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Thread: Can't unlock gas cap door

  1. #1
    Join Date
    Oct 2007
    Posts
    2

    Default Can't unlock gas cap door

    I have a 2001 Volvo XC70 - can't get gas cap door opened. Lock will not release. Fuses OK. Locked and unlocked doors with key and key fob - filler door still locked. All doors and tailgate lock and unlock OK. Pulled right rear interior panel off - got hand on lock mechanism but black plastic latch will not move or slide back. Wire connection on lock mechanism seems OK.

    How can I get the door open ? The car needs gas and my wife is planning on going out of town tomorrow with kids. I know a crow bar will ultimately work, but will do alot of damage !!!!

    Any thoughts would be greatly appreciated !!!!

  2. #2
    Join Date
    Jan 2008
    Location
    Arlington/Newport News, VA
    Posts
    929

    Default

    I know there is an emergency release lever but i don't know where it is. Sorry, but i just wanted to make sure you wouldn't crowbar it lol

    '05 XC70
    -Pioneer Avic F700bt headunit
    -12 inch Alpine Type R Sub
    -Flat Black Pegs
    -Custom Tinted Windows
    -Custom Mesh Grille
    -OBX Catback Exhaust
    -IPD Silicone Hoses

  3. #3
    Join Date
    Sep 2002
    Location
    Belgium
    Posts
    2,103

    Default

    Quote Originally Posted by n00bkiller944 View Post
    I know there is an emergency release lever but i don't know where it is. Sorry, but i just wanted to make sure you wouldn't crowbar it lol
    That must be a well kept secret, never heard about it.
    If it is there, I would certainly like to know where
    Willy
    144 GL (1974)--->244 GL (1982)--->940 GLE 2.3i (1992)--->XC70 2.5T (2004)

  4. #4
    Join Date
    Jun 2008
    Location
    Southeast Wisconsin, USA
    Posts
    60

    Default

    I found this in my MY04 owner's manual:
    NOTE: If the fuel filler door does not unlock after the button has been pressed, drive the car at a speed
    of at least 5 mph (8 km/h), stop the car, and press the button again.
    Vehicles I have owned in the past (no Volvos) always had a manual emergency release for the filler door.

  5. #5
    Join Date
    Jan 2008
    Location
    Northern Alberta
    Posts
    115

    Default

    You don't mention where you are but in the past I have had trouble with frozen fuel doors after a combination of a carwash and freezing temperatures.
    Just a thought.
    Colin
    Kinuso, Alberta
    Canada
    2004 XC70 25T, Ruby Red
    2002 V40 (Wife's)
    2001 Nissan X-terra
    2006 Suzuki V-Strom


  6. #6
    Join Date
    Jun 2003
    Location
    South Lake Tahoe, CA
    Posts
    604

    Default

    This is a well discussed problem. Look here for four pages of discussion and two solutions.

    http://www.volvoxc.com/forums/showth...light=gas+door

    One solution involves pressing of the car next to the door and unlocking the car with the remote and the other is getting to the back of the door and pressing the plunger in.

    Good luck.
    Wait Griswold
    2003 XC70
    South Lake Tahoe, CA

  7. #7
    Join Date
    Sep 2002
    Location
    Belgium
    Posts
    2,103

    Default

    No emergency button or procedure reported until now!
    This problem makes me wonder if it worth having a lockable fuel filler door.
    Suppose it won't unlock when you are travelling and need to fill up urgently
    Perhaps it is better to have a lock on the filler cap instead (the locking lip from
    the door can be amputated easily, but are there still caps with a lock available these days?)
    Just a thought, please don't rush out and do it (yet)
    Willy
    144 GL (1974)--->244 GL (1982)--->940 GLE 2.3i (1992)--->XC70 2.5T (2004)

  8. #8
    Join Date
    Jan 2008
    Location
    Arlington/Newport News, VA
    Posts
    929

    Default

    Okay, maybe I am a liar... I thought you could just reach around and push the plunger out?

    '05 XC70
    -Pioneer Avic F700bt headunit
    -12 inch Alpine Type R Sub
    -Flat Black Pegs
    -Custom Tinted Windows
    -Custom Mesh Grille
    -OBX Catback Exhaust
    -IPD Silicone Hoses

  9. #9
    Join Date
    Oct 2007
    Posts
    2

    Default Gas filler door update

    Thanks for all the responses. As I mentioned, I could not move the plunger rod back with my fingers. So I removed the outer interior panel - one bolt at seat belt retractor. Then removed inner panel.

    I tapped lock actuator housing with screwdriver handle while hitting unlock button on remote and BINGO it unlocked. I removed both screws next to gas cap under filler door and removed actuator/bracket.

    After removing actuator from bracket, I took 3 screws off actuator housing and exposed motor and gear/rod assembly. Very simple stuff (looks like stuff I made with my Erector set 40 years ago - and Volvo gets $100). Everything looked good. But for good measure I relubed all gears and shafts with WD40 and lithium grease.

    Reinstalled everything and it all works. There was no cable or magic release button. But I was able to fix it with simple tools in had it done in 30 minutes.

    Unfortunately, I am sure many people have had to go to dealer for emergency repair. Just another example of overengineering that the new Volvos fall victim to. I wish they would simplify these cars.

    Here's a diagram of the part from www.alldatadiy.com
    Attached Thumbnails Attached Thumbnails FillerDoorLock.gif  

  10. #10
    Join Date
    Sep 2002
    Location
    Belgium
    Posts
    2,103

    Default

    Quote Originally Posted by n00bkiller944 View Post
    Okay, maybe I am a liar... I thought you could just reach around and push the plunger out?
    I had sincerely hoped you were right about the emergency release
    Willy
    144 GL (1974)--->244 GL (1982)--->940 GLE 2.3i (1992)--->XC70 2.5T (2004)

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