Fuel filler flap - removal and refitting

Removal
1 Open the filler flap and the tailgate or boot lid, as applicable.

2 Remove the fuel filler cap and then remove the screw securing the filler housing to the fuel tank neck (see illustration).

37.2 Fuel filler housing securing screw (arrowed)
37.2 Fuel filler housing securing screw (arrowed)

3 Working inside the luggage compartment, depress the filler housing retaining tangs, and push the assembly out through the body panel. Recover the gasket.

4 Immerse the housing assembly in a container of hot water for approximately ten minutes, then prise the hinge cover from the housing, and using a screwdriver, prise the filler flap hinge legs out of the sockets in the housing.

Refitting
5 Commence refitting by warming the filler flap and housing, as during removal, then push the flap hinge legs into the housing.

6 Further refitting is a reversal of removal, ensuring that the housing gasket and retaining tangs are correctly located.

    See also:

    Exhaust manifold - removal and refitting
    2.0 litre SOHC models 1 Refer to Chapter 4 Part A, Section 26, but note the following points. 2 Ignore the references to removal and refitting of the air cleaner and hot air pick-up pipe, and not ...

    Carburettor (Pierburg 2V type) - removal and refitting
    1 Proceed as described for the Ford VV carburettor but note the following. 2 The Pierburg carburettor is not fitted with an anti-dieselling valve. 3 Disconnect all relevant wiring plugs and vacuu ...

    Hinge and lock check and lubrication (Every 12 000 miles or 12 months)
    1 Work around the vehicle, and lubricate the bonnet, door and tailgate hinges with a light machine oil such as Duckhams Home Oil. 2 Lightly lubricate the bonnet release mechanism and exposed secti ...