still happen as I have done nothing to mitigate it. I don't put the truck in the situation enough to consider it a problem I need to address at this point. Not to belittle it as boiling fuel is a terrifying thing. It has happened in the typical situations of slow, bouncy 4x4 warm weather driving that gain considerable altitude. I've kept my truck where you put it at 100% in factory spec, other than the TT spark plugs(which I installed after the times it happened). This isn't a comment against you or your meticulous attention to detail with your work on my rig or any of the others you have had. In fact, all your observations are correct in that they will help contribute to the boiling happening. I'm just putting my experience out there as a data point. Factory spec will get the truck to the best chance at not boiling but is not a 100% guarantee that it won't happen.
There is no single reason for this problem. There have been a few solutions on here that have worked for some but don't show as the main reason as not everyone has had the same success.
At this point, I believe the main factors for this are:
- These trucks weren't designed for ethanol fuel. So the baseline from which we start is skewed right there.
- Agitating the fuel in the off-road scenario adds to that.
- Moving the evap canister didn't help this problem.
Those three factors are, IMHO, the main contributors to this problem. After that, all the other things like fuel line placement, friction from the pump, etc. factor in.
Hey Dace, good to hear from you.
I agree, for the most part. In "At this point, I believe the main factors for this are:
- These trucks weren't designed for ethanol fuel. So the baseline from which we start is skewed right there.
- Agitating the fuel in the off-road scenario adds to that.
- Moving the evap canister didn't help this problem."
Ethanol seems to be a contributor, to fuel boiling. As some have report, at least some relief using 100% gasoline. But I also know of ones, that were boiling fuel, that saw no relief switching to 100%.
But Toyota does imply, they did engineer for up to E10.
06-07 gas cap:
Dace, I don't recall if I ever mention. A one off issue I had in Butter. It was 7 years ago, when I was driving back from SoCA. Because I love driving 100s cross county. I took, the longer Northern rout back to Denver from SoCA, where I bough it. It was Sept and even driving along the CA/NV desert, it only hit about 90f OAT that day. That even after stopping for Dinner, at the eastern base of ridge to Lake Tahoe. We drove up and over to Lake Tahoe. Near the top of the ridge, I felt a shutter and saw RPM bounced a bit. Next day I check air filter, and found it to be the factory installed still in at 54k miles. It was the dirties I'd even seen.
What's interesting, is PO (I felt sold) do to shutter. Service history at Toyota showed he bought in for a shutter. I was shocked Dealerships, didn't replace the air filter. But perhaps a little more was going, perhaps with tank pressure. IDK. But, I replace air filter while on may way to Salt lake City, a day or two later. The shutter never happen again. It also was very clear, the dirty filter was affecting fuel trims (ECM). As the MPG drop drastically, after installing the new air filter. Perhaps Butter has had an event, where Charcoal Canister has flood, before or after my 3 months I had it.
- "Agitating the fuel in the off-road scenario adds to that."
I couldn't agree more. This is a big deal. The earliest advice in mud I recall, from the off road crowd: DO NOT TOP FUEL TANK, BEFORE A TRAIL RUN.
It seem the idea there, was to leave expansion room. Which trail agitating, result in expansion and increase tank pressure. Adding that, high summer OAT, sun and lower boiling point with increase in altitude. Would be the same as overfilling fuel tank by squeezing pump handle after auto shut off. Even filling fuel tank, stopping at first at first auto pump handle shutoff. Could result in over filling, on a hot day. Since fuel comes out of storage underground storage cooler than OAT and expands with great OAT and road temps in the summer. Also we need to consider, angles. As incline's and tilt, can be much greater off road,. This too, if a full tank, could flood the CC.
Why does over filling matter. Your next point:
- "Moving the evap canister didn't help this problem."
This is a bad design by Toyota, IMHO. I see much less issue in the 98-02 CC, than the 03-up was when Toyota moved the 100s CC to the rear.
Since I starting, looking at the fuel boiling issue around 2020. It's the Charcoal Canister (CC), I've found to be an issue with most fuel boiling. That is once all upstream issue with coolant system, engine and transmission corrected back to factory spec. Which most 100 series, that come and ask me to look over. Have many upstream issues. Most are running hot (above 200F), and don't know it. The CC being issue that must also be corrected, is much more prevalent in the 03-07.
One 05, was the worst cases I've seen. Even after all upstream issues corrected, which there were many. It was so badly "fuel boiling", even driving around Denver on an 70F OAT day, vapors could be seen and smelt. The smell, started out as bad gas smell. Like gasoline sitting in a gas can for years. Than fresh gasoline mixed in to smell, as engine run for awhile. It then started stalling, while idling at a stop in D. Once CC replaced, problem solved. At least on my test drives, and lack of report to the contrary over the last year. I'll note: It was being fuel to the top, squeeze pump handle repeatedly after auto shut off of pump handle. Until I warned them not to. It was also, used off road fishing & camping. It's CC felt considerable heavier, than new going in. Heaviest I've pulled.
Also consider:
Some venting is normal. In the OM it states, some hissing when remove gas cap is normal. It's why the cap has a check valve, it release pressure once system design pressure exceeded.
03-05 gas cap