Body - Fuel Door Won't Open

NUMBER: 09-40-04
DATE: 11/23/04

APPLICABILITY:
2005MY Legacy/Outback Vehicles

SUBJECT:
Fuel Door Will Not Open

INTRODUCTION

If you encounter a customer complaint that the fuel door will not open, there is the possibility that the fuel cap tether is catching on the fuel door clip. To correct this condition, a fuel cap tether clip will need to be installed.

PRODUCTION LINE CHANGE





The fuel cap tether dip was used in production starting in October 2004 with the following VINs shown.





Parts Number Information

REPAIR PROCEDURE





1) The fuel cap tether clip is symmetrical and can be installed in any direction (see Figure 1).





2) Route fuel cap tether through upper and lower opening of fuel cap tether clip (see Figure 2).





3) Insert fuel cap tether clip into rectangular slot in fuel door (see Figure 3 and 4).

CLAIM REIMBURSEMENT/WARRANTY INFORMATION





For vehicles within the Basic New Car Limited Warranty period, this repair may be claimed using the table.





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