Mk4 fuel filler flap problem.

[GeoffW]

Has anyone had a problem or failure of the petrol flap locking mechanism? On ours, the plastic moulding on the inside of the flap has started to break, which makes opening the flap difficult. And before anyone says it, there's no sign that it has been forced. New plastic part on order - Honda dealer tried to say it is "wear and tear", claiming it's not a mechanical failure"! Still in warranty - prepare for battle!

[Jazzik]

In answer to your question: No, we did not have a problem or failure of the petrol flap locking mechanism (so far ).

And in case it will not be necessary to prepare for any "battle". I am 100% convinced that our (top) dealer will not start any discussion about "wear and tear", "mechanical failure" and warranty or not.

[Lincolnshire Rambler]

Hiya ! I don’t think wear and tear even comes into its. Look at your mileage of your jazz and divide it by 400 miles- that’s the number of times it’s been refilled .. your dealer should be happy to sort as Honda will reimburse them -it’s not out of their pocket unless they take longer than Honda will pay them for the work. ??  So far I have had no issues with my jazz but I don’t feel my Honda dealer would try that on with any customer!!

[Beaver]

Should it happen to mine, the dealer will be presented with a printout showing the dates, mileage, location, quantities and costs of each refuelling on my car.  Allowing also for one opening each month for cleaning, this will give an (almost) accurate illustration of how many times my filler cap has been operated.

[Lord Voltermore]

Sometimes 'wear and tear' is a polite way of saying 'we think you broke it by misuse '- ie someone tried to open the flap  by pulling, not by pressing it  in  until it pops open as is intended in the design.

Assuming the damage  is to the plastic catch on the inside of metal flap that engages the T stalk thingie  I can see why they have doubts that it failed because of a design fault/manufacturing defect.  (no offence intended to the  original poster)   On my car the mechanical action involved seems quite gentle and the plastic fitting looks up to the job. Its possibly designed to be a fail safe weakest point  to minimise more expensive damage to the flap/bodywork if someone does effectively put  force the flap, either by mistake, or as a criminal.   

I think most manufacturers would regard  replacement in these circumstances being outside the terms of warranty. - specifically   misuse or the result of crime  rather than 'fair wear and tear  to be expected on some parts over a reasonable space of time.  parts where  its to be expected over time.  to be expected on oving ppartsEither as due to misuse or the result of a crime, rather than fair wear and tear due to frequent use or expected old age.  But they may replace it as a goodwill gesture or may acknowledge there is a design fault.

[GeoffW]

It's being replaced under the warranty. The warranty states that the car will be "free from material and manufacturing defects for 3 years". It's a material defect. What I found annoying was the automatic "try on" of claiming it was wear and tear, and wasn't even a mechanical defect. All for a £6 part. Everyone knew it was a warranty matter. Anyway - problem solved now.

[GeoffW]

UPDATE! I now realise the plastic block on the flap was probably broken when we bought the car in February. Prbably because the flap wouldn't open for the previous owner (or garage). I also realised after speaking to my wife and son that the fuel flap wasn't ever locked when the doors were locked, and would on occasion lock itself when the doors were unlocked! This happened when my wife went to buy petrol and had difficulty opening the flap to refuel - even with the doors unlocked. When needing to refuel last week the flap wouldn't open no matter what we did. It did however open enough to get my fingers in and manipulate the mechanism, which broke the new plastic block - but at least we could then refuel to get home. It would also do strange things like springing open when you unlocked the doors - even though it wasn't locked!
It appears the actuator for the locking mechanism was faulty. It was replaced today under warranty and seems OK now.
It woudln't necessarily have helped us, but there is a page in the handbook which tells you how to remove a plastic panel in the boot to access a manual release for the flap.