Replacing Rv Fuel Filler Neck: A Step-By-Step Guide

If you're experiencing issues with your RV's fuel filler neck, such as exterior damage or fuel vapour leaks, it may be time to replace it. The fuel filler neck is an essential component that connects the fuel filler inlet and the rubber fuel hose on the gas tank. Over time, it can rust and leak, leading to dangerous fuel leakage. To replace the fuel filler neck on your RV, you'll need to locate and remove the old neck, and then install a new one, ensuring all connections are secure to prevent leaks. This process may involve jacking up your RV, removing tires, and accessing hard-to-reach areas, so it's important to follow safety precautions and refer to your RV's manual for specific instructions.

Locate the fuel filler neck and check for exterior damage

To locate the fuel filler neck on your RV, open the fuel filler door, which is usually located on the side of the vehicle. Inside the fuel filler door, you will find the fuel filler cap, which you can unscrew by hand or with a flathead screwdriver.

Once the fuel filler cap is removed, you will expose the fuel tank filler neck. This is typically a solid piece of formed tubular steel that connects the fuel filler inlet to the rubber fuel fill hose on the gas tank.

To check for exterior damage, visually inspect the fuel filler neck for any signs of corrosion, leaks, or other damage. Pay close attention to the rubber hose and clamp connected to the fuel filler neck, as these components can become weathered and cracked over time, leading to fuel leaks. Make sure that all the mounting screws are securely in place inside the fuel door area.

Additionally, you can check for vapor leaks by looking for specific engine light codes related to fuel vapors near the fuel filler neck, such as P0093, P0094, P0442, and P0455. These codes are recorded by the engine management system and can indicate the presence of vapor leaks.

Check for vapour leaks

Vapour leaks from the fuel filler neck can be extremely dangerous, as the vapours are highly flammable. If there is a leak, there is a risk of the fuel vapours igniting when rocks are thrown up into the wheel well or under the vehicle, causing a spark. Therefore, it is important to check for vapour leaks after replacing your fuel filler neck.

First, locate the fuel filler neck and visually inspect it for any exterior damage. Check that all the mounting screws are inside the fuel door area and verify that the rubber hose and clamp are visible and undamaged. On some vehicles, there may be a cover protecting the fuel hose from debris, which will need to be removed for inspection.

Next, determine if the fuel filler neck is leaking vapours. If it is, the engine management system will record this, and sensors will make the engine light come on when vapours are present. Some common engine light codes related to fuel vapours near the fuel filler neck include P0093, P0094, P0442, and P0455.

If you suspect a vapour leak, you can use a combustible gas detector to check for any leaks that you cannot smell. Wait 15 minutes away from the vehicle, then return and check for leaks. Look under the vehicle for any fuel drops and sniff around to detect any vapours.

If you find a leak, check the connections to ensure they are tight. If adjustments are made, be sure to check for leaks again before continuing. If there are any vapour leaks while driving, the vapour sensor will pick up the leak and display the engine light.

It is important to note that if you smell fuel, you are smelling the vapours, which are highly flammable. Do not smoke around the vehicle if you smell fuel vapours.

Park your vehicle on a flat, hard surface

When preparing to replace a fuel filler neck, it is important to park your vehicle on a flat, hard surface. This is a crucial step to ensure a stable and level foundation for the work to be carried out safely and effectively. Here are some detailed instructions and considerations to keep in mind regarding parking your vehicle on a flat, hard surface:

Firstly, find a suitable flat and solid surface to park your RV. This could be a concrete driveway, a level parking lot, or any spacious area that can accommodate the vehicle without obstruction. Ensure there is ample room to manoeuvre around the vehicle and that it is legally permitted to perform such repairs in that location.

Secondly, engage the parking brake to lock the rear tires from moving. This is a standard safety precaution to prevent accidental movement of the vehicle during the repair process. It is also recommended to put wheel chocks around the front tires, as the rear of the vehicle will be lifted later in the process. These wheel chocks provide additional stability and act as a physical barrier to keep the vehicle securely in place.

Thirdly, consider the transmission of your vehicle. If you have an automatic transmission, make sure it is in "Park." For manual transmissions, put the vehicle in first gear. This step is essential for safety and to prevent any unexpected movement of the vehicle during the repair work.

By following these steps, you can ensure that your vehicle is securely parked on a flat, hard surface, providing a stable foundation for the upcoming fuel filler neck replacement process. Remember to take all necessary safety precautions and refer to the vehicle's owner's manual for any specific recommendations or variations for your RV model.

Raise the vehicle

To raise your RV, you will need a floor jack and jack stands. Place the RV on a flat, hard surface and ensure that the vehicle is in park (for automatics) or in 1st gear (for manuals). Engage the parking brake to prevent the rear tires from moving. Place wheel chocks around the front tires, as the rear of the vehicle will be lifted.

Using a floor jack, lift the RV at its specified jacking points until the wheels are completely off the ground. You can refer to the owner's manual for the exact jacking points. Once the RV is lifted, place the jack stands under the jacking points and carefully lower the vehicle onto them.

Now that the RV is securely raised, you can proceed with the next steps to replace the fuel filler neck. Remember to exercise extreme caution when working with fuel systems, as fuel vapors are highly flammable.

Remove the fuel filler cap cable from the fuel neck

To remove the fuel filler cap cable from the fuel neck, you will need to follow these steps:

Firstly, locate the fuel filler neck. This is usually found inside the fuel filler housing or the fuel filler door. Once located, proceed to remove the mounting screws or bolts attached to the cutaway. These screws or bolts hold the fuel filler neck in place, so removing them will allow you to access the fuel filler cap cable.

Next, carefully remove the fuel filler cap cable from the fuel neck. It is important to set this aside in a safe place, as you will need to reattach it later. In some vehicles, you may need to remove the fuel filler door or a plastic shield inside the fender well to access the cable. Make sure to note how it is attached so that you can properly reinstall it later.

If your vehicle has a fuel filler cap with a brace, you will need to unscrew the brace before removing the cable. This will give you more room to work and make it easier to detach the cable from the fuel neck.

Once the cable is removed, you can proceed with the rest of the fuel filler neck replacement process. Remember to follow all safety precautions when working with fuel systems, including working in a well-ventilated area and avoiding open flames or sparks.

Reinstalling the fuel filler cap cable:

When reinstalling the fuel filler cap cable, make sure to follow these steps in reverse. First, locate the cable that you set aside earlier and position it back into place on the fuel neck. Ensure that it is properly aligned and secured before tightening any screws or bolts.

Next, reattach any components that you had to remove to access the cable, such as the fuel filler door or plastic shield. Make sure that all screws or bolts are tightened securely. Finally, you can close the fuel filler housing or door, ensuring that everything is properly secured and aligned.

Remember to always refer to your RV's specific manual for detailed instructions and safety precautions when performing any maintenance or repairs.

Frequently asked questions