[xrad]

If you have fuel smell after filling up, check filler neck for cracks. Remove trunk carpet right side, remove sound insulation over filler neck, remove cover (5screws and two nuts). Gently pry cover off (sealed with weather strip). gently unclamp all clamps attached to the central plastic neck. loosen two lower hose clamps.



BE CAREFUL NOTHING FALLS INTO TANK!!!



gently remove the plastic filler neck. now remove two screws holding on the filler door (outside of car...so you don;t break off the door when repairing)





remove outer metal ring. pull out rubber neck. clean everything and replace with new parts in opposite order. I put upper filler neck in first, then lower hose, then the middle plastic piece, and then fit the upper neck to the plastic piece. lubed everything with a spray of WD40. gently reconnect all hoses (DON'T FORCE ANYTHING AND BREAK IT)



there is a little ball float in the lower part of the plastic piece, DO NOT LOSE IT DOWN THE TANK!!



final step is to replace covers (upper and lower metal covers) Use rope caulk (available at home depot for 3$)



pics inlcude rotten cxracked upper neck and new complete set installed

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[mikeo]

I want to remove the metal insert that has the flapper door that is pushed open when the fill nozzle is inserted. It appears to be spot welded and/or brazed to the larger diameter metal tube that the gas cap screws into. Is the metal entry section part of the filler tube (11 in the PET drawing)? Is it possible to separate the metal section from the plastic tube?



If you have ever tried to fill the tank with a 5 gal gas jug and a funnel, you know why I want to do this.

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[xrad]

Hey, those pics remind me of good times back when I was only spending 'catch up' money!!



Once you undo the upper fill hose and clamps, and remove the ball valve black plastic piece (between two big hoses) you can get to the flapper. But it is part of the center black plastic piece...looks press fit and not easily removed.

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[mikeo]

If I can get it out of the car I can cut the restriction out with a small cut-off wheel. I'm pretty sure I don't want to do that while its still connected to the gas tank!



Thanks!

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[xrad]

yep, agree with you on that one. I also know what you mean about getting a plastic filler nozzle stuck in there and gas getting all over.....



easier solution would be to get yourself a short curved metal pipe for your gas jug and just hose clamp it on there!

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[ryker]

Old thread but very helpful with the photos. Unfortunately, I got everything apart and no cracks! I was hoping to find the easy fix. All looks in great shape. Where is that fuel smell coming from? It is very strong right after I fill up, and horrible with the windows down or sunroof open.

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[bva]

Fuel pump (or fuel filter) inlet or outlet maybe, but you should have seen evidence of the leak under the tank. It would also smell worse when the fuel pump has pressurized the lines.

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[Grandpa#3]

One cause of Gas Fumes is the Vent Hose on top of the Fuel Tank going to the Charcoal Canister will deteriorate over time. This will allow raw gas fumes into the co-pit area of the car.



Cheers,

Larry

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[ryker]

OK, I filled it up with gas with the filler neck exposed, and bva, you're right, it is definitely leaking. It appears to be leaking out of the neck of the gas tank. Does this mean a new tank? There is a sleeve that comes out of the tank that looks like it is permanently "welded" in. Dropping the transaxle and tank is probably more than I'm wiling to do in my garage.

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[Peter B]

Thanks for the nice write-up. I need to do this soon.



The top 2 candidates seem to be the filler tube, the flange at the top of the gas tank and hose between the tank and charcol filter. Is there anywhere better than the dealer to get the filler tube?



I'm not sure about where to look for the charcol filter. Advice is welcome here.

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[DaveN]

Sunset in Oregon is always a good bet.

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