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Zee

Remove and inspect the fuel filler door release plunger and cable.

The fuel filler door release on my 2002 Z06 quit operating and as a result, the door stayed OPEN all the time. Here I attempt to document the removal, inspection and diagnosis of problems with the release mechanism on a C5 Corvette.

Tools Required:

  • 7.0 or 9/32" socket 1/4" drive
  • 15mm open end wrench
  • 1/4" drive ratchet wrench.
  • small screw driver
  • silicone grease or equivalent
    Break the torque on the left rear wheel lugnuts and then lift the car high enough to work on the inner fender.


    MY Z jacked up.

    Remove the tire/wheel

    Remove the small bolts holding the inner fender panel. On a Z06, the bolts also secure the rear brake duct. The duct is not present on coupes/verts. There are 8 bolts the secure the inner fender - be sure to remove them all.

    Once the inner fender is removed, you can see the fuel fuller door release cable inserted into the fuel filler pocket from inside under the fender.
    Where the cable is found under the fender
    Remove the 15mm nut from the plunger inside the fuel filler pocket and the fuel filler door release plunger/guide will drop down for service in the wheel well.
    The plunger from inside the fuel filler pocket showing the 15mm nut.
    Use a small screwdriver to gently pry the locking tabs on each side of the plunger guide off of the tabs on the cable housing and pull he plunger guide from the plunger/spring assembly.

    Push the rubber boot back up the cable and then push the spring back to allow the cable to be removed from the plunger notch (reference pictures).

    Blurry picture of the plunger thingy.
    Once the plunger is free, the spring and the plunger can be cleaned and inspected.
    Inner fender bolt locations
    Follow the pictures on this page to clean and reassemble the guide/plunger assembly.

    I used a spring assortment that I bought a my local Lowes - there were a few springs in the assortment that would work to fix the fuel filler on a C5.
    I bought this spring assortment at Lowes for $4.29.

    Choose one that is small enough to slide into the plunger housing and allows the rear of the plunger to fit on the inside diameter.
    Spring Fitment Detail.


    Clean all the gunk out of the plunger housing and off of the plunger.
    Inner fender bolt locations
    To re-assemble, slide the spring onto the cable and into the plunger housing. Compress the spring with your thumb to expose as much of the cable as possible.
    Thread the cable into the notch in the plunger and then release the spring. The spring will hold the cable in place.
    Inner fender bolt locations
    When you insert the plunger/spring/cable assembly into the plunger housing, be careful to align the "key" on the plunger into the slot in the housing. Make sure the plunger operates smoothly. I used silicone grease to lubricate and (hopefully) prevent water from getting inside.
    Detail of plunger

    This is one of those things that would have the dealership installing a whole new part
    or assembly, when it is fairly easily fixed for a few cents and a couple of hours of
    "quality time" with your Corvette.

    You really can sometimes fix it yourself!