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Discussion Starter #1
So here we are again, warm spring days are getting me to use the AC a little. I get fuel smell in my car with the AC on. I am unsure if it does it with the heat on, I should test that.

It only does it after driving the car for a while.

Little history here;

1. Just replaced FPR
2. repaired charcoal canister and system upfront last summer. Made no difference then and no difference now
3. gas tank gets horribly pressurized, I assume this is where the problem lies.

I assume I need to replace the rest of the lines at the fuel tank area to fix a collapsed hose within the EVAP system. There are only soft lines at the tank and charcoal can right?

Is it possible that fuel vapor smell in the cab is coming from the tank area? This is the only thing I can think to be the problem at this point. I have no fuel leaks at the rail or injectors. I have no fuel leaks period actually..

I do need to replace the tank area lines, just havent had the want to get under this stupid thing to mess with it.
 

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Discussion Starter #3
check this again for any leaks. also pull the vacuum nipple on FPR after you shut the motor off....is there any fuel in that nipple?
I've pulled the vacuum line with car running. Its dry.

I've even sniffed that vacuum line for possible fuel soaking smell. Nothing.

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The EVAP purge valve may be FU letting fumes in engine bay migrate into vents...

at the age of our cars EVAP components and the lines and hoses involved fatigue

if you smell gas fumes...gotta find the Why

Confirm the main fuel lines are not weeping at the connection to fuel rail
 

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Though this doesn't address your root cause, it might be why it's getting into the cabin. Check you body seals. For me, it was the trunk after I got hit in the back. The trunk no longer sealed. It was fine during the winter, spring, fall when using heat or vent as it maintained positive cabin pressure. Once it got warm enough to be driving with windows open, it's like it created negative pressure at highway speeds and i could smell the exhaust coming into the car. Once I replace the bumper and straightened out the tail light panel so it sealed again, the fumes went away.
 

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Discussion Starter #6
Though this doesn't address your root cause, it might be why it's getting into the cabin. Check you body seals. For me, it was the trunk after I got hit in the back. The trunk no longer sealed. It was fine during the winter, spring, fall when using heat or vent as it maintained positive cabin pressure. Once it got warm enough to be driving with windows open, it's like it created negative pressure at highway speeds and i could smell the exhaust coming into the car. Once I replace the bumper and straightened out the tail light panel so it sealed again, the fumes went away.
I guess I forgot one detail..

It only smells through the vents when I am dead stopped. Even the slightest movement keeps the smell out of the vents.

Crazy to think I never had this issue when I lived in Dallas and used the AC a lot in the summer and never had problems. It only started after I moved cities.

The only thing I did right before I moved from there to here was 'reseal' the intake manifold. But I did it right. All new seals and orings etc.

Nothing to do but get the evap system working and go from there. The gas cap always has a TON of pressure. Even when I command 100%evapDC through scan9495, the pressure remains the same.

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