Replacing Fuel Filler Neck In 2003 Camry: Step-By-Step Guide

The fuel filler neck connects the gas cap and the fuel tank. It is usually made of metal or rubber. Over time, it can become corroded, cracked, or damaged, leading to fuel leaks, which are dangerous as they can cause fires. If you have a 2003 Toyota Camry and suspect that you need to replace the fuel filler neck, there are online guides and videos that can help you through the process. You can also buy replacement parts from auto parts stores or dealerships.

Disconnect the battery and fuel tank

To disconnect the battery and fuel tank of a 2003 Camry, follow these steps:

First, park your vehicle on a flat, hard surface and ensure that the transmission is in park for automatics or in first gear for manuals. Place wheel chocks, preferably around the front tires, as the rear of the vehicle will be lifted. Engage the parking brake to prevent the rear tires from moving.

Next, open the vehicle's hood and disconnect the battery. Take the ground cable off the battery's negative post to disable the power to the fuel pump or sending unit.

Now, use a floor jack to lift the vehicle from underneath, at its specified jacking points, until the wheels are off the ground. Place jack stands under the jacking points and lower the vehicle onto them. For modern cars, the jacking points for the jack stands are usually on the pinch weld, just under the doors along the bottom of the car. However, it is best to refer to the vehicle owner's manual for the proper jacking locations.

With the vehicle securely raised and supported, open the fuel door to access the fuel filler neck. Remove the mounting screws or bolts attached to the cutaway. Detach the fuel filler cap cable from the fuel neck and set it aside.

At this stage, you have successfully disconnected the battery and begun the process of accessing the fuel tank. The next steps will involve locating and lowering the fuel tank, as well as disconnecting various components such as the harness, vent hose, and rubber hose, before finally removing the fuel filler neck itself. These steps should be performed with caution and in accordance with the specific guidelines for your vehicle.

Remove the wheel and inner fender

To remove the wheel and inner fender of your 2003 Toyota Camry, you will need to gather the necessary tools and materials, including a jack and jack stands, a socket wrench set, a Torx screwdriver set, a flat-blade screwdriver, ratchet and extensions, and protective gloves.

Once you have the required tools, follow these steps:

Safety First: Prepare Your Camry:

• Park your car on a level surface, preferably in a well-lit area.
• Engage the parking brake to prevent the vehicle from rolling.
• Chock the rear wheels by placing wheel chocks behind the rear wheels for added security.
• Consult your Camry's owner's manual to familiarise yourself with specific safety precautions.

Removing the Wheel and Inner Fender:

• Loosen the lug nuts on the left (driver's side) rear wheel. Block the front tires.
• Raise the rear of the car using a jack and support it securely on jack stands.
• Remove the wheel.
• Remove the splash guard. This typically involves removing three Phillips screws.
• Remove the plastic fender liner by first taking out the bolts, usually two or three, with a socket wrench.
• Gently but firmly pull the plastic fender liner away from the fender. You may need to use a slot screwdriver to push the plastic latch down to release the liner.
• Set the fender liner aside.

With the wheel and inner fender removed, you can now access the fuel filler neck for replacement. Remember to work safely and follow the manufacturer's guidelines when performing any repairs on your vehicle.

Remove the old fuel filler neck

To remove the old fuel filler neck from your 2003 Toyota Camry, you will need to follow these steps:

First, park your car on a flat, hard surface and ensure that the car is in park (for automatics) or in first gear (for manuals). Place wheel chocks, preferably around the front tires, as you will be lifting the rear of the vehicle. Engage the parking brake to prevent the rear tires from moving.

Next, you will need to disconnect the battery. Open the vehicle's hood and take the ground cable off the battery's negative post, disabling the power to the fuel pump or sending unit.

Now, use a floor jack to lift the vehicle from the specified jacking points until the wheels are completely off the ground. Place jack stands under the jacking points and lower the vehicle onto them. For most modern cars, the jacking points for the jack stands will be on the pinch weld just under the doors along the bottom of the car.

With the car safely lifted, open the fuel door to gain access to the fuel filler neck. Remove the mounting screws or bolts attached to the cutaway. Detach the fuel filler cap cable from the fuel neck and set it aside.

At this point, you will need to locate and lower the fuel tank. Place a transmission jack or a similar jack under the fuel tank and loosen and remove the straps holding it in place. Lower the fuel tank slightly and reach up to feel for the harness attached to the top of the fuel tank. This is the harness for the fuel pump or sending unit on older vehicles.

The next step is to remove the small vent hose to allow more clearance. For vehicles from 1996 onwards, there will be a return fuel charcoal canister attached to the vent hose to collect fuel vapors for emissions. After removing the vent hose, locate the clamp on the rubber hose attaching the fuel filler neck to the fuel tank. Remove this clamp and twist the fuel filler neck to pull it out of the rubber hose. Guide the fuel filler neck out of the area and remove it from the vehicle.

Note: If you are unable to twist the fuel filler neck out of the rubber hose, you may need to use a screwdriver to gently pry it loose. Be careful not to damage the rubber hose, as it may need to be reused.

Once the fuel filler neck is removed, inspect the rubber hose for any cracks or damage. If the rubber hose is cracked, it must be replaced.

Now, you can proceed to install the new fuel filler neck.

Clean the harness and connector to the fuel pump

To clean the harness and connector to the fuel pump of your 2003 Camry, you will need to purchase some electrical cleaner and a lint-free cloth.

First, locate the fuel tank and lower it. You will need to use a transmission jack or a similar jack to do this. Loosen and remove the straps to the fuel tank and lower it enough so that you can reach the harness and the vent hose.

Next, disconnect the harness from the connector by reaching up on top of the fuel tank and feeling for the harness attached to the tank. This is the harness for the fuel pump or sending unit.

Now, you can clean the harness and connector. Use the electrical cleaner and lint-free cloth to remove any moisture and debris.

Finally, you can raise the fuel tank back up and reattach the vent hose. Tighten the clamp until the hose will not twist and turn 1/8 turn.

It is important to note that fuel leakage in a vehicle can be very dangerous. Liquid fuel does not burn, but the vapors are extremely flammable. If there is a leak, there is a risk of the fuel vapors igniting when rocks are thrown up into the wheel well or under the vehicle, causing a spark. Therefore, it is recommended to wear fuel-resistant gloves and work in a well-ventilated area when cleaning the harness and connector to the fuel pump.

Install the new fuel filler neck

To install the new fuel filler neck, follow these steps:

Firstly, ensure the rubber hose on the fuel tank is wiped clean with a lint-free cloth. Place a new clamp onto the rubber hose. Take the new fuel filler neck and twist it into the rubber hose. Put the clamp in place and tighten up the slack. Allow the fuel filler neck to twist but not the clamp.

Next, raise the fuel tank to the vent hose. Attach the vent hose using a new clamp. Tighten the clamp until the hose will not twist and turn 1/8 turn. Make sure to not use the old clamps as they will not hold tight and may cause a vapor leak.

Now, raise the fuel tank to align the fuel filler neck to the cutaway and align the fuel filler neck mounting holes. Lower the fuel tank and tighten the clamp. Keep the fuel filler neck from moving.

Then, raise the fuel tank to the harness. Connect the fuel pump or sending unit harness to the fuel tank connector. Attach the fuel tank straps and tighten them until they stop. Torque the mounting nuts to the specifications on the fuel tank. If you do not know the torque value, you can tighten the nuts 1/8 turn more with blue locktite.

Finally, align the fuel filler neck to the cutaway in the fuel door area. Install the mounting screws or bolts into the neck and secure it tight. Attach the cable of the fuel filler cap to the neck and screw on the fuel filler cap until it locks in place.

Frequently asked questions