Tools and Supplies Needed:
- Replacement fuel filler neck
- Safety goggles
- Wrench set
- Flat-head screwdriver
- Pliers
- Funnel
- New fuel cap (optional, if replacing)
- Rubber mallet (optional, for tapping in the new filler neck)
Steps:
1. Fuel Tank Preparation:
- Park your car on a level surface and turn off the engine.
- Engage the parking brake.
- Open the fuel filler door to access the filler neck.
2. Relieve Fuel Pressure:
- Disconnect the negative terminal of the car battery to disable the fuel pump.
- Start the engine and let it run until it stalls. This helps relieve the fuel pressure in the lines.
3. Remove the Old Fuel Cap:
- Pry open the fuel filler door if necessary.
- Unscrew the fuel cap counterclockwise and set it aside.
4. Disconnect Fuel Filler Neck:
- Locate the fuel filler neck, which is the curved tube connecting the fuel filler port to the fuel tank.
- Remove the retaining bolts or screws that hold the filler neck in place. There may be one or more bolts at different locations.
- Use a flat-head screwdriver or pliers to pry open any clips or connectors holding the filler neck.
- Detach the fuel filler neck from the fuel tank.
5. Remove the Old Rubber Seal:
- Remove the old rubber seal (gasket) from the old filler neck.
6. Install New Rubber Seal:
- Place a new rubber seal (gasket) on the new filler neck, making sure it is seated properly.
7. Insert New Fuel Filler Neck:
- Carefully insert the new fuel filler neck into the opening of the fuel tank. Make sure it aligns properly with the fuel filler port.
- Secure the new fuel filler neck by tightening the retaining bolts or screws you removed earlier.
8. Reconnect Fuel Filler Cap:
- Screw the fuel cap back onto the fuel filler neck, ensuring it is tight.
9. Reconnect Battery:
- Reconnect the negative terminal of the car battery to restore power.
10. Test Filler Neck:
- Start the engine and let it run for a few minutes.
- Check for any leaks around the fuel filler neck area. If there are any leaks, tighten the bolts or screws further or check the rubber seal.
Additional Notes:
- If your Contour has an evaporative emission control system (EVAP), there may be additional hoses or connections near the filler neck that need to be disconnected and reconnected.
- If the fuel filler neck needs to be replaced due to damage, inspect other nearby parts such as the fuel tank and fuel lines to ensure they are not damaged as well.
- If the check fuel cap indicator light is still illuminated after following these steps, you may need to inspect or replace the fuel cap, filler neck seal, or fuel tank pressure sensor.
Always refer to your vehicle's repair manual or consult with a professional mechanic if you are not confident performing this task yourself.
