How to remove a Gen II Viper GTS Fuel Door for refinishing

1996 – 2002 GTS Fuel Door Refinishing

The polished aluminum fuel door is a signature trait of the Gen II Viper GTS. Unfortunately, over time, most of them have corroded. To bring it back to like-new condition, it’s necessary to remove it from the car. Read the tutorial below to learn how to do it.

How-to Guide

Step 1: Use the 5/32” allen key to remove the 4 bolts around the outside of the fuel door.

Step 2: Remove the fuel cap and spray the rubber gasket with WD-40. This will make it easier to pull the gasket over the filler neck when removing the door.

Step 3: Pull the fuel door off of the gasket that is holding the door to the filler neck.

Step 4: Lubricate all the pins that hold the door together. Use a clamp on the fuel door latch when hammering out the pin that holds it in place. This will prevent the latch from stressing and breaking. Note that the pin is square on one side. Hammer it from the circular side, not the square side. It should be on the bottom side of the latch as pictured.

Step 5: Remove the pin on the door hinge. Make sure this pin is lubricated to aid in removal. Similar to the latch side, use a punch to press the pin out.

Step 6: Remove the spring plate that seals the door and cap with a 1/2” socket to remove the bolt. Be careful to not lose the spring, it is required for reassembly.

Step 7: Now all the components removed and separated. This is where the fun begins! You can get it re-chromed or have it refinished in a specific color. At Havik Performance, we send out the fuel doors to calchrome.com where we typically order the cap in black chrome.

Step 8: Reassembly of the refinished fuel door is the reverse of these disassembly steps.

Pro Tips

• Use painter’s tape to prevent scratching the finish on your new door.

• When pressing in the pins, make sure they are properly lubricated.

• Do not forget the plastic washers or spacers between the hinge and door.

• When pressing in the pin for the latch, make sure you put the spring back over the ping when you begin. This will keep the latch spring loaded.

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