Apologies in advance assuming the car may be new to you. the car needs to be unlocked then push the flap it should pop open.

 

Hi Grant, apologies not needed. Confirming car is unlocked however fuel flap remains locked. Have owned the car since new back in 2013 and never had this issue before.

 

Ok then clearly you how it is supposed to work 😀
Just looking at my Touareg, the latch is plastic spring loaded and rotates, maybe just jammed up with grit / dust. Or the spring has broken.
I cannot see any way to open it without damaging the latch. It may be able to be sorted from inside after removing the trim.

 

Pending any better response from others...
I don’t like to suggest it but brute force may be the only option if you are low on fuel.
Make sure you cover any tool you are using to protect the paint.
It’s going to cost for parts and fitting as Touareg maintenance is rarely inexpensive

 

Thanks, yeah it has got me stumped. After looking at it, removing the inside lining looks like a big job...to big for me and still not absolute that there is a manual release from the inside.. I’ll try and avoid forcing the flap open, as you mentioned VW repair costs are certainly high. Hopefully someone may have some ideas.

 

There are some threads on different forums about bad/failing fuel door lock actuators and a lot have mentioned that there is no manual release on the T3's.
The only thing I would try is push in on the fuel door a little and then lock and then unlock the car. Maybe without the pressure of the door catch on the actuator it will turn... maybe.
I have a spare lock actuator ( part # 7P0810773F) in case mine starts acting up I'll just change it out before it totally fails. I found a page where a member gives a tutorial on how to change it out on a Passat. The actuator looks similar to the part# I referenced above but the connector disconnects at the actuator so I don't think there's a need to take off any interior panels. Link w/tutorial below.

Link >>> How To Install a Fuel Door Locking Actuator

 

I also found an interesting video on YouTube . It's a 2012 Passat but again the actuator looks similar. Dealer showed the guy how to emergency unlock it. Hope it helps.

 

I guess there are two possible failure points.
1. Mechanical, the component failed or jammed
2. Electrical, the component failed to unlock

not sure if 2013 is the same but if my car is locked when I grab the drivers door handle I hear the actuator unlock the fuel filler door. That at least would confirm the electrics are working

 

I'm sure this has been dealt with before. My (very) vague memory was that it involved getting at it from the inside.

 

Many thanks for this information. It does sound like an actuator issue as I can’t hear it unlock. I’ll keep trying otherwise will need to see VW when they re-open on Tuesday. Thanks again, much appreciate.

 

The dealer can get in and unlock,I had thew same problem and they got in and opened and changed the actuator .Stupid system to say the least. I now keep my actuator lubbed with white lithium grease. I would frankly like to get rid of the lock altogether. I'm not concerned someone will steal my diesel fuel , actually they would probably not realize it's diesel and ruin their gas car. LOL

 

I now keep my actuator lubbed with white lithium grease. I would frankly like to get rid of the lock altogether.

Which brand do you use? WD-40 Specialist?

On a related lube note, what are folks using to lube their locks on a T3? Had to use the emergency key a couple times and almost tore the key trying to roll the barrel.

 

That is not uncommon! Many people bottle out! A steel key is a must really.

 

I was about to fill mine up for my holidays the following morning and found it was stuck in the locked position. I was amazed that VW had not put an alternative release mechanism in the luggage compartment. It was an electrical issue which gave a fault code on the diagnostics. I managed to get it open by repeatedly cycling the lock between open and closed until I got lucky and it released. I then disconnected it by pulling the plug off the back of the actuator so it remained unlocked until I obtained a replacement actuator. I got the replacement by googling the part number and finished up buying a Skoda one with the same part number from Eastern Europe!

 

Im not sure if yours has this but I have a 2010 Touareg and there is a manual override that is accessible from inside the trunk area on that side after removing the little carpet covered cover. I would google “manual gas tank open year make model” and I’m sure you can find the one on yours.

 

The manual release was only fitted to the Generation 1 cars.

 

Hi Maria. I wondered about a fuse, so did a quick check. Didn't find a fuse answer, but apparently it can be gently pried open.

Help! Fuel Flap wont open...

Hi There, as always happens the night before a long weekend, I went in to fill up(995km travelled) and the fuel filler flap wont open, no matter how I push it, it wont come open.... I have noticed the last few days when I open the car I no longer hear a click from the fuel filler flap that I...

www.clubtouareg.com

Good luck

 

I was experiencing fuel door unlock issues on my 2014 Gasser and was resolved with replacing the battery in the key fob.

 

That just doesn't make sense! But who cares if it worked!!

 

Hi, just an update on this. I took it into VW who have rectified the issue. It needed an actuator replacement for the fuel flap. Cost incl labour $295.

 

Good stuff @Maria55
Thanks for keeping us updated.
Did they show you/explain how they actually got it open to replace the actuator?

 

There is an emergency opening cord inside the car behind the side panel.

 

Read post #21. Apparently the VW bean counters found another place to save $$ on the 2nd generation (T3/T4) Tregs. Possibly even the next generations. Further leaving the owners at the mercy of the stealerships when the problem arises.

 

This is truly a terrible design for a fuel door, Hard to imagine on VW's top of the line product that you could find yourself running out of fuel on a long trip if you can't find a dealer to fix the problem. I personally never let the tank go below 1/4 of a tank for just that reason.

 

Was just at the BP ready to fuel up and couldn't get the fuel flap open. Left without refueling and tried to get it open once home. Finally opened after cycling lock unlock a bunch of times. Does anyone see any issue with just filing down the little rectangular flange bits that i assume twist to lock the door so this won't be a hassle anymore? Besides the obvious stealing or tampering of fuel which I'm not really concerned about.

 

Should work...
Not sure if the spring to pop open work in the locked position.

 

Good point. If i can get it to the unlocked position again and disconnect it somehow perhaps it would be right. Or maybe easier to keep some paddle pop sticks around to pry it open when its stuck in the lock position. At least there's an excuse to get some icecream

 

Dang might just head out there and bust mine so I can buy ice cream each time I fill up. What a great idea!

 

The part is fairly easy to change and not that expensive. Why not just change it while you have it opened and plan on doing it every five years or so as preventative maintenance?

 

Have you replaced yours mate? Mine actually won't lock with the doors and I would like to replace the mechanism so that it does. Cheers.

 

Great. How did you find the part number? Did you partially dismantle the fuel flap assembly to find it stamped on your part installed in your car?? I'd really like to do mine. There might even be an updated version of the part but I'm a little scared to purchase something unless I know it will fit and work, so I would tend to try and find the original part number and revision number that matches my car. Anyway, any assistance you can provide would be very much appreciated. Thanks.

 

To get the part number I didn't do anything but Google using the keywords. When I had a part number I went to an online VW parts site, plugged in my VIN# and in the search bar put the part# I got using Google. The online site told me whether or not it fits my vehicle based in the VIN#.
As a side note I believe the part# is the same for most 2nd Gen (T3+4) Tregs. Latest version of the part# that I bought was 7P0-810-773-F.

 

Oh, that's interesting. Can you please post a photo of where the holes are? Cheers.

 

I didn't take a picture.
I used the video below which isn't on a Touareg but is exactly the same. Watch where he puts in the flat blade screwdriver, that's where you have to initially "puncture" through. Check yours out and you'll understand.

 

Thanks a million mate. I appreciate it. Shame you have to "destroy" a part to get to another one by essentially punching holes in it!! 🤦‍♀️

 

I don't look at it as "destroying" a part, more of creating an access point. Besides the holes made can be sealed up after the job and I have a new actuator installed.

 

Same problem with my 2013 Touareg. Tried all the below including trying to lever the flap open, to no avail. Then parked the car in the direct sun and let the flap and innards warm up. Hey presto, it opened. Now will apply lots of lube.

 

parked the car in the direct sun and let the flap and innards warm up. Hey presto, it opened. Now will apply lots of lube.

Maybe a job for a hair dryer?

 

Update, even after removing the flap actuator and lubricating it thoroughly, the actuator would randomly refuse to unlock the flap. I found I could open the flap in that situation by giving it a sharp blow with the palm of my hand. Ordered a new one from eBay (approx US$ 50) and just fitted it to my 2013 7P. The new unit has a manual release cord attached. The 7P model does not feature a manual release, but I thought I would take advantage of the cord release so I found a way of running it from latch back through the rear panel to a small removable access point cover located in the luggage compartment. No holes drilled, no panels removed. I used a cable “snake” chaser and found a small opening from behind the fuel filler assembly into the interior towards the rear. Lots of jiggling to get the snake to pass (be careful as there lots of wires in there so don’t force anything). I had to add a length of cord to the supplied plastic cord as it was not quite long enough. I taped the loose end to the cover trim before clipping the trim back in place. In stall time 30 minutes. New unit works well.