I have just bought a 2003 S60T, and it's annual car test is due at the end of April. The locking petrol cap has the remains of a key in it, is it the same as the ignition key? I will probably have to sort this one way or the other as fuel tank security is taken very seriously in Ireland.

 

is the car test about the security of the gas cap or about the way the gas cap seals the tank to allow the emissions systems to function properly? In the US, our testing does check the gas cap, but for its seal as that relates to how the EVAP system works (a loose gas cap can create a check engine code on many cars too). Inspect the rubber gasket and it if appears to be in good shape, you should be fine If its torn or damaged, you can replace. As to the key & lock, you may be able to remove the lock cylinder and fish out the old part - it should work with the ignition key or buy a replacement tumbler with a new key.

 

A decent locksmith should be able to solve this in 10 minutes.

 

Thanks MT, I think the security of the fuel is important so that rioters don't get fuel for Molotov cocktails, or set fire to your car with a rag. When you have a car with a remote control for the petrol cap cover, they insist that this works properly. Of course the tank seal is important as part of the emissions control. Thanks for both replies, there is an Auto locksmith two miles from me, or I could by a cap and key from a breakers so I have options.