Fuel Door: Service and Repair

Fuel Tank Filler Door Replacement

Removal Procedure






Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

1. Open the fuel filler door.
2. Remove the 2 bolts holding the door to the quarter panel.
3. After removing the fuel filler door from the quarter panel, remove the fuel fill cap tether from the door hinge by pushing the tabs together with your fingers and sliding through the hole in the hinge.

Installation Procedure

1. Attach the fuel fill cap to the fuel filler door by snapping the end of the tether retainer into the hole in the door on the hinge.
2. Position the fuel filler door to the quarter panel. Align as necessary.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the 2 bolts holding the door to the quarter panel.

Tighten
Tighten the fuel filler door-to-quarter panel fasteners to 2.5 Nm (22 lb in).