20-004 SRP

Raise Fuel Fill Bezel to ensure proper flow of fuel into tank
Fix as Reported
Bulletin Type:
Standard Repair Publication
SRP
Publication Date:
Bulletin #:
20-004
Make:
Job Code:
**
Model:
Flat Rate:
**
Model Year:
February 2020
Jayco
Entegra
Greyhawk Prestige
Greyhawk
Red Hawk
Esteem and Odyssey
ALL
** If affected unit has warranty remaining, submit your claim following the normal process.
Incident:
Affected
Units:
Parts
Misc. Tools &
Supplies:
Fuel fill bezel is too low, restricting fuel flow into tank.
Greyhawk Prestige: 1BF, 1BX, 1BU
Greyhawk: 1MF, 1MX, 1MU
Red Hawk: 1XF
Esteem: 3BF, 3BX, 3BU
Odyssey: 3EF
1 - Cover, Gas Fill 3.00 x 6.63 x 2.25 (0347509)
4 - Screw, RW QD 8.00 x 1” DT TYP 17 ZC (0059335)
2 - Screw, RW QD #8 x 1-1/2” .67 TWFST NW (0072887)
2 - Screw, FL QD 8.00 X 4.00 .67 TWFST PL (0017682)
Air saw
Screw gun with #2 sq. drive bit
Utility Knife
Reciprocating saw
Flat screwdriver
Creeper
2 ft Putty tape
1 Tube white silicone caulking
Gas Fill
1 can undercoating spray
Cover
Fiberglass repair is required in preparation for the new location of the Fuel Fill Bezel.
SRP 20-004 Relocate fuel fill bezel
February 2020
Page 1 of 9
INSTRUCTIONS
FUEL FILL BEZEL
3 SCREWS IN FILL
NECK
FIG 1
FIG 2
FIG 1:
 Remove the fuel fill bezel located on the driver side rear of motorhome.
FIG 2:
 Remove 3 screws holding the fill neck to the bezel. Save the screws to reinstall at end of repair.
FIG 3
FIG 4
FIG 3:
 Remove the 12 screws holding the bezel to the sidewall. Save the screws to reinstall at end of
repair.
FIG 4:
 Carefully, cut the seal around the bezel with a utility knife.
SRP 20-004 Relocate fuel fill bezel
February 2020
Page 2 of 9
FIG 5
FIG 6
FIG 5:
 Remove fuel fill bezel and push the filler neck down toward the ground inside the opening.
FIG 6:
 Trim off the curved ends of the skirt trim with an air saw.
 Trim even with the outer edge of the footprint left by the fuel fill bezel.
ENLARGE THE FUEL BEZEL HOLE BY 1 INCH
FIG 7
FIG 8
FIG 7:
 Measure and mark the location on the sidewall with a pencil or grease pencil.
FIG 8:
 Enlarge the fuel bezel opening by 1 inch with a reciprocating saw.
SRP 20-004 Relocate fuel fill bezel
February 2020
Page 3 of 9
CUT A HOLE
APPROXIMATELY
3 X 7 INCHES
FROM BACK LIP
BACK LIP
FIG 9
FIG 10
FIG 9:
 The fuel fill bezel hole enlarged by 1 inch.
FIG 10:
 Inside the fuel fill bezel hole, cut another hole to install the gas fill cover.
 Use the air saw and cut a hole up into the floor of the vehicle inside the fuel bezel opening.
 Hole must be 3 inches away from the back lip as shown in Fig 10 and 12.
 Hole size is approximately 3” x 7” in the area shown with dashed lines in the photo.
HOLE CUT UP
INTO THE
FLOOR 3
INCHES FROM
BACK LIP
FIG 11
LEAVE 3”
BACK LIP
FIG 12
FIG 11:
 Cutting the 3” x 7” hole into the floor with the air saw.
FIG 12:
 Finished hole cut into the floor
SRP 20-004 Relocate fuel fill bezel
February 2020
Page 4 of 9
PART OF THE
HOLE IN THE
FLOOR
SHOWN
INSIDE THE
VEHICLE
FIG 14
FIG 13
INSTALL THE 3” X 7” X 1-1/4”
WOOD BLOCK AGAINST THE
REAR LIP
FIG 13:
 Hole from inside the RV at the driver side slide. Most of it will be under the bed platform.
FIG 14:
 Cut a wooden spacer block (piece of a 2 x 4) (3” x 7” x 1-1/2”) and install it against the rear lip
 Attach the block to the rear lip using two 4” screws.
 NOTE: The cover should fit in the hole with no interference. The ends of the hole may
Require trimming, so the cover will fit correctly in the hole.
CUT
CUT THE
VERTICAL
FLANGES OFF
OF EACH SIDE
CUT
FIG 15
FIG 16
GAS FILL COVER AFTER LIPS
HAVE BEEN CUT OFF
FIG 15:
 Cut off both the vertical flanges on each end of the gas fill cover. LEAVE THE BOTTOM FLANGES
INTACT SO THEY WILL SEAL THE COVER AROUND THE BOTTOM.
 Flanges labeled A, B, C, and D will remain attached to the cover.
 Place putty tape on flanges A, B, C, and D.
FIG 16:
 Gas fill cover after trimming off only the flanges on each end of the cover.
 Flange A shown to reference the top of the cover.
SRP 20-004 Relocate fuel fill bezel
February 2020
Page 5 of 9
FLANGES REMOVED
ON EACH END
FIG 17
FIG 18
VIEW LOOKING UP FROM THE
GROUND
FIG 17:
 Another view showing the flanges removed from the cover.
 Flange A - shown to reference the top of the cover.
FIG 18:
 Place the gas fill cover up inside the sidewall above the gas bezel opening.
 The top flange of the cover will butt against the sidewall.
 Install four-#8 x 1” screws through the bottom flange into the wood block and two end screws
through end flanges and into floor.
INSTALL 4 SCREWS
TO HOLD GAS
COVER IN PLACE
FIG 19
FIG 20
GAS COVER AND WOOD
BLOCK INSTALLED IN THE
OPENING
FIG 19:
 Install 4 screws to secure the cover to the wood block.
FIG 20:
 Shows the gas cover installed in the gas fill bezel opening.
SRP 20-004 Relocate fuel fill bezel
February 2020
Page 6 of 9
CUT ANOTHER WOOD BLOCK
1” X 1” X 6”
FIG 21
BEVEL THE BOTTOM CORNERS
FIG 22
BLOCK WILL FIT INTO THE
FUEL BEZEL OPENING
FIG 21:
 Cut another wood block approximately 1” x 1” x 6”.
 NOTE: The block must fill the complete width of the fuel fill bezel (Fig 22).
 Measure the width of the opening, so the block will fit completely in the opening.
FIG 22:
 Insert the block into the fuel fill bezel opening as shown.
 Beveled corners will be toward the bottom of the fuel bezel opening.
 If it doesn’t sit flat across the bottom, the bezel opening may require slight trimming.
FIG 23
INSTALL BLOCK WITH TWO
1-1/2” SCREWS
FIG 24
FIBERGLASS REPAIR
FINISHED
FIG 23:
 When the block sits flush in the opening, secure it in place using the two 1-1/2” screws.
At this point, the lower 1” area where this block is located will need to be glassed in as this will show
when the fuel fill bezel is reinstalled 1 inch higher up on the wall.
FIG 24:
 Fiberglass repair is completed. Proceed to complete repair.
SRP 20-004 Relocate fuel fill bezel
February 2020
Page 7 of 9
APPLY BEAD OF SILICON
CAULK AROUND OPENING
FIG 25
CAULK
AROUND
THE
OPENING
FIG 26
FIG 25:
 Apply a bead of white silicon caulk around the perimeter of the opening.
FIG 26:
 Caulk applied around the fuel bezel opening.
FIG 27
INSTALL 3
SCREWS ON
FUEL NECK
FIG 28
SECURE THE
BEZEL TO
THE
SIDEWALL
FIG 27:
 Pull the fuel fill neck up into the bezel and install the 3 screws removed previously.
 Secure the filler neck with the screws.
FIG 28:
 Secure the fuel bezel (removed previously) to the sidewall using the 12 screws removed
previously.
SRP 20-004 Relocate fuel fill bezel
February 2020
Page 8 of 9
APPLY
WHITE
CAULK
FUEL FILL
BEZEL
INSTALLED
FIG 29
FIG 30
FIG 29:
 Fuel fill bezel installed on the sidewall.
FIG 30:
 Apply white silicon caulk around the top of the bezel, and around each side to the skirt trim
molding.
 Fill in the area between the bezel and the trim pieces on each side with white caulking.
FIG 31
BARE WOOD
INSIDE
FENDER
FIG 32
SPRAY
UNDERCOATING
OVER THE WOOD
FIG 31:
 Inside the fender well, the wood block is still unprotected.
FIG 32:
 Spray undercoating all around the area to seal any gaps and the wood block.
Jayco’s sole obligation under our limited warranty is to repair or replace defective materials and/or workmanship deemed our responsibility as determined
by Jayco in our sole discretion. Jayco reserves the right to use new and/or remanufactured parts or materials of similar quality to complete any work, and to
make parts and/or design changes as appropriate without notice to anyone. Jayco designs and/or materials changes are done without obligation to
incorporate such changes in previously manufactured product. Jayco makes every reasonable effort to ensure field remedies will not adversely affect
performance and/or safety of the unit. This field remedy is not intended to extend to future performance of this RV, or any of its materials, components or
parts beyond the standard warranty period. The RV owner’s obligation to notify Jayco, or one of its independent, authorized dealers, of a claimed defect
does not modify any obligation placed on the RV owner to contact Jayco directly when attempting to pursue remedies under state or federal law. Jan. 2019.
903 South Main Street • P.O. Box 460 • Middlebury, IN 46540
SRP 20-004 Relocate fuel fill bezel
February 2020
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