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:

    Facia panels - removal and refitting
    Models up to 1992 1 Note the locations of the facia panel securing screws (see illustration). 43.1 Facia panel securing screw locations (arrowed) A Upper facia panel B Passenger side lower faci ...

    CFI unit (1.6 and 1.8 litre (R6A type) CVH) - removal and refitting
    Caution: Refer to the precautions in Section 1 before proceeding. A new gasket must be used on refitting. Removal 1 Disconnect the battery negative lead. 2 Remove the air cleaner assembly. 3 De ...

    Battery terminal check (Every 12 000 miles (20 000 km) or 12 months)
    Caution: Before carrying out any work on the vehicle battery, read through the precautions given in “Safety first!” at the beginning of this manual. 1 The battery fitted as original equipment is ...