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:

    Master cylinder - removal, overhaul and refitting
    Note: Before starting work, refer to the warning at the beginning of Section 3 concerning the dangers of hydraulic fluid. Removal 1 Disconnect the leads from the level warning switch in the reser ...

    Battery
    Your vehicle is equipped with a Motorcraft maintenance-free battery which normally does not require additional water during its life of service. However, for severe usage or in high temperature ...

    Engine/manual gearbox assembly - reconnection and refitting
    1 Reverse the procedure described in Section 11, noting the following points. 2 Before attempting to reconnect the engine to the gearbox, check that the clutch friction disc is centralised. This i ...