A problem just dveleoped with the fuel filler cap locking mechansim on my my Mazda 2/ Demio although the mechanism is exactly the same in my, now dearly departed, UK spec MX-5/Miatra.

In the UK, the fuel filler cap is opened by a lever on the floor in the driver's footwell. Pulling the lever up, pulls a cable which retracts a probe in the fuel filler cap area. Once the probe retracts, a spring in the fuel filler cap recess causes the fuel filler cap door to spring open.

My problem is that the probe appears too long, so that when I manually try to close the fuel filler cap door, it will not push the proble back to allow the door to close. I have greased the probe and the catch in the cover that is supposed to push it back, but this has not worked. I could maybe bend the "striking plate" that the probe clips into but that could end in tears.

I had hoped to see a mechansim that either tightens the cable (probably at the lever end) or one that adjusts the probe. However, I cannot see any adjustment device.

I guess I could just buy a whole new mechanism but I wondered if there is an easier solution. I can imagine that feeding a whole new cable under the seats / around under the carpet etc could be a real PITA.

 

It sounds like the cable housing or sheath is now too long. Perhaps removing the mechanism at the fuel filler cap will expose an adjustment for that?
I replaced the fuel door on my 3 and had to remove the cable in order to accomplish that. But its been so long now that I don't remember much about it, just that it wasn't that hard.
Perhaps even a washer or two between the cable sheath and mount point would be enough to allow the locking pin to pull back far enough?

I'm guessing the car is out of warranty? 'Cause this would certainly be a warranty issue.

 

Virgin1,

Basically the probe that locks and unlocks the fuel door was 2mm too long.

Taking the machanism apart was simple but needed care because the mechanism was attached to the cable by snap-offs / almost-one-use-only barbs.

Using your idea - I put a washer the size of a my smallest finger nail inside the barrel cartridge kinda thing that holds the probe mechanism. The result was that the probe mechanism was then 2mm less forward than it would have been and wow! - everything now works 100% ok.

I will see if the result stays working but, so far it all looks good. IF not I might try cutting off 2mm from the probe end (but reshaping it might be difficult)

Thank you so much for your clever solution.

You gave me some advice before. PM me if you need any help with a VW or Audi vehcile, a Yamaha Fazer motorcycle, wifi networks or UK accounting policies. :-)

Cheers

Headache56