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Old 12-14-2012, 09:50 AM   #1
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Join Date: Dec 2012
Fan#: 107269
Location: Eaton Rapids, MI
What I Drive: 2005, Silver, ZX5

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Dreaded Can't fill gas tank problem

Okay, I have a 2005 zx5. Owned it since new.

All of the sudden it takes 30 minutes to fill up because of fuel splash back on the pump nozzle turning pump off.

I have read many posts on the problem, but really don't see where anyone has found a solution.

1) Spider nests in vent tube.
- I have removed both the vent tube. No clogs

2) Some type of clog in fill tube.
- I have pulled the fill tube. First I tried running a siphon hose through. Hose would not go through, so I thought this might be the problem. After pulling the tube have declared it clear.

3) Pulled gas tank to check tank venting.
- Tube is clear to the charcoal/EVAP canister.
- Exit tube from EVAP Canister clear to Fuel Vent, up to Fuel Fill.

Apears the The Charcoal Canister/EVAP is the problem.

So, here's where I need help. The Charcoal Canister/EVAP is wedged above and between the rear end and the bottom of the vehicle body. How is this thing suppose to come out?

After looking at it for a few nights, I am thinking I will cut a huge hole in the floor panel by the spare tire and pull it out the top. Otherwise I think I need to drop the rear end - at least one side.

Anyone ever replace the Charcoal Canister/EVAP that can help me out here. Anyone have the Ford Service manual that can shoot me the directions for Removal/replacement?

Thanks, any advice appreciated.

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