I had this problem last year, and after trying all the various fixes on this site, I took off the inner panel and still could not retract the plunger. I had to cut the plunger to remove the mechanism, and upon disassembly, found that a tiny plastic gear tooth had broken off and jammed up the mechanism.
I put a piece of electrical tape with a slit in it over the hole in the body to minimize water entry and to hold onto the filler door tab. In 10 months the door has never come open.
Overly complicated design.
'04 XC70 (petrol/auto), Nautic Blue / Graphite, Premium, Touring, Boosters, Xenia Wheels w/235x60 Nokian WR's (wife's kid-hauler)
'09 C70 retractable hard top convertible. Red with black interior.
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