Replacing Mercedes C-Class Coupe Fuel Door: Step-By-Step Guide

If the fuel door on your Mercedes-Benz C-Class Coupe is damaged and needs to be replaced, you can do it yourself by following these steps: First, make sure you have the correct part for your car model and year. You will need to remove the fuel cap cover surround assembly and carefully disconnect the motor responsible for locking and unlocking the door without damaging the wiring. You can then install the new fuel door and reconnect the wiring. Additionally, you can refer to online forums for specific instructions and advice from other Mercedes-Benz owners who have faced similar issues with their fuel doors.

Removing the fuel door

To remove the fuel door of a Mercedes C-Class Coupe, you will need a Phillips screwdriver, a plastic trim removal tool, and a small flathead screwdriver. Here is a step-by-step guide:

Step 1: Disconnect the battery

Disconnect the negative (black) terminal of the battery. This is a safety precaution before proceeding with any work on your vehicle.

Step 2: Remove the screws under the door armrest

Using the Phillips screwdriver, remove the two screws located underneath the door armrest. These screws hold the door panel in place, and removing them will allow you to access the fuel door mechanism.

Step 3: Pry out the door panel

Using the plastic trim removal tool, start prying out the door panel from the side closest to the door hinges. There are nine plastic clips holding the door panel in place, and you should hear each clip pop out as you work your way towards the end of the door. Be careful not to force the panel, as there are connectors attached to it.

Step 4: Lift and remove the door panel

Once all the clips are released, firmly hold the door panel from two opposing ends and lift it up. Gently pull it outward to remove it completely. Be cautious not to yank the panel, as you may damage the connectors.

Step 5: Disconnect the door lock cable

Near the center of the inside door panel, you will find the door lock cable. Pull it up from the actuator latch to detach it from the door panel.

Step 6: Unclip and remove the connectors

There will be a small connector behind the door panel speaker. Use the plastic pick tool to unclip the latch and gently pull the connector out. Additionally, there are two light blue connectors plugged into the module of the door frame. Carefully unclip each connector and gently pull them out.

Step 7: Remove the fuel door mechanism

At this point, you should have access to the fuel door mechanism. Depending on your model, there may be a plastic cover over this area. Remove the cover if present. You will now be able to see the motor responsible for locking and unlocking the fuel door. Use the small flathead screwdriver to pry down on the retaining tabs while pulling the top side of the motor out, being careful not to damage the wiring.

Step 8: Release the recess

To completely remove the fuel door assembly, you will need to release the recess. Use a drill or a sharp punch/pick to make a hole in each of the four corners where you see small round indentations. Then, use a small pick to pry on each locking clip from the inside while pulling the recess out of the body.

By following these steps, you should be able to successfully remove the fuel door of your Mercedes C-Class Coupe. Remember to work carefully and consult a professional if you are unsure about any part of the process.

Locating the release button

To locate the release button for the fuel door of your Mercedes C-Class Coupe, first make sure that the driver-side door is unlocked. This will also unlock the gas tank door. There is no separate control button for the fuel door. Instead, you need to press on the front part of the gas tank door until the rear part pops out.

If your Mercedes C-Class is a 1996 model, the procedure is slightly different. In this case, there is no button, but you need to push inward at the back edge of the fuel door to open it.

Replacing the fuel door

Step 1: Prepare the Car

Before starting, park your car on level ground and engage the parking brake. You will need to access the fuel door, so make sure there is enough space around the car to work comfortably. It is also recommended to wear safety gloves and eye protection.

Step 2: Open the Fuel Door

Unlock the driver-side door to unlock the fuel door as well. Then, press on the front part of the fuel door until the rear part pops out slightly.

Step 3: Remove the Old Fuel Door

To remove the old fuel door, carefully pry it open and locate the hinge mechanism. You will need to drill out the four indents in the corners—a 5mm drill bit should be sufficient. Do not drill too deeply; just break through the outer surface.

Step 4: Install the New Fuel Door

Install the new fuel door by attaching it to the hinge mechanism. Ensure that the door is securely attached before proceeding.

Step 5: Test the Fuel Door

Once the new fuel door is installed, test it by opening and closing it several times. Ensure that it opens and closes smoothly and securely.

Notes and Tips:

• If the fuel door starts to stick when you try to open it or if it takes more than one push to close it, this may indicate a problem with the part.
• When drilling, be careful not to drill too deeply, as you only need to break through the outer surface.
• If you encounter any issues or complications during the replacement process, consult a professional mechanic or a Mercedes-Benz dealer.

Drilling out the corners

Gather the Right Tools:

Before starting, ensure you have the necessary tools, including a suitable drill bit that matches the size of the indentations. A 5mm drill bit is often recommended for this task.

Identify the Indentations:

Locate the four corners of the fuel door recess, which is the component that houses the fuel door. You should see small round indentations at each corner. These indentations are the areas you'll be drilling through.

Drill with Precision:

Using your drill, carefully break through the outer layer of each indentation. You don't need to drill too deeply; just enough to pierce the outer surface. Be cautious not to apply too much pressure or drill too far in, as you don't want to damage any underlying components or wiring.

Clean and Deburr:

Once you've drilled through the indentations, use a suitable tool to clean and deburr the holes. Remove any metal shavings or debris that may have accumulated during the drilling process. It's important to ensure that the holes are clear and free of any obstructions.

Test the Fit:

After drilling and cleaning the holes, it's a good idea to test the fit of the new fuel door or the repaired component. Carefully align the new fuel door with the recess and check if the holes line up correctly. This will ensure that your new fuel door is ready for installation and that the drilling process achieved the desired result.

Prepare for Final Assembly:

With the corners drilled out and the new fuel door fitting properly, you're almost ready for final assembly. Refer to the fuel door replacement instructions specific to your Mercedes-Benz C-Class Coupe model for the remaining steps, which may include attaching wires, securing locking clips, and reconnecting any relevant components.

Remember to work carefully and methodically throughout the process, and always refer to reliable sources or seek professional guidance if you're unsure about any steps.

Removing the lock cover

To remove the lock cover of a Mercedes-Benz C-Class fuel door, you will need a T20 Torx screwdriver and a plastic trim removal tool.

First, use the T20 Torx screwdriver to remove the lock cover. Be careful when levering off the cover from the door handle, as you may need to shimmy it back and forth a bit. Once the cover is off, you will see two Torx bolts under the handle cover, which you should also remove.

Next, carefully lever around the edge of the door trim with the plastic trim removal tool and lift it off. Pull up and forward on the door trim to remove it. Disconnect all hook linkages, and remove the insulation to access the actuator housing area.

At this point, you will be able to access and remove the fuel door lock cover.

If you are looking to replace the fuel door, you will also need to drill or use a sharp punch/pick in each of the four corners of the recess, where you will see small round indentations. Then, use a small pick to pry on each locking clip from the inside while pulling the recess out of the body.

Frequently asked questions