Body - Fuel Filler Door Hard To Open

Retailer Technical Journal 20709
Fuel Filler Door Adjustment

Date 3-6-2009

Note!
If using a printed copy of this Retailer Technical Journal, first check for the latest online version.

AFFECTED VEHICLES:

DESCRIPTION:
Under certain conditions there is a possibility that the fuel filler door may be difficult to open. The lock arm may be caught in the latch mechanism. Adjustment to the fuel filler door arm is necessary to eliminate any possible binding. This should be completed to all
the vehicles listed in the attached retailer letter prior to customer delivery if possible.

TOOLS: Bone Tool, Utility Knife

SERVICE:
Remove the fuel filler door lid and adjust the arm as described in the following.

The repair will be completed with the hinge assembly on the vehicle; be cautious so you do not damage the paint finish or the body panels.

IMPORTANT:
Read the entire document before you begin!

Remove the Fuel Filler Door Lid





While holding the lid with one hand; insert a bone tool into the "square" hole at the end of the arm.





Press until the release button disengages
and the lid can slide off the arm.





Slide the lid off the arm as shown.

NOTE:
The lid is the only part that needs to be removed from the vehicle!





For reference; this is the release button described above. It's on the outer side of the arm.





NOTE:
This tank filler module is shown on a bench; there is no need to remove it from the vehicle.

With the lid removed and the arm in the
open position locate the "lower rib" on the
underside of the locking tab.





With the utility knife; carefully remove the
lower rib.

Arm shown here with rib still in place.





Arm shown here with the rib removed.





Once the rib has been removed; reinstall the fuel filler door lid. Align the lid and the arm and slide back into place.

Be sure to slide the lid back on completely.





If the upper tab is just at the left side of the sticker part number the lid is not completely installed!

Be sure to slide the lid back on completely.
If the upper tab is almost to the right end of the sticker part number; the lid is completely installed!

NOTE:
You should have felt and / or heard the locking tab engage.
Gently pull on the lid to be sure it's locked in place.

Once you have verified the lid is locked in place; close the fuel filler door and check the alignment.

The door should have a similar gap all around the opening.