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The following is from a previous post that I did a while back. My answer to the whole problem? Make sure that the opening of the filler neck is clean and rust free, even a light surface discoloration should be rubbed away with a fine steelwool. Then put an extremely light coat of vaseline on the surface of the threads down to the filler neck opening,
just a thin film. Every couple of months , wipe with a rag and repeat. According to Toyota, they have a rust problem
that allows a leak in the fuel system pressurization, which triggers a code, turning on the check engine light. Effectively, the seal between the filler neck and the screw type gas cap is compromised.
A few days ago my wife gets a "check engine" light on her 2004 Toyota Corolla. This is an extremely well maintained, low mileage (55,000 miles),
never abused vehicle. I told her to make sure that the gas cap was screwed down all the way...it was. She made an appointment with our local Toyota dealership, car is under warranty, and took it in the next day. The service manager called her a couple of hours later to say that they put it on the diagnostic machine, and they got back a code that tells them that there is something wrong with the fuel filler neck. Probably corrosion, he tells her, and $400 and something, labour included, to replace it, filler tube and gas cap
complete. I told her to pay the diagnostic fee, ($70.00) and get the car out of there.
The next morning, I jacked up the back of this car,disconnected the battery negative post, and pulled the left rear wheel. Everything is clean,dry, and not rusty. I removed the three 10mm bolts that retain the plastic shroud in the wheel well that protects the filler tube, and aside from an accumulation of powdery dry dirt that washed away easily, everything is in excellent shape. I the replaced the shroud, replaced the wheel, and dropped it back down on the ground. I reconnected the battery, and started the engine. Absolutely no light, car runs great, and has been fine for almost five days now. For good measure, I swapped the gas cap from her car with my 2003 Corolla, just to see if I will now get a light. So far so good. What really irks me, is that the dealer threw out this pop diagnosis
without even checking out the car properly. In wonder how many people have been suckered into expensive non-existent repairs by an unscrupulous
dealer and a stupid yellow light.
However, it would be a prudent idea to jack up your Corolla on the left side, you don't have to take the wheel off, remove the shroud, and clean up the
dirt accumulated in there. It will prevent possible trouble in the future.
Footnote: After browbeating the service manager as to how inept his mechanics diagnosis was and how disappointed I was with the way everything was handled, I was refunded the $70.00 charge.
Last edited by impala409; 12-25-2009 at 12:19 PM.
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