Filler tube assembly for a fuel vapor recirculation system

A fuel tank filler tube assembly, comprising:

• a filler tube having an enlarged end for receiving a refueling nozzle, wherein a vapor recirculation port is formed in the wall of the enlarged end;
• a flexible flapper that opens and closes the port in response to at least one of a differential pressure across the flapper and a viscosity of the fuel in the tubular member such that the flapper substantially prevents passage of liquid fuel from the filler tube into the port and permits fuel vapor flow into the port when in the open position, and wherein the flapper is in the closed position during a failed nozzle condition;
• a nozzle chamber formed below the enlarged end, wherein the nozzle chamber has a substantially constant diameter;
• and
• a failed nozzle relief (FNR) valve having a reset lever adapted to contact a fuel cap when said fuel cap is placed on the fuel tank filler tube, wherein the FNR valve moves during the failed nozzle condition to generate an alternative fluid flow path.

A method of making a fuel tank filler tube for use in a system with fuel vapor recirculation comprising:

• forming a tubular member with an enlarged end for receiving a refueling nozzle and forming a vapor recirculation port in the enlarged end for vapor recirculation;
• forming a nozzle chamber having a substantially constant diameter below the enlarged diameter end;
• disposing a flexible flapper for movement between an open and closed position with respect to the vapor recirculation port;
• and
• disposing a failed nozzle relief (FNR) valve in the filler tube, wherein the FNR valve is positioned so that a reset lever on the FNR valve is adapted to contact a fuel cap when said fuel cap is placed on the fuel tank filler tube.