Replacing fuel flap actuator

[greggie]

Hi just need a little help with removing the old actuator that locks unlock the fuel flap, a6 s line saloon 2006, I can see it from the boot in the wing just how do u remove it? Any pictures or description would be a big help. Thanks

[gupsterg]

Hi,

I couldn't see anything in the guides I use ... info I did dig up is the element is given a code of V155 "Motor for tank cap locking" and is activated/controlled by the "central control unit for the convenience system J393" ...

Also by this digging around I found an answer to what this red hanging chord was in my boot area behind the trim ... it's an emergency release for the fuel filler cover (probably stated in the owners manual! LOL ) ...

Depending on VIN either 4F0 862 153 or 4F0 862 153 B is fitted, approx. £15@dealers ...

From searching P/N on ebay it look like it is just held on by two screws ...





Perhaps another member has done it and share info ... be great to see a "How to ... " created by yourself ...

Regards
G

[greggie]

Thank you for he reply I managed to change it last night the 2 screws slot into the body work, all u have 2do Is push the actuator forward toward the front of the car 2 release it then just guide it out, put the release cord onto the new actuator and do the reverse to fit, it's abit fiddly guiding the locking arm through to the fuel cap, took me about 10/15mins start 2 finish.

[kamranshah]

Thank you everyone who contributed to this thread. All above had been useful but wasn't complete solution for my case so I thought to put together some tips which will help others who come across this issue. So what do I have, I have an Audi A6 2.0 TDI 2009 (2010 shape) and fuel cap lock actuator flap stopped working but luckily it was in UNLOCK position. It had happened in the past (unfortunately outside warranty) and a bit of gentle push while operating and WD40 helped to resurrect it for few weeks if not months... But alas it broke now.


So I had couple of failed attempts, dropped into all sorts of components stores to find a tool including Audi who don't sell tools to get it out but couldn't find an appropriate tool to open the hex shape end of screw which looked like very small ALLEN KEY. I decided to get it out today and using an adjustable wrench I managed to fit it on the screw tail and open it. Getting it on the screw wasn't hard but in this age bending myself to get in there was a bit harder. The TRICK you have to remember here is that you open it CLOCKWISE since the actual philips type + screw head is on the other side of bolt that you cannot access. So I managed to twist it clockwise couple of turns and that was enough to feel the actuator free'd up and I pushed it towards the boot lid (forward) for it to come out of the body and it worked. Unfortunately when I pulled it back out the locking pin attached with the actuator came out and putting that back in sounds very challenging and I know it wouldn't be straight forward. I then unplugged it and like everything else I always open and try to fix things but after opening it I found a motor similar to the motors you find in kids toys which was JAM so a push allowed it to rotate but upon connecting it again and clicking lock button on car key it attempted to operate but ended up in a spark within the motor, not sure if it was fused and what fuse will I have to replace if it was blown. So my next ADVICE is that you do not decide to open or repair it since it is only £16 part from dealer. Buy a new one before you take old one out and do replace it as motor has electronic contacts that get worn and can't be repaired. The actual TIP when taking it out is that you disconnect the locking arm and push it forward in lock position into the flap and don't let it come out while not losing the access to it. Remove and install the new actuator and then bring the arm back and connect it to new actuator.


After taking it out I took few pictures and measurements and can now tell you that the screw has exactly 3mm (three millimeter) hex or allen key type head (actually tail) that you need to rotate clockwise. I can now see that there are some parts that you can buy but not sure if the screwdriver type tool will get in there. You can do this using 3mm NUT SPINNER, 3mm SPANNER, 3mm wrench or similar tool. If you had a 3mm nut and bold that takes 3mm ALLEN key, you could convert it into nut spinner easily but I didn't have any.


So I am off to Audi dealer tomorrow to buy the part or may give them a call to order one since it is an ORDER part not always in stock. When I get one I'll put it back on which is absolutely not a problem except the locking arm. I took some pictures and will see if my microsoft webcam can get in there while putting the arm back in but I am sure I'll manage. I am also planning to create a paper or plastic cone through the hold where I could slide the pin in. The problem is that you have to be a Ninja to do this since you will be blind and wouldn't see anything and if you were ninja you could feel and put it straight in.

Some pictures that I had taken during this process will help you and are included below.

a) You can see the actuator is taken out and there are two holes in the wall where its screws slide in. The bigger hole in the left is where the locking arm goes.
a.jpg
b) This is the hole where the locking arm goes and very difficult to put through as you can't get your head in here to see through. The white dot in the middle is daylight suggesting it is where the hole will be.
b.jpg
c) You get to see this side of actuator in the car and the bold heads you can see are 3mm HEX L key shape so you need to get the reverse or female of 3mm Allen Key to open it (clockwise).
c.jpg
d) This is the hidden side of actuator, you can see the part number is 3B0959781 - costs around £16 from dealer, never buy a used one.
d.jpg
e) Here is interesting bit from inside the motor is a conductor that gets worn and really needs replacing.
e.jpg

Hope this helps but any comments or feedback will be welcome.

Kamran

[rnblade69]

Great post mate, pics and everything. Mine is stuck in 'Locked' position and even though owner manual says you can open it with the manual pull cord, this can't apply to a 'locked' position, the cord will just snap. I am going to go use kamranshah's tips. Will post update when complete.
Once again, outstanding help from this site.

[rnblade69]

Well, I took all the good advice, bought a OEM part from Audi at £18.25, which was pleasantly surprising.
Fitting!! OMG, you need hands like a gynaecologist !! However, after shining a bright light through from filler cap area and about a dozen attempts, it eventually slipped into place.
It would be interesting to see how long it would take a garage to do this job.
Thanks again for all the excellent advice. Seems I can nearly always find the answers for snags here.

[A6@georgemac]

My one was stuck - found the red wire and this released it. When open, locked and unlocked the car and it's working OK - so don't know what the problem is, but can definitely see how hard a job it is to replace it.