Fuel Filler Flap

Discuss the 406's Bodywork stuff in here (what parts fit what, what can be interchanged with what etc etc).

Moderator: Moderators

User avatar
jonsowman
3.0 24v
Posts: 1705
Joined: Wed Sep 21, 2011 4:19 pm
Location: Surrey, UK (J9 M25)

Fuel Filler Flap

Post by jonsowman » Thu Apr 26, 2012 10:15 pm

So after having the usual "broken spring" problem, I used the ingenious solution of a clothes peg spring on my fuel filler flap. Unfortunately it looks like the spring was a bit too strong, and another of the hingepin holes on the flap has snapped off, leaving only one, which is rather too little to hold the flap on securely.

So question is, what do I do? Should I bother trying to glue the hinge piece back onto the flap? Servicebox gives me a part number 1517 A4. If I can get a flap from a scrap car, how hard is it to paint it? I assume I'd need to remove the old paint, then a coat of plastic primer and several coats of colour (Regency Red - P0JZ)?

Other thing is, are the D8 and D9 flaps interchangeable? Are they exactly the same or did Pug see fit to reinforce these pieces of plastic?
Image
2002 V6 SE Coupé (210bhp) - (Aegean Blue)
2002 D9 2.2 HDi Exec Estate - Samarkand Blue
PM me for PP2000 diagnostics around Surrey

scotty73
3.0 24v
Posts: 2579
Joined: Mon Jan 16, 2012 1:38 pm
Location: Rhymney, south Wales.

Re: Fuel Filler Flap

Post by scotty73 » Thu Apr 26, 2012 10:57 pm

My flap wont open unless someone pulls up on the release catch by the seat while i open the flap (oh err misses) :lol:
So now i open the back door and pull on the piece of rope i tied around the catch... is this the same kind of problem?
2000 W 2.0hdi 110 7 seat estate Blue.
Image

Image
And this glue is for my submarine not for putting up you're f*c*ing noses, and dont think i dont notice cos i do... Buy your own f*c*ing glue!!! Fatty Lewis Twin town 1997.

User avatar
jonsowman
3.0 24v
Posts: 1705
Joined: Wed Sep 21, 2011 4:19 pm
Location: Surrey, UK (J9 M25)

Re: Fuel Filler Flap

Post by jonsowman » Thu Apr 26, 2012 11:40 pm

Yeah, you pull the release lever and it doesn't open. Someone invented a clever solution of inserting a clothes peg spring over the hingepin to sort this out.

Unfortunately it's caused the plastic piece on the flap to break :(
Image
2002 V6 SE Coupé (210bhp) - (Aegean Blue)
2002 D9 2.2 HDi Exec Estate - Samarkand Blue
PM me for PP2000 diagnostics around Surrey

User avatar
lozz
3.0 24v
Posts: 11912
Joined: Thu Oct 07, 2010 10:18 pm
Location: where-ever

Re: Fuel Filler Flap

Post by lozz » Thu Apr 26, 2012 11:46 pm

glue it back on, 8)

User avatar
jonsowman
3.0 24v
Posts: 1705
Joined: Wed Sep 21, 2011 4:19 pm
Location: Surrey, UK (J9 M25)

Re: Fuel Filler Flap

Post by jonsowman » Thu Apr 26, 2012 11:50 pm

lozz wrote:glue it back on, 8)
Ta, I thought this might be the answer.

How do you get the hingepin out? I managed to slide it up to get the spring on. But I can't see how to push it up far enough to remove the flap?
Image
2002 V6 SE Coupé (210bhp) - (Aegean Blue)
2002 D9 2.2 HDi Exec Estate - Samarkand Blue
PM me for PP2000 diagnostics around Surrey

User avatar
lozz
3.0 24v
Posts: 11912
Joined: Thu Oct 07, 2010 10:18 pm
Location: where-ever

Re: Fuel Filler Flap

Post by lozz » Thu Apr 26, 2012 11:56 pm

if you glueing it back on id use Quik Steel putty, you can Mold it to any shape you want,
B&q or motorists shops sell it, very handy stuff,
Last edited by lozz on Thu Apr 26, 2012 11:59 pm, edited 1 time in total.

User avatar
lozz
3.0 24v
Posts: 11912
Joined: Thu Oct 07, 2010 10:18 pm
Location: where-ever

Re: Fuel Filler Flap

Post by lozz » Thu Apr 26, 2012 11:58 pm


scotty73
3.0 24v
Posts: 2579
Joined: Mon Jan 16, 2012 1:38 pm
Location: Rhymney, south Wales.

Re: Fuel Filler Flap

Post by scotty73 » Fri Apr 27, 2012 1:02 am

jonsowman wrote:Yeah, you pull the release lever and it doesn't open. Someone invented a clever solution of inserting a clothes peg spring over the hingepin to sort this out.

Unfortunately it's caused the plastic piece on the flap to break :(
Sounds like i'm better off sticking to my method for now then?
2000 W 2.0hdi 110 7 seat estate Blue.
Image

Image
And this glue is for my submarine not for putting up you're f*c*ing noses, and dont think i dont notice cos i do... Buy your own f*c*ing glue!!! Fatty Lewis Twin town 1997.

omega
3.0 24v
Posts: 1745
Joined: Wed Dec 31, 2008 1:25 am
Location: nottingham

Re: Fuel Filler Flap

Post by omega » Fri Apr 27, 2012 8:37 am

the spring is simple and works and its cheap
all you need to do is slacken off the self tapping screw thats in the bottom left hand corner[as you open the flap] slide spring in behind it tighten screw.
30sec job

User avatar
waue1978
HDi don't believe it!
Posts: 2341
Joined: Fri Jan 29, 2010 2:56 pm
Location: Andover, Hampshire

Re: Fuel Filler Flap

Post by waue1978 » Fri Apr 27, 2012 9:39 am

scotty73 wrote:
jonsowman wrote:Yeah, you pull the release lever and it doesn't open. Someone invented a clever solution of inserting a clothes peg spring over the hingepin to sort this out.

Unfortunately it's caused the plastic piece on the flap to break :(
Sounds like i'm better off sticking to my method for now then?
Is this how you fixed your spring?

Image

Mine never gave any bother after I did it. Spring doesn't have to be too strong as it only needs to just nudge the flap out enough to grab & the flap is only a flimsy bit of plastic.
2000/X Peugeot 406 110 HDi LX Family 93k to 2000/W BMW 530D SE Auto 84k to 2003/03 Peugeot Partner Hdi Escapade 98k to 2003/53 Vauxhall Zafira DTi Elegance 74k

Image

User avatar
jonsowman
3.0 24v
Posts: 1705
Joined: Wed Sep 21, 2011 4:19 pm
Location: Surrey, UK (J9 M25)

Re: Fuel Filler Flap

Post by jonsowman » Fri Apr 27, 2012 9:44 am

Yes indeed waue.

In the image below, piece 1 snapped off a long time ago. Piece 2 snapped off yesterday only leaving the top one, which doesn't really hold the flap on very firmly.

Also the reinforcing bits (circled) don't exist on my car, I assume that picture is from a D9? This seems to be some Peugeot added when they realised reinforcement was required.

Image
Image
2002 V6 SE Coupé (210bhp) - (Aegean Blue)
2002 D9 2.2 HDi Exec Estate - Samarkand Blue
PM me for PP2000 diagnostics around Surrey

User avatar
waue1978
HDi don't believe it!
Posts: 2341
Joined: Fri Jan 29, 2010 2:56 pm
Location: Andover, Hampshire

Re: Fuel Filler Flap

Post by waue1978 » Fri Apr 27, 2012 9:59 am

jonsowman wrote:Yes indeed waue.

In the image below, piece 1 snapped off a long time ago. Piece 2 snapped off yesterday only leaving the top one, which doesn't really hold the flap on very firmly.

Also the reinforcing bits (circled) don't exist on my car, I assume that picture is from a D9?
That was from my car, so yes.
jonsowman wrote: This seems to be some Peugeot added when they realised reinforcement was required.
Really? Pity they didn't reinforce the bit that bloody broke. There does seem to be a school of thought that believes it is caused by diesel spillage as petrol models rarely suffer this problem.
2000/X Peugeot 406 110 HDi LX Family 93k to 2000/W BMW 530D SE Auto 84k to 2003/03 Peugeot Partner Hdi Escapade 98k to 2003/53 Vauxhall Zafira DTi Elegance 74k

Image

User avatar
jonsowman
3.0 24v
Posts: 1705
Joined: Wed Sep 21, 2011 4:19 pm
Location: Surrey, UK (J9 M25)

Re: Fuel Filler Flap

Post by jonsowman » Fri Apr 27, 2012 10:06 am

waue1978 wrote:
That was from my car, so yes.

Really? Pity they didn't reinforce the bit that bloody broke. There does seem to be a school of thought that believes it is caused by diesel spillage as petrol models rarely suffer this problem.
Yes, those reinforcing struts definitely do not exist on my car. Interestingly the ServiceBox part numbers for the D8 and D9 diesel fuel flaps are the same. So who knows what's going on there.

You could be onto something with the diesel theory, although I try and be careful not to spill any, I suppose it is inevitable.

Any ideas on removing the flap completely so I can glue bits back together?
Image
2002 V6 SE Coupé (210bhp) - (Aegean Blue)
2002 D9 2.2 HDi Exec Estate - Samarkand Blue
PM me for PP2000 diagnostics around Surrey

gumby6371
3.0 24v
Posts: 1638
Joined: Thu Jan 28, 2010 10:01 pm
Location: Telford

Re: Fuel Filler Flap

Post by gumby6371 » Fri Apr 27, 2012 10:31 am

Can't help on removing the flap to swap/repair it, I'd take a guess that the whole filler tube assembly would need to come out due to the hinge pin not clearing the surrounding bodywork.
When I did both my D8's I pushed the hinge pin up an inch and hooked the clothes peg spring under the pin and pushed it back down. You do have to ease the stopper in at the top of the pin while pushing the pin up with some thin pliers but it works fine.
You get just enough tension on the spring to open the flap.
1996 1.9 TD LX (Gone but not forgotten)
2003 2.2 HDI SE

scotty73
3.0 24v
Posts: 2579
Joined: Mon Jan 16, 2012 1:38 pm
Location: Rhymney, south Wales.

Re: Fuel Filler Flap

Post by scotty73 » Fri Apr 27, 2012 10:54 am

Ah i see where your going on this now bloody genius idea, Is off out the garden am sure theres an old broken peg at the end of my line. :lol:
2000 W 2.0hdi 110 7 seat estate Blue.
Image

Image
And this glue is for my submarine not for putting up you're f*c*ing noses, and dont think i dont notice cos i do... Buy your own f*c*ing glue!!! Fatty Lewis Twin town 1997.

Post Reply