Fuel Filler Neck: Service and Repair

Service repair no - 19.55.07

Remove


WARNING: Ensure that fuel handling precautions given in 01 - Introduction are strictly adhered to when carrying out following instructions.


WARNING: If the fuel tank is full, the fuel level may be close to the filler neck aperture. If gauge indicates over 75%, drain a minimum of 10 liters (2.6 US Gallons) from fuel tank. Service and Repair


CAUTION: Before disconnecting any part of the 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. Open fuel filler flap and remove filler cap.
2. Disconnect battery earth lead.
3. Remove RH rear wheel arch liner. See CHASSIS AND BODY, Repair.
4. Remove nut securing filler neck bracket to stud.
5. Disconnect vent line quick fit connectors at fuel/vapor separator and under body connection.
6. Disconnect pressure sensor breather pipe connection.







7. Remove shear cap from clip securing neck assembly to tank.
8. Slacken clip securing neck assembly to tank.
9. Release filler neck bracket from body stud. Push filler neck down then forwards to release from aperture grommet.
10. Remove tiller neck assembly.







Refit


CAUTION: Hose clips used on the filler neck of advanced EVAPS vehicles have a special 'shear' cap to ensure the correct tightening torque is achieved. Always use NEW clips of the correct type.


11. Loosely position new clip to filler neck hose.
12. Position filler neck assembly to fuel tank stub, rotated anti-clockwise as shown.
13. Engage internal breather hose to fuel tank inner stub.







14. Engage filler neck hose with fuel tank stub.
15. Manoeuvre filler neck into position and engage with grommet.
16. Engage filler neck bracket with body stud and secure with nut.
17. Tighten clip securing hose to fuel tank stub until cap shears off.
18. Connect vent lines to fuel/vapor separator and under floor connection, ensuring that quick fit connections fully engage.
19. Connect pressure sensor breather line.
20. Replenish fuel if necessary.
21. Fit filler cap and tighten in accordance with instructions.
22. Close filler flap.
23. Connect battery earth lead.