IIRC There is a TSB on early AP1s about the fuel filler neck deforming causing problems when putting on the fuel cap. I can't find the TSB report or # anywhere on here anymore. Anyone know where that info might be? Also anyone else had this problem, and did you have any luck with Honda replacing it? My fuel filler neck is now so deformed i had the gas cap get stuck on and took breaking the outer part of the cap off and using a screw driver to get the inner "screw" part out. Basically this has been going from bad to worse for a while and now its so far gone its going to need replacing. So any info on the TSB about this i saw on here before would be a great help.

 

TSB is 04-002. Issue was with 02 and some 03 models per the TSB. As far as Honda replacing them for you the normal warranty applies for these.

 

 

suck

 

I have this issue. Most likely the cap threads just got worse over time. It's the plastic cap v.s. the brass filler neck. Short of replacing the neck get a new cap, and use WD40 on the cap treads when re-applying. It lasts about 2-3 fill ups for me. Still a PITA though

 

my 02 cap wasn't closing properly after 8 years, I just replaced it with a new cap and it is working reasonably well. I might have a slightly deformed filler (not really sure) but the new cap seemed to solve the issue right now. Love that Mugen cap ftw.

 

Fixed! Took my dremel with a sanding stone bit and sanded off about a mm of the plastic threads on the cap. Caps screws in and tightens down like a "normal" cap should.

 

Just make sure that bad boy is air tight. you will know if cel comes on.
Let us know, I may do the same. Good luck

 

My '00 also has cap sealing problems. Previous owner threw a code and replaced the cap once. I've thrown the code a few times too, but hasn't happened ever since I identified the problem and really make sure the cap tightens nicely.

 

I used some motor oil on the rubber seal in case it was an issue with that drying out.