Service Procedure

SERVICE PROCEDURE

1. Raise the vehicle off the ground with a vehicle hoist.

2. Remove the right rear wheel.





3. Remove 2 bolts from the fuel filler tube bracket.





4. Remove the plastic cover (4 clips).





5. Unhook the fuel filler tube bracket from the body.





6. Unclip the recirculation tube.





7. Apply auto body painting tape to the top and rear of the wheel opening as shown.

NOTE:
This tape will protect the paint during the procedure.





8. Use a protective cloth to cover the items shown in Figure 6.





9. Remove the fuel filler cap and install a spare fuel fill cap.

NOTE:
If a spare fuel filler cap is not available, disconnect the tether and leave the original cap in place.





10. Hold the fuel filler tube with both hands and carefully pull the flange loose from the fuel door opening.

WARNING:
Make sure the fuel filler cap is installed and tight. If the fuel filler cap is not installed and tight, fuel may leak from the fuel filler tube when it is lowered.





11. Carefully pull down on the fuel filler tube and then pull the top of the tube from the wheel well (see Figure 8).

^ Do not scratch or chip the fuel filler tube paint.

^ Do not pull, stretch, or stress the fuel filler rubber tube.





12. Rest the fuel filler tube on the brake drum.

WARNING:
Do not remove the fuel fuller cap with the fuel filler tube in this position. Fuel may leak from the fuel filler tube.





13. Thoroughly clean the following with isopropyl alcohol:

^ Flange

^ Fuel filler tube, 6 inches from the flange

^ Recirculation tube, 6 inches from the flange





IMPORTANT:
^ In the next few steps you will be installing the Fuel Filler Tube Protector.

^ Steps 14 through 20 must be completed within 6 minutes.

^ Before continuing, read and understand steps 14 through 20.








14. Apply adhesive sealant to both halves of the Fuel Filler Tube Protector as shown in Figure 13.

IMPORTANT:
Use only adhesive sealant P/N 17290 - 1FC2A.

^ Use adhesive sealant generously.

^ Outer half is shown; inner half is a mirror image.





15. Place the inner half of the protector on the fuel filler tube as shown.

16. Make sure the recirculation tube is in the grove of the inner half of the protector.





17. Hold the inner half in place while instilling the outer half.

18. Install washers and bolts.





19. Install washers and nuts.

20. Torque the nuts/bolts to:
5.5 Nm (0.56 kg-m, 49 in-lb)





21. Install the rubber grommet on the fuel filler tube flange.





22. Make sure the flap is positioned at the bottom of the flange.





23. Reinstall the flange (with grommet) into the fuel door opening.





24. Make sure the grommet is properly in place.

25. Reinstall the original fuel filler cap.

NOTE:
If tether was removed, make sure it is reattached.





26. Make sure the recirculation tube is snapped into the clip.





27. Make sure the fuel filler tube bracket is hooked into the body.





28. Reinstall the 2 bracket bolts.
Bolt torque: 25 Nm (2.6 kg-m, 18 ft-lb)

29. Reinstall the plastic cover (4 clips).





30. Locate the bracket at the lower end of the fuel filler tube (see Figure 24).





31. Thoroughly clean the entire bracket surface with isopropyl alcohol.





32. Remove the adhesive backing from the bracket protector.





33. Slide the protector over the top of the bracket as shown.





NOTE:
Do not let the protector touch the flange at the end of the bracket.





34. Press the protector against the bracket to ensure good adhesion of the adhesive tape.

35. Reinstall the right rear wheel.
Wheel nut torque: 108 Nm (11 kg-m, 80 ft-lb)

36. Lower the vehicle.