jmgard58

My car has about 55,000 on it so it's out of warranty...are you saying that there's an exception to the standard warranty for these?

John Simcox

It seems to be a common problem so even though your car is out of warranty I would speak to your dealer and see if they can get it replaced as a goodwill gesture. Key to that of course is to (at least at the start) be very polite and perhaps point out how you are thinking of replacing the car. Asking never hurt anyone!

Terry Gentry

I have a 2004 Audi A8L and just replaced the Fuel Flap Actuator switch but the fuel flap still will not release. The switch is working fine but still not releasing the flap. any ideas?

John Simcox

Have you replaced the whole locking unit or just the electrical part? The problem (on the C7 at least) is mechanical not electrical and basically the locking pin stops moving in and out and rotating as it does so thus unlocking the filler cap

Terry Gentry

No, I just replaced the Actuator. When I push the button with the flap open the latch seems to move just fine. It is as though the release pin doesn't move far enough back when the button is pushed with the door closed. The Actuator switch works properly

i0zjh02

Sorry I know this is an old thread. My Fuel flap (2015 TDI ultra Avant) failed to open today. Tried pulling the emergency release and pushing the flap from outside but eventually the thin plastic wire broke off :-( Managed to eventually get the flap open manually but prizing the flap open as much as i dared and using a scredriver to force/break one of the lugs on the actuator.
How do I get to the actuator ?? I've looked at a number of guides and some mention 2 slots in the filler housing but cant see them on mine. I've tried using plastic sprungers and screwdrivers (whilst protecting the paintwork) but cant get the housing to budge, gave up when i started to crack the filler housing itself.
Have tried taking the internal side panel off but no way from the inside either
At moment have snapped the other lug from the actuator and have a "manual" fuel flap, does anybody have any idea how to safely remove the filler housing to replace the mechanism/actualtor without wrecking the bodywork
FYI its the housing with both the Fuel and AdBlue filer caps
Cheers for any advice :-)

bpd

This might help. You tube has others

https://www.audiworld.com/forums/q7-.../#post24736833

ByByBMW

I had this issue on my 2016 A6 TDI and after looking at the fixes, and the real likelihood they would show up again at some point, I did this. I cut off the two tabs on the plunger. Those tabs are what locks the fuel flap to the plunger. Voila, no more locked fuel flap. Also, it keeps the plunger apparatus in place which my dealer informed me is part of the security circuit so the system won't throw a fault by having a missing plunger.
Lastly, the spring on the fuel flap door will keep the flap shut while driving yet the flap is easy enough to open by finger when you need to refuel.

968racer

I had one of these landscape edging spikes laying around the garage which I used to put the short bent end around the filler cap gap and was able to pull the housing out to access the solenoid.

Denis Martin

Help! I have a 2016 A6 and am experiencing the same problem with the fuel door not opening. I could try a number of the options posted here but my conundrum is I can't get the darn thing open and my 18 year old used it last night and there is barely any gas left in it. Any ideas/tricks to get it open so I can refuel? The manual red cable doesn't work. Tried it with someone pulling and me pushing and no result. When I press the unlock button on the FOB I can hear a switch click but nothing happens. Any idea?