Broken Fuel Door Actuator Pin DIY Fix (2011 BMW X5/E70)

[SpaceGrey_E70]

Hello all, this is my first post on the forum.

When I bought my X5 the previous owner had broken the actuator pin for locking the fuel door (probably trying to force it open). I've seen other posts about how to remove it, replace it, etc. but I didn't want to spend the $284 that my BMW quoted me nor buy a replacement part for $30-40, so I tried to fix it myself.

Mine broke flush where it would poke out of in the gas cap area, I figured I could just extend the locking pin quite easily.

To do this I took an aluminum bracket hanger and cut off the long straight part (the portion where my index finger is touching in the picture below).



Once I had a straight piece I put it into the fuel door where it slides into to lock and marked how much length I needed to add onto the broken locking pin.

Next I Gorilla glued my piece onto my original locking pin, overhanging it the amount that I had just measured. The way it currently stands in the photo below the black part of the original unit would hit/interfere when sliding back and forth, so next thing I did was cut more off the black tip.




Close up of last photo.



I cut about 13/16" more so that this piece wouldn't interfere later when it sides back and forth (see below).



The video below shows where the actuator is located (behind the fuse box in the right rear of the vehicle). You only need to remove 3 screws to get the fuse box out of the way. Then loosen 2 screws on the actuator behind the fuse box to slide out the actuator (there will also be an electrical plug to undo in order to remove the actuator. I took the video mainly to show the unit sliding back and forth without any interference, if I hadn't cut more off the black tip it would hit before the aluminum rod was fully inserted into the locking position.

This last video shows everything working as normal. I'm thinking this should hold up quite well and be as strong as the original plastic locking pin.

[NorthCountryGuy]

Strong work SpaceGrey.
I’ve done a few original fixes to keep my 87 S4 functioning as stock.
Welcome to the Forum.

[Lviv777]

Great DIY, hopefully I will never need it but good to have!

[shark715]

Thanks for posting!