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Rusty fuel filler pipe


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Is this acceptable for a 9 year old car with 80k miles on it? The car has full Lexus service history (up to last year) and it's never been mentioned to me.

I'm going to clean it up and see how bad the rust is but surely it should've had some kind of protection from new like brake pipes do?

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Yes I know, there's more than what the Accord has and that's nearly twice the age!

From 2013-2016 it lived in Stoke on Trent and then with us since. I don't know where it lives for the first 2 years.

I've never really looked underneath the car before as I was getting it serviced by Lexus and nothing has gone wrong with it.

 

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I was Googling earlier and it's surprising how many makes of cars have rusty filler pipes. Reminds me of when I was in a petrol station once and a woman was standing next to her car in a massive puddle of fuel. I guess that pipe had a hole in it and she didn't realise!! In a situation like that it could be very dangerous.

I'm going to take the arch liner out next week (looks like it needs a good clean) and check the whole pipe to make sure it hasn't rusted through. It looks bad in some places.

It's just another job to add to the list that I could've done without TBH. Plus I'll want to paint all of the subframe.

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16 hours ago, liner33 said:

Had to replace the filler pipe on my Evo 6 think it was a few years older though. Not a fun job as I recall 

It looks like it could be a PITA where it goes over the subframe. I need to get a price for a new one just in case it has rusted through. I have a feeling it won't be cheap! :(

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Found some pics of my Evo one 

 

OocezjMh.jpg

 

jHp8F4Wh.jpg

 

This is after wire brushing the loose stuff off

 

I cleaned it up , treated the rust and painted with epoxy paint and got £60 for it on the Evo forum 

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I was thinking £200 for one sounds right but I'll get a price. I didn't get time to check the pipe today but I'm also concerned that if I poke it too hard I might put a hole in it! I did the oil change today and there's quite a bit of rust on the front too.

If yours was ok after cleaning it up maybe that is all it needs. What does epoxy paint offer over hammerite, I thought that was for floors?

As it's a filler pipe I'm assuming there is no fuel in them at all but when changing obviously make sure the tank is low as possible.

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Well got a quote for £220 for the twin pipe and clips/bolts. There are 3 pipes that are rusty though so I need a price for the other one. I think I'm looking at £300+ for this! :(

I stripped everything out today and I couldn't believe how much dried mud and dirt there was under the liner and plastics!

Having looked again I think this will be easier to replace on a ramp as it goes over the subframe and going to be a PITA to access the hoses. I can reach the big one but the smaller ones will be difficult laying on my back. I also can't get a small undertray off which restricts some access. The bolts and nuts are so rusty I can't get a socket on them. I think they're 10mm and I managed to get a spanner on one but it felt like it was going to snap so I left it. They're going to need drilling out I think.

After some wire brushing the pipes still feel solid but looking at the condition I think it'll be wise to replace them.

Lexus have also quoted nearly £20 for 2 clips. One is definitely a jubilee and the other I think is one of those bands you need a special tool to do up. Is it worth paying extra for these or just use normal jubilee clips or even reuse if they look ok?

Tony, is this a job that you can quote for? If I leave the arch liner and trims out it should be a simple job on a ramp. Literally 3 clips to the hoses and the large end to the filler cap.

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Well what was going to be a quick look at something this afternoon resulted in me removing the pipe and I managed to get the undertray off.

I wanted to see what the 3rd pipe was and it's a breather one. So literally a pipe with some hose on the end that doesn't connect to anything. I removed this pipe and luckily it seems to be savable. I used a grinder and some white vinegar to clean it up. I'll paint it with some Hydrate 80, hammerite and then protect with S50. I contacted Bilt Hamber and they said that'll be fine to treat the new fuel pipe with too.

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I then decided to try the undertray again and removed 2 of the bolts. They were very tight but I got them out. Unfortunately one nut started to undo and then snapped! As the stud is welded to the chassis any ideas on how to sort this out? I thought maybe snap it off, drill a hole and use a plastic clip.

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Then I started removing the main pipe. After unbolting everything and snapping both plastic clips that hold them in place (I think they were brittle) I nearly didn't get it out. It is a very tight awkward angle over the subframe. I'll definitely be replacing this and ordering new clips/bolts. At least I can fit myself now.

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I'm also going to order some more Bilt Hamber products to treat the underneath. I have some wire brushes as seen in the photo above but they don't seem to be cleaning the subframe and chassis that we'll. Is there anything I can order that'll do a better job? 

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13 hours ago, Viking said:

Re the broken bolt, will a starlock washer push over it?

That could work. There's a little bit of stud left so I'll have to get some and try.

13 hours ago, SMARTLY said:

Could you use a wire brush fitted to an electric or cordless drill, that should remove it a lot quicker?

Or spray it with something like this:

https://www.amazon.co.uk/JENOLITE-Rust-Converter-Trigger-Spray/dp/B07TGKC2DL

 

What's the best type though? I tried some wire ones on my Dremel to clean the small pipe and they didn't really do anything. I switched to a stone and found that more effective.

I've ordered some Bilt Hamber products to protect it afterwards, it's similar to waxoyl. It's what I used on the Mondeo when I had it.

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The Jenolite converts the rust back to metal and effectively cleans it up, I used it years ago on the cars I had. As for the wire brush it needs to be 2 or 3 inches in diameter so you do a large area fairly quickly. hand held wire brushes are OK for flat surfaces you can easily get to ;)

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That's what Bilt Hamber does too. This is the pipe with 2 coats of Hydrate 80.

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Other products to protect everything once it's cleaned up arrived today. I've ordered some more wire brushes and wheels coming tomorrow and also ordered the new pipe I need from Lexus. Plus 2 plastic brackets that snapped. Those were £30!!

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I removed all the trim from the other side this morning ready to clean everything up. I can't see me doing it tomorrow or Friday as it'll be too hot so I'll probably start next week now.

Looking at both sides the NS has more corrosion than the OS. With most puddles being towards the kerb I'm wondering if driving through those has contributed to this. 

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  • 1 month later...

Well nearly 2 months later and I finally fitted the new pipe. I had no idea it's been so long since I started it, where does the time go!!

The condition of the new pipe wasn't ideal, some of the coating had come off exposing bare metal. So if some are fitted like this from new I'm not surprised the rust gets to them!

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After wiping it down with spirits I coated it in Bilt Hamber UB. This is a wax like product similar to S50 but it's for areas that are more exposed so is harder wearing. What I wasn't expecting was how tacky it would be!! But hopefully it'll do the job and offer some protection.

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When it came to fitting I realised that the new pipe was missing the bracket that bolts it to the chassis! The parts diagram Lexus sent me showed it on there but there wasn't a part number so I assumed it came with the pipe. The bolt to hold it on and the plastic clip for the smaller pipes I bought. So I emailed Lexus and I'm waiting for a reply but in the meantime I've got the old bracket soaking in some Detox C.

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I did try using a wire wheel on it first with my drill but unfortunately it skipped off the bracket and shredded my glove along with my hand! Note to self, buy better gloves!! :rolleyes:

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So I got the new pipe fitted, cleaned all of the arch up and treated that to a coat of S50. I did both sides too. Refitted most of the trim and I've just got the bracket and clips left to fit. I'll also treat the other rusty parts at some point.

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Hopefully when it comes to filling up I've done the jubilee clips up tight enough. I never know how tight they should be as I've always thought if they're over tightened they can damage the rubber hoses.

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It didn't take that long to replace the pipe really but obviously the time spent on prepping and treating it, along with the arches added quite a bit extra.

The gloves were only work ones and not anti cut but I guess they saved me from losing a bit more skin. It's not too bad unless I catch it!!

I had a reply from Lexus. Apparently the pipe has been revised on the diagrams a few times and whereas it used to come with the bracket they now charge for that separately. They want just over £10 for it plus £6 postage! Hopefully I can use the existing one.

I'll also clean up the old pipe and paint it providing there are no holes. On first inspection it still seems solid. If I can sell that on ebay and make some cash back that'll be handy.

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That's true and also being a Jap they don't underseal them. 

My hand is scabbing over nicely now!

Managed to save the bracket. All rust removed and just need to paint now once the rust treatment has dried.

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