Fuel Filler Neck: Service and Repair

Fuel Tank Filler Pipe

Removal

WARNING: After carrying out repairs, the fuel system must be checked visually for leaks. Failure to follow this instruction may result in personal injury.

WARNING: After the fuel tank drain is complete always fit the sealing covers over the drain ports. Failure to do so will mean that fuel vapor can escape.

WARNING: This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.

WARNING: Wash hands thoroughly after fuel handling, as prolonged contact may cause irritation. Should irritation develop, seek medical attention.

CAUTION: Always carry out the cleaning process before carrying out any repairs to the fuel injection system components. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

CAUTION: Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible. Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel system and may result in later malfunction.

NOTE:
Removal steps in this procedure may contain installation details.
1 Disconnect the battery ground cable. For additional information, refer to Procedures
2
WARNING: Make sure to support the vehicle with axle stands.
Raise and support the vehicle.
3 For additional information, refer to Fuel Tank Draining Procedures
4 For additional information, refer to Exhaust System Service and Repair
5 For additional information, refer to Rear Fender Splash Shield Service and Repair




6 TORQUE: 5 Nm




7 TORQUE: 25 Nm
- Remove the 7 bolts.
- Remove the 2 nuts.




8
CAUTION: Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

- Remove and discard the hose clip.
- Install a new clip.
- Install blanking caps to the exposed ports.
9 Position a container to collect the fuel spillage.





10

11 Remove the container.
- Dispose of the collected fuel in accordance with local regulations.
- Clean any fuel residue remaining in the container.





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13 TORQUE M6: 9 Nm TORQUE M5: 4 Nm

Installation
1 To install reverse the removal procedure.