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Hello. A7 BiTDI 2013- Fuel flap door stuck closed. History- Couple of times in then last year needed to press fuel flap door (FFD) couple of times to release, when filling up. Tried the usual WD40 approach. No real change to smooth operation. Well eventually the indignity of not being able to open FFD at fuel pump came around.
Therefore, came to scour forums and threads across all Audi sites. There is alot of information, however, they almost all state to use the "Orange Emergency (or manual) release plastic (ugh) lanyard. Well I executed this action once, and yes it worked. The second time it occurred not so fortunate. The lanyard snapped and FFD remained firmly closed. Action: Clearly it was in need of a new actuator. Plenty available with next day delivery also available. (Going to need fuel and soon as its is festive time) Plenty of advice on line on how to change actuator, but how to access it in the first place. FFD needs to be open.
To do the entire operation of changing the actuator you should set aside an hour just to be circumspect.
Parts: Actuator- Part numbers vary however, 4LO.862.153.D is the item I removed manufactured 27-06-2013 Tools:
Flat bladed screwdrivers 2mm, 3mm and 4mm tips, preferably insulated as the plastic shaft protects paint work.
The plastic of a soda (coke) bottle cut into 4 inch wide strips. Insert these around the edge(rim) of fuel flap. Explanation in method later
Torx T20 bit and holder and drive
Pipe Grips
length of wire stiff four feet
Rags to protect paint work. Method:
Open boot (trunk) layout tools and new actuator.
Gain access to the area where the "orange" manual release pull lanyard would be if it hadn't snapped as its feeble.
The FFD can be lifted a little away from the locking mechanism by about 4-7mm, which is just enough to inert a wide flat tipped screwdriver into the tang which can be pushed back to release the door (item 9) cover by sliding towards you. A7 Fuel flap door, the RED spots are the tangs(clips) that need pressing down whilst pulling on the cover away from the car.
Now the door cover is off, you can get to work on the most tricky and delicate part of the operation. Removing the assembly. Remove filler cap, clean around the area to ensure no debris enters filler neck and tank.
The flat bladed screwdrivers, rags and soda bottle pieces come into their own now. Starting at the fwd top position work your way counterclockwise by unlatching each catch at the corners, they are marked as to there location by the symbol on the assembly. Be very careful regards your paintwork, take your time, its like removing a tyre from a wheel start slowly and inching around it will release. As each tang/catch is removed slide the soda bottle plastic behind it to prevent it from re-seating. As each tang is released maintain a pulling pressure on the assembly, you will notice as you move around the perimeter the assembly begins to protrude more and more. It will come away and be left hanging or attached by the drain and the electrical connector, possibly the remnants of that orange useless piece of plastic.
If like me your manual release lanyard snapped, then use a the stiff wire to thread the new lanyard through from the new actuator.
Release the old actuator by unscrewing the 2 off torx screws.
Release the electrical connector STOP. Do not pull the wires, never pull the wires. Using a combination of small flat tip screwdriver to coax the tang into the lip under the catch of the body of the actuator as you slide the connector out of the actuator body.
Now the actuator is launched into bin.
Install new one, connect it, this is where the pipe grips come in handy. The connector is very tight to insert, so using the pipe grips set at just under the width of the actuator, gently squeeze the connector into the actuator body assembley.
All the other disassembly conducted can be reassembled by snapping things back into place. Refit fuel filler cap.
Check operation of door actuator.
Tools away, tidy up and cup of tea.
Bosh, done.
Hello. A7 BiTDI 2013- Fuel flap door stuck closed. History- Couple of times in then last year needed to press fuel flap door (FFD) couple of times to release, when filling up. Tried the usual WD40 approach. No real change to smooth operation. Well eventually the indignity of not being able to open FFD at fuel pump came around.
Therefore, came to scour forums and threads across all Audi sites. There is alot of information, however, they almost all state to use the "Orange Emergency (or manual) release plastic (ugh) lanyard. Well I executed this action once, and yes it worked. The second time it occurred not so fortunate. The lanyard snapped and FFD remained firmly closed. Action: Clearly it was in need of a new actuator. Plenty available with next day delivery also available. (Going to need fuel and soon as its is festive time) Plenty of advice on line on how to change actuator, but how to access it in the first place. FFD needs to be open.
To do the entire operation of changing the actuator you should set aside an hour just to be circumspect.
Parts: Actuator- Part numbers vary however, 4LO.862.153.D is the item I removed manufactured 27-06-2013 Tools:
Flat bladed screwdrivers 2mm, 3mm and 4mm tips, preferably insulated as the plastic shaft protects paint work.
The plastic of a soda (coke) bottle cut into 4 inch wide strips. Insert these around the edge(rim) of fuel flap. Explanation in method later
Torx T20 bit and holder and drive
Pipe Grips
length of wire stiff four feet
Rags to protect paint work. Method:
Open boot (trunk) layout tools and new actuator.
Gain access to the area where the "orange" manual release pull lanyard would be if it hadn't snapped as its feeble.
The FFD can be lifted a little away from the locking mechanism by about 4-7mm, which is just enough to inert a wide flat tipped screwdriver into the tang which can be pushed back to release the door (item 9) cover by sliding towards you. A7 Fuel flap door, the RED spots are the tangs(clips) that need pressing down whilst pulling on the cover away from the car.
Now the door cover is off, you can get to work on the most tricky and delicate part of the operation. Removing the assembly. Remove filler cap, clean around the area to ensure no debris enters filler neck and tank.
The flat bladed screwdrivers, rags and soda bottle pieces come into their own now. Starting at the fwd top position work your way counterclockwise by unlatching each catch at the corners, they are marked as to there location by the symbol on the assembly. Be very careful regards your paintwork, take your time, its like removing a tyre from a wheel start slowly and inching around it will release. As each tang/catch is removed slide the soda bottle plastic behind it to prevent it from re-seating. As each tang is released maintain a pulling pressure on the assembly, you will notice as you move around the perimeter the assembly begins to protrude more and more. It will come away and be left hanging or attached by the drain and the electrical connector, possibly the remnants of that orange useless piece of plastic.
If like me your manual release lanyard snapped, then use a the stiff wire to thread the new lanyard through from the new actuator.
Release the old actuator by unscrewing the 2 off torx screws.
Release the electrical connector STOP. Do not pull the wires, never pull the wires. Using a combination of small flat tip screwdriver to coax the tang into the lip under the catch of the body of the actuator as you slide the connector out of the actuator body.
Now the actuator is launched into bin.
Install new one, connect it, this is where the pipe grips come in handy. The connector is very tight to insert, so using the pipe grips set at just under the width of the actuator, gently squeeze the connector into the actuator body assembley.
All the other disassembly conducted can be reassembled by snapping things back into place. Refit fuel filler cap.
Check operation of door actuator.
Tools away, tidy up and cup of tea.
Bosh, done.
Excellent information. Thanks!
Last edited by fkaufman; 01-01-2020 at 09:20 AM.
Reason: Add title
I had mine changed under warranty. The mechanism is pretty flakey. The new one doesn't always work either and I have to hit the remote unlock or door unlock again, sometimes.
It worked thanks! The trick is to press the middle section (Middle curve) with the pry tool, all the other edges are almost impossible to pry. Got mine on Amazon - https://a.co/d/ioYpive Part number for Audi A4 2017 Quattro - 8V0862153A.
01-01-2020, 04:27 AM
Fuel Flap Door Stuck Closed.
