Audi A5 Fuel Door Won't Open, Actuator Failure

Had the same problem with my 2020 Audi A4 when the fuel door got stuck. The electric actuator completely failed, leaving the fuel filler flap inoperable. The error code triggered several system limitations as a safety measure. The issue turned out to be more complex than expected. Diagnosis revealed a failed linkage between the release mechanism and the actuator, plus corrosion in the electrical connections. The entire fuel door assembly needed replacement, including the actuator and wiring harness. This is a known weak point in several Audi models. The repair requires specialized diagnostic equipment to reset the system properly after replacement. A general mechanic might struggle without proper Audi diagnostic tools. The fix is not a quick job, took about 4 hours at the dealer workshop. They had to remove interior trim panels to access the mechanism. However, once fixed properly, the system has worked flawlessly for 2 years now. Would strongly recommend having this repaired at a certified shop. The key fob emergency release can work as a temporary solution, but the underlying issue needs proper attention to prevent further electrical system complications.

Thanks for sharing your experience. I also faced a similar electrical fault with my Audi A5 lock actuator last year. The fuel flap issue was causing real headaches since I couldnt refuel normally. Your solution matches what I ended up doing, going to a certified shop really was the best call. Just curious, do you remember roughly what you paid for the complete repair? Also, has everything worked perfectly since the fix or have you noticed any other quirks with the fuel filler system?

Since getting the repair done at the certified shop, the fuel filler system has worked perfectly without any issues. The lock actuator and complete cable release mechanism were replaced due to the electrical fault in the original system. The total repair cost came to 210 Euro for parts and labor, which included replacing the defective linkage and performing a full system reset. The investment was worth it since the fuel flap release now works smoothly every time. No additional quirks or problems have surfaced in the months following the repair. The certified technicians clearly knew what they were doing with the Audi diagnostic equipment. They identified and fixed all the underlying issues, not just the obvious symptoms. Its good to hear you also had success going the certified shop route with your A5.

Thanks for the helpful advice. I took my A5 to a certified Audi shop last week and wanted to share how it went. The fuel flap issue was indeed the actuator, just as suggested. They found corroded wiring that was causing the release button malfunction. The repair took about 3 hours total. They replaced the entire fuel door assembly and rewired the electrical connections. Total cost was 280 Euro, bit more than expected but worth it for a proper fix. The mechanic showed me the damaged parts and explained everything clearly. The fuel filler system now works perfectly, no more error codes or system limitations. Really glad I went with a certified shop instead of trying cheaper alternatives. They even updated some software while the car was in, which was a nice bonus. Already put 500km on it since the repair with no issues. The release button works smoothly every time. Definitely learned my lesson about getting specialized repairs done right the first time at proper shops.