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:

    Fuel evaporative emission control system components (Central Fuel Injection/CFI engines) - removal and refitting
    Carbon canister Removal 1 The carbon canister is located behind the bumper, under the front right-hand wheelarch (see illustration). 5.1 Carbon canister location (wheelarch liner removed) - CFI ...

    Hinge and lock check and lubrication (Every 12 000 miles or 12 months)
    1 Work around the vehicle, and lubricate the bonnet, door and tailgate hinges with a light machine oil such as Duckhams Home Oil. 2 Lightly lubricate the bonnet release mechanism and exposed secti ...

    Alternator - testing
    Note: To carry out the complete test procedure use only the following test equipment - a 0 to 20 volt moving coil voltmeter, a 0 to 100 amp moving coil ammeter, and a rheostat rated at 30 amps. 1 ...