[Okocha-No10]

After reading several threads on the forum regarding the fuel flap locking actuator, I decided to check whether mine still worked. Guess what it didn't! so off I went to my local dealers and I purchased a new one for £14.83. It took me 15 minutes to do the job and I took some pictures to help if anybody else fancies doing it themselves. So here goes,

Locate the the storage well in the boot, it just folds down revealing this...

You can see the red pull cord loop

I attached a length of string to it, so to aid the re-fit

Remove the Torx screw with a T20 torx bit and very carefully in the corners of the fuel flap surround, using a flat blade screwdriver lift and pull the securing clips out, be careful it,s easy to break the clips. The fuel cap and flap needs to come off with it as well.

You now can see the Actuator on the lip on the bodywork this just pulls off and unplug the connector.

Actuator off the car


Cut the string off and now tie it onto the new Actuator, place it back on the bodywork and pull the string back though

Sorry about the quality of the this one

Pulled back though, makes this process dead easy.

All back together, the fuel flap and surround just slots back in place.

Tested and now you can hear the Actuator locking the fuel flap.

Sorted and it didn't cost £100 in an hours labour charge at the dealer.

I hope this helps.

 

[danjwilson]

Well done Okocha. Nice work. Had mine done under warranty, but if it goes again I'll definitely do it myself.

:thumbsup:

 

[j30max]

hi mate

my cars fuel flap works on the basis of push in to unlatch and then push it when closing to lock. Do your UK spec cars have an auto lock, unlock feature or am I missing the point here?

 

[Okocha-No10]

When you lock your car, the fuel flap should lock as well and vice versa, you can hear the fuel flap actuator lock, it's a very distinct noise. See if you can open the flap with the car locked. If you can the actuator is goosed

 

[j30max]

check actuator and it didn't open when car was locked. Funny thing though, the steady orange CEL came on afterwards when I started the car after playing around with the fuel flap. I just posted it may be carbon buildup, but could it possibly be related to the sensor on the acutator or something?

 

[Master]

Thanks!! I've got a spare actuator ready for replacement (mine needs a second unlock to really unlock).

Now I know how to do it

 

[Okocha-No10]

check actuator and it didn't open when car was locked. Funny thing though, the steady orange CEL came on afterwards when I started the car after playing around with the fuel flap. I just posted it may be carbon buildup, but could it possibly be related to the sensor on the acutator or something?[/QUOTE





No, not related at all, must be pure coincidence

 

[INEFILO]

Fuel Flap Purchasing

Hi
Can anyone recommend where to buy Audi parts like the Fuel Flap Locking Actuator?
Thanks

 

[danjwilson]

Hi
Can anyone recommend where to buy Audi parts like the Fuel Flap Locking Actuator?
Thanks

Directly from the dealer is one option. Many can also be sourced from ebay (just talking genuine Audi parts of course). I expect some of the better general motor factors can also source OEM Audi parts too.
For this particular part, I would go straight to the dealer parts department.

 

[nino]

Excellent write up, do you have a part number for the Actuator.

I have a feeling mine is on the way out as when I unlock the car it sounds like someone is torturing a goat!!!

 

[Okocha-No10]

nino,

I think it's this 8K0 862 153 F, I just popped into the Local dealership and they had one in stock, £14.83, Thank you very much.

 

[JonnieB]

After reading several threads on the forum regarding the fuel flap locking actuator, I decided to check whether mine still worked. Guess what it didn't! so off I went to my local dealers and I purchased a new one for £14.83. It took me 15 minutes to do the job and I took some pictures to help if anybody else fancies doing it themselves. So here goes,

View attachment 16290

Locate the the storage well in the boot, it just folds down revealing this...

View attachment 16289

You can see the red pull cord loop

View attachment 16288


I attached a length of string to it, so to aid the re-fit

View attachment 16283

Remove the Torx screw with a T20 torx bit and very carefully in the corners of the fuel flap surround, using a flat blade screwdriver lift and pull the securing clips out, be careful it,s easy to break the clips. The fuel cap and flap needs to come off with it as well.

View attachment 16287

You now can see the Actuator on the lip on the bodywork this just pulls off and unplug the connector.

View attachment 16286

Actuator off the car


Cut the string off and now tie it onto the new Actuator, place it back on the bodywork and pull the string back though

View attachment 16285

Sorry about the quality of the this one

View attachment 16284

Pulled back though, makes this process dead easy.

View attachment 16283

All back together, the fuel flap and surround just slots back in place.

Tested and now you can hear the Actuator locking the fuel flap.

Sorted and it didn't cost £100 in an hours labour charge at the dealer.

I hope this helps.

thanks Oko,

so the actual fuel flap and cap come off when you carefully prise the plastic surround out? Where do you feed the red plastic pull cord? Does the new actuator come with a pull cord attached.

rgds
JB

 

[Evil Derboy]

Nice beard...

 

[Okocha-No10]

JB,

so the actual fuel flap and cap come off when you carefully prise the plastic surround out? Yes




Where do you feed the red plastic pull cord? If you attach the string to the old pull cord before you remove the old actuator from the car, when you fit the new actuator tie the string to the new pull cord and just pull it back through from the boot. As shown in the pictures.

Does the new actuator come with a pull cord attached.Yes it does.

 

[Okocha-No10]

Nice beard...

EB,

Didn't realise until I posted the pics that I looked like I had just been dug up. Not normally longer than 2 mm, must have had an off week, 18 years in the RAF and now refuse to clean shave unless I really have too or the wife complains about it being too long (and that sounds wrong!!!!!!)

 

[JonnieB]

Thanks Oko,

I see what Ed means now! thought he was losing the plot for a moment:thumbsup:

 

[j30max]

dammit, tried unlocking my fuel flap using the red cable and snapped it. now I have to replace the actuator! Loving my A5 everyday

 

[Okocha-No10]

dammit, tried unlocking my fuel flap using the red cable and snapped it. now I have to replace the actuator! Loving my A5 everyday

I take it you were just checking the operation of the mechanism ?

 

[j30max]

I take it you were just checking the operation of the mechanism ?

yes, and in the process, snapped the cable and did some other damage to my hand smashing it against the sharp edges in the fuse area. fun times

any suggestions as to how to replace and thread the red cable from a new actuator now.

 

[j30max]

all replaced. Even replaced the plastic surround of the fuel filler neck. No onto the next project, twin muffler setup...:thumbsup: