I don't believe you should have any liquid gas in the charcoal canister. It's function is collect gas fumes from the tank and then release them into the manifold when you start the vehicle to burn them, thus keeping the fuel system a closed loop. Seems to me there is a symptom rather than the problem.
Do you "top off" when you are fueling your Sporty? Meaning, after the pump initially shuts down, do you continue to put in more gas? This could overfill the tank to the point where gas makes it into the lines for the charcoal canister.
Liquid gas in the lines for the lines charcoal canister would prevent the fumes from making it there and would then build up pressure in your tank as it warmed throughout the day.
As for the clunk, it doesn't seem likely, but there is a flap in the fuel line at the fuel filler inlet of tank. Perhaps it was stuck up from the high pressure and dropped back down when you released the pressure by removing the cap. I say it doesn't seem likely because the flap is fairly small and light and shouldn't make much noise if it did this.
You may want to try to disconnect the vapor lines and see if there is any fuel in there you can drain off. If the charcoal canister is saturated, you may be able to leave the lines disconnected to see if you can get the fuel to evaporate but I'm not sure how effective that would be.
For the record, we do have a return line to our tank. I think this is pretty standard with an electric fuel pump/fuel injector system.
-------------------- 01 Convertible; Electric Fan; 3" Up Your Kia lift spacers; Tj 104's; 31x10.5x15's on Centerlines; Rear LSD.
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