Body - Erratic Fuel Door Operation
No: 76/12/99/NASRef:
*Issue: 2*
Date: 05/19/99
Fuel Door Fails to Open
AFFECTED VEHICLE RANGE:
*DISCOVERY Series II (LT) Up to XA223795*
* indicates updated information
SITUATION:
FUEL DOOR DOES NOT PROPERLY LATCH OR UNLATCH
Several different reasons for poor fuel door operation have been discovered:
^ The body buffers originally installed tend to stick to fuel flap back surface. This prohibits the door from opening consistently.
^ The fuel door plastic latch may bind in its pivot hole, causing poor latching and unlatching.
^ The actuator rod grommet can dislodge, jamming the latch and mechanism.
^ Improper latch alignment can cause poor latching and unlatching.
RESOLUTION:
IMPROVE FUEL DOOR LATCH PERFORMANCE
Should a customer complain of the above symptoms, installation of new components and some minor modifications can repair the situation:
^ Install new body bumpers which do not stick.
^ Remove material in the latch pivot hole to eliminate binding.
^ Bond the actuator rod grommet into the body to ensure the grommet does not dislodge. Proper latch alignment as described in the procedure will provide improvements for correct latching and unlatching operations.
PARTS INFORMATION:
AYB10019 Filler Flap Buffer Quantity 2
RTC7769125 Dinitrol(R) Sealant As required
Locally sourced:
^ Loctite(R) 4210 As required
WARRANTY CLAIMS:
19.55.89/33 Time 0.30 hrs.
Fuel Flap Performance Enhancements
Material allowance has been incorporated into the labor operation
FAULT CODE: C
Normal warranty policy and procedures apply
REPAIR PROCEDURE:
FUEL DOOR LATCH IMPROVEMENTS
1. Remove plastic fuel door latch (ALR6949) from filler door tab.
CAUTION:
The material thickness must be kept between 0.8-1.0 mm (0.032-0.040 inch) in the area around the pivot hole.
2. Refer to Figure 1. Center a hand held 13 mm (1/2 inch) drill bit on the plastic door latch pivot hole of the fuel door tab.
3. Carefully rotate the drill by hand to remove paint and material from a localized area on the back of the fuel door tab around the latch pivot hole.
4. Thoroughly clean the bare metal and surrounding area of the tab.
5. Apply a sparing amount of Dinitrol (RTC7769/25) to exposed metal on the tab.
6. Continue with repair procedure while Dinitrol(R) is drying.
SECURE ACTUATOR ROD GROMMET
1. Carefully remove actuator rod grommet from body.
CAUTION:
Adhesive on the inside diameter of actuator rod grommet could cause binding or other impairment to rod actuation.
2. Apply Loctite 4210 to backside of grommet shoulder.
3. Install grommet into body opening.
4. Clean off any excess adhesive and ensure that no adhesive has found its way into inside diameter of grommet where actuator rod travels.
REPLACE BODY BUFFERS
1. Remove both fuel door body buffers from rear quarter panel.
2. Install two new body buffers (AYB1OO19).
PLASTIC LATCH ALIGNMENT
1. After the Dinitrol has completely dried, install the plastic fuel door latch previously removed.
2. Verify that latch is free to move about its pivot point.
CAUTION:
Insure that the tab and latch do not make contact with the end of the actuator rod or face of actuator rod grommet.
3. Refer to Figure 4. Carefully bend filler door tab as required to align face of plastic latch parallel to the body at actuator rod.
4. Verify that there is no contact between the latch and the grommet or between the actuator rod and the filler door tab.
5. Latch and unlatch fuel door 3 times to verify correct operation.