Help! Difficulty rating: dropping gas tank..

[91MazdaNava]

So it seems I have a vapor leak somewhere in the area of where the evap/fuel line(s) plug into the the top of the gas tank on my 1991 Mazda navajo. This is causing me to fail the smog pressurized gas tank test (pressure leaks). My question is how difficult would it be for me to drop the tank to gain access to and attempt fixing the leak? How facilitated does such a maneuver need to be. I've done certain repairs on all my vehicles but never dropped a gas tank on any and I'm a little hesitant to do so. I don't have a lot of $ for repairs right now, but if getting into this thing is not advisable I'd like to know now, and I'll just pay what I have to to get it done. Any advice greatly appreciated. Thanks guys!

 

[tweakedlogic]

I'm surprised they do that test. I don't even thing the 91 has evap controls.

change your fuel cap first. They are usually what fails first in my experience.
Dropping the tank is PIA, especially when you don't have a post lift. When I changed my fuel pump I cut a hole under the left rear seat. I made a "door" from aluminum and sealed it with silicone. Much easier. You can access all of the hoses and wires there.

If you can find it to borrow or rent, there are several versions of a machine that fogs the tank so you can see where it's leaking from.

 

[Dano!]

the hose that catches the vapors from the gas tank goes the the charcoal scrub container located under the hood on the driver side next to the radiator. if the hose is rotted there, it will make you fail that test.
i would check there there is a hose coming in from the gas tank and a hose going to your throttle body, make sure those hoses are good to go first before you drop the tank.

The charcoal container looks like a white plastic rectangle with two black caps on it. if either of those caps are broken or if there is a crack in that canister, than it would possibly fail you because it cant hold pressure.

 

[91MazdaNava]

HOOOLY SH*T...so the leak is in the fuel pump module. They say I gotta replace the whole thing which is at least $200 on top of the $300 in labor and diagnostics. This thing is gonna cost me like $500 unless I can get a great deal on the part somewhere. CAN ANYBODY HELP ME!!? I really don't have the $ to be throwing into this vehicle with 167k miles on it right now.

 

[tweakedlogic]

It sounds like you need a new fuel pump assembly gasket, but it's possible the plastic has broken on the assembly. Buy the parts from rockauto.com. then cut a hole in the floor under the rear passenger seat. The whole job will take less than 2 hours if things go poorly.

 

[91MazdaNava]

It sounds like you need a new fuel pump assembly gasket, but it's possible the plastic has broken on the assembly. Buy the parts from rockauto.com. then cut a hole in the floor under the rear passenger seat. The whole job will take less than 2 hours if things go poorly.

Nope to the gasket. Yes to the plastic breaking/corroding on the cap of the actual assembly-why couldn't they have made them out of a different material? Cuz if it goes, you have to buy the whoooole frickin thing. Lame, Mazda/Ford!

 

[Kevlar7R]

search on this site for rockauto discount code. As members here we get 5% off.

I never dropped the tank on my old 94, but if it's anything like every other vehicle out there, it's really not that bad. You dont need any special tools or lifts if you can empty the tank first. Drive till your on fumes (keep a can of gas on board in case). Disconnect the filler lines, block it up with some wood, and start loosening the bolts. Empty, even a BIG metal tank only weighs about 30 pounds.

You will need to go to AutoZone and rent a ford fuel line disconnect tool.

 

[tweakedlogic]

I'm not going to say it again.
http://www.explorerforum.com/forums/showthread.php?t=182160&highlight=gas+tank+access+panel
http://www.explorerforum.com/forums/showthread.php?t=368439&highlight=fuel+hole+in+floor
http://www.explorerforum.com/forums/showthread.php?t=368960&highlight=fuel+trap+door

 

[91MazdaNava]

I'm not going to say it again.
http://www.explorerforum.com/forums/showthread.php?t=182160&highlight=gas+tank+access+panel
http://www.explorerforum.com/forums/showthread.php?t=368439&highlight=fuel+hole+in+floor
http://www.explorerforum.com/forums/showthread.php?t=368960&highlight=fuel+trap+door

I know, I know Tank's already dropped though.

 

[Kevlar7R]

And? How bad was it?

 

[91MazdaNava]

And? How bad was it?

Not bad at all if you think about it being just a corrosion leak on the cap for the fuel pump assembly...and absolutely ####ing terrible when you consider that you cannot buy...just the cap-you gott buy the entire "hanger assembly". Sweet. Wasn't that bad again later on when I found that part (Carter, made in the U.S. with warranty) for $90 shipped, but it sure looked bad when the shop told me the dealer wanted $500, he could get a good one for $300, and a cheap one for $175

 

[Kevlar7R]

I meant how bad was the job of dropping the tank?