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Fuel Filler Replacement- 2000 Mk 1 Berlingo Multispace
#1
I became aware that the off side sliding door was being obstructed when it was sliding shut. Initial reaction is that the rollers on one of the rails was worn or something. On closer inspection it became clear that it was catching on a hook catch that protruded from the door shut. There is no similar catch on the near side because it is designed to stop the door being opened when the fuel cap is removed. 
The problem was that the top of the plastic filler neck was splitting and the fuel cap was not shutting fully, stopping the plunger that is located in the fuel filler recess, from being pushed home. 
Remedy is to either disable the hook catch or to fit another fuel filler pipe. 
To replace the filler pipe :
Remove the three screws around the top of the filler. Remove inner wing liner – two star clips mid way up the inside and one bolt at rear bottom.  Disconnect the hose that goes to the tank from bottom of filler pipe- secured with a stainless hose clip, best released by inserting a pointed bradle or similar between the three balls where clip fastens , and prising apart, later replace with jubilee hose clip. Disconnect smaller breather hose by squeezing both sides of the black push fit sealing clip, and pulling at same time – not easy if you are unfamiliar with this type of joint. The unit is clipped onto vehicle with another star clip or with a nut on the stud. Unclip the plunger device from top of filler neck and the unit will be free to lift away. 
This all sounds straight forward but if you are unfamiliar with the hose clip designs it is a challenge! I purchased a replacement from  a 2007 multispace that was identical to mine for £2 but without the split at the filler cap end.
[-] The following 1 user says Thank You to timpascoe for this post:
  • Tomcat3
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#2
I have been trying to add some photos to illustrate the account above but struggling to upload anything.
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#3
I have the same issue, the filler cap no longer fastens, so I'm driving around with a temporary cap.
Unfortunately, I have yet to be able to get hold of a replacement neck (none of the scrappies have it listed, and the one I asked souned like they didn't want the bother of removing it from a wreck)
So I have temporarily disabled the hook by loosening the bolts holding the hook assembly in place, pulling it out, drilling two holes at the back of it and threading a zip-tie through to bind up the hook.
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