Fuel System - Unable to Remove Fuel Filler Cap

No.: 19/01/01/NAS

Ref:

Issue: 1

Date: 02/23/01

Fuel Filler Cap Removal Procedure

AFFECTED VEHICLE RANGE:
Discovery Series II All

SITUATION:
UNABLE TO REMOVE FUEL FILLER CAP

A failure of the ratchet mechanism within the filler cap may cause the fuel filler cap to spin freely, preventing it from being removed from the fuel filler neck.

RESOLUTION:
REMOVE THE FILLER CAP

When a customer complains of an inoperative filler cap, use the procedure in this TIB to remove the filler cap without causing damage to the fuel filler neck.

PARTS INFORMATION:

WLD100770 Fuel Filler Cap





WARRANTY CLAIMS:
Normal warranty policy and procedures apply.

REPAIR PROCEDURE
REMOVE FILLER CAP





1. Rotate the filler cap so that the handbook symbol is aligned with the lower edge of the filler neck. (Figure 1)

2. Identify a point at the base of the hand symbol, and mark with punch. (Arrow in Figure 1)

CAUTION:
The hole must be no deeper than 10 mm (0.393 in) to avoid damage to the filler neck. A drill stop must be used.

3. Carefully hand drill a 3 mm (0.118 in) diameter hole at the punch mark, to a maximum depth of 10 mm (0.393 in).

4. Obtain a round head, pointed self-tapping screw, 4 to 5 mm in diameter x 10 mm maximum length (US equivalent # 8x3/8 in).

5. Insert and tighten the self-tapping screw.

6. The filler cap can now be removed by turning counterclockwise.

7. Install a new replacement cap (WLD100770).