6.16 - Fuel Filler Door Release ( Jim Moore,  December 25, 2001 )

If the fuel filler door release stops working you can still use the boot lever to open and procrastinate until you are really tired of opening the boot everytime you need to fill up...

To remove the unit loosen the clamps on the filler extension, and the vent hose(at rear of filler extension). Pull off the drain hoses (1 at rubber cover, 1 at solenoid). Pull the extension out the top through the rubber.

From inside trunk, take out the 4 bolts holding the solenoid unit from the bottom. Unplug it and take it out of the car. Take out the 6 small phillips head screws on top and remove the solenoid and electrical unit from the plastic housing. Sticking out the end is a pressure switch.

Carefully remove the foam cover and lift up the plastic contact strip. You will see the 2 brass colored contacts under it. which can be covered with carbon from arcing. Clean them up (scrape with a knife blade) also clean between them.

Next clean the contact secton of the plastic strip (has a metal section in the center that contacts the brass strips when pushed down).

Before reassembling the solenoid unit, plug it into the car and test it by pushing down on the contact plastic section with you finger. Due to wear, it may take more pressure than could be asserted with the foam piece installed. You can put some silicon sealant on top of the plastic strip and set a small washer the size of the contact section into it, did not use the foam piece.

Now the plunger that is activated when pushing down on the filler cover sits on the washer and has no problem making the preasure switch activate.

Reistall everything (reverse of removal) and it should work perfectly if the inline fuse is not blowing, this is probably the problem. If the fuse is blowing it is probably the soleniod itself.