02 Polo fuel filler won't open

[Midge]

Folks,

Fuel filler cap on my wife's 02 Polo has decided it won't open. All other central locking operations are fine. Any idea what this is and how to overide it?

TIA,

Midge

[Midge]

Well, it took some sorting out but the plunger of the motor which locks the fuel cap is just about visible behind the boot light - but the plunger was jammed solid.

To get to it was a bit of a pig:

1. Remove parcel shelf

2. Remove the plastic trim running along the top edge of the tailgate (just pulls straight down).

3. The trim across the bottom of the tailgate opening needs to be unclipped at the R/H edge. This allows access to a) a plastic plug which secures the offside wheel arch cover behind it and b) a hidden T25 torx screw which helps secure the plastic ledge the parcel shelf clips into.

4. Remove two further T25 screws securing the plastic ledge

5. The trim through which the rear seat belt goes, needs to be carefully prised away and the motor will now be visible.

6. Loosen the two hex screws on the motor itself (note these need to be turned CLOCKWISE to loosen them)

7. Pull motor back slightly so the screw heads on the other side of the motor can be pulled through the holes.

8. There is a simple plastic coupling between the rod which locks the fuel flap, and the plunger. Slide the plunger to one side to unclip it.

9. Unclip cable by squeezing together the tabs sticking out the top of the connector.

I actually managed to unclip the motor cover and it is just three parts inside. A simple reversable little DC motor/brass drive cog, the plastic plunger, and a threaded plastic drive rod/cog which pushes the plunger out. I regreased it but every so often, the cogs would just separate slightly at one end of the pungers stroke or the other, and just jam - probably through wear and tear. I'll be replacing it given how awkward it is to get to!

Midge.