Damn gas tank cover!!

[ANMS4]

Just venting. I've had my A6 for about 4 months and the damn cover has been frozen closed, 5 times!!! Today the cheap plastic cord finally broke off, I had to pry the cover open to get gas. Is there an updated part for this or do I just have to deal with this always getting stuck. [evilmad][evilmad]

[mintytoo]

Just venting. I've had my A6 for about 4 months and the damn cover has been frozen closed, 5 times!!! Today the cheap plastic cord finally broke off, I had to pry the cover open to get gas. Is there an updated part for this or do I just have to deal with this always getting stuck. [evilmad][evilmad]It's the actuator mechanism, you can try wd40 into the piston that twists as it goes into the gas door and there's also a replacement that you can diy

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[gk1]

There is indeed an updated actuator. (It is a common failure.) (It would have been covered by warranty.)
4L0862153D ~$30 (This is the 4th or 5th revision.)

I think it also recommends replacing the filler housing according to spec, but may not necessarily be required.
4G0809906C ~$60

[ANMS4]

^^^ nice thanx guys, I wonder if my extended warranty would cover it, if not at least it's not $$$. Thanx!

[bpd]

Should be similar to this posting for Q7. Several youtube videos on it too.

https://www.audiworld.com/forums/q7-discussion-112/fuel-filler-door-acutator-replacement-diy-2891090/

[PeytonBrandt]

^^^ nice thanx guys, I wonder if my extended warranty would cover it, if not at least it's not $$$. Thanx!

My extended warranty through Axiom covered mine (had it replaced at the dealership). Total cost was like $170, and I *only* had to pay the $100 deductible.


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[fmonteiro444]

^^^ nice thanx guys, I wonder if my extended warranty would cover it, if not at least it's not $$$. Thanx!

Audi replaced mine under CPO warranty.

[christianb5s4]

Does this issue happen on all years of the C7? Or is there a MY that started utilizing the updated actuator?

[gk1]

Does this issue happen on all years of the C7? Or is there a MY that started utilizing the updated actuator?

Good question.
I've not heard of anyone with a C7.5 2016+ having this issue.
Mine was one of the last US C7's 2015 before the facelift and mine failed (Vehicle build date 6/2014)
I'm sure there is someone out there with more access to information than myself who could tell us when exactly the p/n 4L0862153D went into production.

From some google images you can see the part build date on the boxes of some as Jan 2016 and later. (Earliest I could find on a non US site with a quick search was Nov. 2015)
https://i.ebayimg.com/images/g/zeAAAOSwdL9djJpz/s-l1600.jpg
https://i.ebayimg.com/images/g/-DwAAOSweGxZcuXq/s-l1600.jpg
https://i.ebayimg.com/images/g/BI8AAOSwq-ddGryA/s-l1600.jpg

[JaredA6]

I've got a 2016 A6, and my actuator died, but it died in the open position, so instead of getting it fixed and risking a failure in the closed position, I just decided not to get it fixed. I just ignore the errors when I scan the car.

[bahiaeternal]

I've got a 2016 A6, and my actuator died, but it died in the open position, so instead of getting it fixed and risking a failure in the closed position, I just decided not to get it fixed. I just ignore the errors when I scan the car.

How do you pop your fuel door open?

[ANMS4]

My extended warranty through Axiom covered mine (had it replaced at the dealership). Total cost was like $170, and I *only* had to pay the $100 deductible.


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This is good to hear, I’ll have the ship call mine, I don’t have a deductible either :)

[DoItAllGarage]

Got my part from Amazon and no issues thus far. I didn't replace the inner liner or whatever it's called. Only drilled out 2 holes on the lower section and replaced the holes with some push-in grommets. Please use some masking tape to protect the paint while working around that area. I banged against the paint a few and glad I had some tape there. 159667159668

[Wkraus]

Good question.
I've not heard of anyone with a C7.5 2016+ having this issue.
Mine was one of the last US C7's 2015 before the facelift and mine failed (Vehicle build date 6/2014)
I'm sure there is someone out there with more access to information than myself who could tell us when exactly the p/n 4L0862153D went into production.

From some google images you can see the part build date on the boxes of some as Jan 2016 and later. (Earliest I could find on a non US site with a quick search was Nov. 2015)
https://i.ebayimg.com/images/g/zeAAAOSwdL9djJpz/s-l1600.jpg
https://i.ebayimg.com/images/g/-DwAAOSweGxZcuXq/s-l1600.jpg
https://i.ebayimg.com/images/g/BI8AAOSwq-ddGryA/s-l1600.jpg

Just had them do my 2016 rs7 performance. Was out of gas and had no choice but pry the piece of crap open. Wouldn’t latch after that. I could push the plunger in and it would turn as it went in but not latch closed. Cost me $155.

[isellpower]

Good question.
I've not heard of anyone with a C7.5 2016+ having this issue.
Mine was one of the last US C7's 2015 before the facelift and mine failed (Vehicle build date 6/2014)

Unfortunately, now you have. 2017 RS7 15k miles and mine is kaput. Was running on fumes and pulled into the station about 3 blocks form my house. Popped, banged, jiggled, everything I could think of, no go. Drove it home and parked it. That was a month ago, haven't had a chance to take it in. Car is under factory warranty so I shouldn't have to pay, but it's annoying as heck.

[gk1]

Unfortunately, now you have. 2017 RS7 15k miles and mine is kaput. Was running on fumes and pulled into the station about 3 blocks form my house. Popped, banged, jiggled, everything I could think of, no go. Drove it home and parked it. That was a month ago, haven't had a chance to take it in. Car is under factory warranty so I shouldn't have to pay, but it's annoying as heck.

Yep, so it sounds like no one is safe.
Maybe the 2018? Lol

[christianb5s4]

Yep, so it sounds like no one is safe.
Maybe the 2018? Lol

Well technically, you still haven't heard of a 2016+ A6 that had it fail. [:p]

[gk1]

Well technically, you still haven't heard of a 2016+ A6 that had it fail. [:p]

True, but Wkrasu had his 2016 RS7 fail so just based on model years we've pretty much covered up to and including 2017 for all inclusive C7/C7.5 models.
It would be good if these later model failures could get confirmation of the failed part number. Perhaps there is need for an "E" revision. [=(]

[JaredA6]

Just push the fuel door and it pops open. close it an it stays in place.

Cars been like this since i got it, so I guess I assumed pushing to open was the standard, and mine just doesnt lock. I could be driving down the highway and open it, or have the car parked and locked and open it.

I assumed that the gas tank is supposed to be locked when the car is locked based on the error i get when i scan the car.

Am I wrong (completely possible)?

[gk1]

Just push the fuel door and it pops open. close it an it stays in place.

Cars been like this since i got it, so I guess I assumed pushing to open was the standard, and mine just doesnt lock. I could be driving down the highway and open it, or have the car parked and locked and open it.

I assumed that the gas tank is supposed to be locked when the car is locked based on the error i get when i scan the car.

Am I wrong (completely possible)?

OK. It sounds like in your case just the lock broke, but the push to close/open actuator still functions. Most reported failures are of the close/open actuator itself and then you cannot open the door to refuel without pulling the emergency "cable" or prying it. Your issue is definitely more livable unless you live in a location where there is a lot of attempted gasoline theft. Ha.

[A665]

Just push the fuel door and it pops open. close it an it stays in place.

Cars been like this since i got it, so I guess I assumed pushing to open was the standard, and mine just doesnt lock. I could be driving down the highway and open it, or have the car parked and locked and open it.

I assumed that the gas tank is supposed to be locked when the car is locked based on the error i get when i scan the car.

Am I wrong (completely possible)?

I've been reading through this thread in bewilderment, as I don't have any 'actuator' that I know of in my '13 A6 Prestige. I push the fuel door to open it, and push it back closed. I love this low-tech functionality for this function----not much to potentially fail (?).

Did the actuator thing become a new feature at some point?

[JaredA6]

OK. It sounds like in your case just the lock broke, but the push to close/open actuator still functions. Most reported failures are of the close/open actuator itself and then you cannot open the door to refuel without pulling the emergency "cable" or prying it. Your issue is definitely more livable unless you live in a location where there is a lot of attempted gasoline theft. Ha.

Wow. I always took people saying the actuator failed as the locking mechanism failed into the lock position so they couldnt open the tank. I wouldnt have ever thought a basic part push to close actuator thats been used on cars for the last 20+ years would fail so often on $60k+ cars. Not like a locking gas tank is really a novel idea... but i could understand that a little more then a basic mechanical part. Learn something new every day!

[gk1]

Wow. I always took people saying the actuator failed as the locking mechanism failed into the lock position so they couldnt open the tank. I wouldnt have ever thought a basic part push to close actuator thats been used on cars for the last 20+ years would fail so often on $60k+ cars. Not like a locking gas tank is really a novel idea... but i could understand that a little more then a basic mechanical part. Learn something new every day!

Well...20+ years is a bit of a stretch for Audi anyway my B5 in 2001 did not have this current system. There was a metal pin that slid into a catch on the door flap to lock the flap shut. (And amazingly was still vacuum operated in 2001) Now the lock and push close/open actuator are one electromechanical unit as you see above. Maybe circa 2010 for Audi.
It is a shame something so seemingly simple has such a high failure rate and can cause such a nuisance.

2001 B5 gas door lock. (simple, never failed)
https://www.autodemont.eu/content/images/thumbs/0040340_000-103-255-001-4b3d2487-45cd-4594-ac3d-444c3691199d.jpeg

[christianb5s4]

There was a metal pin that slid into a catch on the door flap to lock the flap shut. (And amazingly was still vacuum operated in 2001) Now the lock and push close/open actuator are one electromechanical unit as you see above.

2001 B5 gas door lock. (simple, never failed)


And you know the amazing thing about the vacuum actuated door locks and fuel flap? They have near zero issues, my B5 has 317K miles on it and has all original door locks, vacuum system, vacuum lines, etc and still works perfectly.

Kind of a silly failure point for these cars although at least it's easy to swap and the actuator is cheap.

[ANMS4]

The part was cheap, 31$ :O

[SWONER]

My 2016 S6 starting sticking. Dealer replaced it on CPO warranty but they scratched the paint under the fuel door. [emoji35]

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[low-profile]

Unfortunately, now you have. 2017 RS7 15k miles and mine is kaput. Was running on fumes and pulled into the station about 3 blocks form my house. Popped, banged, jiggled, everything I could think of, no go. Drove it home and parked it. That was a month ago, haven't had a chance to take it in. Car is under factory warranty so I shouldn't have to pay, but it's annoying as heck.

Just a heads up, there is an emergency release cable inside the trunk behind the access panel. This will allow you to keep using your car until you are able to bring it in for service. It is the red plastic leash you see in the pics posted here.


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[daytona rs7]

Mine has had to be replaced twice on a my 17 rs7

First time, think it was my fault. I had the car washed when it was 15 degrees. The next day it wouldnt open. I drove to audi from the gas station. They took care of it right away.

Second time, less than 1 year later, it failed. 50 degree weather. And the "emergency" cable wasn't worth a damn. It snapped when I tugged on it.
I went to audi and they said I needed an appointment. So I walked over to parts and bought the actuator for $30. changed it in my driveway in 20 minutes.

Based on all the google results for similar vw / audi complaints....this is somthing audi should revise again, and do a better job.

[ANMS4]

Just a heads up, there is an emergency release cable inside the trunk behind the access panel. This will allow you to keep using your car until you are able to bring it in for service. It is the red plastic leash you see in the pics posted here.


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Yea but don't do this to often it will break. Happened to me right before I replaced it

[WatchMeSpend]

So, I got a surprise last night when I went to put fuel in my car and I couldn't get the fuel filler door open. Try as a might, I had to pass up on the deal on gas and drive the speed limit home to conserve fuel.

I found this depressing thread and tried to get the door to open. It would not.

I banged on the door and pulled on the red piece of plastic expecting it to break off but it didn't and the door still didn't open.

I found a YouTube video where a guy who claimed that pressing the unlock button on the remote when it is unlocked 1 minute after will fix the issue. It didn't.

So I tried a combo. I pulled the red cord and pressed the unlock button and it popped open right away!!

Thanks for the tips and hints. Hope mine adds to the pile.

[westcoastrs7]

2016 RS7

Noted in the vehicle history that the original owner had the actuator replace under warranty.

Now 4 years later stuck again.
The red emergency cable was tucked behind some sound deadening, once found pulled , pulled and pushed the button , pulled again and the end came off the acutator.

Put some painters tape around the filler door and using some trim tools I could peek in and see the tip of the actuator engaged in the catch.

Audi thoughtfully left a slot that allowed me to get a footprint chisel in there and knock the ears off the piston. That allowed the door to open so I could switch the actuator out .

I took the old one apart and the spring inside the piston was quite rusted .

I hope the chisel trick helps someone else with a stuck door and non functional or missing emergency cable

[bpd]

Looks like a new part# for this

https://www.audiusaparts.com/oem-parts/audi-actuator-8v0862153b?c=bD0xJm49U2VhcmNoIFJlc3VsdHM%3D

[@llroadC7]

Hi guys,
A side note regardng the gas cap; is there a way to open the clogged drainage under the gas filler cap? Tried a bit but seemed to stop against something? Is there a valve of some sort here, or is it just to force it to a certain degree?

[westcoastrs7]

I can confirm 8V0-862-153-B is the part I used and it works

[WatchMeSpend]

Hi guys,
A side note regardng the gas cap; is there a way to open the clogged drainage under the gas filler cap? Tried a bit but seemed to stop against something? Is there a valve of some sort here, or is it just to force it to a certain degree?

I've unclogged mine with a leaf stem and it worked. I've just shot the drain with a pressure washer and it worked. A kids pipe cleaner should work as well.

Back to the door lock thing, after I got it open, I locked the door actuator by pushing it in and filed the locking tabs down. When I go to sell the car, I might replace it.

[petarat]

Oh how funny this thread pops up right when I couldn't get my gas flap open. Once again saved by the forums for the fix. I was able to get it open if I locked and unlocked the car a few times to get one more tank in there.

[bonafyd]

I've changed 2 in the past 7yrs the second time i didn't plug it in for the power locking.. i have simple push to open and push to close and done.