Ford Focus PRO-FIT Linear Fuel Doors – Installation Instructions
Do not perform this install near a flame source due to the risk of fire or explosion from gas fumes. Use a jack to lift rear of vehicle. Remove the passenger side rear tire. Remove the wheel well cover to expose the fuel filler neck behind the quarterpanel.
Note: For manual locking or manual non-locking fuel doors, do steps 1-4 only. For electric locking fuel doors, do all steps.
Step 1 – Remove stock fuel door
Remove the stock fuel door and plastic surround. The stock fuel door and plastic surround are a single unit. To remove, reach up behind the quarterpanel and release the tab at the top of the plastic surround. You may need to use a screwdriver to release the tab. Pull the stock fuel door and plastic surround straight out from the front.
Step 2 – Bend tabs
Bend the four tabs around the quarterpanel hole slightly inward using the back of a screwdriver handle or other blunt object. This is to allow clearance for the back of the fuel door ring (Fig. 1, black arrows).
Step 3 – Shift fuel filler neck
In order for the fuel door linear mechanism to function correctly, it must clear the metal collar surrounding the fuel filler neck (Fig. 5, arrow shows contact between the linear mechanism and collar). The fuel filler neck must be shifted to the left (towards the rear of the car) to make room (Fig. 1, white arrow). Loosen the 2 bolts holding the fuel filler neck to the body (Fig. 2 and 3, arrows) and shift the entire fuel filler neck towards the rear of the vehicle. Retighten. Check clearance by test fitting fuel door (Fig. 4). If there is still a clearance problem (Fig. 5), repeat the loosen bolts/shift neck/tighten bolts procedure. If necessary, elongate the holes on the brackets holding the fuel filler neck with a small drill or round file (Fig. 2 and 3, arrows).
Step 4 – Attach fuel door
Remove stock gas cap. WARNING – Do not perform the install near a flame source. Ensure adequate ventilation of gas fumes. Stuff opening with a small rag to prevent small items from falling into the gas tank. Insert the 4 long hex bolts into the ring as shown (Fig. 6, black arrows). Attach the L-brackets to the bolts from behind the fuel door ring. Fig. 7 shows the proper L- bracket orientation for the top left hex bolt. Attach a washer and nylock nut. Tighten using the supplied wrenches as shown (Fig. 8). Insert the short hex bolts into the remaining ring holes. Insert the replacement gas cap. Note that this gas cap has a trap door in the middle to allow fueling up without removing the cap.
Step 5 – Mount and attach actuator
Position the pull cable so that it goes up and over the wheel well towards the front of the car (Fig. 9, arrow). Mount the end of the pull cable into the slot on the end of the actuator bracket (Fig. 10). Remove the screw on the end of the actuator. Thread the screw through the eyelet at the end of the pull cable, then screw back in. Note that the screw is not tightened completely. Find a flat spot on the car body to mount the actuator (Fig. 9, arrow) with the screw-end of the actuator facing up. Clean the area thoroughly with alcohol or other degreaser, then peel the backing and….
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