Difference between revisions of "Petrol Cap"

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'''Some info on how to swap the unit over - info taken from Basil on the BCBBS'''
 
  
"Best way I found was to prise the metal ring out, then vandalise all the white placcy bits which came out pretty easily. All you're left with then is the black placcy part. I ran a small screwdriver round the edge, then got hold of it with some pliers and tried to 'roll' it up. A bit of this and it popped out.
 
  
Fitting the new one I used 2 minute epoxy (time's money!) Left overnight it now works as it says it should in the manual - result.
 
  
Couple of other points, prolly stating the bleedin obvious but;
 
Don't forget to switch the keys over on yer keyring!
 
Don't be tempted to 'try' it in-situ before fixing. It does fit and is a bugger to get out if you're daft enough to 'try' it first.
 
Of course I didn't do that! ;>)"
 
  
  
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I started from the point of having had the filler cap disintegrate on me, so almost all the parts had come out of the cap.
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[[image:fuel cap 1.jpg|thumb|left]]
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All that was left inside were the plastic ratchet (1), metal collar (2) and black plastic retainer (3)[[image:fuel cap 2.jpg|thumb|left]].
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Using a screw driver, prize the bottom part of the plastic ratchet out from behind the metal collar [[image:fuel cap 3.jpg|thumb|left]]
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The top part of the ratchet will now come out freely from behind the metal collar.
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[[image:fuel cap 4.jpg|thumb|left]]Be very careful not to damage the black plastic retainer. You need this to fit the new components.
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Take the new filler cap and use a Stanley knife to cut tabs into the side of the filler cap.
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[[image:fuel cap 5.jpg|thumb|left]] Be careful not to cut into the white plastic components covered by the cap. Gradually cut away the cap, until most of the white plastic components (except the barrel lock) and the metal collar are free from the ). Once you’re able, remove the white plastic components and the metal collar from what’s left of the filler cap.
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Carefully cut around the lock barrel, again making sure that you don’t damage the white plastic [[image:fuel cap 6.jpg|thumb|left]].
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Remove the barrel and push it into the hole in the old filler cap. The barrel has a key-way so locking tabs which keep it in place [[image:fuel cap 7.jpg|thumb|left]] – make sure you’re putting it in the right way. Note the location of the spring pin
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Push a screwdriver down the side of the old metal collar, lever it out of shape and remove it from the old cap. Again, take care not to damage the black plastic retainer. [[image:fuel cap 8.jpg|thumb|left]]
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[[image:fuel cap 9.jpg|thumb|left]]Take the lock mechanism  from the new cap and place it on top of the lock barrel [[image:fuel cap 10.jpg|thumb|left]]. Note that the long tongue goes into the deeper recess in the cap. This is on the opposite side of the lock barrel from the spring pin.
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Put the two parts of the ratchet mechanism into the old cap, making sure the one with the row of teeth is towards the cap and the other part of the ratchet is towards the “fuel tank”. Put the threaded stopper onto the top of the lock mechanism.[[image:fuel cap 11.jpg|thumb|left]]
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Take the metal collar from the new cap. [[image:fuel cap 12.jpg|thumb|left]]With the channel in the collar facing you, put it into the cap and using a flat screwdriver, gently push it past the lugs on the black plastic retainer.
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Grip the threaded stopper in your hand and check that the lock and ratchet operate normally. Use a silicone lubricant (not WD40) on the ratchet and in the key hole. Job done.
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All pictures copyright (C) John Fletcher 2008
  
 
[[Category:Body]]
 
[[Category:Body]]
 
[[Category:Lotus Elise]]
 
[[Category:Lotus Elise]]
 
[[Category:S1]]
 
[[Category:S1]]

Revision as of 20:23, 12 August 2008

S1 Elise. part.10501

The internals of the Elise S1 petrol cap are manufactured by Stant. It's also used by Jeep, from whom you're more likely to be able to readily obtain it.

On-line sources include Rock Auto in America. The part number that you need to order is 10501, delivery should be expected in about 1 week. You may also be able to get it from a UK Jeep dealer - please add your sources here if successful.









I started from the point of having had the filler cap disintegrate on me, so almost all the parts had come out of the cap.

Fuel cap 1.jpg








All that was left inside were the plastic ratchet (1), metal collar (2) and black plastic retainer (3)

Fuel cap 2.jpg

.








Using a screw driver, prize the bottom part of the plastic ratchet out from behind the metal collar

Fuel cap 3.jpg








The top part of the ratchet will now come out freely from behind the metal collar.

Fuel cap 4.jpg

Be very careful not to damage the black plastic retainer. You need this to fit the new components.













Take the new filler cap and use a Stanley knife to cut tabs into the side of the filler cap.

Fuel cap 5.jpg

Be careful not to cut into the white plastic components covered by the cap. Gradually cut away the cap, until most of the white plastic components (except the barrel lock) and the metal collar are free from the ). Once you’re able, remove the white plastic components and the metal collar from what’s left of the filler cap.








Carefully cut around the lock barrel, again making sure that you don’t damage the white plastic

Fuel cap 6.jpg

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Remove the barrel and push it into the hole in the old filler cap. The barrel has a key-way so locking tabs which keep it in place

Fuel cap 7.jpg

– make sure you’re putting it in the right way. Note the location of the spring pin









Push a screwdriver down the side of the old metal collar, lever it out of shape and remove it from the old cap. Again, take care not to damage the black plastic retainer.

Fuel cap 8.jpg










Fuel cap 9.jpg

Take the lock mechanism from the new cap and place it on top of the lock barrel

Fuel cap 10.jpg

. Note that the long tongue goes into the deeper recess in the cap. This is on the opposite side of the lock barrel from the spring pin.










Put the two parts of the ratchet mechanism into the old cap, making sure the one with the row of teeth is towards the cap and the other part of the ratchet is towards the “fuel tank”. Put the threaded stopper onto the top of the lock mechanism.

Fuel cap 11.jpg








Take the metal collar from the new cap.

Fuel cap 12.jpg

With the channel in the collar facing you, put it into the cap and using a flat screwdriver, gently push it past the lugs on the black plastic retainer.

Grip the threaded stopper in your hand and check that the lock and ratchet operate normally. Use a silicone lubricant (not WD40) on the ratchet and in the key hole. Job done.





All pictures copyright (C) John Fletcher 2008