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BYD PHEV/Fuel Filler Box Plunger
How to install the plunger on your PHEV and Fuel Filler box
How to install the plunger on your PHEV and Fuel Filler box
1
Step 1 of 9

Take the drivers side 3D printed part and match the shape with the strengthener



Take the Strengthener and twist the plunger on then add the 3D printed latch behind the strengthener. 

2
Step 2 of 9

Your plunger and latch parts should be looking like this.

3
Step 3 of 9

Fasten to the clinch studs on the PHEV door using M5 washers and nylocs. 

4
Step 4 of 9

Fasten the nylocs and place a piece of tape over the locking plug. 


Close the door to see if the plunger is in the correct spot and lines up with the plug. 


If it does not line up, undo the nylocs, adjust, fasten and test again. 

5
Step 5 of 9

Once in the correct spot the door should open and close smoothly like so.

6
Step 6 of 9

For the fuel filler box, make sure you have the 3D printed piece with 'PS' on it.


Twist the strengthener that matches the shape of the PS 3D printed part on to the plunger.


Place the 3D printed latch behind the strengthener making sure the notches line up and fasten to the fuel filler door. 



7
Step 7 of 9

Fasten to the fuel filler door using M5 washers and nylocs.


Repeat the lining up process using the tape and adjust if needed. Remember you need to press the fuel flap button on the drivers side of the dash to release this side.


Your strengthener and plunger installation is now complete. 

8
Step 8 of 9
<p>Next, you need to place stickers on your charging and fuel filler doors.</p><p><br></p><p>Wipe the surface with iso to make sure the door is clean.&nbsp;</p><p><br></p><p>Place the 'push to open' sticker on the PHEV charger door in the shown location.&nbsp;</p>

Next, you need to place stickers on your charging and fuel filler doors.


Wipe the surface with iso to make sure the door is clean. 


Place the 'push to open' sticker on the PHEV charger door in the shown location. 

9
Step 9 of 9
<p>Once again, clean the surface and place the 'push to open after releasing fuel flap button on dash' sticker on the fuel filler door in the shown location.&nbsp;</p><p><br></p><p>Ensure that the stickers are on the correct door.&nbsp;</p>

Once again, clean the surface and place the 'push to open after releasing fuel flap button on dash' sticker on the fuel filler door in the shown location. 


Ensure that the stickers are on the correct door.