Fuel flap dropped - again

blueleontsi

Active Member
Jan 21, 2013
41
0
2017 Ibiza - fuel flap dropped (bottom left hitting car chipping body paint). Replaced by Seat under warranty but 2 months later same issue. Replacement of hinge and flap. Flap requires painting as Seat will not change flap over - even though a 30 second job, could make matching paint so much easier.

I'm not a petrol flap stalker but some random pictures of other Ibiza's online seems to show an issue - anyone else had a repeat issue?

flap.JPG
 

SEAT Rule

Active Member
Nov 19, 2019
188
62
Ello ello ello this is the fuel flap police here, we've had some completes of someone taking loads of photos ??

I've had a look online and looks like this is a weak part with the latest new Ibiza models, all the previous models had the fuel flap & hinge moulded as one piece, but this new model since 2017 has the hinge housing separate from the actual fuel flap that clips attaches to hinge housing.
The VW Polo also has issues regarding the fuel flap, where it won't open properly or doesn't line up correctly.

Hinge housing assembly
Part number 6F0 809 906C

Fuel flap cover
Part number 6F0 809 905


It's possibly a poor weak design that VAG may address in the near future with an updated/upgraded stronger part.
That's what most car manufacturers have done in the past, if they get loads of complaints for the same fault/issue with a certain part.

I remember many moons ago now when Ford had issues with some of their cam belts on the diesel engines, that were prone to snapping on the MK5/6 Escort vans and Transit vans, also on some MK1 Mondeo's.
Ford brought out a reinforced cam belt and replaced the plastic idlers with metal ones.
Also weak front suspension bushes were a known issue on the MK1/2 Ford Sierra's, so upgraded reinforced bushes were made.
On the Toyota GT86 they're known to have leaking rear light clusters, and idling problems on the early models from 2012.
I think there's been a recall on those issues for the GT86.
With the VAG they've had issues with ECU updates, water leaks, timing chains snapping, TSI engine's burning too much oil, electronic problems, some of this has been recalled but not all.

Like I say hopefully VAG will recall the issue with this poor designed fuel flap, or someone might come up with a modification to fix the issue ?

Hope this helps
Si
 
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SRGTD

Active Member
May 26, 2014
2,388
1,279
@SEAT Rule; There are also instances of VW not issuing a recall notice where defective parts are concerned;
  • The infamous timing chain tensioner issue on the 2.0 EA888 engine in the mk6 Golf GTI where there were several instances of tensioner failures, with resultant damage to the engine that in many cases required a replacement engine to be fitted. The tensioner went through three revisions during the life of the mk6 Golf GTI (is the need to redesign a part three times an acknowledgment by VW that the previous design was defective?) but VW didn’t issue a recall. I think the mk2 Leon Cupra may have also been affected by this issue.
  • Failing thermostats and leaking thermostat housings - a common issue with the mk7 Golf.​
I think that as a general rule, VAG are likely to only issue a recall if a fault / defect has been identified that’s considered to be safety-related; like the centre rear seat belt buckle fault on the current model Polo a couple of years ago where there was a risk of the centre seat belt coming undone when the rear centre seat was occupied by a passenger (may have affected the Ibiza as well?).

Currently, there are quite a few current model Polo GTI owners on uk-polos.net whose rear disc brakes make a ‘mooing’ noise while reversing. Recall has been discussed on the forum, but as the noise doesn’t affect the performance of the brakes or the safety of the vehicle, then the chances of VW either implementing a fix or issuing a recall notice are slim to none IMO.

Back to the OP’s issue of the poorly fitting fuel filler flap; I’ve seen a few current model VW Polos with this issue. Fortunately, mine seems to be OK at the moment, although the flap design doesn’t seem to be as sturdy as the one on the previous generation Polo. I think the design used on the current model Ibiza and Polo was used on the mk7 and mk7.5 Golf - maybe it was also used on the mk3 Leon too? On the Golf, I think the main filler flap related issue on early cars was with the locking pin getting stuck in the locking loop on the inside of the filler flap. The dealer fix for this issue was to shave some of the plastic off the loop so the locking pin could move more freely in and out of the locking loop.

@blueleontsi; I would make sure that the repeat of this issue is logged by your dealer on their system so they can’t deny you’ve not informed them if the chipped paint issue becomes worse and you decide to persue getting a further new flap fitted or the existing flap adjusted and repainted.
 

Mike Coulter

Active Member
Jun 13, 2020
58
23
United Kingdom
Drat, my fuel filler flap has dropped. It’s not even 6 months old yet and I noticed it caught today when I went for fuel.

Are people managing to get this covered by warranty?
 

SEAT Rule

Active Member
Nov 19, 2019
188
62
Drat, my fuel filler flap has dropped. It’s not even 6 months old yet and I noticed it caught today when I went for fuel.

Are people managing to get this covered by warranty?

I'd definitely make enquiries with your local SEAT main dealership, most things are covered under warranty on a brand new vehicle, so if you've owned it for 6 months from new, you've still got 2-1/2 months left on the original manufacturer's warranty.
If this issue keeps happening with the fuel flap on the Mk6, SEAT surely have got to address this fault in the future, the part in question is obviously weak/defective.

Hope you get yours fixed under warranty.

Si
 

Mike Coulter

Active Member
Jun 13, 2020
58
23
United Kingdom
I'd definitely make enquiries with your local SEAT main dealership, most things are covered under warranty on a brand new vehicle, so if you've owned it for 6 months from new, you've still got 2-1/2 months left on the original manufacturer's warranty.
If this issue keeps happening with the fuel flap on the Mk6, SEAT surely have got to address this fault in the future, the part in question is obviously weak/defective.

Hope you get yours fixed under warranty.

Si

Thanks! I think I’ll give them a call tomorrow and see if I can get it booked in.
 

blueleontsi

Active Member
Jan 21, 2013
41
0
Update on original post.... 3rd fuel flap hinge fitted 6 weeks ago along with new painted flap. Flap rejected as you could see primer instead of paint on edges of flap (smart repair job, not body shop). Back at dealer last week as flap catching bodywork again. Dealer readjusted flap (no idea how as it's fixed) but no better.

Similar reported issues with 2018 polo's.

Seat UK don't want to know.

Either weak part or issue of how it's attached to body of car.
 

kurac338

Active Member
Mar 30, 2020
52
16
Croatia
Hi all,
it appears that my MY08/2018 also caught this disease, after only 22000 km, and not so many fuel flap open/close actions to justify its current state.

The lid opening mechanism was bad and often resisted since day one. You had to massage it at an angle to get it to open, but I got used to it...

Yesterday I noticed something was off with the flap...
I compared the photos to how it was when the car was delivered. Even when new, it wasnt perfectly centered, but it wasnt sagging like it is now.

Now it looks similar to the red photo in the original post.
I can definetly see a larger gap on the right edge (and a little on the top edge) of the flap/cover, and less of it on the lower left side relative to old photos.
So it is starting to sag diagonally to the lower left corner.

The hinge has a little bit of wabble, but nothing concerning to its structural rigidity. The flap itself is also firmly attached to the hinge, although I can see a small gap where the flap and hinge mechanism meets. I can see the attaching clips right in between the two. Not sure if this is expected or if it should be flush...

Any info on how to resolve, or any news from the service shop would be appreciated.
Definetly a unpleasnt experience and stupid design for such a new car...
 

Cristian CH

Active Member
Mar 19, 2018
23
4
This happened to me twice already and had the fuel flap changed both times on warranty. Last time it took more than a month to have it replaced but I did find out a tip on how to open it if it is completely stuck:
Open from the key and while pushing the flap towards the hinge (towards the front of the car) press on the flap to open it.
 
2017 Ibiza - fuel flap dropped (bottom left hitting car chipping body paint). Replaced by Seat under warranty but 2 months later same issue. Replacement of hinge and flap. Flap requires painting as Seat will not change flap over - even though a 30 second job, could make matching paint so much easier.

I'm not a petrol flap stalker but some random pictures of other Ibiza's online seems to show an issue - anyone else had a repeat issue?

View attachment 18175
The flap on my 18 plate FR is on the move towards the rear of the aperture. I'm interested to hear from "LeonTSI " whether any adjustment is possible by detaching the flap from the hinge - if so this may fix the issue. How do you detach the flap?
 
Well it seems they won't change it under warranty. I said I'd rather rip it off than pay so to leave it.

I'll see what the dealer says. You can buy the full part which includes the actuator on Ebay from Synetiq. I've just bought one in Mystic Blue metallic for £30 in excellent condition. To replace, it seems straight forward look for the four marks(two at bottom and two below on the face of the rectangular liner and press down on an inserted small screwdriver to release the two spring plastic clips at the top and the bottom of the fuel aperture and then the whole unit releases. Unlike the VW golf part the actuator is screwed to the back of the plastic shroud. You can detach the actuator two torque screws and the drain pipe. The whole thing is poorly made.

I would like to know whether any adjustment can be made by unclipping the body flap from the hinge -but I guess even if you can it will be a clip on clip off with no adjustment possible. Would like to hear if anyone has tried.
 
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