Autopapyrus · Toyota Mark II (X100)
https://autopapyrus.com/guides/toyota/mark-ii/fuel-filler-door-replacement/
https://autopapyrus.com/guides/toyota/mark-ii/fuel-filler-door-replacement/
Compiled automatically from service literature and owner experience. Specs are for the typical configuration — check them against your exact car before you start.
Toyota Mark II (X100): Fuel Filler Door Replacement
The fuel filler door is located in the right rear fender and is opened by a lever on the floor next to the driver's seat via a cable. The exact procedure for this model is not documented in publicly available service materials, so the general principle is given below. Check the hinge mounting (screws or bolts) and the way the door is retained on the vehicle itself during inspection.
Parts
3| № | Part |
|---|---|
| 01 | Fuel filler door assembly (door with hinge and spring) for X100 bodybody color matched |
| 02 | Fuel filler door springseparate, if needed |
| 03 | Fuel door release cable repair kit (interior)if needed |
Tools
6- Phillips screwdriver
- 8-10 mm socket set
- plastic trim removal tool
- flat-blade screwdriver
- masking tape
- hinge grease
Step by step
10 steps- Determine the cause. If the door does not open, first check the release mechanism: the lever on the floor to the left of the driver and the cable running to the latch in the recess. If the door is loose, broken or bent, replace it as an assembly. If only the spring is missing or the retainer is broken, repairing those parts is enough.
- Open the door. If the lever does not work, open it manually: press the latch with a screwdriver through the gap, or remove the right-side trunk trim and pull the cable at the latch.
- Remove the fuel filler cap and cover the filler opening so dirt does not collect in it. Keep in mind that gasoline vapors may be present in the system. Work away from open flames and do not smoke.
- To access the hinge mounting, remove the plastic liner from the fuel filler door recess. If the mounting is hidden, remove the right-side trunk trim. To do this, pry out the plastic clips with the trim removal tool.
- Mark the position of the old door around its outline with masking tape or a marker. This will help you set the gaps during installation.
- Remove the hinge mounting screws or bolts, usually 2-3 of them. Take off the door together with the spring. Note how the spring is positioned.
- Clean the mounting area of dirt and corrosion. If there is rust, treat it with a rust converter and paint over it. Apply a thin layer of grease to the hinge pin.
- Install the new door and spring. First tighten the fasteners lightly, then align the gaps using the mark. The gaps must be even around the whole outline, with no misalignment relative to the fender. Then tighten the fasteners fully. These are small fasteners, with a torque of about 5-8 N·m (4-6 lb-ft). Do not overtighten, or you may strip the threads or deform the fender.
- Check operation: open and close the door several times using the lever inside the cabin. It should open firmly and close with a light click, without sticking. If needed, tighten the cable or adjust the position of the latch striker.
- Reinstall the liner and trim, put the clips back in place, install the filler cap and check that it tightens until it clicks.
Common mistakes and warnings
- This work is done near the fuel system: keep sparks and open flames away, and do not open or damage the filler hoses
- If you find a leak or a crack in the filler neck, take the car to a repair shop; do not attempt to repair fuel lines yourself
- Choose the color of the door in advance, otherwise it will need to be painted