Body - Fuel Filler Door Hard To Open/Close
NUMBERST310-008
DATE
16 Oct 2006
MODEL
S-TYPE
SECTION:
310-00 - FUEL SYSTEM
Fuel Filler Door Hard to Close/Open
AFFECTED VEHICLE RANGE:
S-TYPE
VIN:
N13089 onwards
Model Year:
2005 onwards
CONDITION SUMMARY:
THE FUEL FILLER DOOR IS HARD TO CLOSE OR OPEN
Situation:
A customer may report a concern that the fuel filler door is hard to close or open. The door release actuator pin profile or a broken pin/actuator housing may be the cause.
Action:
Should a customer express this concern, and there is no obvious fault or major electromechanical failure, refer to the Repair Procedure detailed in this bulletin to verify the cause and resolve the concern.
PARTS:
NOTE:
The locking pin and actuator housing components are now available separately from the actuator mechanism.
XR8 55934.......Fuel filler door release actuator housing, foam and locking pin (kit) Qty 1
WARRANTY:
NOTE:
An obvious fault or major electro-mechanical failure should be carried out as a separate Warranty claim.
Repair procedures are under constant review, and therefore times are subject to change; those quoted here must be taken as guidance only. Always refer to DDW to obtain the latest repair time.
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply.
REPAIR PROCEDURE
INSPECT FOR DAMAGE AND MODIFY FUEL FILLER DOOR RELEASE ACTUATOR PIN
NOTE:
Global Technical Reference (GTR) lookup sequence is as follows:
GTR Home > NAS > Service Information/ X200 - S-TYPE/2005 > Workshop Manuals > Bookmark "Electrical/Battery and Charging System/414-01: Battery, Mounting and Cables/Removal and Installation" > Link > "Battery Ground Cable (86.15.19)"
1. Refer to GTR Workshop Manual Section 414-01 Battery Ground Cable operation 86.15.19 and disconnect the battery ground cable.
2. Remove the luggage compartment side trim panel retaining clips. (Figure 1)
3. Remove the side trim panel for access.
4. Remove the four rear electronic control module (ECM) bolts. (Figure 2)
5. Position the rear ECM assembly aside for access to fuel filler door release actuator.
6. Disconnect the fuel filler door release actuator electrical connector. (Arrowed in Figure 3)
7. Release the clips and remove the actuator assembly. (Figure 3)
NOTE:
If the actuator housing is broken the housing should be replaced. Either the current or the replacement actuator pin must be modified as detailed below.
8. Inspect the actuator housing and locking pin for damage.
9. If either the actuator housing or locking pin are damaged, replace the housing and locking pin using parts from kit (XR8 55934) as follows:
^ Remove the two screws securing the actuator to the housing/mounting bracket. (Solid arrows in Figure 4)
^ Remove actuator and locking pin from the housing/mounting bracket. (Dashed arrow in Figure 4)
^ If the locking pin is damaged, remove the locking pin extension from the actuator assembly.
^ Discard the damaged locking pin extension.
10. Modify the existing (undamaged) or new locking pin as follows:
^ Using either a sharp blade or file, chamfer the tip of the locking pin to the dimensions illustrated in Figure 5.
^ Remove any burrs or debris.
11. If the housing and locking pin have been replaced, perform the following:
^ Install the modified locking pin to the actuator.
^ Install the actuator and locking pin assembly into the new housing.
^ Install two screws, ensuring the screws are located fully forward into the elongated holes.
^ Verify that the actuator pin retracts freely into the actuator housing.
12. Install the fuel filler door release actuator assembly, with modified locking pin tip, to the vehicle, ensuring the two clips engage fully. (Figure 3)
13. Connect the fuel filler door release actuator electrical connector. (Figure 3)
14. Position the rear ECM in place. (Figure 2)
15. Install the four rear ECM bolts and tighten to 10 Nm (7.5 lbf-ft). (Figure 2)
16. Install the luggage compartment side trim panel, and secure with clips. (Figure 1)
17. Refer to GTR section 414-01 and connect the battery ground cable.
18. Check operation of the fuel filler door.
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