My 2002 was throwing a code for an evap leak. I replaced the fuel cap and all of the fittings I could see in the engine bay. Still got the code. I learned it is super helpful to have a smoke test kit. Once I had that, I found the fittings at the fuel tank were leaking heavily.
Once I dropped the tank I found the Y connector that connects the evap lines was broken. This is a 1/4 X 1/4 X 3/16. I also found that I could not find this connector anywhere locally, so I used a 1/4 X 1/4 X 1/4 brass fitting that I found at the hardware store. I am sure there are other options out there as well as brass, but that is what I found. I was able to attach a piece of 3/16" hose to the 1/4" fitting and that seems to work. I also found a 1/4" to 3/16" reducer nipple that I was going to use, but it worked without it, so I figured less fittings is better. I also had a leak from one of the rollover valve nipples, but it turned out it was just the hose. Once I put a new 1/4" hose on it, there was no leak.
Here is the biggest thing I learned. The gas tank with over half a tank of gas in it is heavy. I knew it would be, but if I had to do it again, I would wait until it was damn near empty before I pulled it. I used an ATV jack to lift it up while I pulled the nuts, and then I used the ATV jack to slowly lower it to do the work. The same jack worked well to put it back in place, but there is a certain amount of wiggling that has to be done to line up all of the bolts. This would have been much easier if the tank was closer to empty. In hindsight, I have a pump and could have emptied the tank, I was just too lazy to empty it and figured I would fight with it. In hindsight, it would have been faster to empty it and my shoulders would hurt less this morning.
Lastly, I found 2-3 other very small pinhole leaks in the top of the tank. I just decided to leave them alone (mostly) for now. I am not sure if they are big enough to throw a code. I guess I will find out. I did have some clear silicone caulk, so I brushed and cleaned the areas and smeared some of that on there. I am reasonably sure that fix is temporary at best. My other option was duct tape, maybe I should have used both. I am going to see if I can find a decent used tank locally or I may pick up a plastic welding setup and try that. Dropping the tank should be a bit easier next time. The bolts and nuts I used are new and won't need to be cut off. I should be able to drop the tank with less gas in it, drag it to my driveway and give it a good cleaning as well. The thing is nasty and the straps need to be replaced. Once I have the parts and stuff I need, I will tear it off again.
As I was working on this system it made me wonder why I couldn't bypass the gas tank in the evap system. I realize it would essentially remove the entire reason for having the evap system and it would vent fuel vapor to the atmosphere. I would imagine if I tied the two 1/4" hoses from the rollover valves to each other it would seal the system and not throw a code. The tank would vent out of the rollover vents and would possibly cause a fuel smell in the cab. May also not pass emissions, but I don't have emissions testing here. Anyway, anyone ever bypassed the tank?
That's all I got, fun project. Seemed daunting at first, but the only hard part was dealing with the heavy ass gas tank.
Tin Man
Once I dropped the tank I found the Y connector that connects the evap lines was broken. This is a 1/4 X 1/4 X 3/16. I also found that I could not find this connector anywhere locally, so I used a 1/4 X 1/4 X 1/4 brass fitting that I found at the hardware store. I am sure there are other options out there as well as brass, but that is what I found. I was able to attach a piece of 3/16" hose to the 1/4" fitting and that seems to work. I also found a 1/4" to 3/16" reducer nipple that I was going to use, but it worked without it, so I figured less fittings is better. I also had a leak from one of the rollover valve nipples, but it turned out it was just the hose. Once I put a new 1/4" hose on it, there was no leak.
Here is the biggest thing I learned. The gas tank with over half a tank of gas in it is heavy. I knew it would be, but if I had to do it again, I would wait until it was damn near empty before I pulled it. I used an ATV jack to lift it up while I pulled the nuts, and then I used the ATV jack to slowly lower it to do the work. The same jack worked well to put it back in place, but there is a certain amount of wiggling that has to be done to line up all of the bolts. This would have been much easier if the tank was closer to empty. In hindsight, I have a pump and could have emptied the tank, I was just too lazy to empty it and figured I would fight with it. In hindsight, it would have been faster to empty it and my shoulders would hurt less this morning.
Lastly, I found 2-3 other very small pinhole leaks in the top of the tank. I just decided to leave them alone (mostly) for now. I am not sure if they are big enough to throw a code. I guess I will find out. I did have some clear silicone caulk, so I brushed and cleaned the areas and smeared some of that on there. I am reasonably sure that fix is temporary at best. My other option was duct tape, maybe I should have used both. I am going to see if I can find a decent used tank locally or I may pick up a plastic welding setup and try that. Dropping the tank should be a bit easier next time. The bolts and nuts I used are new and won't need to be cut off. I should be able to drop the tank with less gas in it, drag it to my driveway and give it a good cleaning as well. The thing is nasty and the straps need to be replaced. Once I have the parts and stuff I need, I will tear it off again.
As I was working on this system it made me wonder why I couldn't bypass the gas tank in the evap system. I realize it would essentially remove the entire reason for having the evap system and it would vent fuel vapor to the atmosphere. I would imagine if I tied the two 1/4" hoses from the rollover valves to each other it would seal the system and not throw a code. The tank would vent out of the rollover vents and would possibly cause a fuel smell in the cab. May also not pass emissions, but I don't have emissions testing here. Anyway, anyone ever bypassed the tank?
That's all I got, fun project. Seemed daunting at first, but the only hard part was dealing with the heavy ass gas tank.
Tin Man
