Fuel Filler Door, Fuel Filler Door

Fuel Filler Door






1 Fuel Filler Door Cup

• When installing, ensure correct fuel filler door cup seating on side part and in fuel filler insert. Refer to => [ Fuel Filler Door Unit ] Fuel Filler Door Unit.

• Before installing, insert drain hose in fuel filler door cup.

2 Fuel Filler Door Unit

• Removal:

• Must be replaced after removing.

- Before removal, remove guide sleeve.

• Before removing or installing guide sleeve, the fuel filler door locking pin must be completely released using the emergency release.

- Rotate guide sleeve left out of locking mechanism using point of circlip pliers.

- Remove guide sleeve from fuel filler door insert.

- Open the catches - arrows -, refer to with a small screwdriver and remove the fuel tank insert.

• Installing:

- Insert drain hose into insert cup.

- Push insert cup into cut-out in side panel.

- When doing this, align markings on insert cup and side panel - arrows - to each other.

- Insert fuel filler insert into cut-out and let it engage in fuel filler door cup, refer to => [ (Item 3) Fuel Filler Door Unit ] Fuel Filler Door Unit.

3 Fuel Filler Flap

• Insert flap onto hinge arm and let it engage.

4 Rear Lid Locking Mechanism Guide Sleeve

• Before removing or installing guide sleeve, the fuel filler door locking pin must be completely released using the emergency release.

• Use commercially available circlip pliers for removal.

• Put point of circlip pliers in both guide sleeve holes and turn them about 90° left, loosening lock.

• Remove guide sleeve from fuel filler door insert.

5 Installation Hose

• Use this hose for easier installation of locking rod in guide sleeves.

• Before installing fuel filler insert, remove hose from locking rod.

• Move installation hose sideways through guide sleeve mounting opening, as shown.

• Insert fuel filler door insert in body cutout and until you hear it engage.

• Remove hose from locking bar and insert guide sleeve.

• Engage guide sleeve with commercially available needle-nose pliers.

6 Drain Hose

• Move drain hose down with clamp - 7 - onto side piece flange.

Remove The Tank Flap Unit

• Beginning with VIN 4L 9-014 901, the emergency release for the Fuel filler door unlock motor (V155) must be disengaged from the Comfort system central control module (J393) before removal.

- Release the tank flap insert at the markings - arrows -.






- To do this, insert a small screwdriver diagonally from underneath through the marking in the tank flap insert over the latches.






- Gently lift the screwdriver and release the latches.

- Pull the tank flap insert in steps out of its cut-out.

Unlocking The Fuel Tank Insert Cover






- Insert a screwdriver as shown between flap - 2 - and flap mount - 1 - and release the lug.

- Pull flap slightly toward rear - arrow - out of lug.

- Remove flap from the side.

Installing The Fuel Tank Insert Cover





- Insert flap into cutout in mounts.

- Slide lid - 2 - forward until locking mechanism - arrows - on mount - 1 - engages.