Ford Fusion: Body Closures / Fuel Filler Door Assembly. Removal and Installation

Special Tool(s) / General Equipment

Removal

NOTE: The fuel filler door assembly is damaged during the removal process and requires a new fuel filler door assembly to be installed.

1. Remove the fuel tank filler pipe.
   Refer to: Fuel Tank Filler Pipe (310-01A Fuel Tank and Lines - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
   Refer to: Fuel Tank Filler Pipe (310-01B Fuel Tank and Lines - 2.0L EcoBoost (184kW/250PS) – MI4, Removal and Installation).
   Refer to: Fuel Tank Filler Pipe (310-01C Fuel Tank and Lines - 2.5L Duratec (125kW/170PS), Removal and Installation).
   Refer to: Fuel Tank Filler Pipe (310-01D Fuel Tank and Lines - 2.7L EcoBoost (238kW/324PS), Removal and Installation).
   

1. Remove the fuel filler door.
   Refer to: Fuel Filler Door (501-03 Body Closures, Removal and Installation).
   

1. Unseat the fuel filler door assembly boot from inside the wheel opening.
   

1. Slice the holes in the indicated areas.
   Use the General Equipment: Knife

1. Insert the screwdriver and release the clips while pulling the fuel filler door housing away from the vehicle.
   Use the General Equipment: Flat Headed Screw Driver

1. NOTE: Clearance is limited. When all four clips release, the fuel filler door housing can be rotated.

   Rotate the fuel filler door housing.
   

1. Remove the drain tube.
   

1. Pull the fuel filler door assembly away from the vehicle and remove.
   

Installation

1. To install, reverse the removal procedure.