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Nick-L
Newbie


Joined: 09 Aug 2018
Posts: 23
Location: Cheshire


PostPosted: Sun Jan 05, 2020 7:13 pm    Post subject: Fuel cap replacement? Reply with quote

Hi all,

This is potentially a dumb question but it’s stumped me today so here goes...

I’ve tried to replace my fuel filler cap today as the tether strap broke and the cap itself was looking tired anyway.

Bought a new genuine cap and fitting looked really straightforward...

However I cannot for the life of me get the old plastic rivet out as the hinge mechanism for the fuel flap seems to be in the way??
I’ve punched the Centre pin out of the rivet to free it off but the main part of the rivet is blocked by the hinge?

Even if I got brutal with it to remove it, (which I’m reluctant to do incase I break anything or scratch the paint), I can’t see how I’d get the new one in without damaging it too?

Does the hinge mech have to be removed and if so how?

If not what am I missing here as I’m stumped?!

TIA

Nick
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2003 996 Carrera 4S Tip
 
  
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Winny911
Montreal


Joined: 13 Dec 2012
Posts: 596



PostPosted: Sun Jan 05, 2020 7:22 pm    Post subject: Reply with quote

Once you punch the centre of the plastic rivet out the body should just pull straight out just use a screwdriver with tape on the end to pry it out if stiff

Winny
 
  
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deMort
Dijon


Joined: 21 Mar 2015
Posts: 7806
Location: Brighton


PostPosted: Sun Jan 05, 2020 7:42 pm    Post subject: Reply with quote

use a tiny punch in the center of the rivet .. a small screwdriver will do .

A tiny plastic tube will fall out .. don't loose it down the drain hole !!

You push this bit back into the rivet .. just a few mm .. refit the rivet then knock it home so it's flush .
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Robertb
Dijon


Joined: 01 Sep 2003
Posts: 7559
Location: South Oxfordshire

2002 Porsche 996 Carrera 4S

PostPosted: Sun Jan 05, 2020 8:10 pm    Post subject: Reply with quote

I recommend the tip of a thin Allen key, having just fitted an alu-look one on mine.

Good tip from DeMort... cover the drain hole with something in case some little bit goes astray!
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"911- the guilt-free supercar"

Current: 2003 C4S Coupe, seal/black

Ex: '02 C4S Coupe, '96 993 Targa, '88 Carrera Sport Coupe
 
  
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Nick-L
Newbie


Joined: 09 Aug 2018
Posts: 23
Location: Cheshire


PostPosted: Sun Jan 05, 2020 8:25 pm    Post subject: Reply with quote

Thanks for the replies so far guys.

However I’ve already successfully removed the centre of the rivet, the tube bit, and retrieved it.

The problem seems to be that the hinge mechanism is blocking the main body of the rivet from removal. It overlaps by enough that it won’t pull far enough out to free itself from the hole?

As I try and lever it out it hits the back of the hinge and won’t pull out any further?
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nickyg63
Trainee


Joined: 25 Aug 2019
Posts: 59



PostPosted: Sun Jan 05, 2020 8:33 pm    Post subject: Reply with quote

Nick-L wrote:
Thanks for the replies so far guys.

However I’ve already successfully removed the centre of the rivet, the tube bit, and retrieved it.

The problem seems to be that the hinge mechanism is blocking the main body of the rivet from removal. It overlaps by enough that it won’t pull far enough out to free itself from the hole?

As I try and lever it out it hits the back of the hinge and won’t pull out any further?


I swapped mine recently and im sure the rivet is about 1cm tall so clears? I can only assume its been swapped out??

I just pressed the centre through and prised the rivet upwards and it came up, i had to fish it out with the hinge in the way but it wasn't a massive issue.

cheers
 
  
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kurlykris
Magny-Cours


Joined: 30 Jun 2014
Posts: 2640
Location: Warwickshire


PostPosted: Sun Jan 05, 2020 9:29 pm    Post subject: Reply with quote

I seem to remember reading another thread regarding this and it was because a previous repair attempt somenone had put the "rivet" back in the opposite way from standard, which made it difficult to remove again Dont know
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2006 987.1 Boxster S 3.2 sport chrono
2010 Mercedes E350 AMG Sport

 
  
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Mac996t
Montreal


Joined: 26 Mar 2011
Posts: 518


2004 Porsche 996 Turbo

PostPosted: Mon Jan 06, 2020 6:53 pm    Post subject: Reply with quote

Mines like post number 7 in the thread below

http://986forum.com/forums/boxster-general-discussions/45907-gas-cap-tether-installed-correctly.html
 
  
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deMort
Dijon


Joined: 21 Mar 2015
Posts: 7806
Location: Brighton


PostPosted: Mon Jan 06, 2020 7:22 pm    Post subject: Reply with quote

I see your problem and yes i've seen it before .. i'm not sure but i'm of the opinion not all cars have a lanyard fixing for the fuel caps ..

The hole under the flap spring is a possible place but it needs to be fitted from the top side .. im sure i have done it in the past but a bit of cutting down the rivet feet .. messing about with long nose pliers and a screwdriver to press home the pin kinda rings a bell ... either that or remove the flap lid and bracket .. not a nice job .

The other option is the 10 mm bolt to the left .. a couple of washers each side of the lanyard would do .. not ideal and you can't tighten it too much but its an option .
_________________
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My Daughter's Crowdfunding has hit the target .

Thank you all so Very much .

She's not going until july 2020 though .



Mechanic

7pm - 9pm

Indy Mechanic .

Last edited by deMort on Mon Jan 06, 2020 7:23 pm; edited 1 time in total
 
  
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Robertb
Dijon


Joined: 01 Sep 2003
Posts: 7559
Location: South Oxfordshire

2002 Porsche 996 Carrera 4S

PostPosted: Mon Jan 06, 2020 7:23 pm    Post subject: Reply with quote

I fitted mine through the hole under the hinge. However I had to refit it so that the tether end was on the other side of the hole with the rivet head uppermost otherwise the tether end caught on the hinge spring.

I had to partially push in the pin to get enough clearance under the hinge while I was fitting the rivet through.

Id post some pics if I could work out how...
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Current: 2003 C4S Coupe, seal/black

Ex: '02 C4S Coupe, '96 993 Targa, '88 Carrera Sport Coupe
 
  
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