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Autopapyrus · Mitsubishi RVR (1st generation)
https://autopapyrus.com/guides/mitsubishi/rvr/replacing-the-fuel-filler-door-release-cable/
Compiled automatically from service literature and owner experience. Specs are for the typical configuration — check them against your exact car before you start.

Mitsubishi RVR (1st generation): Replacing the Fuel Filler Door Release Cable

The fuel filler door is opened by a cable that runs from a handle inside the cabin (usually near the driver's door sill or beside the seat) to the latch in the rear quarter panel. The exact procedure for this model and engine is not documented in publicly available service materials, so the general principle is given below. The 4G93 engine does not affect this job. The cable routing depends on the body, so make a note of where the cable runs.

Difficulty: Medium Time: 1-2 hours Steps: 12 Tools: socket and wrench set (usually 8-12 mm), Phillips and flat-blade screwdrivers, plastic trim removal tools, flashlight, thin wire or zip ties, cable lubricant

Part

  • 🔩 fuel filler door release cable (complete with the handle, if the handle is not removable). If you only need the cable and end fitting, first check whether the cable is sold without the handle

Step by step

12 steps
  1. Find the cause of the problem. Pull the handle inside the cabin and see whether the latch at the filler door moves. If the handle feels stiff, the cable is binding or frozen. If the handle moves freely but the latch does not respond, the cable is broken or has slipped out of its end fitting. Sometimes lubricant fixes the problem, and then no replacement is needed.
  2. Open the filler door manually: reach the latch through the cabin or the trunk and release it with your finger or a screwdriver. If that does not work, wait for the door to thaw, or pry it open carefully so you do not bend the panel.
  3. Turn off the engine and disconnect the negative battery terminal. This is necessary if there is sill lighting wiring near the handle.
  4. Remove the sill trim and the interior trim near the handle. Pop the plastic clips out with a trim tool, not a screwdriver, or you will break them. Keep all the fasteners together in one place.
  5. Remove the screws that hold the handle to the body. Disconnect the cable from the handle lever: this is usually a barrel-type end fitting or an L-shaped hook in a slot. Note how the cable housing is positioned and how the stopper is secured.
  6. Open the side trim of the trunk or the rear quarter panel on the fuel tank side. If you cannot get access, remove part of the trim. Find the filler door latch and the other end of the cable.
  7. Disconnect the cable from the latch: remove the retaining washer or clip and slide the end fitting out of the lever. Pull the cable housing out of its bracket.
  8. Tie a piece of wire or a zip tie to the old cable on the latch side. Pull the cable out from the cabin side and draw the wire through along the factory routing. If the cable runs along the floor, remove the sill trim strips and the retainers along the way.
  9. Tie the wire to the new cable and pull it back through along the same route. Avoid sharp bends and do not pinch the housing. Make sure the cable does not touch any sharp edges.
  10. Attach the new cable to the latch and to the handle. Secure the housing with the stoppers so that the lever has its full travel. Apply a little lubricant to the end fittings and the inside of the cable.
  11. Before reassembling the trim, close the filler door and operate the handle several times. The door should open smoothly without jerking and close with a click. If necessary, adjust the free play at the housing retainer.
  12. Reinstall the trim, sill and covers in reverse order. Reconnect the battery.

Common mistakes and warnings

  • Work with the engine off and away from open flames. Gasoline vapors may be present around the filler neck, so do not use tools that can spark and do not smoke. Do not pull the cable with force if it is stuck, or you may break the filler door latch. Fastener torques here are low, so just tighten without overtightening. Use the manufacturer's specified values for your body.