My 2006 Prius Died Today...

Yes by far the most likely place it entered would have been the last fill point. I would have gone straight back to that station on the very same day and taken a sample from the same pump. To avoid the liability the service station might not admit to the problem, not if they think they can get away with it.

 

Well, we went back to the station this morning, and that particular station (ARCO) doesn't even carry diesel. I asked them if anyone has come in the past couple of days complaining about diesel in their gas, and they said I was the first. And it looked like the station was running business as usual, nothing shut down like I would expect if they would have to clean out their storage tanks.

So I'm very tempted to have the car towed to a smaller local shop with a good reputation, especially after reading the mixed reviews of the dealership on Yelp.

 

Ouch, flushing twice (plus the original tank of fuel) would cost $205 over here...

 

Indeed, but still less expensive by a factor of eight or so than replacing the tank.

 

I don't imagine you'd need to fill the tank all the way for each flush, and the flushed fuel could probably still be used in your lawn mower.

 

My lawn mower is a set of shears and some good exercise!

 

For the OP. How would they know that the catalytic converter is working properly? Did they perform and emissions test?

 

As my question is relevant to this thread, I thought I should attempt to resurrect this thread instead of starting a new one.

Problem and mechanic diagnosis:

My cousin (new driver) accidently filled up diesel (7 Gallons). Drove the car home (~ 5 miles). The car failed to start next morning. Towed to a local mechanic who diagnosed the fuel pump to be bad and replaced the fuel tank, spark plugs and fuel injectors. The car still did not start. DTC P3090. After sitting with mechanic for 10 days, I towed the car home.

DIY / Work at home:

At home, I have flushed the fuel tank / fuel lines again, cleaned MAF sensor / Throttle body and intake manifold. The car starts but dies after ~ 15 seconds. A lot of fuel is coming out of exhaust pipe. I tried disconnecting the fuel pump by removing the connectors under the rear seat and then tried starting the car with spraying the engine starter fluid in the throttle body. I was able to keep the engine going for ~ 5 minutes. I shut the car down and connected the tank again - but the car again started spewing fuel from exhaust pipe and the car shut down after ~ 15 seconds. I have checked and verified fuel injectors and they are in working order. DTC is still shown as P3090.

Looks like air / fuel ratio is not being correctly measured which is causing injectors to inject more fuel than required. Besides Air / Fuel Sensor (Upstream O2 sensor) what other sensors are responsible for Air / Fuel ratio? Any advise about what other sensors should I check?

Thanks

 

Correction: The DTC code is P3190.

Update: On a whim I removed the Purge line connected to Throttle body and started the car. The car started and engine ran for more than 2 minutes. No fuel in the exhaust but I collected 2 Gallons of fuel through purge line. I believe I have found the source of fuel coming through the exhaust but the problem still remains to be fixed i.e. why is Purge line spewing fuel. The tank is new so I would think the canister box is OK. I am hesitant to drop the tank to check all the connectors but looks like that is my only option. Any other thoughts / ideas ?

 

It sounds from your description that the fuel pressure and vapor purge lines that connect at the right front corner of the fuel tank (underneath the car) were swapped. Both plastic lines have similar connectors on them and I believe you can swap them and they will lock in place.

FYI the pressure line has the orange plastic clip on it and should go to the upper steel tube(the one that is disconnected here). On this pic I had a fitting and hose attached to the fuel pump line in order to pump the tank out.

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Thank You @ mr_guy_mann. This appears to exactly be the issue. The purge line was connected to the upper line and fuel line was connected to the lower line. I removed both the lines and connected the purge line to lower line. The fuel line connector however is not fully seating on the upper line. The plastic coating on the fuel line connector is bunged up and the fuel line connector. I am not sure if I remove all the plastic, will the fuel connector seat properly?

 

Wow, curious how he made the dots connect from diesel to new fuel tank/plugs and injectors...…..after that work, it may have been cheaper to buy another 2007.

 

Update: I removed the bunged up plastic from fuel line connector and was able to seat the fuel connector. No leakage so far.

With switching the fuel line and purge line, the car has now started. Ran it for more than 5 minutes. There is fuel leakage around the injectors which I believe were not seated properly when I opened them up for checking injectors. Will update once the car is fully running.

Thanks again @ mr_guy_mann for your insight about purge line and fuel line being swapped.