Body - Fuel Door Rubs On Quarter Panel Moulding

10-003

January 16, 2010

Applies To:
2009 Element - ALL

Fuel Fill Door Rubs Against the Quarter Panel Cladding

SYMPTOM

The fuel fill door rubs or binds against the quarter panel cladding, just in front of the fuel fill door opening.

PROBABLE CAUSE

During warm weather, the quarter panel cladding expands slightly, causing it to bow away from the body, and allowing the fuel door to rub or bind when you open it.

CORRECTIVE ACTION

Secure the quarter panel cladding to the quarter panel with Dual Lock Fasteners.

PARTS INFORMATION

Dual Lock Fastener (two required):
P/N 70020-SDN-A01

WARRANTY CLAIM INFORMATION





The normal warranty applies.

Failed Part: P/N 74450-SCV-A30ZA

Defect Code: 01801

Symptom Code: 07303

Skill Level: Repair Technician

DIAGNOSIS

Pull the fuel fill door open, and look for any contact points or binding. If there is contact or binding, or if it looks close, push on the cladding to see if it has bowed out.

^ If the cladding is bowed and flexible, go to REPAIR PROCEDURE.

^ If the cladding is not bowed, this service bulletin does not apply. Proceed with normal troubleshooting for fuel door alignment.

REPAIR PROCEDURE





1. Remove the fuel fill door bolts, then remove the fuel fill door.

2. Remove the left rear wheel.





3. Open the tailgate, and remove the two bolts attaching the door hinge lower cover.





4. Open the rear door. Remove the clip, and pull out on the rear door hinge lower cover to release it from the clips in the doorjamb.

5. Remove the remaining clips from the doorjamb with a clip remover.





6. Remove the screw securing the rear side sill panel.





7. Pull out the front edge of the rear side sill panel, and hold it. Detach the clip, and slide the panel to the rear to release it from the clips, then remove the panel. The five clips will stay in the body.

NOTE:
If any clips are damaged or stress-whitened, replace them.





8. Close the rear door half-way. Pull out the rear quarter panel cladding to detach the five clips securing it.





9. Pull up the rear quarter panel cladding to release the hooks from the body, then remove the cladding.

10. Clean the cladding and the body area above the fuel filler opening with isopropyl alcohol.





11. Remove the paper backing from the adhesive side of the dual lock fastener, and position the fastener on the metal body right above the fuel filler opening pictured below.

12. Place the second piece of dual lock on top of the piece you just attached. Make sure that they are facing each other. Remove the paper backing to expose the adhesive side of the second piece of dual lock to the quarter panel cladding.





13. Make sure all of the clips are in place on the cladding, then reinstall the cladding on the vehicle, pushing firmly to secure the dual lock fastener to the backside of the cladding.

14. Reinstall the clips that were removed from the doorjamb in step 5.





15. Position the rear door hinge lower cover, and fit the clips into the holes in the body. Push on the cover until the clips snap into place, and install the remaining clip.





16. Reinstall the door hinge lower cover, and torque the two bolts to 9.8 N.m (7.2 lb-ft).

17. Remove the clips from the lower sill, and install them into the lower sill panel that was removed in step 7.





18. Position the lower sill panel and fit the clips into the holes on the body, then push on the panel until the clips snap into place. Install the remaining screw.





19. Reinstall the fuel fill door.

NOTE:

^ Adjust the fuel fill door position alignment if needed.





^ Apply multipurpose grease to the pivot area of the fuel fill door hinge as indicated by the arrow.

20. Check for contact or binding.





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