Disassembly And Assembly: Assembly

NOTE: This lock cylinder cannot be disassembled. This procedure is for assembly only.

NOTE: The tumblers required can be determined from the vehicle keycode. If necessary, the factory keycode can be obtained from authorized dealership personnel.

Fig 1: Identifying Key Cut Depths

Courtesy of FORD MOTOR CO.

Select the required tumblers according to the key cut depths for each position from A through F according to the following rules:
- 3 "D" tumblers have to be used.
- "D" tumblers cannot be used in position A or F.
- At least one "4" tumbler has to be used.

NOTE: Make sure that the tumbler and spacer indents align with the locking pin slot.

Fig 2: Locating Fuel Door Lock Cylinder Tumblers And Spacers

Courtesy of FORD MOTOR CO.

Install the fuel door lock cylinder tumblers and spacers into the fuel door lock cylinder barrel as follows:

COMPONENT DESCRIPTION

Assembly Sequence	Component
1	Tumbler for key position F
2	Spacer
3	Tumbler for key position E
4	Spacer
5	Tumbler for key position D
6	Spacer
7	Tumbler for key position C
8	Spacer
9	Tumbler for key position B
10	Spring washer
11	Tumbler for key position A

Apply the multi-purpose grease on the lock cylinder barrel in and around the locking pin slot.

Fig 3: Locating Multi-Purpose Grease Applying Area On Lock Cylinder Barrel And Locking Pin Slot
Courtesy of FORD MOTOR CO.
Place the locking pin into the locking pin slot.
Slide the fuel door lock cylinder body onto the fuel door lock cylinder barrel.
Install the shutter housing into the fuel door lock cylinder body.
Install the shutter assembly.
1. Slide the pin through the shutter spring.
2. Install the shutter pin and spring into the shutter housing.
3. Install the shutter over the spring and down into the housing.
Apply a small amount of the multi-purpose grease on the fuel door keyway plate where it contacts the shutter assembly.

NOTE: The smooth side of the keyway plate faces outwards.

While pushing down on the shutter, install the keyway plate onto the fuel door lock cylinder body.
Using a suitable tool (such as a chisel), crimp the fuel door lock cylinder body to secure the keyway plate in place.

Fig 4: Locating Fuel Door Lock Cylinder Body Crimping Area
Courtesy of FORD MOTOR CO.
Stick the water seal to the face of the keyway plate.
Install the fuel door lock cylinder lock lever and circlip.
Spray a small amount of the multi-purpose grease into the key hole.