You mentioned an aftermarket fuel pump; how is it installed?

I'd start looking there; something like it spews fuel out a breather if the tank level is too high, or something - I'm guessing without knowing much about the fueling setup in the car, let alone what you have.

csg installed the pump, already gave David a holler waiting for a response

Fuel pump runs when you turn on the ignition. I believe it only shuts off after ecu detects target fuel pressure on the low pressure rail. If you have a leak [maybe] the pump just keeps going. The access panel is glued on underneath the left rear seat.

Or maybe it's a slow leak. A liter?

edit: Clarified intent to suggest possibility, not to state as fact. What the hell do I know?

Huffing gas while smoking cigarettes ....... ahhhh, the good old days ...... :D


humfrz

check the hoses around the evap cannister. It could be the rollover valve too. I'm betting that when the new fueling system was put in they missed a hose or the rollover valve was stuck open.

Crazy question- when you fuel up, does the fuel fill click off (when the tank is full) like it did before the new fuel pump was installed?

Yeah it clicks

update now happens every morning upon startup leaves puddle of fuel. Tried contacting csg but too slow to respond. Brought it to a Toyota dealership and they can't find a problem. Anyone know the cost to fix a gasket for the fuel tank? if that is the case.

every morning and you're still driving it, huh? after a month? we're talking about gasoline right? like you're car's leaking gas and you're still driving it every day? I can't possibly be understanding this correctly.

What's your point?

Only thing I can suggest is to have someone raise the car up and get the leak to occur, then just trace it to it's exact location and diagnose from there. From everything you've said I want to say it's the tank itself but it's mainly covered by protection pans, which means that if it really is the tank then it's a much worse leak than it looks like because the unburned fuel is pooling inside the pan and slowly leaking through. That could explain why you're always smelling unburned fuel in the back. That still wouldn't explain why the leaking only occurs at specific times and isn't constant, though.

Perhaps the tank is leaking constantly. Is your fuel gauge dropping suddenly between every drive? Is there always a pool of fuel when you start up and move? Or is it only when you start up in the morning and fill up the tank like you said?

He has had it checked by a Toyota dealer

He never said that they looked at the tank, though. If the leak only happens at the specific times he mentioned then Toyota wouldn't have seen it. The fact that he hasn't mentioned the exact spot where the fuel is leaking means that neither he nor Toyota have found it yet.

He never said that they didn't look at the tank either.

I only get a leak during start up and before it warms up small drops of gas til it's completely warmed.