B8.5 fuel door cover not unlocking automatically for me

[Rectangle]

So I've done a little research on this but this seems like it was mostly a common issue with the A7 and I just want to make sure that I don't buy the wrong parts.

Basically, what's been happening lately is that when I go to gas the car up, and go to press the door in, it does not click out for me to open it. What I have to do is go and pull the little trunk cable that 'unlocks' it and that will either pop the door completely or, more likely, it just 'unlocks' it, which allows me to press it in, hear a click and then it pops out like normal for me to open.

What part is broken here that I should be replacing?

[Rectangle]

Okay, more research indicates that this is the part in question: https://www.fcpeuro.com/products/aud...udi-8k0862153j

And that the issue is that the actuator lock/unlock motor has failed. If anyone knows if this is usually the case, or if it's more likely to be a problem with a connector or fuse, that would be helpful. Also, if anyone has a DIY writeup for this for the B8/B8.5, that would be helpful, thanks.

[Smac770]

It's a common issue on B8.0. But without the DTC scan to confirm it's code 02615 and/or 02616, then we can't really say if you are having the "yeah, that's what we all get eventually" issue.

But your physical exhibits sound exactly like mine when it was happening. You could lock/unlock cycle a few times and maybe it would finally work, or just pull the emergency release.

That's the part to replace. It's easy, but getting the fuel door holder out of the body can be trying. I just put the original back in, hole slits in place. Been not an issue, though I guess I could have put tape over them.

[Rectangle]

Ah, okay, thanks for the info. Hopefully mine will go as easily as yours did. Do you think the B8 replacement is similar enough to the A7 and the B7 A4 (I assume that's what yours is based on your sig) that if I find videos or guides for those that they'd be good enough for my attempt?

[LYKUNO]

As Smac mentions above, getting the fuel door holder can be a challenge. Most of the videos I saw show poking a flathead screwdriver through the rubber diaphragm to pry it out. Doesn't seem like the holes from doing that would cause water leaks or other issues, but perhaps a flexible sealer (flex seal?) could be used to prevent water intrusion. Here's one of the videos that illustrates the steps. The design seems common among VW/Audi models. Also wondered if simply cleaning and lubricating the moving parts with something like WD40 or equivalent could solve your problem without replacing the actuator.



Oh yeah, one more video from the "Naptown Tuner" who shows the process of removal and replacement of the actuator, providing a better view of the 4 plastic clips on the back of the door assembly that create the difficulty in removal. Quite the character as you'll see in the video.

[svt]

Currently happening on my A4 with 129k miles. I was gonna try to lube it first before replacing.

[LYKUNO]

Here's one additional video on a 2017 Passat with the actuator problem. In this example, the owner was able to pull out the plastic surround/door assembly without having to resort to poking holes in the perimeter and then prying it out with a screwdriver. Will it work similarly on an Audi? It might! Check out this video ...

[Rectangle]

Follow up for those that are also having the issue. I found this video that was specific for a B8 S4, which was really helpful. https://youtu.be/0HqY8RMSNUE

In the video, after the T20 torx was removed, the owner was able to just snap the door assembly out by pulling on the plastic toward the rear of the car, which didn't really work for me. One of the commenters in the video though mentioned using some kind of pry bar or screw driver as a lever to push the part of the inner plastic door assembly by the gas filler neck, levering it against the filler neck itself to move the plastic assembly toward the back. This worked VERY easily for me and didn't damage any clips or anything. The actual swapping of the actuator itself is ridiculously easy and actually requires no screws of any sort.