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Large MPVs -- Ford Galaxy / VW Sharan / SEAT Alhambra: => Mk3 Ford Galaxy / Ford S-Max => Topic started by: Chocaholic on June 06, 2018, 09:31:00 AM

Title: Mk 3 fuel filler housing replace
Post by: Chocaholic on June 06, 2018, 09:31:00 AM
Hi all are there any updates ony whats involved in replacing this ?
I have not had any luck finding info on the Web or U Tube.
Title: Re: Mk 3 fuel filler housing replace
Post by: Watkinson10 on June 06, 2018, 11:11:44 AM
Filler or FILTER if it's the filter I have the Haynes manual and can supply you with pictures of the pages
Title: Re: Mk 3 fuel filler housing replace
Post by: Chocaholic on June 06, 2018, 04:22:46 PM
 That would be very helpfull thanks
Title: Re: Mk 3 fuel filler housing replace
Post by: Chocaholic on June 06, 2018, 04:27:06 PM
Sorry fuel filler hosing not filter
Title: Re: Mk 3 fuel filler housing replace
Post by: Watkinson10 on June 06, 2018, 07:28:58 PM
ok ive been through the haynes and unfortunately i dont see anything about the filter housing, just the renewal of the filter which i have atatched.

Sorry its external. it was too large for the forum

https://www.dropbox.com/s/0n21734ti1mvpeu/Fuel%20filter%20Renewal.pdf?dl=0 (https://www.dropbox.com/s/0n21734ti1mvpeu/Fuel%20filter%20Renewal.pdf?dl=0)
Title: Re: Mk 3 fuel filler housing replace
Post by: Chocaholic on June 07, 2018, 12:25:45 PM
Thanks Richard but it is the fuel flap assembly  ,
Title: Re: Mk 3 fuel filler housing replace
Post by: GraceCourt on June 30, 2018, 04:07:45 PM
Thanks Richard but it is the fuel flap assembly

Chocaholic, I have just found your post and can prvide some help but I'm stuck part-way through the process.

Remove the large plastic access panel on the offside interior, and carefully remove both the rectangular plastic foam block from inside the bodywork, and the thick black plastic bag containing foam chips that is squeezed in above the flap assembly as well - both of these are, of course, components of the sound deadening insulation.

Next, carefully remove the solenoid assembly that locks the filler cap from the central locking, by reaching inside the bodywork to the flap assembly and - as you look at it - giving it a 1/8th turn anti-clockwise... you can then just lift it out of the way, you don't need to disconnect it.

Open the filler flap and remove the filler cap - if you have a petrol engine, then you must carefully consider mitigating the risks from petrol vapour in your working environment and I'd strongly recommend that this work is NOT undertaken inside a closed workshop or garage, or anywhere near any naked flames, etc.

The black plastic filler flap assembly is fixed to the bodywork by plastic lugs that clip to the steel bodywork... in theory you are supposed to "punch through" the marked areas of plastic with a screwdriver so that you can depress these plastic lugs, but in fact if you are dextrous you can reach inside the bodywork from the interior of the car, and depress them with your fingers whilst pressing the assembly outwards.

But here is where I got stuck.  Although all of the edges of the plastic assembly were free of the bodywork, I couldn't remove it... it feels as though it is attached to something inside the bodywork, somewhere in the area of the internal hinge, and for the life of me I couldn't finish the job, which was to repair/replace that internal hinge, because my Galaxy has exactly the same problem as you reported at https://www.fordmpv.com/smf2/mk3-ford-galaxy-ford-s-max/mk3galaxy/msg20605/#msg20605 - the flap no longer hangs properly and "waggles" when open.

Can anyone else advise? Thanks.
Title: Re: Mk 3 fuel filler housing replace
Post by: Chocaholic on June 30, 2018, 05:29:49 PM
Hi I managed to replace fuel filler now .
You have to jack up and remove wheel , and  wheel liner .held in place
With nylon nuts.you can then access the fuel pipe remove the bolt holding  the pipe in order for a bit of free play the fuel  filler can the be pushed up from under side of wheel arch .The rubber  surround has a lip seal that has to be pushed throgh wheel arch
You need to be patient  when  carrying  out  this .
So Good Luck ..
Title: Re: Mk 3 fuel filler housing replace
Post by: GraceCourt on June 30, 2018, 05:34:05 PM
OK, I have cracked this now.

The problem with being unable to remove this housing was because there are two flexible rubber collars at the back... one is obvious, because it can be seen when the filler flap is open, but the second one is inside and is a snap-fit into the internal bodywork.  That probably doesn't make much sense but it will if you look at the three photographs that I've attached to this post.

I was able to fix the problem because the plastic hinge pin is a tight push-fit into the housing and it had just xome loose... but the slight bad news is that the spring that provides the "action" for the covering flap fell down inside the bodywork during the removal.  But it all still works, and those who don't mind splashing out can get a Ford replacement unit (with spring!) for 50 - my Ford part number was 1761066 for a WA6 2009 model Galaxy, but as always check carefully before buying.

NB - the outside filler flap is removed by inserting a thin screwdriver blade or similar into the slot on the rear-facing black plastic part of the flap to depress a thin plastic lug, then whilst still depressing the lug, slide the painted flap cover towards the rear of the car about a centimeter or so, and it comes straight off.  I recommend that you do this as step 1, to give yourself more room to work and, more importantly, to avoid unnecessary scratches anywhere on the paintwork of the car or the flap.