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When I lock the car I still have about a 5mm gap with the fuel cap, does anyone elses do this or does it sit flush with the car?

It should sit flush with the car.

There is a rubber sleeve and a tag which attaches the round cap to the car and stops you loosing it, try turning the sleeve and tag round, this is what stops the flap closing properly.

Hope that helps

I'll give it a go, it just seems that where the locking pin goes in, the hole is too big to keep it where it should be?

EDIT: I just poked the bit in connected to the cap on the filler neck, and it has made it a lot better, cheers Del.