I noticed a couple of weeks ago that my filler cap was not sitting flush. The car was in the dealers yesterday for a sensor replacement and i asked them to look at it and the garage said the only fix was to replace the flap and the hinge but as the car is out of warranty this would need to be covered my myself. The dealer said they had seen a few of these.

 

Today i thought i would have a look and see if i could do anything, after a bit of fiddling i notice the catch was not locating correctly and it looks like the filler cap had a little play in it which makes it drop slightly. The fix is simple by raising the flap slightly as you close it the socket engages correctly and the filler is flush once again.

 

Don't know how much the replacement parts would have cost but i am sure it would not have been cheap so i am happy with this fix and i will have to remember to raise it slightly each time i close it.

 

Just in case anyone else has this problem try this fix it worked for me.

I looked at this again today and have worked out a permanent fix. Lifting the flap when closing was working but remembering to do it all the time is a bit of a pain, my wife would never remember. 

 

I removed the colour coordinated part of the flap which slides towards you with the flap open and simply lifts off. Having done this you can now see what is happening when you push the flap to the closed position. This enabled me to see that the spring loaded pin was not locating correctly and lifting it was allowing the necessary clearance for it to work. The answer was to get a mini file and file a tiny amount from the LHS of the flap probably less than a millimetre in total. This is enough for the pin to connect correctly allowing the flap to close perfectly flush.

 

My one frustration is my dealer looked at this and removed the outer flap but said they could do nothing other than order new flap and hinge at my cost. Must be because the computer did not tell them how to do it, what happened to initiative.

Well done. That may help a few of us in future.

 

Dealers !!!!!!!!!!!!!!!!!!!!

My spring that supports the flap has come out as I have attempted to jet wash the inside while the flap was open 🥴 do you know how to insert it again properly? 

No i don't, start a new topic and ask the question someone on here will know the answer.