Having now screwed this up myself once, then watching my neighborhood independent shop screw it up two more times, I had to look closer at the seal design, take some measurements, and draw it up to determine how it was designed to work.
Thanks to this forum for defining the part numbers required:
· Retaining Clip XS2Z-9149-AA
· Seal XS7Z-9072-AA
· Also to the descriptions for the tank R and R – such as post 25
A number of people have suggested that the seal should be placed on the filler tube, then the tube and seal inserted into the tank – this is how attempted it the first time (as well as how my local shop did it) – it leaked, and here is why.
The seal MUST be “snapped” into the tank fitting in order to seal – I believe this can only be done PRIOR inserting the filler neck - see figures below:
Note that the top of the seal is approximately ˝” below the windows in the tank fitting. There is a very clearly felt “snap” when pushing the seal in. If the top of the seal is even with the windows in the tank fitting, it is incorrect, and will leak.
Lightly grease (I used Vaseline) the filler neck. Place the white snap ring on the filler neck. Carefully center the filler neck in the seal as you push the tank onto the filler neck – when greased it doesn’t take much force to slide the tank with seal up the filler neck, but there is some maneuvering of the tank around the floor pan and other obstructions. Concentrate on getting the filler neck fully seated into the tank and seal before trying to push the tank up into the floor pan cavity.
Here is what the finished joint should look like in cutaway: