gas cap closure

[Daly]

I took the outer gas cap closure off to repaint. I can get all the screw/bolts back in except I can't seem to get the piece that holds the lock mechanism flat to the vehicle reattached. Is there a trick to this. The screw goes in through the hole, then the metal piecewhich is sort of an L bracket, fits only one way, then the round nut goes on, but it is not possible to get nut on if L bracket is positioned, nut goes on fine without L bracket but then the locking mechanism has nothing to hold onto to keep flush.
I believe I am putting everything back the way I took it apart, I think. If anyone has a picture of gas cover open this L barcket I am referring to is opposite the hing, hing would be at 3:00, bracket at 9:00
Help

[mdwyer]

I pulled the gas cap off a junked VX, and I don't recall anything especially strange about it. Well, that's not entirely true. The bolts go through the top piece, through the cladding, then thread into the black backer ring. So, I don't think the additional black nuts do anything with the exception of the one that holds the tab on as you described.

So, my guess is that you haven't threaded the bolt far enough through the black backer ring. Is it somehow pinched on your cladding?

[Daly]

No it is all the way through. The way the L bracket sits it is not possible to get the nut in the back on. If the screw was two inches longer then you could, so I think there has to be some trick to getting it on.
I am doing this with the side cladding on, I did not want to go through taking off cladding, maybe you have to take off cladding so you can get behind the area and put nut on.

[Etfren]

I changed mine a few weeks ago and didn't have any issues with it with the cladding on. You just need small hands to be able to hold everything in place and lined up while getting the nut on. It would help if the screws were a little longer, but it is possible.

[Child's Play]

Daly,
I just got done re-painting and re-installing my gas cap and ran into the same problem you are having.... What I ended up doing was Super Gluing the nut onto the latch mechanism. Tighten from there.....



CP

[deermagnet]

I had the same problem. It was a little tricky, but I got it with some patience and trial and error.

As I recall, the problem is the inner ring is threaded and then you have to deal with the nut also that holds on the closure piece. Drill out the threads of the ring with a bit just larger than the bolt. Then you have a clear shot all the way thru to the nut, which will hold everything tight. The threads are not needed in just that one spot 'cuz the nut is all that's needed.

Mark

[WormGod]

Yep, it's a case of patience and trial and error. I have done it a handful of times and it has gotten easier since I know what to expect. Glad you brought this up cause I was considering pulling it apart sometime and brushed aluminum polishing it. +1 for the reminder.

[Daly]

Got it.
I think it is a bit easier if that is the first screw you put in, and yes small hands and tons of patience help.

[Y33TREKker]

For future reference it may help to put all the pieces into place then get them lined up and held in place with something like small drillbits or metal punches in a few of the holes. If all the pieces are at least closely lined up to begin with, getting the first few bolts threaded may prove easier.

[vxcp]

When locked my gas cap still opens up a bit.



Is there a piece installed incorrectly or missing to keep it closed?

[tom4bren]

When locked my gas cap still opens up a bit.



Is there a piece installed incorrectly or missing to keep it closed?

IIRC, you can fix that by just bending the metal tab towards the locking mechanism. I bent mine one time when I was removing the rear cladding and it ended up doing that same thing. You don't have to disassemble anything, just open the fuel door and you'll see the tab that you need to bend.

[vxcp]

Found the tab and bent it back but think I'm missing something. The fuel door is now close to remaining closed but I don't think the tab will reach any further -- also if the tab were any longer it wouldn't fit through the circular opening.

Here is the tab now



Here are some clips I found near the gas cap



Thoughts? Pictures of what its supposed to look like?

Thanks.

[deermagnet]

I think you're missing a part on the inside. It's the one part that's hard to put back on, so someone may have not bothered with it. It's the L bracket mentioned in the first post here.

The black tab that moves with the key is curved on the end, but it goes straight out at 90° to the key to catch on the part that may be missing.

The lock cylinder and the black tab extend about 1" inside the ring. The part you need is attached on the back side of the ring and goes back about 1" to allow the black tab to catch on it after the key is turned to the lock position. Without that part on the inside of the ring, the black tab has nothing to catch on except for the inside of the ring. Without that 1" part, the black tab has to be bent way toward the key, like in your photo. It probably can't be bent far enough to touch the back of the ring when closed.

I hope I explained that right. You need that small 1" silver part on the inside of the ring to make it work right.

I think you could easily make that L bracket part yourself if you knew exactly what you needed.

Edit: I just found the part numbers for what you apparently need. Call an Isuzu parts dealer to see if they can be ordered.
Fuel filler lock hook- # 8-97164-850-1
Hook nut- #8-97068-819-0

Mark

[deermagnet]

I just went out in the rain and took a quick pic of mine. It's a little rusty.



If that part is installed correctly, then nothing needs to be bent.

Mark

[vxcp]

Yup, I'm missing those parts! That photo and those part numbers are a huge help. Now to see if I can get them...