Passat (B5) :: 2002 - Fuel Door Would Not Open / Actuator Replacement?


Apr 24, 2013

2002 Passat Wagon. My fuel door wouldn't open last week. Did some reading here, and found that I could manually push in the plunger to pop my door open. Great! Now I could fuel the car. I'm a bit bummed that there's no cable or some other way to manually actuate the motor. Maybe I missed it? I had to open the right cargo door and reach in and around a plastic tray to pull open the door.

Anyway, I grabbed the multi-meter, and tested the harness, while I had a buddy pull the switch. I'm getting 12v when the switch is pulled. OK, so that means the actuator is bad.

I need to remove and reinstall a new actuator. I'm not quite sure how to get enough access to get at the mounting bolts for the actuator. I assume I need to remove interior trim and molding to get at it, but I'm not sure how to do that.

The access door on the right side of the cargo bay allowed me to get my hands in there to pull the door open, and to unplug the harness, but I'm going to need to pull apart interior stuff to get at the motor.

Any pictures or directions on how to disassemble the interior trim to get at this motor?

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After a few tries the lock tab chatters but the door still does not open. What could be wrong? As far as i know i put it back together, like i took it out.

How to take the panel off from inside then i can atleast get to the two wires that go to the lock and see if i can open the door to take the actuator out once again.

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The front passenger door also did not lock under any circumstance.

Took it into Toyota, they absolutely screwed me I now realize, $900 to replace a door actuator in that passenger door.

Worked fine for a few weeks. Then all of a sudden, problem started again. Just like last time, slowly slowly over the course of 2 months, it got worse and worse until today I could not open the driver side front or rear door at all.

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Does the lock system of the fuel door is different in G7 than in previous models?

How can I reach from inside the trunk to manual release the lock and check the motor is working?

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Anyway I plugged everything back in and now the trunk won't release either from the Keyfob, or from the interior. The fuel door also won't release either and I've already tried the Valet button to no effect. I'm wondering if the computer that handles the trunk or whatnot got deactivated from the other computers and is no longer talking to it or something to that effect. I'm hoping I just blew a fuse but otherwise I just don't know how to proceed from here. It sucks this car has no way to open the trunk with a key, I think that was a huge oversight. I also cannot open the trunk by opening the pass through because the internal trunk release cable was broken by my dad several years ago and was never repaired.

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