Replacing E70 Fuel Door Assembly: Step-By-Step Guide

The fuel door assembly is a crucial component of your vehicle, providing access to the fuel filler cap and safeguarding your fuel tank from dirt, moisture, and potential theft. However, issues with the fuel door, such as difficulty opening or closing it, can arise over time. In this guide, we will walk you through the process of replacing the fuel door assembly on your E70 vehicle, covering everything from the tools you'll need to the step-by-step procedure, so you can get back on the road safely and efficiently.

Removing the fuel filler cover

To remove the fuel filler cover, you will need to first open the fuel door. If you have a sticker inside the fuel filler door, you can remove it to expose the locking tab. With a screwdriver, gently pry up on this tab while pulling outwards on the cover. It should slide right off.

Now you can see the backside of the pin and can see that it takes a simple twist to push it out. Grasp the pin with pliers, using just enough force to push it in on the pin while turning it clockwise. Turn it 90 degrees and push the pin out the backside.

Alternatively, you can remove the fuel filler door by prying lightly on the tab inside the door and sliding the door out towards you.

Replacing the fuel door pin

To replace the fuel door pin of an E70 fuel door assembly, you will first need to remove the fuel filler cover. You can do this by prying up the locking tab inside the fuel filler door with a screwdriver while simultaneously pulling outwards on the cover. Once the cover is removed, you will be able to see the backside of the pin.

The next step is to remove the pin by grasping it with pliers and pushing it in while turning it clockwise. Turn it 90 degrees and then push the pin out from the backside. To put a new pin in place, simply reverse these steps. Ensure that you apply just enough force when handling the pin, as it is made of soft plastic and can be damaged easily.

If you are upgrading to a MegaOhm pin, the process is slightly different. This type of pin uses a T15 screw instead of the twisting mechanism of the OEM pin. When installing, be mindful to clock the pin correctly, with the slot in the pin facing up.

Drilling the old assembly

Drilling out the old assembly is a crucial step in replacing the fuel door assembly. Here is a detailed, step-by-step guide on how to approach this process:

Firstly, it is important to gather the necessary tools and materials. You will need a cordless drill or a cordless dremel to drill out the old assembly. A 3/16 drill bit is recommended for this task. It is also important to wear the appropriate safety gear, including eye protection and gloves, to protect yourself from any debris. Ensure you have a clear and well-lit workspace to accurately identify the areas that need to be drilled.

Once you are ready, start by opening the fuel door and locating the small indentions on the fuel door assembly. These indentions correlate with the tabs that hold the assembly in place. Mark the holes with visible paint if they are difficult to identify. This will ensure that you drill in the correct spots.

Now, you can begin drilling. Carefully drill into the marked areas, creating holes. After creating the holes, switch to a drill bit that can create a slot shape. Drill into the indentions to break the tabs holding the fuel door in place. You may need to use a slotted screwdriver to carefully break these tabs after drilling. Be cautious during this step to avoid bending the sheet metal by applying too much force.

After breaking the tabs, carefully pull the fuel door assembly to the right and slide or pull it out. The assembly is partially rubber where the fuel neck connects, so you should be able to pull it over and remove it. Take care not to damage the surrounding components or the fuel neck itself during this process.

Once the old assembly is removed, you can prepare to install the new fuel door assembly. Ensure you have all the necessary parts and that they are compatible with your vehicle's make and model. It is also important to refer to the manufacturer's instructions or a trusted guide for the specific steps required for your vehicle.

Removing the fuel door assembly

To remove the fuel door assembly, first open the fuel door and remove the fuel filler door by gently prying on the tab inside the door and sliding it out. Next, locate the small indentations on the fuel door assembly that correlate with the tabs holding it in place. Using a cordless drill or dremel, carefully drill holes where the indentations are. Drill a slot shape in these areas to break the tabs holding the fuel door in place. Be careful not to drill into the fuel filler.

Once all the tabs are broken, you should be able to remove the fuel door assembly by pulling and sliding it out. The assembly is partially rubber where the fuel neck is, so pull it over the fuel neck and off. Now, you can install your new fuel door assembly by sliding it into place and pushing the rubber part over the fuel neck. Remember to hook up the fuel door sensor and route the emergency fuel door wire pull string correctly. Give the assembly a final tug and pull to ensure it is seated correctly, and then reinstall the fuel door cover.

Installing the new fuel door assembly

To install the new fuel door assembly, follow these steps:

Firstly, you will need to attach the new door to the hinge. If you are reusing the old hinge, attach the new door to that. If you are using a completely new hinge, attach this to the old door. Once you have attached the door and hinge together, you can then fix the hinge to the body of your car.

When removing the old door and hinge, you may have to unscrew the filler cap to get to the fasteners. While the cap is off, place a clean cloth in the filler neck to prevent gasoline vapour from escaping and to stop dirt from getting into the gas tank. Be careful not to scratch the paintwork when working around the fuel door.

If you are replacing a fuel door actuator or cable, you will need to remove a panel inside the trunk to access these parts. To remove the fuel door cable, you will have to take out other parts to reach it. The route of the cable will vary depending on the model of your car, but you may have to remove kick panels and seats.

Before beginning any work, it is important to disconnect the battery for safety reasons. You should also ensure that your fuel tank is as empty as possible before starting work.

Frequently asked questions