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How to remove gas tank filler cap

Started by aigram, December 07, 2019, 02:41:52 PM

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aigram

Unfortunately there is a foreign object in my gas tank, and it's stuck. I need to remove the entire gas cap assembly in order to have better access with a parts grabber tool. Are the allen bolts around the outer ring of the gas cap all that need to come out in order to remove the gas cap assembly? Are there any seals or gaskets that could likely be destroyed by removing the gas cap?
Alex
1989 FJ1200 3CV

Pat Conlon

Going by memory, there are only 3 Allen bolts that actually secure the cap assembly to the tank, with one of the allens under the cap hinge....you have to unlock and open the cap to get to it.
You can remove all the extra allens on the trim ring.
No gaskets are involved.

1) Free Owners Manual download: https://tinyurl.com/fmsz7hk9
2) Don't store your FJ with E10 fuel https://tinyurl.com/3cjrfct5
3) Replace your old stock rubber brake lines.
4) Important items for the '84-87 FJ's:
Safety wire: https://tinyurl.com/99zp8ufh
Fuel line: https://tinyurl.com/bdff9bf3

ribbert

Quote from: aigram on December 07, 2019, 02:41:52 PM

Unfortunately there is a foreign object in my gas tank, and it's stuck. I need to remove the entire gas cap assembly in order to have better access with a parts grabber tool....

If it's big enough to require removing the cap assembly to remove it and it's "stuck", how did it get in there and how did it get stuck, are you sure you're not looking at the sender unit for the fuel gauge?

Noel
"Tell a wise man something he doesn't know and he'll thank you, tell a fool something he doesn't know and he'll abuse you"

aigram

It is most certainly not the fuel level float :)
How did it get in? It fell in. And then found a nice nook to jam itself in.

Thanks, Pat. I found the 3 Allen's you mentioned. Are you saying that the Allen's around the ring of the fill cap are just for that piece of trim?
Alex
1989 FJ1200 3CV

RPM - Robert

To remove, there are thee on the outer ring and one under the cap for all flush mount FJ caps.

Pat Conlon

Just take all of them out, no biggie.....you'll see where the long ones are....
1) Free Owners Manual download: https://tinyurl.com/fmsz7hk9
2) Don't store your FJ with E10 fuel https://tinyurl.com/3cjrfct5
3) Replace your old stock rubber brake lines.
4) Important items for the '84-87 FJ's:
Safety wire: https://tinyurl.com/99zp8ufh
Fuel line: https://tinyurl.com/bdff9bf3

ribbert

Quote from: aigram on December 09, 2019, 04:58:49 PM

It is most certainly not the fuel level float :)
How did it get in? It fell in. And then found a nice nook to jam itself in.


Whoa....ease up there....we're only trying to help.

I don't know you, so all I have to go on is your question at face value and that set the bar for the response. You asked how to remove the fuel cap, if you need to ask that question (and there's nothing wrong with that) it is reasonable that the appearance of the fuel sender unit may not be familiar to you (and the fact that large unidentified foreign objects wedged in fuel tanks without explanation is hardly common!).

Noel
"Tell a wise man something he doesn't know and he'll thank you, tell a fool something he doesn't know and he'll abuse you"

ribbert

....just out of interest, what is the foreign object?
"Tell a wise man something he doesn't know and he'll thank you, tell a fool something he doesn't know and he'll abuse you"

aigram

Thanks Robert, cheers.
The culprit is a skinny flathead driver. While draining the tank I inadvertently knocked it in. Trying to get it out I believe I may have pinned it behind the fuel level assembly.

It wasn't the best of Sunday afternoons in the garage.
Alex
1989 FJ1200 3CV

Paul.1478

2006 GL1800
2009 KLR650
1976 RD400
1993 FJ 1200 ABS

T Legg

I couldn't help imagining an illegal alien hiding in the tank.
T Legg

aigram

Got it out, thanks all for the insight. The trim ring holding the filler cap assembly together really seems a lot less official now that I know only 3 bolts in the whole thing actually attach it to the gas tank body...
Alex
1989 FJ1200 3CV

ZOA NOM

Quote from: T Legg on December 10, 2019, 03:40:00 PM
I couldn't help imagining an illegal alien hiding in the tank.

NO ONE is ILLEGAL! How DARE YOU! /s
Rick

Current:
2010 Honda VFR1200 DCT (Full Auto!)
1993 FJ/GSXR 1200 (-ABS)
1987 Porsche 911 Carrera (Race)
1988 Porsche Carrera (Street)
Previous:
1993 FJ1200 (FIREBALL)
1993 FJ1200ABS (RIP my collar bone)
1986 FZ750
1984 FJ600
1982 Seca

FJmonkey

Quote from: ZOA NOM on January 07, 2020, 12:40:55 PM
Quote from: T Legg on December 10, 2019, 03:40:00 PM
I couldn't help imagining an illegal alien hiding in the tank.

NO ONE is ILLEGAL! How DARE YOU! /s

Maybe Travis meant unauthorized for entry of enclosed spaces. Don't want to OSHA involved.
The glass is not half full, it was engineered with a 2X safety factor.

'86 Ambulance - Bent frame, cracked case, due for an overhaul
'89 Stormy Blue - Suits my Dark Side