Fuel Flap won’t open …. E500 Cabrio A207

[PaulXC]

Took the E500 for an MOT yesterday and it failed.

The examiner couldn’t open the fuel flap to check the fuel cap seals OK, so he failed it on…

• Fuel cap/sealing device ineffective (6.1.3 (b) (i))

Last time I put fuel in it was fine but now it won’t open. I can hear a click noise when unlocking the car so I think the solenoid and pin assembly has jammed.

On my old CLS there was a remote release in the boot for the filler flap but I can’t find any evidence of one in the E500.

Does anyone have a parts diagram or disassembly procedure for getting at the rear of the filler neck? I think the solenoid should have some sort of manual release at the rear.

I currently have about 30 miles of fuel left in the car … I can call Merc Roadside Assistance and, in-fact the car is still under extended warranty for the next few months, but I won’t mind at least knowing how to fix it myself incase it happens again.

TIA

 

[johnsco]

Hi Paul.
I have a similar problem with the fuel flap actuator on my W203 Kompressor.
The car is quite different, but - You may find the comments in post #4 in this thread helpful:

W203 ... WDB 203742 ... C200 Kompressor Coupe ... Fuel Flap Actuator | Interior

It's time to fix this item which has never worked since I bought the car. I've tried spraying it a couple of times with WD40. It doesn't look like this is going to work. Searching thru the info on the web, it looks like this is the part - accessed from inside the boot lining on the right-hand...

forums.mbclub.co.uk

I'm still working my way thru some further tests.
J.

 

[PaulXC]

Have been looking at this again - I can't figure out how to get behind the trim panels to access the rear of the filler. Problem is there is loads of hood mechanism in that area and some of the trim panels sit under various stops and guides.

The Mobilio RAC man came out and he couldn't figure a way in either.

If anyone has an E Class Cabrio A207 or Coupe C207 pre facelift, and pre ad blue, could you post up a picture of the filler flap open showing where/how the lock mechanism engages? I'm wondering if I can get a plastic trim panel lever under the filler flap and push the mechanism to open it.

The RAC guy said he could force it open but as the car is still under extended warranty I didn't want him to do that. I can't get it into the main dealer for about a week.

Thanks

 

[johnsco]

If the mechanism is anything like either of my cars, (and I'm guessing it will be), then pushing the mechanism won't make it retract.
The rod that engages with the bracket on the flap is driven by a motor.
Pushing the rod does not make it turn the motor.
It may be driven via a worm gear or similar.
I guess that this is for security reasons.
You don't want someone to be able to insert a tool and open your fuel flap.
I would also like to know how to get at the actuator.

 

[zipdip]

In all the MOT's I have witnessed I have never seen the tester open the fuel flap,the only plus point I suppose is you know it does not open if you do not to want to use a tin opener then the main dealer is the only option left at least it is under warranty.

 

[whitenemesis]

Is there nothing in the owner's handbook on this? Usually there's a section on emergency procedures ..

ETA - apparently not, just says consult a qualified specialist workshop!

E-Class - Interactive Owner's Manual

moba.i.daimler.com

 

[geoffus]

If it helps this is a few pictures of mine.
It shows the pin comes in and out when locked.
I did have a problem with mine last year, it would not open at all, to release the flap it has to be pushed in and it releases. But on mine the spring loaded plunger didn't release the flap enough to open it, the lock was fine.
Despite hitting and pushing the flap it wouldn't protrude out so appeared to be still locked.
Simply prying the the flap with bit of rigid plastic would open it, it occasionally still gets stuck even though its treated to WD40 several times.

 

[johnsco]

The locking mechanism in the above photos is very-much the same as on my E280 and the C200.
The rod moves in and out of the "eye" in the flap.
Bad weather and my partner's use of the car has prevented me getting any further.
It must be accessed from inside the right-hand side of the boot.
But - it looks a messy job involving removal of the boot liner.

As on post #5 - I've never seen an MOT tester open the flap to check the tank cap.
...... although I can see why the tank cap is important.

 

[geoffus]

Are you sure the rod is not moving though, it may be as mine and just the flap sticking on the release spring, have a look on YouTube as seems common problem.

 

[PaulXC]

Is there nothing in the owner's handbook on this? Usually there's a section on emergency procedures ..

ETA - apparently not, just says consult a qualified specialist workshop!

E-Class - Interactive Owner's Manual

moba.i.daimler.com

I did eventually remember to RTFM, but nothing!

If it helps this is a few pictures of mine.
It shows the pin comes in and out when locked.
I did have a problem with mine last year, it would not open at all, to release the flap it has to be pushed in and it releases. But on mine the spring loaded plunger didn't release the flap enough to open it, the lock was fine.
Despite hitting and pushing the flap it wouldn't protrude out so appeared to be still locked.
Simply prying the the flap with bit of rigid plastic would open it, it occasionally still gets stuck even though its treated to WD40 several times.View attachment 122063View attachment 122064View attachment 122065

Very helpful picture - Cheers ! I'll have another go at it tomorrow and report back.

 

[PaulXC]

Are you sure the rod is not moving though, it may be as mine and just the flap sticking on the release spring, have a look on YouTube as seems common problem.

I can here it clicking when I lock or unlock the car but it doesn't sound strong enough.

 

[Gbrowncls55]

on my wifes SL the rod became a bit siezed and stopped it closing rather than opening. A few squirts of WD40 and its been fine for two years.

 

[PaulXC]

Well ... got it fixed by the main dealer under the extended warranty. Would have been £196 inc vat apparently, which included a new fuel cover flap - which is in the paint-shop so will be fitted next week - in the meantime they have gaffer-tapped the old one in place.

I also had new rear discs and pads and an MOT done at the same time. Stops really well now! They were cheaper than the local indie by nearly 20% on the pads and discs fitting. Very good service from LSH Auto Mercedes at Macclesfield.

Filled it with fuel and took it for a long blast, top down, over the Peak District today. A proper New Year's Day outing...

 

[Bobby Dazzler]

Well ... got it fixed by the main dealer under the extended warranty. Would have been £196 inc vat apparently, which included a new fuel cover flap - which is in the paint-shop so will be fitted next week - in the meantime they have gaffer-tapped the old one in place.

I also had new rear discs and pads and an MOT done at the same time. Stops really well now! They were cheaper than the local indie by nearly 20% on the pads and discs fitting. Very good service from LSH Auto Mercedes at Macclesfield.

Filled it with fuel and took it for a long blast, top down, over the Peak District today. A proper New Year's Day outing...

A month or so ago LSH said the same daily wasn’t covered on mine, and I had to pay, I think it was £212 on mine for the internal surround and release mechanism but they reused the painted flap and screw cap. An email to MBUK got £200 back in the form of a credit. I was delighted to see that kt wouldn’t open again yesterday…

 

[markjay]

Well ... got it fixed by the main dealer under the extended warranty. Would have been £196 inc vat apparently, which included a new fuel cover flap - which is in the paint-shop so will be fitted next week - in the meantime they have gaffer-tapped the old one in place.

I also had new rear discs and pads and an MOT done at the same time. Stops really well now! They were cheaper than the local indie by nearly 20% on the pads and discs fitting. Very good service from LSH Auto Mercedes at Macclesfield.

Filled it with fuel and took it for a long blast, top down, over the Peak District today. A proper New Year's Day outing...

You're lucky to have the extended warranty.

I think it's poor design if the only option is to force open the existing fuel flap and then replace it with a new one.....

 

[markjay]

In all the MOT's I have witnessed I have never seen the tester open the fuel flap,the only plus point I suppose is you know it does not open if you do not to want to use a tin opener then the main dealer is the only option left at least it is under warranty.

Never heard of that either, but it does make sense that it should be checked, because Diesel oil spillage when cornering with a full tank is a major hazard that has caused accidents before when other vehicles skidded on the slippery road.

 

[whitenemesis]

From the tester's manual
Refusal to test
g. A proper examination cannot be carried out because any door, tailgate, boot, engine cover, fuel cap or other device designed to be easily opened cannot be easily opened.
In which case the test isn't carried out and the fee refunded.

MOT inspection manual: cars and passenger vehicles - Introduction - Guidance - GOV.UK

Definitions, vehicle classes, reasons to refuse to test a vehicle, narrow track vehicles, historic vehicles and inspection procedures for car and passenger vehicle MOT tests.

www.gov.uk

The tester "should carry out appropriate pre-checks before starting the test, to ensure the suitability and general condition of the vehicle". He shouldn't have failed the car, just refuse to test it?

 

[Bobby Dazzler]

You're lucky to have the extended warranty.

I think it's poor design if the only option is to force open the existing fuel flap and then replace it with a new one.....

There’s no emergency release or access from the boot on my car. Mobilo pried it open with a trim tool - the sort used for removing interior trim.

Mobilo carry the mechanism as stock in their vans and replace them FOC at the roadside. From memory they would cost £12 plus fitting and VAT at the dealer.

Unfortunately replacing it didn’t work on mine and it had to have a new internal surround too which must be done at the main dealer.

 

[PaulXC]

From the tester's manual
Refusal to test
g. A proper examination cannot be carried out because any door, tailgate, boot, engine cover, fuel cap or other device designed to be easily opened cannot be easily opened.
In which case the test isn't carried out and the fee refunded.

MOT inspection manual: cars and passenger vehicles - Introduction - Guidance - GOV.UK

Definitions, vehicle classes, reasons to refuse to test a vehicle, narrow track vehicles, historic vehicles and inspection procedures for car and passenger vehicle MOT tests.

www.gov.uk

The tester "should carry out appropriate pre-checks before starting the test, to ensure the suitability and general condition of the vehicle". He shouldn't have failed the car, just refuse to test it?

The local garage who did the first MOT charged me for the fail, and quoted me more than the main dealer to do the discs and pads!