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NitroMan 12-14-2012 09:50 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 10:33 AM

[welcome] to FF [ffrocks]

Is this what you are looking for:

I hope this helps!

NitroMan 12-14-2012 11:10 AM

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 11:50 AM

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 12:29 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.

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