Fuel System/Body - Fuel Filler Flap Won't Stay Closed
No: 76/17/03/NASRef:
Issue: 1
Date: 08/22/03
Unintended Opening of Fuel Flap
AFFECTED VEHICLE RANGE:
Discovery Series II (LT) up to 3A804796
SITUATION:
FUEL FILLER FLAP DIFFICULT TO CLOSE
The customer may complain that the fuel filler flap will not stay closed after a refueling or will open at unexplained times and varying conditions. The fuel filler flap may be in contact with the filler cap or damage to the catch may have occurred which prevents flap from latching correctly.
RESOLUTION:
REPLACE THE FILLER FLAP AND LATCH SYSTEM WITH NEW COMPONENTS
Where a complaint of the above condition is confirmed, follow the procedure in this TIB to replace the fuel filler flap with the new flap and upgraded associated parts. The new flap components properly installed address the conditions that lead to the "self-opening" flap.
PARTS INFORMATION:
BPA00030 Fuel filler flap 1 required
BPX700010 Fuel filler latch 1 required
FSU000010 Cushion 1 required
WARRANTY CLAIMS:
19.55.89/39 Time 1.50 hrs.
Install new filler flap and latch components and paint to match body color
FAULT CODE: C
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
INSTALL NEW FLAP COMPONENTS
1. Release the fuel filler flap.
2. Release the two bolts securing the fuel filler flap and remove the flap.
3. Verify that the actuator rod is approximately 7.5 mm in length. (Figure 1)
4. If the actuator rod is above or below the required length, perform the following steps:
^ Refer to RAVE, section 76.13.12 and remove the RH side load space trim casing.
^ Loosen actuator fasteners and adjust the actuator to obtain the required length on the actuator rod.
^ If the actuator rod is still above or below the required length, release the actuator from its fasteners and disconnect the actuator multiplug.
^ Use a round file or other suitable tool to elongate the actuator installation holes to permit extra adjustment as required.
^ Etch prime any bare metal prior to painting.
^ If required, repair body paint finish.
^ Install actuator and verify that actuator rod is at the required length.
^ Tighten securing nuts and connect the multiplug to the actuator.
5. Paint the new fuel filler flap BPA000030 to the required body color.
6. Install the new fuel filler latch BPX700010 and cushion FSU000010 to fuel filler flap. (Figure 2)
7. Position fuel filler flap to vehicle and tighten screws.
8. Check operation and alignment of new fuel filler flap and adjust if necessary.
9. Refer to RAVE section 76.13.12 and install RH side load space trim upholstery.