ASTON MARTIN CLIENT SERVICES

SERVICE BULLETIN
Reference number:

SB-01-0327V2

Issued: 12 May, 2017

Subject:

Rapide Fuel Filler Door Alignment Problem

Model(s):

Rapide Only

VIN Range:

F00001 - F05462

Applicable to:

All Dealers

Distribute to:

After Sales Manager
Executive Manager
Service Manager
Sales Manager

Warranty Staff
Technician(s)
Parts Staff

Reason for Version 2 of this Service Bulletin: SPL-01-001-0327
The torsion spring on the fuel filler door has been changed so the VIN range and reason for this Service Bulletin has
been amended. Changes to this document have a black line against them in the left margin. Please destroy all copies of
SB-01-0327 that you have and replace them with this Service Bulletin SB-01-0327V2.

Reason for this Service Bulletin
On Rapide vehicles up to chassis number F01419, the fuel filler door had a gas strut installed that applied a higher force
to open the door. The hinge material of the fuel filler door, in addition to the force of the gas strut, can cause the
assembly to move. This can cause the fuel filler door to catch and stay closed when the release button is operated. Also,
the fuel filler door does not align correctly in its aperture.
Rapides from F01419 thru F05462 do not have a gas strut installed, but the torsion spring that is part of the hinge
assembly can still cause the fuel filler door assembly to move after some time. Vehicles after F05462 have a different
torsion spring and should not be affected by this problem.
If a Customer complains that the fuel filler door is not correctly aligned or does not open correctly, do the applicable
procedures that follow to correct it.

Figure 1 - Fuel Filler Door Not Aligned

This Workshop Procedure has the parts that follow:
Note:

Part B is only applicable to Rapides up to F01419.

•

Part A - Preparation

•

Part B - Remove the gas strut

•

Part C - Adjust and assemble

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Workshop Procedure
Part A - Preparation
1.

Set the ignition to on.

2.

Push the fuel filler release button to open the fuel filler door. If the fuel filler door will not open, do steps 3
thru 5 that follow:

3.

Get the help of one more person to push and hold the fuel filler release button.

4.

Use a thin tool that will not damage the body or paint, as a lever to open the fuel filler door.

5.

Release the fuel filler flap button.

6.

Set the ignition to off.

7.

Release the fuel filler bezel from the extension
for the fuel filler neck (refer to Figure 2)

Figure 2

8.

Remove the fuel filler bezel (refer to Figure 3)

Figure 3

9.

Remove the wheel arch liner at the rear left side. (Refer to Workshop Manual procedure 01.02.JB - Rear
Left Side Wheel Arch Liner).

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10. Remove the two nuts that attach the fuel filler
neck to the body (refer to Figure 4).

Figure 4

11. Move the fuel filler neck down (refer to
Figure 5).

Figure 5

12. Remove the three Torx screws that attach the
mechanism for the fuel filler door to the body
(refer to Figure 6).

Figure 6

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13. Remove the mechanism for the fuel filler door
(refer to Figure 7).

Figure 7

Part B - Remove the gas strut
14. Remove the clip (1) that attaches the ball joint
socket of the gas strut (2) to the hinge bracket
(refer to Figure 8).
15. Push the retaining cover (3) in the direction of
the arrow to release it from the gas strut (3)
16. Remove and discard the gas strut (2).

Figure 8

Part C - Adjust and assemble
17. Apply applicable protective masking materials to the painted surface of the fuel filler door to prevent
damage.
18. Use an 8.5 mm diameter drill to carefully
make the three hinge mounting holes larger
(refer to Figure 9).
19. Remove the burrs from the three holes.
20. Apply applicable paint to the bare metal areas
of drilled the holes and let it dry

Figure 9

21. Remove the protective masking materials from the filler door.

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22. Put the mechanism for the fuel filler door into position and align the door with the opening.
23. Install and torque the three Torx screws that attach the mechanism for the fuel filler door to the body to
5 Nm.
24. Move the fuel filler neck into position (refer to
Figure 10).

Figure 10

25. Install and torque the two nuts that attach the
fuel filler to the body to 9 Nm (refer to
Figure 11).

Figure 11

26. Install the rear left side wheel-arch liner (Refer to Workshop Manual procedure 01.02.JB - Rear Left Side
Wheel-Arch Liner)
27. Put the fuel filler bezel into position (refer to
Figure 12).
28. Install the bezel onto the extension for the fuel
filler neck.

Figure 12

29. Close the fuel filler door.
30. Clean fuel flap paintwork and the adjacent area of the body.
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Warranty Data
Procedure and Labour Time
Description
Modification of the Mechanism for the Fuel Filler
Door

Labour Time

ROT Code

Causal Part Number

0.80 hours.

01.14.FG

AD43-F405B96-AB
AD43-F405B96-AC

Failure Mode Description
Select the failure modes that follow when you make a claim through the Warranty system:
Subsystem

Location

Component

Mode of Failure

POWERTRAIN

- ENGINE - FUEL SYSTEM

- SB0327

- RAPIDE FUEL FILLER
DOOR ALIGNMENT
PROBLEM

If you have any questions related to this Service Bulletin, please contact: Aston Martin Technical Services
on: +44 (0) 1926 644720, email: [email protected],
Or contact your After Sales Manager.
The English version of this Service Bulletin is written in
Simplified Technical English to ASD-STE100™.

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