Fuel door stuck - and fixed

My (rarely used) fuel door did not pop open after pulling the switch. I found in the manual there is a manual override in the trunk - a pull cord. That worked the 1st time, but the second time it remained shut - hence I could not pump gas.

I eventually was able to pry the door open with a wooden kitchen spatula... After watching some youtube videos I learned how to take the filler door out and disassemble the door control module. Water came dripping out and the pin was stuck. I cracked it open and found the electro-motor inside was rusted and stuck (see photo).

I ordered a replacement from audipartsstore.com:
Part Number Part Name Price Quantity Total
8V4-862-153-B Actuator $15.41 1 $15.41

Pretty inexpensive (the similar part for the A4 was ~$25).

I put the new part in (2 screws) and everything working again. I did have a check engine light which may or may not be due to this issue (fuel door is one of the OBD2 codes) - I was able to clear the check engine light using a generic Bluetooth OBD2 scanner with iOS app.

My car is parked outside, and we did have a few big rain storms. That could have caused it. But the car wash I typically use has high pressure jets, so that may be a more likely cause of the water getting into the module. Something to keep in mind.

My tip: if the door starts to act up, replace the module before the door gets stuck at a bad time. Do it yourself, as I'm sure the dealer charges $500 or so (that's what they charged for changing the 12V battery, which actually was because they did not tighten the cable property after a service visit... ugh, dealers!).

AvH said:

My (rarely used) fuel door did not pop open after pulling the switch. I found in the manual there is a manual override in the trunk - a pull cord. That worked the 1st time, but the second time it remained shut - hence I could not pump gas.

I eventually was able to pry the door open with a wooden kitchen spatula... After watching some youtube videos I learned how to take the filler door out and disassemble the door control module. Water came dripping out and the pin was stuck. I cracked it open and found the electro-motor inside was rusted and stuck (see photo).

I ordered a replacement from audipartsstore.com:
Part Number Part Name Price Quantity Total
8V4-862-153-B Actuator $15.41 1 $15.41

Pretty inexpensive (the similar part for the A4 was ~$25).

I put the new part in (2 screws) and everything working again. I did have a check engine light which may or may not be due to this issue (fuel door is one of the OBD2 codes) - I was able to clear the check engine light using a generic Bluetooth OBD2 scanner with iOS app.

My car is parked outside, and we did have a few big rain storms. That could have caused it. But the car wash I typically use has high pressure jets, so that may be a more likely cause of the water getting into the module. Something to keep in mind.

My tip: if the door starts to act up, replace the module before the door gets stuck at a bad time. Do it yourself, as I'm sure the dealer charges $500 or so (that's what they charged for changing the 12V battery, which actually was because they did not tighten the cable property after a service visit... ugh, dealers!).

Click to expand...

I now have this problem on my 2016. I usually put gas in at least once a month, so lack of use not my issue. I have about 70K miles on the car. Googling around, I note that the failure of this part is common across many VAG cars for many years, even newer models.

The first sign I had that something was amiss was last Wednesday when the check engine light came on. (I'm writing this on a Saturday). I used a BT/WiFi OBD II scanner and iPadOS app and looked up the code that suggested a fuel cap leak could be the problem. It was when I tried to check the fuel cap that I first experienced the intermittent fuel door open problem. I had to make several attempts with release button and pulling manual release cable before fuel door opened. Once opened, I cleaned the seal and gasket with a little WD-40, and went ahead and cleared the code. On Friday, drove to gas station and again had to make several attempts with release button and pulling manual release cable (whew! glad that worked). Check engine light stayed off on multiple trips on Friday.

The part is no longer that inexpensive! Usually ~$50 plus shipping most places including audipartsstore.com. There are YouTube videos on how to swap it out, so I'm still considering getting the part...

I filled in online part quote request form last night to my local Audi dealer and today they came back with $72! I've replied to them to see how much they would charge to do the work, and even asked if they might consider a reduced repair rate or at least lower part price, given how common a problem this is. I'm not holding my breath that it will be less than $500 to do the repair, but we'll see what they come back with. Frankly, if they charge less than $250 or so, I would have them do it.

I'll report back...to be continued...

If you are in USA AND just want the part, threre is an Audi Dealer in Las Vegas that will discount parts, via web. I saved considerable $ on a new Key and other parts.

Jacks A3 ET said:

If you are in USA AND just want the part, threre is an Audi Dealer in Las Vegas that will discount parts, via web. I saved considerable $ on a new Key and other parts.

Click to expand...

I still haven't heard back from my dealer (Audi Beverly Hills), so who is the dealer in Vegas that has discount parts?