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VW B5 Passat TDIs This is a general discussion about B5 Passat(>98 (2004-2005 in North America)). Non TDI related postings will be moved or removed.

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Old December 14th, 2012, 20:15   #1
outthere
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Join Date: Apr 2004
Default Fuel Flap Door

Hope someone can point me in the right direction.

I knocked the fuel nozzle into the fuel flap door on my B5 Wagon. The flap snapped at the hinge. Does anyone have a diagram or pics of how this goes together? I'd like to remove the hinge thats still attached to the car, epoxy, replace but not sure exactly how this goes apart & back together. worst case replace it.

Your awesome help is always appreciated! (Coming up on 13 years of TDIClub- I owe a lot of folks props/beers!)
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Old December 15th, 2012, 05:25   #2
thundershorts
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probably lots of used ones available as its not tdi specific. forget trying to glue it.
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Old December 15th, 2012, 19:39   #3
MattS
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Location: Bloomington, IN
TDI(s): 2005 Passat
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Quote:
Originally Posted by outthere View Post
Hope someone can point me in the right direction.
I knocked the fuel nozzle into the fuel flap door on my B5 Wagon. The flap snapped at the hinge. Does anyone have a diagram or pics of how this goes together? I'd like to remove the hinge thats still attached to the car, epoxy, replace but not sure exactly how this goes apart & back together. worst case replace it.
Your awesome help is always appreciated! (Coming up on 13 years of TDIClub- I owe a lot of folks props/beers!)
There is a single Torx screw accessible with the door open (or broken off!) that holds the whole assembly in place. Removal is very easy. I swapped mine with one I found on a gasser in the junk yard. (Had to manualy activate the release on the junk car after removing the side panel in the trunk.) Paint is a perfect match. I was even able to peel off and reuse my diesel label on the inside of the flap.
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Old December 16th, 2012, 12:10   #4
auntulna
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Join Date: Mar 2005
Location: Springfield, MO
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I had one break where the hinge meets the door. Took it out, just one screw.

Glued it indoors for better temperature and control; used super glue to hold the parts, then covered that with epoxy glue.

Gave it about ten open/close cycles. Doing OK so far.
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Old December 21st, 2012, 17:00   #5
outthere
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Thumbs up

Many thanks - found a used match online $50 later part arrived today. I hadnt thought to look at gasser's and other model years, duh.

This is from a '99 passat gasser. Hope to pop it in tomorrow AM.

Thanks again I appreciate the feedback!
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Old January 3rd, 2013, 19:18   #6
outthere
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Shout out to Tom's Foreign Auto Parts in CT. exact fit, color, and arrived in 36 hours from order for $49. tomsforeign.com
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