PRE-RELEASE

Fuel filler pipe

Fuel filler pipe

Warning

Removal of the fuel filler pipe involves partial dismantling of the car's fuel system. The following points must therefore be observed in connection with this work:
•	Work only in a well-ventilated area! If approved equipment for the extraction of fuel vapours is available, be sure to use it.
•	Wear suitable gloves! Prolonged contact with fuel can cause skin irritation or dermatitis.
•	Keep a class BE fire extinguisher near at hand. Be mindful of the danger of sparks caused by short circuits and when connecting and disconnecting leads in electrical circuits.
•	No smoking anywhere in the vicinity.
•	Wear protective goggles.

Important
Be particulary observant regardning cleanliness when working on the fuel system. Loss of function may occur due to very small particles. Prevent dirt and grime from entering the fuel system by cleaning the connections and plugging pipes and lines during disassembly. Use 82 92 948 Plugs, A/C system assembly. Keep components free from contaminants during storage.

To remove

Make sure that the tank is not more than 3/4 full. If necessary, see Emptying the fuel tank .

Raise the car and remove the rear right wheel. See Wheels .

Remove the wing edging strip and the wing liner. The wing edging strip must be removed first.

US (E85) : Loosen the filler pipe hose clip from the tank. Split the ventilation pipe with 83 95 261 Tool, fuel line .

Other : Loosen the hose clips on the filler pipe and split the ventilation pipe with 83 95 261 Tool, fuel line .

Remove the screw that secures the pipe. (EU tank has a plastic screw).

Open the filler flap and remove the filler cap.

Remove the filler pipe. Bend aside the flange on the rubber sleeve when removing the filler pipe.

Important
To prevent dirt from entering the filler pipe when it is removed, plug the pipe with a cloth.

To fit

Important
When fitting the filler pipe it is important to replace the rubber hoses between the filler pipe and the fuel tank. There is a risk of cracks forming on the hoses after repeated tightening of the hose clips and this can lead to fuel leakage.
It is also important to replace the old plastic screw by a new screw of plastic. In the event of a collision, the plastic screw will break thus avoiding any damage to the filler pipe which is also made of plastic.

Fasten the filler pipe to the connecting hoses leading to the fuel tank.

Insert the filler pipe into the filler hole.

Fit the screw that secures the pipe. If the car has a plastic screw, fit a new one.

Tightening torque, plastic screw 1.5 Nm (1 lbf ft)

US (E85) : Fit the filler pipe hose clip on the tank.

Other : Fit the hose clips on the connection hoses with 30 16 235 Pliers .

Fit the wing liner and wing edging strip.

Fit the rear right wheel.

Lower the car to the floor.

Refit the filler cap.