Fuel filler restrictor leak Soarer - FIXED - with pics.

[pearl_white]

I posted this on another Soarer forum, but figured I may as well post it here also.
This fix works for any import with a fuel filler restrictor - or any car in general basically.

Hi guys, so for the last while I've had a leaky fuel issue.

Fuel seeps out from the petrol cap area, down out the flap towards the exhaust - thus ruining paint and so on. Luckily my paint is fine as I washed the residue off each day.
Other people are not so lucky.

After the repair - i have no more leak.


Anyway, today I finally fixed the restrictor leak by resealing it.

I used a 2 part epoxy (radiator/petrol tank repairer) which you simply squash together (with haste being used) and the end result is like chewing gum.
It sets like steel in around 3 minutes.
After 2 minutes it is too hard to work with.
You have a 1-2 minute window to do this job.

So this is what I did (see pics):

I bought this from Supercheap auto for $10. *** http://i.imgur.com/rvVTYwn.jpg



1. I opened the fuel lid and inspected the restrictor. Seemed snug at the time. Noticed a bit of silicon that was brittle. I actually had already taken it out before snapping this pic... It was 'tightly sealed' before removing it. You'd think it was fine.

http://i.imgur.com/8OezM9x.jpg


2. I put a screwdriver in between the restrictor and fuel filler tube - then twisted it.

http://imgur.com/fGfkvSz


3. The thing actually popped right off. No resistance at all. It was obviously ready to be resealed. 1 twist and it popped off.
Note how gunky and brittle the thing was.

http://imgur.com/s3CauwU
http://imgur.com/vyIqkPG


4. Now the interesting thing. Whoever mucked about with the filler tube before i bought the car, had actually warped the tube itself.
I could not put the restrictor back in properly without wiggling/angling it strangely.

http://imgur.com/H5O87Gj

You can see in this picture where the bottom right of the tube is deformed. I raged as I only noticed this after I already put the epoxy on the restrictor - and it wouldn't fit back in the hole in time... (now the restrictor is sitting 1cm higher than fuel filler tube, but still sealed - we will get to that shortly).


5. These are pics showing what the restrictor looks like.

http://imgur.com/QJeQC43
http://imgur.com/gdD9mt7
http://i.imgur.com/zR1XWvt.jpg


6. Clean it with metho to make sure the epoxy sets properly - same with your hands. Use soap and water or similar. No grease, no contamination.

http://imgur.com/XDlL3aw


7. The inside of the filler tube, with no restrictor. This was cleaned also.

http://imgur.com/7p9Ev66


8. Roll the epoxy together into a sausage and fit it under the fuel restrictor lip.
9. Press it firmly back into the fuel filler tube.
10. Wait 2 hours at least before driving.


Note:
The restrictor would not allow me to push it in the tube again due to warping of the tube somehow.
I had 30 seconds before the goop set like steel.
I had tried to put the restrictor in, but always had about a 1cm gap - the steel goop was setting fast.
In the end, I put it the right way up, used more goop - and it is now sealed, although 1cm higher than it should be if the tube wasn't warped.

http://imgur.com/wvEJ75g
http://imgur.com/82fDva5
http://imgur.com/P7MrnLr

Anyway - Hope this helps someone out.