Hi Bgw 70. Thanks for the pix. My SC was manufactured in August 2001, & is referred to as a 2001 here in OZ. As far as I know in the States it would be referred to as & 2002. It would be gratefully appreciated, if some one else was to check whether one or two screws holding the inner part of the Gas Door. I don't have any problem opening or closing the Gas Door. Maybe it originally did come with just the bottom screw & over the years the inner plastic has lost its tension hence the bulge. What I'll do is remove the inner part & see if I can drill a hole for the extra screw like yours, & hopefully solve the problem.
Thank you to all.

Chris.....From OZ.

 

....just checked mine & it has only 1 screw also, so maybe this is why mine isn't fitting flush also. I'll take a look at mine this weekend & see about adding a screw, hopefully mine will fit flush then

 

Finished drilling the extra hole, & fitting the extra screw in mine about an hour ago, & it looks 100% to the way it was before, but it's still not 100% flush to the body. Before, it was sticking out a good 1/4" plus, but now only about 1/16" hardly noticeable.
Take out the plastic behind the door first, by unscrewing the bottom screw, & pull outwards as it fits (slides) into a top & bottom guide.
Pull out the Gas Cap connector. Now you ca see exactly where to drill the new hole, which would be about 1/4" to the right of the Guiding hole.
I first drilled the hole in the plastic being OUT of the cap,with a 5/32" Bit.
Then I put it back together in place with the bottom screw fastened,& drilled with a smaller bit to suit the new screw only to mark it.
I pulled the plastic out again & placed a bit of wood directly behind the new hole to be drilled, so that I wouldn't go too deep & wreck the Gas Cap Door.
I used a self tapping screw with a washer. Make sure it's not too long as you DON'T want to hit the back of the GAS CAP DOOR.
I hope this helps.

Chris......From OZ.

 

My 03 had both screws.

 

Same for my 2004 SC430, two screws.

 

My '02 has both screws. You might see if you can adjust the latching bolt back farther into the recessed area.

 

That's the first thing that I was going to do, but there is no adjustment inside the door compartment, as it just spins. The only way that I could see about an adjustment, is to remove coverings from the trunk to hopefully do something. After fitting the second screw I'm quite happy, so I'll leave it at that without opening up a can of worms.

Chris....From OZ.

 

Sounds like you got it reasonably resolved Lesly.

 

My fuel door is not in perfect alignment either. I haven't examined it closely to see if it has and adjustable movement.