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:

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    Coolant pump - removal and refitting
    1 Disconnect the battery negative lead. 2 Drain the cooling system. 3 Proceed as follows according to model: SOHC models 4 Disconnect the heater and radiator bottom hoses from the coolant pump. ...

    General description
    The body is of welded steel construction available in 3 or 5-door Hatchback, 3 or 5- door Estate, soft-top Cabriolet, or Van configurations. The body is of monocoque construction and is of energy ...