Actuator fuel flap won't open A3 E-Tron, how to replace?

Tuttivini

Registered User
The fuel door/flap of my A3 E-Tron often does not open anymore.
I think it's a slightly more 'special' system than with other Audi's (am I correct?):

The system is automatically vented when the tank valve is closed.
This is to 'preserve' the fuel. Because there are people who always drive fully electric with this plug-in hybrid. So if you have the same unused gasoline in your tank for months/years, it's not degrading (or less...).

If you want to refuel (petrol), you pull a electronic switch on the driver's door.
Then the system bleeds itself and indicates on the virtual dashboard (Facelift 2017 A3 E-Tron) that the system is bled and then that you can refuel.
You will hear that it electronically unlocks the fuel filler flap and the flap will open/pop a few centimeters so that you can insert your fingers between it and open it all the way, unscrew the fuel cap and refuel ...

I think with 'normal' A3 8v's (facelift) it does not open with a switch inside the drivers door, but you have to 'press' on the fuel filler flap, after which it opens? And the actuator only serves as an automatic lock as soon as the car is locked ... (so there is no button on the inside of the driver's door and nothing is vented). Correct?

Now this automatic pushing open no longer works for me.
The A3 E-Tron indicates that the system has been bled and that I can refuel, but the tank valve isn't opening (popping).

I get it open via manual red pull cord / emergency release. Sometimes I also have to use a plastic card or something while you pull that red emergency handle.

Silicone spray on the actuator didn't solve it...

I understand this is presumably a faulty ACTUATOR.
Read a lot about it on forums (with normal A3s, not so much about the E-Tron).

But in order to get to it, you have to 'punch four holes' on the fuel filler housing and buy a new fuel filler housing, because the old one is broken.
Is this correct?

And if so, how do I do this?
Anyone happen to have access to ETKA drawings how I can replace this with the A3 E-Tron?
And what order number (specific actuator with automatic opening for the A3 E-Tron, partnr 6 on picture) and possibly order number for the comple fuel filler housing, partnr 5 on picture (if old one needs to be punched).

I Guess my local Dutch dealer will charge >+150,- euro's for replacement ...

(tried to describe my problem in English, which is not my native language)
 

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JohnM100

Registered User
VCDS Map User
Gold Supporter
Don’t know about the e-tron but the fuel filler cap locking solenoid is a common fault on the A3 ICE cars. It just seizes and the red plastic release wire in the boot just breaks - mine did at 2.5 years old. Solenoid design weakness. I now open mine every 2-3 weeks just to ensure it doesn’t seize again.
 

Tuttivini

Registered User
Who knows how to remove the 'fuel filler flap', without damaging it/punching 4 holes, to get to/replace the actuator?
 

RAF_S7

Well-Known Member
Gold Supporter
It’s actually quite a common problem across a wide range of Audi models.

This YT video gives you a good general view of what needs to be done


You can carefully remove the the surround and just replace the actuator.
 

Tuttivini

Registered User
@RAF_S7 Thanks for the info.
Would it be possible to remove the cover (so I can reuse it) without punching/damaging the 4 holes, like the guy in the youtube clip does?
 

RAF_S7

Well-Known Member
Gold Supporter
@RAF_S7 Thanks for the info.
Would it be possible to remove the cover (so I can reuse it) without punching/damaging the 4 holes, like the guy in the youtube clip does?

Ive not had to do this on my S7, but came close on my previous A7, where I struggled a few times to get it open.

It’s quite a “hard plastic” surround, held onto the car body by four clips - just where he uses the tool to break the clips through the hole covers.

You could reuse the old one, as long as you don’t mind a little damage showing when you open the fuel flap. I’m not sure if you can remove the surround from inside...

John. :racer:
 

ZeA38VSport

Registered User
I am having issue with actuator not opening. I managed to remove the plastic surround using plastic trim tools without breaking it at all, I only had to scrape thin rubber lip around it so I can push the trim into the gap. Slight pull with trim tool around each point where the workshop guide suggests to make a hole through. I have got the actuator working again after lots of lithium grease.
 

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