Time: about 45min to an hour:
Either replacing the gas fuel door actuator or fixing it, when you lock the car, plastic pin goes inside the fuel door, so it stays locked and you can't open the fuel door by hand. When I locked my car, I was able to open the fuel door, when I grabbed by O-ring I was holding it in my hand, someone just left it in there, hanging- I looked inside by bending the plastic and I see the pin (stuck) inside the fender, no wonder why my fuel door stays open when I lock the car---

- First, grab a beer or two, I basically fixed mine, -someone probably pulled the manual release so hard he pulled the pin out, (thinking that maybe it was for front trunk) Also rubber grommet was missing, I found something in my toolbox, and it works, perfect - I'm like a macgyver.



also this is the location of manual release for fuel door, this is not! manual release for the front trunk (passenger side, US cars)


Ok, first: take the wheel off,


We need to take fender liner off, yellow arrows shows location:



Next step, Remove gas the vapor lines (disconnect them, by pulling gently, you dont want cracked lines-
three at the top by squeezing the connectors, gray color shows you where to press and pull gently.


If you have problem to remove the one on far right, use flat head screw driver, and press the other side with finger


remove, use 10mm socket


Inside the fender, when you look up, decided to pull the line out from the plastic holder, that holds the line in place, same goes for 2 lines
that are attached to canister. to make more free play/room


Now the fun part, to remove the canister, took me 15min to take that sucker out, Remove the EVAP canister by pulling gently back and forth, left and right, until it releases from the rubber grommets: Do not force it, You dont want to pull with force and brake some evap lines, here's the pic after removal : I also applied some oil inside and out, just in case i need to remove it next time:



Look back up under the fender and locate the actuator for fuel door. Now using the stubby Torx T-20 loose (but do not remove) Remove the electrical connector (by squeezing the tab).

Put the new part in place making sure you feed the emergency pull line through the fender to its location in the door jam. There is room to slide it through the side so you don't need to try and thread it through the hole.

Re-install everything, done!

 

Nice write up! Thank you.

 

epic post. never seen than manual release before either. hope i never need it. rep pts

 

Great post. Needs to be saved to the DIY.