RAV4 corroded fuel filler pipe

[BSAvale]

Any mechanics on here with any words of wisdom?
My old RAV4 developed a diesel leak last summer - the filler pipe is corroded which appears to be a common issue. Since it was hardly being used I made a temporary bodge with metal putty which has held until this week - I think driving over hard fields has vibrated it or the corrosion is getting worse.
Toyota part is stupid money at £250 ish but I can get a pattern part off eBay for £50.
I’ve just got the wheel off and the wheel arch liner and access seems pretty easy other than one jubilee clip at the bottom which may be a little bit of a pig to get to.
Has anyone changed a fuel filler neck on a Rav? Clearly it won’t be as simple as it appears. I believe from reading online the fuel tank has a flap valve so there should be minimal fuel leakage when I take the pipework off. I am just hoping my metal putty bodge from last year doesn’t make the removal too much more difficult.
Any guidance from the experienced mechanics much appreciated, I have an engineering degree but 0s and 1s don’t leak diesel or corrode so always learning!

 

[Chris J]

I'm afraid it is quite common with the Landcruiser series too. It's a strange material and seems to develop pin holes along its length. Yes sometime we replace the whole thing, but mostly we chop back to good metal, clean, prime and then double jubilee clip flexible fuel hose into the gap.

 

[BSAvale]

I'm afraid it is quite common with the Landcruiser series too. It's a strange material and seems to develop pin holes along its length. Yes sometime we replace the whole thing, but mostly we chop back to good metal, clean, prime and then double jubilee clip flexible fuel hose into the gap.

I considered that but looking at suitable hose, by the time I have done messing about I would only save about £15 over buying the whole part so have gone down that route. Not a great design, the wheel arch lining traps muck and dirt and therefore salt from the winter in against the filler neck so no wonder it corrodes. Cant complain too much though, it’s 13 years old and I have replaced anything on it yet other than consumable parts.

 

[Chris J]

We just find that a chop and flexible is the path of least resistance and added issues trying to fit the new part. It's one of those 5 minute jobs that turns in to a whole weekend.

 

[BSAvale]

We just find that a chop and flexible is the path of least resistance and added issues trying to fit the new part. It's one of those 5 minute jobs that turns in to a whole weekend.

I’m fully expecting it to take 10 times longer than it should...it appears suspiciously simple - 3 bolts holding the filler pipe to the car, a jubilee clip to the rubber hose to the fuel tank and another clip to the breather...it’s bound to take all weekend.

 

[BSAvale]

Well it’s changed, about 3 hours - a lot of that was taking the wheel off and putting back on as I only had the car’s scissor jack so was putting the wheel back on whenever I needed to be underneath the vehicle as I don’t trust scissor jacks.
It was a pain in the arse as none of the brackets on the new part were in the right place so no holes lined up so all needed adjusting but I now have a nice new filler pipe which hopefully won’t drip diesel anywhere now.
At least £250 cheaper than paying someone to do it.

 

[enfieldspares]

If you can now get several layers of good paint on it. David's Isopon 182 is good.

 

[BSAvale]

If you can now get several layers of good paint on it. David's Isopon 182 is good.

The new one is painted to a good standard, I suspect it’ll outlast the rest of the vehicle now (Or certainly until legislation means I can’t run an old diesel).