evap leak cheap fixed. Broken expansion tank

[jchung9825]

First, thanks to all the fellow members here that give all the information I need to fix this problem of the common evap leak.

I just picked up this car knowing the fact that it had a evap leak. So here is the fix. The expansion tank hose neck was broke. The neck wasn't just plastic, but inside was a copper tube.

Supplies needed.

Plastic weld or other bonding epoxy. $5
3/16"x.014 brass tube. $5
fuel line hose. $5
clamps. $5

After taking out the wheel well shied and unscrew the 2 plastic bolt holding the tank. cut the 6mm fuel line hose. This will make it lot easier to take the tank out. It is almost impossible to take the hose out from the connection even the clips has been taken out.



Here is the broken neck from the tank.





I bought a 3/16" brass tube from art supply store and cut it to about 1.5". It is important to clean the inside of the broken neck with steel brush. I make a small brush by twisting small wires with open end and chuck it to a drill.

Make sure that the new tube doesn't go all the way into the tank. It might block the opening.




I apply plastic weld on half the new brass tube and slide it in. Wait until it is cured. Apply the plastic weld on the other half and attached it together and apply more for better strength. The plastic weld actually doesn't bond as good as i thought.



After everything is cured, replace with new fuel line hose and clamps. I bought the fuel line from autopart store instead $30 from dealer.



Connect the hoses and put the tank back in. I only drove 50 miles since and the CEL haven't show up yet. If it doesn't show up at 150 miles. then it is good to go.

[iXguy]

Nice write up.

I've had an evaporative fuel warning occasionally -- what specific code was yours? Any other symptoms?

[uncle]

Good write up on a common problem. I did something similar on my car, but I was able to do so without removeing the tank. I used the 5 Minute expoxy and a new plastic nipple.

[jchung9825]

Nice write up.

I've had an evaporative fuel warning occasionally -- what specific code was yours? Any other symptoms?

I used peake tool to check. It gives and small leak and after every 150 miles, it will give you a large leak with CEL on. There are no symptoms except you can't pass inspection with the CEL on.

[iXguy]

Sounds about the same as what I'm getting.

No fuel smell though?

[mzmtg]

ProTip:

Remove the two fasteners that hold the fuel filler neck in place so you can move it out of the way. There's one up by the filler inlet (13mm) and one down by the rear sway bar (10mm).

This makes removal and re-installation of the tank 100% easier.



Also, I used brass barb fittings & JB Weld to repair my tank, we'll see if they hold up...

[mzmtg]

Also, I used brass barb fittings & JB Weld to repair my tank, we'll see if they hold up...

My check engine light went out on its own tonight. I guess that means my fix worked.

[EThirtySicks]

Nice DIY fix.

[mzmtg]

Other pics:

[e36beemka]

Can I also use caulk or something like that? What size of fuel hose?

[foaxaca]

Great write up! Thanks! Just did the repair of the main tank connection that had cracked and set off the CEL. Used the 3/16" double ended brass barb fitting, some 5-minute epoxy to get it to stick, covered the whole thing with plumber's epoxy putty and then sealed the whole thing with silicone automotive sealant. Also replaced that stupid OEM hose clamp with a normal one that you can tighten with a screwdriver. Cleared the code with my Peake tool and it has not come back. The car started and idled very rough until it got up to temperature and then after a test drive ran perfectly and held idle just like it should. Probably had a good dose of air in the fuel system after having the hose off of the evap tank for several hours.

[nowbimmin]

I just did this, but when installing it I broke the bond. The stress the hose puts on the 'fix' seems to be a bit much. Is there something I could do differently to not put so much stress on it when re mounting?

[mzmtg]

I just did this, but when installing it I broke the bond. The stress the hose puts on the 'fix' seems to be a bit much. Is there something I could do differently to not put so much stress on it when re mounting?

Replace the hoses with longer pieces, it reduces the stress on the connections. See my pic above with a loop in the lower hose.

Also, moving the fuel filler neck makes it easier to get the tank back into place without stressing the hoses.

[nowbimmin]

I didn't replace the hoses, but I did un mount the filler and it was still tough to get the tank back into place.

CEL went off! I guess the 'cup' the epoxy made after it broke was good enough to hold the fuel line that I placed in there thinking "it's better than letting it hang off to the side"

[das borgen]

sorry to bump but this just happened to me


how has your fix held up so far?

what size fuel hose is it too?

[nowbimmin]

I'm not sure who you're asking, but my CEL is still off.

[mzmtg]

I'm not sure who you're asking, but my CEL is still off.

Mine is still off as well.

[das borgen]

what size fuel hose is it too?

anyone?

[bigMphan]

I'm in the middle of this now.... The top nipple was only cracking, so I slathered epoxy on it and buttoned it up again.
If I need the copper tube and the fresh hose I'll chime in with the sizes.....I hope the epoxy fixes it!

Good DIY Thanks!

[jchung9825]

6mm fuel hose was used.

[M3C]

Other pics:

I am using the 2nd picture posted by mzmtg to show what I found on my ccar so far, did not remove the tank yet but I can see the bottom nipple is broken (the one that has some epoxy on 2nd picture) and I am also missing the clamp that holds the hose to the blue pipe (located on the left in 2nd picture).
Can someone please clarify what is the function of the bottom nipple line on the tank.
I do not see any error codes yet.

[mzmtg]

Can someone please clarify what is the function of the bottom nipple line on the tank.
I do not see any error codes yet.

Since the purpose of the expansion tank is to collect vapor from the fuel system, I would assume that the function of the line connected to the bottom of the expansion tank is to drain fuel back into the main fuel tank after it has condensed in the expansion tank.

That's just a guess though

[bigMphan]

6mm
will do mine this weekend!

Thanks for a great write-up

[csmc1013]

Since the purpose of the expansion tank is to collect vapor from the fuel system, I would assume that the function of the line connected to the bottom of the expansion tank is to drain fuel back into the main fuel tank after it has condensed in the expansion tank.

That's just a guess though

Well, since you said it and not me, then why did yu curl the hose? Vapors can travel the loop, raw gas can not, unless it vaporizes.

[M3C]

It looks normal but actually when lifting from bottom it can be seen that lower half is broken-open.
I could not remove the hose from the other end after taking out the clamp, it is kind of stuck there and was afraid not to break something if pulling too hard. Is there a way to remove the hose when it feels stuck, ay spray or tool for this issue? I would not want to cut the hose ends just to remove the tank and having to purchase new hoses again.

So I applied JB Kwik (it dries quicker than regural JB Weld) and after covered it with hi-temp silicone gasket (see pictures).

Not sure how well will it hold but I consider this as temporary fix, will have to get a new tank.
Need some experienced advise here, would this be good as a temporary fix?