SERVICE CAMPAIGN BULLETIN
CAMPAIGN REF :

023

TITLE :

Additional sealant and replacement gasket for fuel filler neck
(Federal)

DOCUMENT # :

11 A 018

SITUATION :

Quality Engineering at McLaren Automotive recommend that a
sealant and aluminium foil tape is applied to the fuel filler neck. It
is also necessary to replace a gasket and three securing bolts.

PROCEDURE :

In order to apply the sealant and aluminium foil tape along with
replacing the gasket and three securing bolts it is necessary to
follow the procedure below.

Care point: Check that bulletin 11 M 017 “Replace water drain hose and retrofit a securing clip (Federal)” is not
outstanding before starting work.
Care point: Fuels are highly flammable and toxic if inhaled. Fuel vapours are explosive, invisible and spread out at
floor level. This vapour is poisonous when inhaled and has an anesthetising effect in high concentrations. Fuel can
damage the skin; for example skin is degreased when it comes into contact with gasoline fuel.
o
o
o
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o
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Keep fuel away from fire, open light or ignition sources.
Ensure the work place is adequately ventilated.
Never drain or pour fuels over assembly pits.
Store drained fuel in a suitable and sealed vessel.
Immediately eliminate any fuel that has flowed out.
Never conduct this work on a vehicle near open flames (e.g. if wielding is being performed in the vicinity).

Care point: Ensure a window is open when leaving an electronic key in the vehicle.
1.

Leave vehicle unlocked with the fuel filler flap open and the electronic key inside of the vehicle.

2.

Please refer to AA-RM-02A04-04-007 - Lift vehicle on lifting platform.

REMOVAL:
1. Please refer to AA-RM-03B03-01-001 - Remove/Install wheel (Rear left).
2. Please refer to AA-RM-02A02-03-001 - Remove/install wheel arch liner – Rear (Rear left)

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3. Using a small flat screwdriver loosen and remove 37.6mm Oetiker clip on fuel filler neck. Unplug hose from the
fuel filler neck as shown in the following image (1).

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Care point: Care must be taken when removing this clip not to damage the vent hose.
4. Using a small flat screwdriver loosen and remove upper 15.7mm Oetiker clip on fuel vent hose (2).

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2

Care point: Please be aware the M6 x 16 bolts are to be replaced with new bolts with a blue lock patch.
5. Remove M6x16 bolts (3) on fuel filler neck.

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Care point: It is necessary to take care not to damage the earth strap when lifting the fuel filler neck.
6. It should now be possible to gently lift the fuel filler neck away from the fuel bowl. The earth strap will still be
connected (4).

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7. In order to remove the earth strap wire McLaren Automotive recommend the connection should be unclipped from
the underneath of the bodyside rear panel (5) with the solenoid loom unplugged (6). This will allow more length on
the earth strap when lifting the filler neck to unclip. The fuel filler neck can then be removed completely.

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8. Remove the old gasket from the fuel filler neck assembly (7).

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9. Clean the fuel filler neck with a degreaser agent such as Betaclean.
Care point: In some circumstance the clip aperture will be covered by a white label. In this circumstance remove the
label, ensuring no residue remains.
10. It is necessary to seal the clip aperture (8).There are two clip apertures in total on the fuel filler neck, both the
inboard and outboard clip apertures need the sealant applied.

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11. Apply masking tape around both inboard and outboard clip apertures on fuel filler neck leaving a gap for both (9).

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Care point: Dow Coring 730 solvent resistant sealant has potential health hazards if contact is made with eyes and
skin, or if it is ingested or inhaled. Personal protective equipment such as gloves or goggles is recommended.
o

If contact is made with eye(s) flush the contaminated area with lukewarm, gently flowing water for 15-20
minutes whilst holding the eyelid open. If contact lens is present immediately attempt to remove the lens and
irrigate. Seek medical attention.

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If contact is made with skin remove contaminated clothing and blot or brush away excess solvent. Immediately
flush skin with lukewarm water. Seek medical advice.
If breathing becomes difficult remove from source of contamination and seek medical attention.
If sealant is ingested or irritation is apparent seek medical advice.

12. Apply solvent resistant sealant to both vents in the fuel filler neck and smooth away residue (10)

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13. Let the sealant set for 25 minutes and then remove the masking tape. Both clip apertures should look similar to
the following image (11).

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14. Wrap the fuel filler neck with two layers of aluminium foil tape as shown in the following image (12).

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15. Rub the aluminium foil tape, that has just been applied, with a rounded bar, a screwdriver shaft could be used if a
rounded bar is not available. This will allow the tape to adhere to the fuel filler neck. Please ensure that the foil
tape has fully adhered to the fuel filler neck before installation. A visual improvement to the finish should be
evident as this process is performed (13).

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16. It is necessary to replace the gasket that was removed from the fuel filler neck assembly with the new variant
supplied. The new gasket is a noticeably thicker material.

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Old
Variant

New
Variant

17. Fit new gasket to the fuel filler neck (14) and push upwards so that it sits just under the lip of the filler neck.

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INSTALLATION:
Care point: When refitting the earth connection it is necessary the fixings are correctly located in place.
Care point: Use a new 37.6mm Oetiker clip on fuel filler neck ensuring full engagement to the spigot. Using Oetiker
pliers crimp the clip.

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Case point: Use a new 15.7mm Oetiker clip on fuel vent hose ensuring full engagement to the spigot. Using Oetiker
pliers crimp the clip taking care not to damage the pipe.
Care point: When installing the fuel hose(s) ensure that no contaminates are present. Degrease the affected area
and secure hose(s).
Care point: When installing the fuel filler neck. Ensure that the new M6x16 3Nm bolts with the blue lock patch are
used.

18. Install all components removed in reverse order with the exception of the wheel and wheel arch liner.
Care point: If fuel vapour is detected check the work performed and if necessary contact your regional Aftersales
Manager.
19. Run vehicle to operating temperature until water cooling fans commence and use an emission evaporation test in
order to check for vapour leaking from the fuel filler neck. Examples of the equipment that can be used is shown
below:

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20. Read and delete Diagnostic Trouble Codes (DTC’s).
21. Install remaining components.
Please contact your Regional Aftersales Manager should you have any queries relating to the information contained
within this bulletin.

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Warranty Information
DesCription
Rework of fuel filler neck

Resolution Code

Total Repair Time

B0K10319A12C2J02

0.50

Parts Information
Parts DesCription

Part Number

Quantity

Aluminium foil tape

N/A

1

Free issue

Oetiker clip 37.6 diameter

N/A

1

Free issue

Oetiker clip 15.7 diameter

N/A

1

Free issue

Dow Coring 730 Solvent

N/A

1

Free issue

N/A

1

Free issue

Fuel Filler Neck Gasket

N/A

1

Free issue

Bolt – Lock Patch - M6x16

N/A

3

Free issue

Resistant Sealant

Order ProCess

* All parts will be supplied free of charge via the McLaren Production Centre. Oetiker pliers will also be supplied free of
charge to the dealer network.

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