Fuel Flap Locking Actuator Replacement
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Sorry Flinders & Moomin. I had a good look in the garage but unfortunately I must have thrown the old one away.
Apologies for raising hopes.
However, all is not lost. When you get the new parts you will be able to see the indentations on the new surround and when you flip it over, you will be able to visualise how the screwdriver passes through the indentations and then locks into the retaining tab,s allowing you to lever against the retaining tabs and releasing the surround from the hole on the bodywork. It sounds more complicated than it actually is. Someone has actually put some thought into how to get these out when they were designing them for Audi - its quite a clever little bit of design.
Moomin - I would advise getting the surround as well as the actuator. If you are retaining your existing surround, you wont be able to use the screwdriver through the indentations method unless you seal the holes back up again, otherwise you'll risk getting weather in. You may also end up getting a smell of fuel in the boot as well.
If you dont pierce through the indentations but instead try to lever it out from round the edges of the surround, you risk slipping and possibly damaging the paint. For the little extra that it costs, I believe that its better to fork out for the surround as well, rather than trying to lever the old one out.
Hope this helps.
Apologies for raising hopes.
However, all is not lost. When you get the new parts you will be able to see the indentations on the new surround and when you flip it over, you will be able to visualise how the screwdriver passes through the indentations and then locks into the retaining tab,s allowing you to lever against the retaining tabs and releasing the surround from the hole on the bodywork. It sounds more complicated than it actually is. Someone has actually put some thought into how to get these out when they were designing them for Audi - its quite a clever little bit of design.
Moomin - I would advise getting the surround as well as the actuator. If you are retaining your existing surround, you wont be able to use the screwdriver through the indentations method unless you seal the holes back up again, otherwise you'll risk getting weather in. You may also end up getting a smell of fuel in the boot as well.
If you dont pierce through the indentations but instead try to lever it out from round the edges of the surround, you risk slipping and possibly damaging the paint. For the little extra that it costs, I believe that its better to fork out for the surround as well, rather than trying to lever the old one out.
Hope this helps.
Marty V8 you're a star! That makes more sense to me now. Thank you. :cheers:
I will order both parts so it doesn't matter if I damage the original. Would rather that than damage my paintwork.
Not got round to ordering the parts. Will do it next week. :thumbsup:
I will order both parts so it doesn't matter if I damage the original. Would rather that than damage my paintwork.
Not got round to ordering the parts. Will do it next week. :thumbsup:
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1,151 Posts
All is clear... so you actually do pierce the rubber to release the tabs. I did think this but wondrred if I could try and save a few quid. Having said that I've just put new Brembo pads and discs on all round so buying a rubber flap as well will seem like peanuts.
Yes thats right. You punch the screwdriver through the 4 little indentations - they are thinner plastic than the rest of the surround and I guess deliberately so to get to the retaining tabs behind.
The whole surround is disposed of, including the fuel flap door hinge.
The outer cover of the fuel flap dor pops off and goes back on to the new surround.
If you go back to the first post you'll see that the OP also tied string to the emergency release - a very good idea for pulling the new one (attached to the new actuator) back through into the boot space.
The surround was just under £15 when I bought it (see post 26 in this thread).
Hope this helps.
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1,151 Posts
I have done it in 20 mins! ..... And I'm a girl! Lol! Audi was going to charge me an hour to do at £120. I told them you guys were doing it in 15 mins so he said ok as we don't have to diagnose the fault we will only charge for half an hour. I said I will try to do it myself and if not will get it done by them.
Will get the parts to do my husbands car next weekend. His car is at the garage having a body kit fitted but that's another thread! Lol!
My stepson is now also looking for a black A5 so that will be 3 in the family in the space of 2 months! :cheers:
Will get the parts to do my husbands car next weekend. His car is at the garage having a body kit fitted but that's another thread! Lol!
My stepson is now also looking for a black A5 so that will be 3 in the family in the space of 2 months! :cheers:
Audi A5 f5 3.0 TDI Quattro S line S tronic Virtual Cockpit Driving assist pack
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Gonna have to revive this thread, as my actuator has finally given up ! I tried the manual release and a bit of WD40 and to no avail, Does anyone here have the part numbers for the current Actuator and the Surround bit? I've already poked holes in the current surround haha
Mucho Appreciated, and if no part numbers, I'll give audi a call and see if they can order for me,
What I'll do it post the numbers up here to save hassle for the next person viewing this thread,
Also this was very helpful for the swap thanks to OP and other contributors for making this!
~Alex
Mucho Appreciated, and if no part numbers, I'll give audi a call and see if they can order for me,
What I'll do it post the numbers up here to save hassle for the next person viewing this thread,
Also this was very helpful for the swap thanks to OP and other contributors for making this!
~Alex
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1,151 Posts
Ha ha ha... finally getting round to doing mine too mate.
Actuator 8K0 862 153 H
Fuel flap housing 8T0 809 999(D)
Both together should be about £30.
From what I gather the surround gets damaged on removal and needs replacing. You clip off the metal painted bit and put it on the new surround / flap. I bought the rubber filler shroud too but can't remember the part no. for that. It's not necessary anyway.
Actuator 8K0 862 153 H
Fuel flap housing 8T0 809 999(D)
Both together should be about £30.
From what I gather the surround gets damaged on removal and needs replacing. You clip off the metal painted bit and put it on the new surround / flap. I bought the rubber filler shroud too but can't remember the part no. for that. It's not necessary anyway.
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1,151 Posts
Meant to add this ages ago too. Just addition to all previously said but you need to pierce the housing with a sharp screwdriver at these four points to push back the retaining clips (see inset photo for direction) I found it best to do two together - can't remember which two I did first (upper or lower 2) Seems crazy but in doing so you need to replace the whole surrounding housing, unless you are not fussy. They are pretty stiff but be careful not to bend the metal body skin!! Oh - and be careful as the metal isn't finished and it's really sharp. I sliced myself without even realising while feeding the red plastic release chord back through. The metal flap cover just clips off.
I've included a picture of the actuator housing after I'd broken the cover off it. It looks fine and even operates... but definitely faulty. You can just make out a little metal wire next to the spring which has gone rusty near the top. I think this is something to do with the holding mechanism (kind of like a retractable biro) and probably the culprit rather than the motor.
I've included a picture of the actuator housing after I'd broken the cover off it. It looks fine and even operates... but definitely faulty. You can just make out a little metal wire next to the spring which has gone rusty near the top. I think this is something to do with the holding mechanism (kind of like a retractable biro) and probably the culprit rather than the motor.
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I fear I may need to refer to this thread in future. I filled up last week and out of nowhere I couldn't open the fuel flap - I must've looked a complete idiot scrabbling about in the boot with my users manual trying to figure out how to open it manually. I guess it's a sign that it's on its way out?
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1,558 Posts
Yes it is...:thumbsdown:
Hi all
Does anybody know if the door/hinge part can be separated from the black surround and then refitted to a new surround?
Im basically replacing the actuator and going to damage the surround in the process. Im therefore trying to source a replacement surround, ive called audi but they can only supply the surround minus the hinge and door (not referring to the external painted panel). So I need to know if I can reuse the original hinge/door and refit to the new surround? Also where have you guys purchased the surround and did it come with the door?
Any info would be helpful, cheers.
Does anybody know if the door/hinge part can be separated from the black surround and then refitted to a new surround?
Im basically replacing the actuator and going to damage the surround in the process. Im therefore trying to source a replacement surround, ive called audi but they can only supply the surround minus the hinge and door (not referring to the external painted panel). So I need to know if I can reuse the original hinge/door and refit to the new surround? Also where have you guys purchased the surround and did it come with the door?
Any info would be helpful, cheers.
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