Sundance Duster L4-153 2.5L VIN K FI (1992)
Fuel Door Release Cable: Service and Repair
Cable Release Handle And Cable
REMOVAL
1. Move driver's seat forward to expose rear of seat adjuster.
2. Remove nuts used to fasten the adjuster to the floor pan.
3. Move driver's seat to the rear.
4. Remove bolts used to fasten the adjuster to the floor pan.
5. Remove the driver's seat.
6. Open the liftgate and remove shelf trim panel.
7. Remove the carpet from the rear seat back by pulling it free from the velcro retainers.
8. Remove two screws from each seat back hinge.
9. Remove the seat back.
10. Remove the shoulder bolts used to fasten the seat back hinge arm to the inner quarter panels.
11. Remove the hinge arm assemblies.
12. Remove two screws used to retain the seat cushion.
13. Remove the rear seat cushion.
14. Remove two screws, a "Christmas Tree" fastener, and the remote release handle cover.
15. Open the fuel filler door.
16. Remove the remote handle retaining screws and lift the remote handle assembly upward.
17. Remove the fuel filler door cable from the remote handle assembly.
18. Remove the rear door roof rail garnish mouldings.
19. Remove two pushpins, the cargo lamp bezel, and two plastic screw hole plugs from the liftgate opening trim panel.
20. Remove three screws and then the liftgate opening trim panel.
21. Remove the rear door sill scuff plates.
22. Remove two plastic screw hole plugs, all quarter trim panel screws, and then remove the quarter trim panel.
23. Repeat step 22 on the other side of the vehicle.
24. Remove two screws used to fasten the rear window washer bottle to the inner quarter panel.
25. Disconnect the wiring harness from the rear window washer motor.
26. Disconnect the filler neck from the rear window washer bottle.
27. Remove the washer bottle.
28. Remove the fuel filler door remote release cable nut from inside of the fuel filler door opening.
29. Cut both ends from the fuel filler door cable using a pair of side cutters.
INSTALLATION
1. The original cables used to operate both fuel filler door and hatchback are clamped to each other and inseparable. For fear of damaging a cable
still in good working condition, do not attempt to separate and remove any cable. Place the replacement cable over the original.
2. Connect the cable to the remote handle assembly.
3. Install the remote handle assembly.
4. Install the other end of the cable through the hole provided on the inside of the fuel filler door opening.
5. Install and torque the nut to 7 Nm (60 In. Lbs.).
