Replacing Capless Fuel Filler: A Step-By-Step Guide For Beginners

Replacing a capless fuel filler can be a challenging task, as some car models do not offer the inner parts of the capless fuel assembly as separate components, requiring the purchase of an entire new assembly. This can be costly and may deter car owners from attempting to replace their capless fuel filler. Additionally, the process of removing and installing the new assembly can be intricate, requiring specific tools and careful manipulation of various components. However, with the right knowledge, tools, and parts, it is possible to successfully replace a capless fuel filler.

Removing the outer cover

First, it is important to gather the necessary tools and materials. You will need a flat-head screwdriver, a pick tool, a wide and thin object such as a chisel, and a replacement cap if needed. It is also recommended to have a funnel and a solvent such as denatured alcohol or WD-40.

Start by removing the liner surrounding the cap. This can be done by simply pulling it off. Next, locate the six plastic tabs that need to be broken off. Using a flat-head screwdriver, carefully break or lift these tabs out of the way. This step can be tricky, and it is important to be cautious to avoid damaging other components. Once the tabs are broken or lifted, insert the flat-head screwdriver into the top slot to unlock the cap. Gently bend the cap upwards and pull it off.

At this point, you should be able to see the inner white shutter. If you are replacing the external cap only, grab your replacement part and push it back on. Ensure it is securely fitted before proceeding.

If you need to replace the inner shutter, the process becomes more intricate. Refer to the dealer instructions or seek professional assistance if possible. You will need to use a pick tool to lift up the latch and flip down the flapper. This will allow you to access the white shutter assembly. Using your wide and thin object, insert it into the tabs of the assembly and turn it clockwise. Finally, pull out the assembly to complete the removal process.

Remember to work carefully and follow the steps in the correct order to avoid damage. Replacing a capless fuel filler can be challenging, but with patience and attention to detail, it can be successfully accomplished.

Removing the inner cover

To remove the inner cover of a capless fuel filler, you will need to refer to the specific instructions provided by your car manufacturer. In some cases, special tools may be required to access and remove the inner cover. However, here is a general step-by-step guide on how to remove the inner cover of a capless fuel filler:

Step 1: Understand the Capless Shutter Set

The capless shutter set consists of two pieces: the external cap and the internal white piece. The external cap is the part you see when filling up your car with fuel. The internal white piece covers the filler tube and provides a seal to the gas tank. Identify which piece you need to replace.

Step 2: Remove the External Cap

To remove the external cap, start by pulling off the liner surrounding the cap. Then, locate and break off the plastic tabs holding the cap in place. You may need to use a flat-head screwdriver to lift and hold the tabs out of the way. Once all the tabs are broken or lifted, use the screwdriver to unlock the cap by inserting it into the top slot and gently prying the cap up.

Step 3: Accessing the Inner Cover

With the external cap removed, you should now be able to see the inner (white) shutter. If you only need to replace the external cap, simply grab your replacement part and push it back on. If you need to replace the inner shutter, continue to the next step.

Step 4: Removing the Inner Cover

Refer to your car manufacturer's instructions or a trusted mechanic for specific guidance on removing the inner cover. In some cases, special tools may be required. However, in general, you will need to flip down the flapper and use a pick tool to lift up the latch. Once the latch is lifted, insert a thin, wide tool into the tabs of the white shutter assembly and turn it clockwise to release it. Then, pull the inner cover out.

Step 5: Clean and Maintain the Area

It is important to keep the capless fuel filler area clean and maintained to prevent issues such as evap leaks and check engine lights. Use a rag or funnel to wipe away any visible dirt or dust that has accumulated around the filler port. You can also spray a small amount of lubricant around the opening to keep the seals in good condition.

Remember to exercise caution and refer to your car's manual or a professional mechanic for specific instructions on removing and replacing the inner cover of your capless fuel filler.

Cleaning the filler port

The filler port of a capless fuel filler must be cleaned periodically to prevent dirt from entering the fuel tank and to ensure that the sealing surfaces are clean. This will also help to prevent engine issues in the future, such as an intermittent check engine light or an OBDII fault.

To clean the filler port, you will need to open the flapper valve, which is the little automatic door inside the filler neck. This will allow you to clean the mating surface, which is the inside valve that creates a vacuum seal to prevent OBDII fault codes.

For a 2013 Ford Mustang GT, the process is as follows:

• Open the flapper valve by inserting a flat-head screwdriver into the top slot and bending it up a little bit.
• Clean the mating surface and sealing surfaces with a suitable cleaning solution and a soft cloth. Ensure that all dirt and debris are removed.
• Close the flapper valve by bending it back down into place.

For a 2009-2014 Ford F150, the process may be similar, but it is always recommended to refer to the specific instructions for your vehicle make and model.

Additionally, if you are experiencing issues with your capless fuel filler, such as an emission control system error, you may need to replace the capless assembly. This process can be more complex and may require special tools, so it is recommended to refer to your vehicle's service manual or seek assistance from a qualified mechanic.

Lubricating the filler port

Firstly, locate the main fuel line. This can usually be found by following the fuel filler tube from the filler port. You may need to look underneath the vehicle or refer to your car's manual for the exact location. Once you have identified the main fuel line, it's important to apply some lubricating oil to the bolt connecting the line to the fuel tank. This is because the bolt is often rusted, and lubrication will make it easier to remove without causing damage.

Next, use the appropriate tool, such as a ratchet, extension, or screwdriver, to remove the bolt. Be careful not to strip the threads of the bolt, as this could create further complications. With the bolt removed, you can now detach the main fuel line from the fuel tank. It is important to also disconnect the line from the plastic canister and any other components it may be attached to. Ensure you keep the brackets and other small parts together in a safe place, as you will need to reassemble them later.

Now, locate the connector that is holding the harness together and unplug it. This will give you better access to the filler neck. Reach into the gas tank and find the connector on the right side. Compress the tabs together and, while sliding it down, grip and remove the neck of the capless fuel filler. At this point, you can install the new filler neck. It is important to remain focused and careful throughout this process to avoid any damage or misalignment.

Finally, once the new filler neck is in place, you can begin to reassemble the components. Reattach the main fuel line to the fuel tank and the plastic canister, using the lubricated bolt. Ensure all brackets and connectors are secure. With the filler neck successfully replaced, you can now test the capless fuel filler system by inserting a fuel nozzle into the port. The spring-loaded door should open automatically, and when fuelling is complete, removing the nozzle should cause the door to close and latch securely.

Replacing the fuel shutter set

The fuel shutter set is made up of two pieces: the external cap and the internal white piece. If you've damaged the external part, you will need to source a replacement. If the internal piece is damaged, you will need to purchase a complete shutter set.

Removal of the External Cap

First, remove the liner surrounding the cap. It should come off easily when pulled. Next, there are six plastic tabs that need to be broken off—their locations are marked by red arrows. After breaking the tabs off, use a flat-head screwdriver to unlock the cap by inserting it into the top slot (marked by a green arrow) and bending the cap up slightly. You can then pull the cap off.

Removal of the Internal White Shutter

You will need a pick tool and something wide and thin enough to fit and span the tabs of the white shutter assembly (a wide chisel, for example). Flip down the flapper and use the pick tool to lift up the latch. Once the latch is lifted, insert the wide tool into the tabs and turn the shutter clockwise, then pull it out.

If your fuel filler system is getting dirty, you may want to clean it out with a rag and spray lubricant. This will help to prevent leaks and error codes.

Frequently asked questions