How to Repair Fuel Flap Solenoid
 

I went to the garage this morning to get some diesel and the fuel flap would not open with the car unlocked so had to effect a sharpish repair

I suspected that the solenoid had failed as the car has now done 197,000 miles and must have been opened and closed via the solenoid numerous times.

So next step was to take a look and results are below:

https://i.imgur.com/9ihEt7Uh.jpg

https://i.imgur.com/guKvJiMh.jpg

https://i.imgur.com/xhumL1Th.jpg

https://i.imgur.com/PjyHJrHh.jpg

https://i.imgur.com/Ty2fyLch.jpg

https://i.imgur.com/ysnF5oCh.jpg

https://i.imgur.com/GrOJAdnh.jpg

https://i.imgur.com/MJ2S4luh.jpg

Hi Rob.
Nice fix if you ever get stuck for any size O-rings drop me a call, i have loads of different sized ones. ;)

If you do ever find the motor not working correctly on these there are a couple of breather holes in the plastic end cap of the motor. A good squirt of contact cleaner in these holes usually does the trick ;)

I need to get this done on the Bear as it doesn’t lock.

Thanks for the advice.

How to
 

I suggest that this is put in the appropriate "How to" for future reference.
Well done Rob,:bowdown:.

Martyn

I did one of these today, very fiddly in this case the motor had indeed packed in, so it was swapped out for a known good one three hands would be good :D also the rubber stop for the fuel flap to butt up to had swollen with the diesel.

The one i swapped out was taken apart cleaned and is not working as it should so into the spares box it has gone. ;)

https://i.imgur.com/rCj8nbxl.jpg1

Three stainless steel self tapers and it was fixed back together nicely.
https://i.imgur.com/SIxsHIvl.jpg2

https://i.imgur.com/Slja8Lrl.jpg3

Before pulling the motor apart, if you havent done this already, check the two plastic clips are in place on the back side of the flap. Specifically, the one on the 3 o'clock position of the flap. They commonly go missing (there have been many posts over the years), and with the number of fuel visits I imagine you would have to do with the Bear, it could have gone walkabout.

The clip on the upper edge of the flap is the same and can be used to replace the locking one.