The fuel door hinge on our 2003 Cooper S broke. It happened on our way to the dealer this weekend. I informed the dealer that is was broke and all they did was look at it and inform me it was for sure broke. Sometimes the dealer can be so helpful.
Was wondering if anyone knew of any DIY info online on how to replace this part. I tried to do it myself but couldn't figure it out the sequence to disassemble. If anyone could help out it would be most appreciated. Thanks

 

Take a look at this---
http://www.outmotoring.com/images/how_to/Fillercap.pdf

 

DAVESTER,
Thanks for the link. This should be a big help.

 

Glad to help---

 

Wow. I have to replace this piece on My 2004 S. This looks to be a long process. Sigh. Thanks for the link, though.

 

The instructions provided in post #2 were very helpful. I do have one correction. The filler neck should be moved back into the wheel well after step 2 and before you try to remove the fuel door "cup" hinge and all. This provides clearance to get it out without bending the metal tab as shown in step 3e.

It helps to have a good set of panel "pryers" as used for interior panels. The clips for the outer body colored cup are at the inner edge of the cup and shoving a screw driver in that far will surely scratch the paint if not damage the cup.

My fuel door was loose because the top hinge had worked its way out. This was due to the locking mechanism breaking off the inner end of the hinge pin. I inserted the broken hinge and put a spot of plastic on it with a plastic welder to keep if from working free again. You can see in the attached picture what the hinge should look like. You can see the split end of the hinge with locking mechanism on the bottom vs. the repaired hinge top.