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( I apologize for the dim lighting in advance )
THIS DIY IS USING "www.fueldoorfix.com" 's Canadian piece to fix the door
Tools needed:
1. 10 mm ratchet
2. 14 mm ratchet
3. Phillips head screw driver
4. 2 flat head screw drivers
5. 2 aspirin
pry off the lock cover carefully, (i cracked mine), use 2 flatheads, insert one into obvious hole on top and the other right next to it. pry up and towards the inside of car until it pops off
use phillips head to unscrew screw next to lock
use flat head to pry cylindrical, silver lock out
lets remove the seatbelt now, it's heavy and can be useful for weight reduction, OR TRIM REMOVAL.
first pry off plastic center cap on bottom of driver side seatbelt harness. Be careful it's plastic and can snap.
next use a 14mm ratchet and remove bottom of seatbelt
removed, now you'll be able to remove both pieces of trim for easy access to fuel door lever
next your going to remove the trim surrounding your hood release. theres 2 plastic clips to release. The white circle clips, 1 top 1 bottom in pic below
pull trim from top first, out and towards the rear of the car. then pull bottom of trim piece the same way. You have to do this to avoid breaking the clip because of the slot the white clip slips into on the trim shown below:
top:
bottom:
the next piece of trim you remove is the running board, i guess you could call it. This is why you detached the seatbelt. CAREFULLY slide your fingers under the outer edge and begin to pop out clips:
as you can see below, there's 4 clips to pop out on top*, then theres like 4 more on the back inner trim wall. These are the clips you have to slide a certain way or they'l break, (which mine did). Try and pry off and slide toward the *rear*(*i think ==>to check it, the slide holes on the back trim wall should be in the opposite direction as the white clips on top(4)*), pushing a little towards the inside of your car.
with that removed you should see the lever setup. It's attached to the inner edge with a 10 mm bolt you need to undo (top left in pic), heres a pic of the inside of the setup:
attach your Canadian black snap-on piece to the 1st white circle and around the wire, snap on other half and test it before putting everything back together. Once it works put back on all the trim and go show off your working fuel door!
NOTE: when re-installing the 10 mm bolt, be careful where exactly you position it because it will affect if the lever rubs against the housing when lifted.
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__________________ Diy:Fuel Door Fix Coupe 2005 civic coupe EX SE 5 Speed AEM V2 Intake|_|A'PEXi GT Spec Cat-Back Exhaust|_|A'PEXi Super Grounding kit|_|AXIS Reverb 18"x7.5" rims|_|DC Carbon Steel Front Strut Bar|_|Fiber glass body kit|_|H&R Front & Rear Sway Bar|_|Skunk2 Rear Lower Tie Bar
STREET DREAMIN C.C.
Last edited by dryft; 04-06-2009 at 12:39 PM.
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Did This, Worked As Stated, My Only Addition Would Be That Those Who Live In The Salt Belt Check The Cable End Where It Goes Into The Release Handle As It Expands, It Corrodes, So Causes Sticking Between The Handle And The Cable End. Clean As Necessary To Bring Back Proper Fit.
Completed this project yesterday! Followed DIY and was so simple! Thank you so much dryft for the awesome write up. On a side note....the FUELDOORFIX product is kick ass.....what an awesome fix!
I actually fixed that plastic piece myself with thread and super glue - you take about a foot of heavy thread, and glue an end down.
Then, wrap the thread tightly around the part, kind of like you are putting thread on a spindle, tight and close. After each layer of thread, saturate with super glue.
Thread + superglue roughly equates to concrete. Very handy for small plastic parts that dont need to do much.
Worked fine for a couple months, until the actual cable itself busted off due to the stress of the angle it is at when held in place. Turns out, that plastic piece of crap was the strongest piece of that assembly once I got through with it, so all the stress went to the cable and it finally busted off. Check your cable for signs of cracking or fatigue. You might be closer to a full replacement of the part than you think.
DIY Fuel Door Fix Coupe! 
