UK-POLOS.NET - THE VW Polo Forum

Medium time poster, first time posting in this section as I ponder the new Polo. Apologies if this has already been answered, I'm asking on behalf of my uncle who owns a 2017 1.2L Petrol DSG Polo Match and a couple of times the fuel flap has stuck closed. It is the 'push the flap in for it to click then spring open', version not cable operated model. He's tried WD-40 which seems to work for a while then its starts sticking again, he's had to force it open and he's worried it may stick shut almost permanently and he won't be able to refuel. Ignoring the obvous solution, at least for the time being, to take it to the dealers as it's still under warranty, I seem to recall the 'sticking fuel flap' occured on Mk7 Golfs, though my current and previous Mk7 were ok, and a quick 'n' easy 'owner fix solution' was suggested, though I don't recall what it was. Thanks in advance for any info / advice....[text edior issues]

The issue on the mk7 Golf was generally the fuel flap actuator pin was catching on the part of the filler flap that it slots into when the car is locked and not retracting next time the car is unlocked. The solution by VW was to shave some of the plastic off the offending part on the inside of the filler flap. Like your uncle’s attempted fix, some Golf owners also used WD40 (or similar) or grease on and around the actuator pin and the part of the filler flap it slots into as a fix; it worked for some but not others.

I’ve not heard of this issue as a common problem on the 6c / 6r Polo before, so that suggests the cause is unlikely to be too tight a fit between the actuator pin and filler flap, otherwise I dare say there’d be quite a few other reported instances on forums of this happening. There have been a few Polos with a faulty fuel flap actuator motor though, so I’d say this is the most likely cause, in which case the dealer can change the actuator motor under warranty.

I do face the same problem several times with my 2012 6R. Along the way, i found that if i unlock the car (pressing the unlock button driver’s door) before shutting off the engine every time i want to refuel, the fuel door open without any issue. but if i shut off the engine then open the door and try to push in to open the fuel door, it will stuck. sounds like the fuel door actuator dont really like anything below 12v? I dont know. I did dismantle the fuel door once to check the actuator but i got nothing out of it. Would be great if someone can share the real culprit behind this issue.


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Thanks for replies,thing is I believe WD-40 is pretty much a cleaning / degreasing agent and not really intended as a semi-premanent lubricant so any freeing effect wears off. My uncle is more than handy with tools, ex-tradesman built aircraft for BAE, and is more than keen to have a go himself, and why not, I seem to recall seom sort of 'opening arm modification' on Golfs though I've never needed to. I'm seeing him prob Wednesday nite and while I'm no expert we'll have a look together and if it appears to be an actuator issue; back to the dealers it will be, and will report our findings....

Quick update: saw my uncle last nite, told me he'd used "silicone" or some such (I forget exactly, tired, not slept well), either way it seems to have fixed the problem. Touch wood. I showed him what posters said and he was pleasantly suprised and also impressed as he isn't 'a forum / internet person' as such. Thanks again for replies.....

Unless fuel theft or malicious fuel contaminations are an issue in your area, id suggest disconecting the motor wiring while its unlocked. You may also be able to get a locking fuel cap for it although I dont know where

idriveapolo wrote: Fri Mar 22, 2019 6:24 pm Unless fuel theft or malicious fuel contaminations are an issue in your area, id suggest disconecting the motor wiring while its unlocked. You may also be able to get a locking fuel cap for it although I dont know where

Trouble with doing that is that, I think, needs that locking element to hold the flap shut, there will be suitable locking caps out there, many Ibizas had no lock on their fuel flaps and so came with a locking fuel cap, though the flaps on them did have a element to keep the closed flap shut firmly.

I think that the best solution is to get the dealer to sort this - though as the problem has now been masked by the silicon grease they might not accept that it is still an issue. He could always buy the new part and sort it himself if faffing around with initial garage visit, hanging around, booking it back in when the spares arrive and again hanging around does not suit him - and I can understand that as I tend to take care of most things were it is possible for me to do so instead of wasting my life visiting the dealership, but comes at a price, not just the parts, but also the danger that some areas are trickier than others for a DIYer to get into and restore back to "as new".

Edit:- there is a Haynes repair book out for the earlier Polo, ie 6R and it covers most common bodywork and suspension areas for 6C.

I didnt say remove the whole lock mechanism!, just remove the boot trim to gain access to the wiring behind and pull the plug out (while its ulocked obviously). When the car is unlocked one cannot hear motors whirring away or solenoids clicking etc when you open and shut the flap. The flap is secured with a latching plunger which rotates 90 degrees as its pressed in which latches down when pressed in and atttches to the back of the flap. Also if one locks the car with the flap open (and plunger extended) then one can continue to open and shut the flap as much as they like which also means that the flap has to be closed for the motor to work at all!

All one needs to do is unlock the car (including filler flap) and make shure the fuel flap motor never works again!!

Yes, I have just washed my wife’s Polo and discovered that! My mistake, OP ignore that part of my posting.

I have just bought a 60 plate 3d Polo 1.2S for my son as his first car. Fuel cap sticks - had to prise it open to fuel it tonight. Is it as simple as a spring in the mechinism or is it more in depth? I locked and u locked repeatedly with the key and eventually it popped open, but I’m a bit OCD and would rather just have it working properly.

It’s probably a failing lock solenoid,just replace it.