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shimon340 · Oct 7th, 2021, 20:58

Hello,

I'm having similar issues with a 2004 facelift S40 (X40).

The fuel filler flap is stuck shut (intermittently) as the solenoid rod / lock isn't moving when you unlock the car on the remote.

By folding the boot liner as per the pics (and as others have also said) you can access the aerial and this solenoid which moves the rod which locks the fuel filler flap/door. There's an elongated Z shape silver rod that connects between the solenoid and at the other end of this rod is the section that sticks out into the fuel filler hose area to lock the door. Due to the angle it's a bit difficult to photograph.

and an annotated pic showing the elongated Z shape rod a bit better

The problem I have is that when in the locked position, pulling on the silver rod e.g. on the vertical section fails to move it at all. However when (intermittent) the solenoid is pulled in / door lock rod open position and the rod isn't in position to hold the door closed, then one can pull on the vertical section of the rod and easily move it in and out, exposing the or retracting the end of the rod from the fuel filler area.

From others that have had this issue, the solenoid is easy to pull inwards from the locked to the open position? Doggone sounds like were able to easily move the solenoid? Was this on a mk1 (1997-2001) or a facelift (2001-2004) model?

I recall on the Mk1 or pre-facelift (1997-2001) S40s there was a removable rubber rectangle in the boot liner on the left side / fuel filler side. Behind this was a wire with a ring in the end that you could pull to retract the rod / solenoid. The access hole and cover is missing in the 2001-2004 facelift models it seems (as an aside as is the access holes for accessing the back of the light clusters to replace the bulbs). But as above folding the boot liner gives access though.

Have others found the whilst the solenoid can fail to move to the open position were you able or unable to be manually pulled it back from inside the boot? This one seems to stick in the outward / locked position and won't budge.

Also, there appears to be no obvious bolts etc holding the solenoid unit into the car from the inside.

Cover is now stuck shut again but might it be these two screws to the right side of the fuel filler pipe be the ones that hold the solenoid unit in?

Thanks

Oct 7th, 2021, 20:58	#6
shimon340 Senior Member Last Online: Mar 2nd, 2023 14:47 Join Date: May 2006 Location: Manchester	Hello, I'm having similar issues with a 2004 facelift S40 (X40). The fuel filler flap is stuck shut (intermittently) as the solenoid rod / lock isn't moving when you unlock the car on the remote. By folding the boot liner as per the pics (and as others have also said) you can access the aerial and this solenoid which moves the rod which locks the fuel filler flap/door. There's an elongated Z shape silver rod that connects between the solenoid and at the other end of this rod is the section that sticks out into the fuel filler hose area to lock the door. Due to the angle it's a bit difficult to photograph. and an annotated pic showing the elongated Z shape rod a bit better The problem I have is that when in the locked position, pulling on the silver rod e.g. on the vertical section fails to move it at all. However when (intermittent) the solenoid is pulled in / door lock rod open position and the rod isn't in position to hold the door closed, then one can pull on the vertical section of the rod and easily move it in and out, exposing the or retracting the end of the rod from the fuel filler area. From others that have had this issue, the solenoid is easy to pull inwards from the locked to the open position? Doggone sounds like were able to easily move the solenoid? Was this on a mk1 (1997-2001) or a facelift (2001-2004) model? I recall on the Mk1 or pre-facelift (1997-2001) S40s there was a removable rubber rectangle in the boot liner on the left side / fuel filler side. Behind this was a wire with a ring in the end that you could pull to retract the rod / solenoid. The access hole and cover is missing in the 2001-2004 facelift models it seems (as an aside as is the access holes for accessing the back of the light clusters to replace the bulbs). But as above folding the boot liner gives access though. Have others found the whilst the solenoid can fail to move to the open position were you able or unable to be manually pulled it back from inside the boot? This one seems to stick in the outward / locked position and won't budge. Also, there appears to be no obvious bolts etc holding the solenoid unit into the car from the inside. Cover is now stuck shut again but might it be these two screws to the right side of the fuel filler pipe be the ones that hold the solenoid unit in? Thanks