Fuel Filler Neck: Service and Repair

Fuel Filler Neck - Advanced EVAPS

WARNING: Ensure that fuel handling precautions given in 1 - Introduction are strictly adhered to when carrying out following instructions.


CAUTION: Before disconnecting any part of fuel system, it is imperative that all dust, dirt and debris is removed from around components to prevent ingress of foreign matter into fuel system.


Remove
1. Depressurise fuel system.Depressurizing Fuel System
2. Disconnect battery earth lead.
3. Check the amount of fuel in the tank. If the tank is full drain 6 US gallons (22 litres) minimum.







4. Remove 6 screws securing tail door tread strip and remove tread strip.
5. Remove RH luggage compartment side panel.
6. Fold back loadspace carpet and sound insulation to gain access to RH mudflap fixing.
7. Raise rear of vehicle.


WARNING: Support on safety stands.







8. Remove nut and bolt securing filler neck support bracket to mud flap bracket.


NOTE: This fixing also retains the filler neck earth strap.


9. Remove 5 nuts and bolts securing mud flap to body.
10. Remove mud flap.







11. Disconnect vent line quickfit connector from liquid/vapour separator.
12. Remove torque screw cap from hose to tank filler neck clip.
13. Loosen clip screw securing hose to tank filler neck.
14. Release hose from filler neck and internal filler neck breather hose from fuel tank.
15. Remove and discard fuel filler neck clip.
16. Disconnect the pressure sensor breather pipe connection.
17. Disconnect the vent line hose connection.







18. Fit ignition key to fuel filler flap lock and open flap.
19. Release fuel filler cap from filler neck.
20. Remove filler neck assembly from vehicle.
Do not carry out further dismantling if component is removed for access only.
21. Remove torque screw cap from hose to filler neck clip.
22. Loosen clip screw securing hose to filler neck.
23. Remove hose from filler neck.
24. Remove and discard fuel filler hose clip.
25. Remove vent line from filler neck.

Refit
26. Fit vent line to filler neck.
27. Fit NEW clip to filler neck hose.
28. Fit hose to filler neck.
29. Position filler neck hose clip and tighten until head shears.
30. Fit filler neck assembly to vehicle.


NOTE: To aid fitment of filler neck through body grommet apply a soap solution to lip of grommet.


31. Fit NEW clip to fuel filler neck hose.
32. Connect fuel filler neck internal breather to tank.
33. Connect fuel filler neck hose to tank.
34. Position fuel filler neck hose clip and tighten until head shears.
35. Connect vent line quickfit connector to liquid/vapour separator.
36. Connect the pressure sensor breather pipe connection.
37. Connect the vent line hose connection.
38. Fit mud flap and secure with nuts and bolts.
39. Position filler neck support bracket and earth strap to mud flap bracket and secure with nut and bolt.
40. Remove stand(s) and lower vehicle.
41. Reposition loadspace sound insulation and carpet.
42. Fit RH luggage compartment side panel.
43. Fit tail door tread strip and secure with screws.
44. Refill tank with drained fuel.
45. Fit fuel filler cap to filler neck.
46. Close filler flap, lock with ignition key and remove key.
47. Connect battery earth lead.