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NitroMan 12-14-2012 10:50 AM

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.

katiekay 12-14-2012 11:33 AM

[welcome] to FF [ffrocks]

Is this what you are looking for:

I hope this helps!

NitroMan 12-14-2012 12:10 PM

That is a sweet write-up for the Fuel sending unit. Thanks.
I already have the fuel tank out though. Since I may be cutting holes, maybe I should do that one too, in addition....

I'm thinking of doing the same thing for the EVAP/Charcoal Canister. Cut the floor panel.

I was hoping not to do that if there was an easy way to drop the rear end or get the damn canister out.

katiekay 12-14-2012 12:50 PM

Sorry it wasn't what you were looking for. But since this works great for the fuel filter, it might just be a good idea to cut a hole where you need it too

Sent from my iPhone using FF Mobile

NitroMan 12-25-2012 01:29 PM

Okay, after searching for several days I found that the rear end is called a rear sub frame. There are 5 bolts on each side that hold the rear sub frame in. I basically put the whole car on jack stands with about 30 inches of clearance. With wheels removed put a hydraulic jack under each rear spring. loosened the 5 bolts on each side and lowered the rear sub frame. I was then able to remove the charcoal canister assembly. As previously diagnosed, the charcoal canister was plugged up.

Recommendation: The EVAP lines have special clips on them and I have not been able to find replacement clips. So use great care in removing the lines and do not break the clips.

After reinstalling everything, I can now pump gas into the vehicle with no issues. Problem solved. Hope this helps others with a similar problem.

pete c 05-31-2015 01:01 PM

I have the same issue with my '05 ZX3. I suspect the same problem. Is it possible to crawl underneath and disconnect the hose to the cannister to prove the problem?

zetecDon 05-31-2015 02:10 PM

1 Attachment(s)
Moved this to "General Technical Chat".

gszpot 05-31-2015 10:31 PM


Originally Posted by pete c (Post 8544217)
I have the same issue with my '05 ZX3. I suspect the same problem. Is it possible to crawl underneath and disconnect the hose to the cannister to prove the problem?

I have the same problem. And yes, I disconnected the line from the tank to charcoal canister and can now fill the tank with no problem. Now the check engine light comes on for gross evap leak.

pete c 06-01-2015 09:26 AM

Is there a thread anywhere for troubleshooting the evap system. Could be a clogged charcoal filter or a bad valve.

amc49 06-01-2015 11:07 AM

That guy in '12 posts was crazy, the carbon canister does NOT vent the tank at fill-up, it is SUPPOSED to be closed, there is a solenoid valve to make sure it is. It only opens to atmosphere when the PCM commands it to and then under vacuum, not pressure as the motor is sucking on it. Any other open condition there is an evap system leak. No way it can vent that kind of large pressure amount, intended for much smaller amounts. A violation of emissions laws to do so anyway as it would be a huge HC discharge. Disconnecting the line at carbon canister simply makes an illegal second vent and why the CEL came on.

The tank vents gross pressure at fill-up through the vent tube to be sucked up by the gas station filling assembly vacuum port.

Meaning somehow he missed a vent hose clog or not telling the truth 100%.

Fill the inlet with the hose just outside of the spring door there and you can see the vent blowing fuel away from it as it vents.

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