Snapped charging port flap hinge on 2022 ZS EV

[Lovemyev]

If a 3D stronger hinge could be produced at a reasonable price point, then this could turn out to be a nice little side line for somebody .

 

[TrevC]

Hello there folks. Ive had my ZS EV since Mar'23 and on the whole a positive experience, I love EV technology and the MG does a good job 12k miles in, given new only £23K pre-reg with 25miles. So firstly a big thank you to Smallbr for his recommendation of specific plastic glue. Same problem, same reason and 3 weeks in after the repair, the door is holding, but I'm realistic to think that winter may weaken the repair and I'm back to the need for a new door. So quote (Sep'25) from Richmonds MG 'Door-Asm-Chrg 10882591' is £160.36+VAT, so not the end of the world, but feel I have enough experience to have a go at fitting the new door myself so the bill doesn't end up at +£400-500. I've scoured the internet for a guide to removal & replacement of the charging port door, but nothing yet. I did see the post with a whole load of MG manuals but sadly the ZS11E section only had two files and neither what I needed. I could buy the whole Service Manual online but at the moment seems overkill!. Has anyone already done this job and have any advise/suggestions please? Thanks Trevor

 

[Lovemyev]

I am pretty sure that one of the forum members has access to the work shop manual and should be able to help you out.
My understanding is the hinge assembly is only held in place with four 10mm bolts I think.
Less than five minutes to replace, but unfortunately to gain access to the bolts, the whole front bumper cover needs removing !.
Probably a couple of hours of worth of work to get it remove for the first time, some plastic pry tools maybe needed to release some of the bumper tabs / clips.
An extra pair of hands will be very handy to lift the bumper cover free of the car.
Please let us know how it goes if you decide to go ahead, photos would be brilliant .

 

[TrevC]

I am pretty sure that one of the form members has access to the work shop manual and should be able to help you out.
My understanding is the hinge assembly is only held in place with four 10mm bolts I think.
Less than five minutes to replace, but unfortunately to gain access to the bolts, the whole front bumper cover needs removing !.
Probably a couple of hours of worth of work to get it remove for the first time, some plastic pry tools maybe needed to release some of the bumper tabs / clips.
An extra pair of hands will be very handy to lift the bumper cover free of the car.
Please let us know how it goes if you decide to go ahead, photos would be brilliant .

Thank you Lovemyev for the response. Can I just check, I'm a 2023 model ZS EV. Does the 'hinge assembly is only held in place with four 10mm bolts' still apply? I had thought that was the case with the Mk1 ZS EV with the front centre charge port, but didn't realise that was the case with the Mk2 as just not seen anything/drawings to confirm. Yes the Bumper cover coming off makes complete sense. It's these darn 're-usable' clips that are the headache as they so often break or have to be broken to get panels off. If any member did have some drawings to confirm that would be helpful. Thanks again.

 

[Lovemyev]

Thank you Lovemyev for the response. Can I just check, I'm a 2023 model ZS EV. Does the 'hinge assembly is only held in place with four 10mm bolts' still apply? I had thought that was the case with the Mk1 ZS EV with the front centre charge port, but didn't realise that was the case with the Mk2 as just not seen anything/drawings to confirm. Yes the Bumper cover coming off makes complete sense. It's these darn 're-usable' clips that are the headache as they so often break or have to be broken to get panels off. If any member did have some drawings to confirm that would be helpful. Thanks again.

Yeah - The charge port door hinge assembly, is attached to the frame via 4 bolts.
I think they are 10mm but I am not 100% sure.
It is a mounting base plate, with the hinged door attached to it.
You will reuse your body coloured external front cover, so you will need to switch it over.
It just slides off I believe ?.
I have a photo of the new hinge assembly somewhere and I have been trying to find it for you.
The part number of this assembly has been super seeded a few times and so as the price !.
It’s the same part, but each time they change the part number, the price appears to increase as well !.
The initial price of this assembly was ( wait for it ) £35.00 - Yes £35.00 !.
Then as parts started to move, the price rocketed up.
It appears to be a similar situation tbh.
When MG first released the spacesaver kit for the ZS EV it was less than £200.
It did not stay at this price long though.
Update !.
I have managed to find a couple of photos that does show how the mounting plate bolts to the frame and a photo of the assembly that you are like to receive.
It also shows the failure point on the original hinge.