Stuck Fuel Door Actuator

[Riker]

Hello,

I'm trying to source a replacement actuator via AudiUSAparts, but I am getting numerous results that look identical but don't necessarily line up with my vehicle (2016 S7). The part number I found is as follows: 8V0-862-153-B.

Does anyone have any potential information this actuator? This is for the rotating actuator that locks the gas tank door upon locking the vehicle. Thank you in advance.

[bonafyd]

I swapped mine out with this one.
https://www.ebay.com/itm/163761006073

I followed this vid it's real easy.
https://www.youtube.com/watch?v=Hwk0...utoMaintenance

[D3LT4N]

The part number I found is as follows: 8V0-862-153-B

The part number you found is the correct one, recently had mine done at the dealership under warranty and that's the latest revision for the actuator listed on my invoice.

[byoungin]

Had that problem on my A7 before. Manual latch unlocked and then sprayed the actuator with wd-40 and pressed it up and down a few times. Fuel door never got stuck since then.
Hope this helps

[jrhgto]

Yes this has to be like the most common problem with these cars, luckily its a $35 fix. I am on my 3rd.
Sadly, if you go over to the B9 boards, People are still having the same problems with their 2018-2019 S5s. I guess audi is still using the same unreliable part.

[WatchMeSpend]

I haven't fixed mine yet. Pushed it in so it doesn't grab the locking receiver and closed the door. I'm recalling the moment of panic that you have when you realize you can't put gas in your car.

[bonafyd]

I haven't fixed mine yet. Pushed it in so it doesn't grab the locking receiver and closed the door. I'm recalling the moment of panic that you have when you realize you can't put gas in your car.

I pulled in to the gas station, paid for the gas and the door wouldn't open.. what a messed up feeling

[WatchMeSpend]

I pulled in to the gas station, paid for the gas and the door wouldn't open.. what a messed up feeling

Lucky me. I was at home and had a 1/8 tank of gas when I discovered it. If they don't fix the part, I'd rather file the locking posts of the old one and push it in. I'll buy one cheap one for if I sell the car and install it then.

[ItsLarryG]

I was coasting into the dealer after I had this happen so was stuck having them fix it, $300 later I’m thinking to myself what a weird random thing to break, surely it can’t be that common or why else would they use that design? The more and more I hear about this, I think I’ll just order one from eBay to keep in the garage if/when I need it in the future and save the $300.

[Four rings fan]

2018 S6 bought new in December of 2018. I've had mine replaced twice now. It's becoming an annual thing like oil changes.

[Audisthesia]

2018 S6 bought new in December of 2018. I've had mine replaced twice now. It's becoming an annual thing like oil changes.

Wow crazy man. I wonder if local climate has anything to do with these failures. Or perhaps lack of use, like low mileage cars? Or perhaps high mileage more us? Has to be something. Freezing/snow maybe? Makes we wonder if a little WD-40 would be PM to prevent failures. Mine is 2018 and no issue.

So when this little bastard goes.... Does it just straight up die or is it trying to actuate but gets stuck?

[A665]

The more and more I hear about this, I think I’ll just order one from eBay to keep in the garage if/when I need it in the future and save the $300.

THIS.

And I have an OCD thing for refueling, such that I NEVER let the tank drop below an indicated 1/4 fuel level. Matter of fact, over the past year, with such little driving, I automatically refill as soon as the fuel level hits 1/2-tank.

[Four rings fan]

Wow crazy man. I wonder if local climate has anything to do with these failures. Or perhaps lack of use, like low mileage cars? Or perhaps high mileage more us? Has to be something. Freezing/snow maybe? Makes we wonder if a little WD-40 would be PM to prevent failures. Mine is 2018 and no issue.

So when this little bastard goes.... Does it just straight up die or is it trying to actuate but gets stuck?

It just straight up dies and pulling on that red ripcord in the trunk doesn't release it. I can't tell if it's trying to release because the rear passenger door lock is very close. I'm thinking that since my car sits outside 24/7 and has dew on it every morning and I wash the car weekly that moisture is the issue. IDK. The cars under warranty so 45 minutes and two lattes later I'm in and out of the dealership. Once the warranty is up I won't be so thrilled.

EDIT: Just lubed both the main piston that slides in and out and the tip that twists to lock with WD-40. Marked my calendar to do it again in six months. Hopefully I get more than a year out of this newest actuator.

[Alabama]

And I have an OCD thing for refueling, such that I NEVER let the tank drop below an indicated 1/4 fuel level. Matter of fact, over the past year, with such little driving, I automatically refill as soon as the fuel level hits 1/2-tank.

A little off topic, but I was taught this as well. Don't get close to empty to minimize drawing up sediment from the tank (albeit there's a fuel filter). Keep close to full in cold weather (even in Alabama temps can get below 32 F) to minimize condensation within the tank. Any truth or just fables?

[Four rings fan]

A little off topic, but I was taught this as well. Don't get close to empty to minimize drawing up sediment from the tank (albeit there's a fuel filter). Keep close to full in cold weather (even in Alabama temps can get below 32 F) to minimize condensation within the tank. Any truth or just fables?

100% truth. I was a yacht captain for many years here in Florida. If the boat sat at the dock for any length of time you needed to keep the diesel tanks full to eliminate condensation from the daily heating and cooling cycle. If you didn't it was a guarantee that you'd be draining water from the Racor fuel/water seperators in the engine room on a hourly basis the next time you ran for an extended time on a trip to the Bahamas or Keys.

[A665]

A little off topic, but I was taught this as well. Don't get close to empty to minimize drawing up sediment from the tank (albeit there's a fuel filter). Keep close to full in cold weather (even in Alabama temps can get below 32 F) to minimize condensation within the tank.

Also, bear in mind that fuel pumps generate considerable heat during operation. Modern auto manufacturers put fuel pumps in the fuel tank so that the fuel itself keeps the pump cool. For this reason, don't run your vehicle with less than 1/4 tank of fuel. Once the fuel level drops below that level, the pump is usually no longer submerged and it has no efficient way to dissipate heat. This will lead to premature pump failure.

[Riker]

I swapped mine out with this one.
https://www.ebay.com/itm/163761006073

I followed this vid it's real easy.
https://www.youtube.com/watch?v=Hwk0...utoMaintenance

Wonderful, thank you for the links and reference!

The part number you found is the correct one, recently had mine done at the dealership under warranty and that's the latest revision for the actuator listed on my invoice.

Great to get confirmation, thanks!

Had that problem on my A7 before. Manual latch unlocked and then sprayed the actuator with wd-40 and pressed it up and down a few times. Fuel door never got stuck since then.
Hope this helps

Haven't given this a shot yet, but I will today, I already ordered the part and plan on tearing down the old actuator to see what's going on inside.

Yes this has to be like the most common problem with these cars, luckily its a $35 fix. I am on my 3rd.
Sadly, if you go over to the B9 boards, People are still having the same problems with their 2018-2019 S5s. I guess audi is still using the same unreliable part.

That's a shame to hear, hopefully they figure this one out soon enough.

I haven't fixed mine yet. Pushed it in so it doesn't grab the locking receiver and closed the door. I'm recalling the moment of panic that you have when you realize you can't put gas in your car.

I was literally at the pump waiting for fuel, had about 50 miles in the tank left but I knew the whole assembly was plastic so it would have some give. I took a credit card and tucked it between the body and gas cap, gave it a good ol' pry at a slight angle and out she came. It currently sits out until I get the part in.

I pulled in to the gas station, paid for the gas and the door wouldn't open.. what a messed up feeling

Right there with ya', but I use a credit card to help getting a prying finger in there and out she came at the pump. Definitely embarrassing, but I fueled up so win.

I was coasting into the dealer after I had this happen so was stuck having them fix it, $300 later I’m thinking to myself what a weird random thing to break, surely it can’t be that common or why else would they use that design? The more and more I hear about this, I think I’ll just order one from eBay to keep in the garage if/when I need it in the future and save the $300.

I highly recommend simply going this route, $300 sounds absurd for this type of repair.

2018 S6 bought new in December of 2018. I've had mine replaced twice now. It's becoming an annual thing like oil changes.

Hell, I might need to buy two actuators at this rate lol.

[Alabama]

Also, bear in mind that fuel pumps generate considerable heat during operation. Modern auto manufacturers put fuel pumps in the fuel tank so that the fuel itself keeps the pump cool. For this reason, don't run your vehicle with less than 1/4 tank of fuel. Once the fuel level drops below that level, the pump is usually no longer submerged and it has no efficient way to dissipate heat. This will lead to premature pump failure.

That's a subtle one! Thanks.

[Alabama]

100% truth. I was a yacht captain for many years here in Florida. If the boat sat at the dock for any length of time you needed to keep the diesel tanks full to eliminate condensation from the daily heating and cooling cycle. If you didn't it was a guarantee that you'd be draining water from the Racor fuel/water seperators in the engine room on a hourly basis the next time you ran for an extended time on a trip to the Bahamas or Keys.

I expect the yacht fuel tank is larger, but the point still holds. Thanks!

[Four rings fan]

Another fuel door actuator replaced.

Something new.........Audi sends a video of the work they did.
https://carfilmapp.com/video.php?k=HHa5TbVrSUu

[Audisthesia]

Another fuel door actuator replaced.

Something new.........Audi sends a video of the work they did.
https://carfilmapp.com/video.php?k=HHa5TbVrSUu

Yeah I got a video for 20K service at the dealer

[mwdelta]

I just ordered the part to do mine. The previous owner did at least once already. Only $27 from the dealer.

[PDXFlyGuy]

Just had this happen to me today. Luckily I have 80 miles left on the tank and it’s under warranty.

[eurospek]

Just fixed mine today. The hardest part was popping off the trim without damaging the seal. But looks like my piece was already off for paint before as there were marks in the seal from lifting. The actuator itself looked original. Dated 2014. The YouTube video above definitely helped.

[Audisthesia]

Another fuel door actuator replaced.

Something new.........Audi sends a video of the work they did.
https://carfilmapp.com/video.php?k=HHa5TbVrSUu

Yeah they've done that at my last 2 audi care services. So kind of the original leasee to buy it for me

[2k16A6]

Just had this happen to me at the gas station. Pulled the red plastic thingy till it broke, didn't unlatch but seemed to loosen it enough that I was able to get my fingers into the door and yank it open. I cut the little tabs off the actuator so at least it wont lock itself on me, but the the door wont latch either so it just kind of flaps in the breeze. I'll have to get one ordered up!

[moesho]

Got mine from rock auto for $20 and some change worked great

Sent from my LE2117 using Audizine Forum mobile app

[billbB7]

Just had to replace mine due to cold temps and the plunger sticking. What worked for me was allowing it to heat up. I parked it in the sun at work, with car unlocked I pushed the door a few times.. came out after work and the actuator eventually had released and popped the door open.

For anyone reading this about the red pull cord in the trunk, that's an electrical failsafe. It's mechanically attached to the actuator to release the lock, it won't help a frozen plunger.

From what I can tell mine was from the factory, date stamp on the part 2017 .. I guess 8 years isn't too bad. Part number I took off the car was 4L0862153D, FCP and ECS couldn't confirm 8V0862153B fits 2018 S6 but it's listed as a superseded part on audiusa.com:
https://parts.audiusa.com/p/70168723/8V0862153B.html

[WatchMeSpend]

Still rocking mine with the filed tabs. No Fear!