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Eric (Plug Guy)

How to remove fuel filler door

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Door - Insert a narrow screwdriver from above in front of the clip arrow A, press the fastening lug in direction of arrow B and hold, and carefully pull off the filler flap 1 upwards.

Hinge - Insert the removal tool at the locking lugs on the left and right and lift via the locking lugs, remove the plastic hinge 2 in direction of arrow from the filler flap 1.

post-2-1112643830_thumb.jpg

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Guys, I am having a BEAR of a time with this. I need to get it to Eric to do some paint matching. Any suggestions?

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My bodyshop could not get the tabs to compress enough to remove the fuel filler door (Step A). Eventually they had to break the plastic around the metal hinge pin (Step Z, not pictured). Even with the door removed, I could not extract the clips cleanly. So, I removed the remaining plastic in pieces(Step @#!%, not pictured).

BMW sells an identical hinge (apparently much cheaper than Porsche). When I picked up the fuel filler door, the new hinge was attached. I just snapped it into place.

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Door - Insert a narrow screwdriver from above in front of the clip arrow A, press the fastening lug in direction of arrow B and hold, and carefully pull off the filler flap 1 upwards.

Hinge - Insert the removal tool at the locking lugs on the left and right and lift via the locking lugs, remove the plastic hinge 2 in direction of arrow from the filler flap 1.

post-2-1112643830_thumb.jpg

Hi Loren,

Do I need a special tool remove or install the fuel door hinge? If so, where can I buy one?

Thanks for all your help.

Ken

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I've done it with a couple of screwdrivers - be careful to not scratch the paint.

Thanks Loren! I'll give it a try.

Ken

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Ah, I need some quick help! I new I needed a new hinge so I ordered one, and thought the 996 number was superseded by a 997 number. The 997 hinge does not fit though! It hits where the tether attaches. Has anyone had this problem? Currently I have no means of attaching my fuel door, since I have a broken 996 hinge, and a non fitting 997 hinge :( Thanks in advance.

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The tether was a strange beast as some cars had and most did not. Perhaps a dealer/ OPC added "convenience"?

If it were my car I would just get rid of the tether.

  • Upvote 1

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There is another hole that is slightly bigger that I think I will put the tether on. I'll post a pic later.

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I moved the tether from the hole on the lower right to where it is now, not sure why that hole is there. However, then the spring hits it. So, I moved it back to the original hole, but put it in backwards. Seems to work well enough.

post-68261-0-40553800-1371771182_thumb.j

Edited by DK570

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I did the same thing as DK570 and it works fine, but you do have to put the tether rivet through the hole from the bottom of the

bracket.

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I never did post what I finally ended up doing. Here's what it looks like now:

post-68261-0-84867000-1387941775_thumb.j

  • Upvote 1

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One of the first things I did when bought my car was to remove the tether. I've been doing this on every car I've bought since 2000, which is the first car I had that came with a gas cap tether. Except for the Porsche, the tether just guarantees that if the gas cap is dropped, instead of falling to the ground, it's going to swing and hit the side of the car. Around where I live, we still have full service gas stations, so you're better off forcing the attendant to put the gas cap on top of the pump when he removes it.

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thanks for this post. just fixed my hinge and was wondering how to put back the spring.

Note that the original hinge 996-201-063-00 has been superseded by 997-201-063-00

The 997 design is much sturdier

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I just installed mine, but left two tiny dimples in the lid trying to break the **** thing off. I need to see how evident it looks in the daylight . I'll need to take it to the body shop to sand it down slightly and re spray it.

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Sorry Im late to this but I never use metal tools for work like this. Keep a set of these handy. There are many jobs they can be used for while working on your Porsche and they wont easily scratch it like a screw driver. Their perfect for CI and they wont scratch peoples cars. $15 at Auto Zone.

post-85078-0-05176200-1391208259.jpeg

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krazyk -- I bought the same set at Harbor Freight for on sale for 4.99.

I don't buy much at HF but at $4.99 these things are throwaways if damaged.

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Easiest way to remove the fuel door without breaking or scratching anything is to use a mini pair of longnose needle nose pliers.  "Not a Screwdriver".

I was able to remove the fuel door hinge in about 30 seconds. use the pliers to pinch the locking lugs.

1.Stick the pliers into the upper section A and pinch the lugs while pulling up slightly.   You will hear & feel the upper section of the hinge pull up slightly (about 1/8" inch)

  • Thanks 1

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2.  this is the tricky part.   keep gently pulling on the upper section with one hand so it does not snap back into the hole and put the pliers into the lower lug and pinch it. Pull up gently on the lower section, you should hear & feel it snap up.  

3.   Now tilt the whole hinge toward the back of the car, it should pivot up & out.

   I wish I had some picture to help you see how this is done,  but I hope this helps.

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I never did post what I finally ended up doing.  Here's what it looks like now:

 

 

Thank you!  I just needed to see where exactly the spring clip went back.  Had no problem with removal of anything, but forgot exactly where the clip attached.  Jenny

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On 6/11/2016 at 10:22 PM, palmerdog said:

Thank you!  I just needed to see where exactly the spring clip went back.  Had no problem with removal of anything, but forgot exactly where the clip attached.  Jenny

Hi, Did you ever get the answer as to where the spring fits on the hinge. My 996 came to me with the spring missing so i have no idea where the spring attaches to on the hinge side. anyone?

Phil

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On 8/1/2014 at 8:49 AM, hbob1 said:

Easiest way to remove the fuel door without breaking or scratching anything is to use a mini pair of longnose needle nose pliers.  "Not a Screwdriver".

I was able to remove the fuel door hinge in about 30 seconds. use the pliers to pinch the locking lugs.

1.Stick the pliers into the upper section A and pinch the lugs while pulling up slightly.   You will hear & feel the upper section of the hinge pull up slightly (about 1/8" inch)

 

 

I spent about 30 minutes trying to removing my fuel door. After I finally got down to your post about removing it with a long pliers, I was then able to remove it in 30 seconds flat. 

 

Here is the pliers that I used. Your description was spot on. The only thing I did different, I removed the fuel cap and put my finger behind the plastic to use as leverage in popping it up. I was concerned about breaking the plastic. Thanks a lot!

8284FAC3-D913-41E0-BAF2-4474654828EF.jpeg

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