HOWTO replace the charge flap
Posted: Sat Jul 23, 2022 10:38 am
Because it sticks out, potentially for hours whilst charging, a snapped off charge flap isn’t uncommon on many EVs. This is how to replace it on the Enyaq if the hinge gets broken.
The charge flap assembly is in two parts, the painted rectangular flap and the black plastic unit that surrounds the socket and includes the hinge and bit the flap fits into.
Time needed: about 15 minutes
Cost: £52.72 (for the black plastic unit)
Part number: 5L9. 809.702
Tools needed: small flat blade screwdriver, Torx T15 driver
1. The unit is held to the bodywork by four plastic clips. If you look at the corners you’ll see an indentation about 4mm x 2mm. Punch through these with a small screwdriver. Have a look at your new part and you’ll see the clips behind these blanked off holes.
2. Angle the screwdriver so that you can push the clip down whilst gently pulling the unit. The clips are easy to break so you may end up having to rip them off with the screwdriver.
3. The end furthest from the hinge needs to come out first (as the hinge sits behind the bodywork). So release (or break) all four clips then gently pull at the lock end until it comes free.
4. As you pull the unit out, release the rubber seal from round the socket. You can use a small screwdriver to free it.
5. Pull the unit to left and out of the car. Once it’s loose, disconnect the drain hose and wiring plus to the lock and LED module. Also unclip the CCS cover rubber strap if you haven’t already.
6. Remove the unit and take to a bench with your new unit.
7. With a Torx driver remove the lock and LED modules and transfer them to the new unit. Also transfer the plastic post the CCS rubber strap fits on. There are two tiny clips on the reverse you can press in to release it.
8. To remove the body coloured flap from the remains of the outer part, lift the tab by the socket cover and slide it off.
9. Slide the flap onto the new unit. Now you’re ready to fit it back on the car.
10. Push the drain tube back into the rubber grommet and plug the wiring to the modules back in.
11. Slide the hinge end under the bodywork and line up the clips with the holes. Then push the unit into place.
12. Finally push the rubber seal back under the lip of the socket and reattach the CCS cover rubber strap.
The charge flap assembly is in two parts, the painted rectangular flap and the black plastic unit that surrounds the socket and includes the hinge and bit the flap fits into.
Time needed: about 15 minutes
Cost: £52.72 (for the black plastic unit)
Part number: 5L9. 809.702
Tools needed: small flat blade screwdriver, Torx T15 driver
1. The unit is held to the bodywork by four plastic clips. If you look at the corners you’ll see an indentation about 4mm x 2mm. Punch through these with a small screwdriver. Have a look at your new part and you’ll see the clips behind these blanked off holes.
2. Angle the screwdriver so that you can push the clip down whilst gently pulling the unit. The clips are easy to break so you may end up having to rip them off with the screwdriver.
3. The end furthest from the hinge needs to come out first (as the hinge sits behind the bodywork). So release (or break) all four clips then gently pull at the lock end until it comes free.
4. As you pull the unit out, release the rubber seal from round the socket. You can use a small screwdriver to free it.
5. Pull the unit to left and out of the car. Once it’s loose, disconnect the drain hose and wiring plus to the lock and LED module. Also unclip the CCS cover rubber strap if you haven’t already.
6. Remove the unit and take to a bench with your new unit.
7. With a Torx driver remove the lock and LED modules and transfer them to the new unit. Also transfer the plastic post the CCS rubber strap fits on. There are two tiny clips on the reverse you can press in to release it.
8. To remove the body coloured flap from the remains of the outer part, lift the tab by the socket cover and slide it off.
9. Slide the flap onto the new unit. Now you’re ready to fit it back on the car.
10. Push the drain tube back into the rubber grommet and plug the wiring to the modules back in.
11. Slide the hinge end under the bodywork and line up the clips with the holes. Then push the unit into place.
12. Finally push the rubber seal back under the lip of the socket and reattach the CCS cover rubber strap.