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Re: Unable to open fuel tank flap on a Volkswagen Passat...
You need to remove the lining by the fuel door in the trunk. Once you get the lining loose you can bend it out of the way and remove the solenoid that is held in place with 2 philips head screws.
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There isnt a button, you just push the fuel door and it opens. If it doesnt, its may be because your door are locked. When you lock the door it also locks the fuel door.
If you have fuel door release cable & door is open, verify that cable moves in & out when you activate it. If yes you can adjust tab that it rests on so it will release properly. Just bend tab slightly inward at first, till it releases correctly.
Push back release rod - 9 - by operating remote control unlock and remove bolt - 2 -.
Remove rubber part - 8 - from tank filler flange and swivel out tank flap unit - 1 - from side panel - 7 -.Assembly piece - 4 - and actuator - 6 - is installed.
Install tank flap unit - 1 - (rubber part rolled up) with hinge side first.
Bolt tank flap unit - 1 - and assembly piece - 4 - with bolt - 2 -.
Tightening torques: Bolts - 2 - 1.5 Nm
Remove side luggage compartment trim.
Disconnect harness connector at actuator - 6 -.
Remove actuator - 6 - using special tool Socket wrench T 10010 from angled mounting bracket.
Remove actuator - 6 - together with release rod - 9 - from seal - 5 - and assembly piece - 4 -.
Installing Installation is reverse of removal. Tightening torques: Bolts for actuator - 6 - 1.5 Nm .
I have a 2003 passat with the same problem, i noticed that the little nipple on the left hand side that releases to open the flap was inside the hole its self .
The book tells you nothing regarding this and i couldnt find on the internet how to get to it other than taking off the guard above the wheel and getting it that way.
I went out today and took the carpet away from the side of the boot closest to where the flap was.
I then saw the flap solenoid which had 2 little wires and a rod attached. The solenoid or motor as i call it was held on by two little bolts which i took off and had look at it but to be honest i had no idea what so ever as to what it should look like or do ha ha.
The rod that is attcahed to solenoid is the rod that comes through the hole to keep flap closed or to release it. I pushed the rod and couldnt see hyow it would release and hold so i took the rod off the motor and pushed the end of the motor that the hook was attached to and it made a noise i hadnt heard before but it was one of those good noises lol i didnt have any wd40 to spray on it as i used this for something else so i used some vaseline to rub on the end where the hooked rod goes onto and put the rod back on.
I then put the bit that comes through to lock or release into position and then bolted solenoid back in place and connected the wire again went to check thinking i am not that lucky and hey presto all mine needed was bit of lube lol and without the dirt and hassle of taking of the guard above the wheel.
Hope this helps as there is no way of opening this manually as i was told this monday when i called vw.
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