Finally got around to replacing the fuel pump gasket that has been leaking and caused the evap drive cycle failure. After shotgunning parts (purge valve, vent valve, canister) we got serious about troubleshooting it and it came to this. We used a smoke machine for a coarse diag, and a little air pressure after narrowing it down.
We (my son Nate and I) replaced the fuel pump about two years ago, using an AC Delco Pro/Gold pump, which included the gasket for the Flex Fuel pump. We're not sure if we messed up the gasket when installing, or if it was received that way. And we're not sure why it didn't fail evap back then; it's been good until about two months ago. I don't recall that we had to install the gasket on the pump that time, I think it was already on it. Anyway, now to get some gas to get it up to half a tank and run the evap drive cycle.
The gasket seems to have rolled a bit, or was malformed. You can see in the pic where it was leaking, all along the part with the light residue. The red triangle points to the start of the defective part, and it goes to the right several inches:
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Here's a comparison of the old (upper pic) and the new (lower) gaskets. The new one (also AC Delco) is a less pliable material and looks like it will hold form better.
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There is a strainer that slips into the tank filler stub, maybe to prevent siphoning? It just slips in and out but is the exact size for the inlet.
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And, lastly, the pump and new lock ring as installed. To remove the old ring and install the new one we used channel lock pliers to put pressure between the ears on the tank and the notches in the ring. We did this on opposing ears with two pliers and so no hammer or punch needed.
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So, on to a few test drives over the next week or so. Glad we were able to confirm the cause of the leak with the physical evidence.