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:

    Method of engine removal
    Warning: Vehicles equipped with air conditioning: Components of the air conditioning system may obstruct work being undertaken on the engine, and it is not always possible to unbolt and move the ...

    Minor body damage - repair
    Note: For more detailed information about bodywork repair, Haynes Publishing produce a book by Lindsay Porter called ”The Car Bodywork Repair Manual”. This incorporates information on such aspects ...

    Condenser (contact breaker system) - testing, removal and refitting
    Note: Refer to the precautions given in Section 1 before proceeding. Testing 1 The purpose of the condenser is to prevent excessive arcing of the contact breaker points, and to ensure that a rapi ...