fuel flap not opening.

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Creek_I.0

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Joined: 16/04/2013
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Post Date: Fri, 19/04/2013 - 8:25pm

Last few months ocassionally had the front lever to open the petrol tank flap will not work,maybe due to dust,had to adjust the flap latch on the fuel tank,anyone else had this problem? It is happening again,not keen on using a screw driver to lever the flap open to refuel each time.

singlecell

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Post Number: #1
Post Date: Fri, 19/04/2013 - 10:54pm

.

Mine has been like that since I bought it over a year ago. I am missing the part that is creating the pressure to open the door, what I suspect is a rubber knob. I just my key to create a small amount of pressure as I pull the open flap. Lucky I got a SWB model!

fordem

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Post Number: #2
Post Date: Sat, 20/04/2013 - 2:46am

No rubber.

It's actually a metal spring that clips to a plate near the hinge.

Claude io

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Post Number: #3
Post Date: Sat, 20/04/2013 - 9:33am

metal spring

Here is what the spring looks like. Mine wasn't working (on the 99 model, same as yours) but it was because the pin on the mechanism, that is connected to the end of the cable, was broken. I drilled what was left and glue a cut nail inside the hole with some red heat shrink to cover it...fixed.

You need to work out if the problem is because of the missing spring (blue pen on the picture) or if it is because the mechanism is not fully moving the pin (red bit on the picture, yours will be black!). If not properly lubed, clean, this pin can grab, or not fully open by 1/2 mm. You can access the mechanism from the inside by removing the black trim.

Happy io

My io is now SOLD Thankshttp://pajerio.com/forum/claudes-io-2002-zr-built-thread-onlyhappy-io

Creek_I.0

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Post Number: #4
Post Date: Sat, 20/04/2013 - 2:29pm

Thanks all.Mine is the same as Claude io.

Thanks all.

I fixed it before buy slightling bending the latch.which worked ok for several months,Now I can see if I can do what Claude io suggests,-thanks.

Edit -it seems the whole petrol flap door has moved over,now hitting the edge body metal stopping it closing? Perhaps I opened it too far ?

Doesnt look like the hinge has stretched/fatigued, but there seems to be a larger gap as the door closes than before (where the metal spring is)

The spring is still there,lifting the driver seat fuel lever seem to do nothing?

FIXED! with the aid of a long occy strap I could pull the lever and see that it is making the relaese button move in and out.

A couple of taps with a hammer on hinge moved the door enough to close properly. Then adjusted to hook latch on the flap door,took a few attempts:)

Now it grabs the latch hook and by using the front lever will release the door-if it isn't just right no amount of pulling the lever would release.

So ok for another while.

singlecell

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Post Number: #5
Post Date: Sat, 20/04/2013 - 6:42pm

.

So thats what I am missing, ive always assumed it was rubber.

Will have to look into sticking something "aftermarket" there.

Claude io

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Post Number: #6
Post Date: Sat, 20/04/2013 - 6:53pm

rubber?

That is why I put the picture, it is hard to guess what this spring looks like if it is missing. Maybe.., with the correct thickness, and density, a piece of rubber/foam, at the same location might do the same job. But I don't think that a wrecker would charge you too much for it...:)