Replacing Vw Polo Fuel Flap: A Step-By-Step Guide

Changing the fuel flap on a VW Polo is a simple task that can be completed in just a few steps. The fuel flap, also known as the fuel filler flap or fuel filler door, is the cover that protects the fuel tank opening. Over time, the fuel flap may become damaged or worn out, and need to be replaced. This can be done by purchasing a new fuel flap from a Volkswagen dealership or a third-party supplier, and installing it onto the car. The process typically involves removing the old fuel flap and securing the new one in its place, often with the help of a hinge.

VW Polo fuel flap colours

The VW Polo fuel flap comes in a variety of colours, depending on the model of the car. The VW Polo 6R 6C MK5 model, for example, has a black fuel flap, while the VW Polo MK6 model has a blue fuel flap. Other colours available for the VW Polo fuel flap include grey, silver, white, orange, and brown.

When looking to replace a VW Polo fuel flap, it is important to consider the colour of the new flap to match the car's existing colour scheme. It is also worth noting that the fuel flap can be painted to match the car's colour, as VW does not paint parts themselves.

Some VW Polo fuel flaps come with stickers, which can be carefully peeled off and reapplied to the new flap. Additionally, when purchasing a new fuel flap, it is important to ensure compatibility with the specific make and model of your vehicle.

VW Polo fuel flap hinge

To replace the fuel flap hinge on a VW Polo, you will first need to open the fuel flap and remove the T20 Torx screw. Then, remove the fuel flap assembly by wiggling it out and replacing the fuel filler pipe lid to prevent dust ingress or fuel vapourising. Next, pull out the actuator assembly and, inside the boot, pull out the boot liner from the right.

After this, locate the 2-pin connector of the actuator harness and disconnect it. The actuator harness has a rubber grommet that attaches to the body of the car, so pull out the grommet and detach the actuator assembly. To attach the cord to the actuator, make a slit or incision in the grommet to route the cord from the boot. Use a precision knife to make a slit that is large enough to route the tip of the cord, but not so large that dust will start creeping into the boot.

Now, route the cord through the slit and attach it to the actuator. Route the other end of the cord and the actuator's connector through the hole into the boot, and secure the grommet to the body. Secure the actuator to the body and replace the fuel filler assembly, as well as the T20 Torx screw of the assembly. Connect the actuator harness's 2-pin connector and secure the other end of the cord inside the boot.

Finally, test the emergency release mechanism to confirm it is working.

VW Polo fuel flap locking motor

The VW Polo fuel flap locking motor is a vital component that ensures the fuel filler flap remains securely closed when not in use. Over time, this locking motor can malfunction or fail, leading to the fuel flap becoming jammed or unable to open. This can be a significant inconvenience, especially when you need to refuel your vehicle urgently.

The locking motor is part of the lock actuator assembly, which includes an emergency release system. This system can be manually operated by accessing the assembly, usually located behind the fuel flap or within the trunk liner. In some cases, removing interior trim panels may be necessary to reach the assembly.

When replacing the fuel flap locking motor, it is essential to ensure you have the correct part for your specific VW Polo model. The LSC 6R0810773F locking motor, for example, is compatible with VW Polo models from 2009 onwards, including the 6R1 and 6C1 variants with engine sizes ranging from 1.0 to 2.0.

The process of replacing the locking motor typically involves the following steps:

• Locating and accessing the lock actuator assembly.
• Disconnecting the actuator harness and removing the assembly.
• Attaching a plastic cord to the actuator, which will serve as the emergency release lever.
• Routing the cord through the trunk and securing it to the actuator.
• Reassembling the fuel filler assembly and connecting the actuator harness.
• Testing the emergency release mechanism to ensure it is functioning correctly.

It is important to note that this process may vary slightly depending on your vehicle's specific make and model. Always refer to a trusted repair guide or seek assistance from a qualified mechanic if you are unsure about any steps.

VW Polo fuel flap cover

Changing the fuel flap cover on your VW Polo is a straightforward process that can be done in just a few steps. Here is a detailed guide on how to do it:

Step 1: Purchase the Correct Fuel Flap Cover

Before you begin, it's important to make sure you have the right fuel flap cover for your VW Polo. The cover needs to match your car's make, model, and year. You can find fuel flap covers for the VW Polo at a variety of online retailers, as well as Volkswagen dealerships. When purchasing a new fuel flap cover, ensure it is the correct colour and has the proper fittings.

Step 2: Locate the Fuel Flap

The fuel flap is usually located on the rear side of the car, towards the right or left side. It is often near the license plate.

Step 3: Open the Fuel Flap

To access the fuel flap cover, you will need to open the fuel flap. This is usually done by pulling a lever or releasing a latch inside the car, typically found near the driver's seat.

Step 4: Remove the Old Fuel Flap Cover

The method for removing the old fuel flap cover will depend on your specific VW Polo model. In some cases, you may need to remove screws or clips holding the cover in place. Be gentle during this process to avoid damaging any surrounding components. Place the screws or clips in a safe place so they don't get lost.

Step 5: Install the New Fuel Flap Cover

Take the new fuel flap cover and line it up with the holes or fittings from the previous cover. Secure the new cover in place using the screws or clips you removed earlier. Ensure the cover is properly aligned and securely fastened before moving on.

Step 6: Test the Fuel Flap

Once the new fuel flap cover is installed, close the fuel flap and test to make sure it opens and closes smoothly. Ensure that the cover sits flush with the surrounding body panels and that there are no gaps or misalignments.

By following these steps, you can easily change the fuel flap cover on your VW Polo, restoring it to a fresh and functional state. Remember to consult a professional or a repair manual if you encounter any issues during the process.

VW Polo fuel flap years

The Volkswagen Polo is a popular car model that has been in production for several years, with various iterations and updates released during different time periods. Here is a detailed guide on the VW Polo fuel flap across different model years:

The VW Polo fuel flap design and compatibility vary across different model years, and it's important to source parts that match your specific model. Here is a breakdown of the VW Polo fuel flap across different model years:

2017 Onwards (MK6 A06):

This model year introduced the MK6 A06 version of the VW Polo, which featured fuel filler flaps in multiple colours, including silver, black, grey, and blue. These fuel flaps are compatible with the 2017 and newer models.

2009-2017 (MK5 6R):

The MK5 6R version of the VW Polo was produced from 2009 to 2017. The fuel filler flaps for this model year range are available in brown, blue, and grey colours.

2002-2009 (MK4 9N3):

The MK4 9N3 VW Polo was on the market from 2002 to 2009. The fuel filler flaps for this model are available in silver and match grey colours.

2011-2019:

Some VW Polo models from 2011 to 2019 used fuel filler flaps with part number 6R0809857. These were available in various colours, including grey, white, blue, silver, and unprimed.

2009-2017:

For certain 2009-2017 models, fuel filler flaps were offered in colours like grey, silver, and white.

1994-2001 (6N1, 6N2):

The earlier VW Polo models from 1994 to 2001 featured black fuel filler flaps, specifically for the 6N1 and 6N2 versions.

2002-2009 (9N, 9N3):

The 9N and 9N3 models of the VW Polo, produced from 2002 to 2009, utilised black fuel filler flaps.

2010-2017 (MK5, MK6):

During this period, the MK5 and MK6 models of the VW Polo were on the market. Fuel filler flaps for these models were available in black and white colours.

2018 Onwards:

Starting in 2018, VW Polo fuel filler flaps were offered in colours like blue, grey, silver, and white. These flaps are compatible with models from 2018 and beyond.

Installation and Maintenance:

When installing or replacing a fuel filler flap on your VW Polo, it is important to consult a professional or refer to a reliable repair guide. Proper installation ensures the fuel flap functions correctly and maintains the vehicle's safety standards. Regular maintenance and lubrication of the locking mechanism can help prevent issues with the fuel flap getting jammed or locked, as some owners have experienced.

Frequently asked questions