What is TSB 2071697/2 about?

TSB 2071697/2 addresses an insufficient gap width between the fuel tank flap and the side panel on certain Audi Q8, SQ8, and RS Q8 models, which can cause the flap to overlap the body.

What are the symptoms of the fuel flap gap issue?

Owners may observe an "insufficient gap width between the tank flap and the side panel," the "tank flap overlaps with the side panel," or the fuel filler door appearing "crooked" or misaligned.

Which Audi models are affected by this TSB?

This TSB applies to 2021-2025 Audi Q8, SQ8, and RS Q8 vehicles.

What is the cause of the insufficient fuel flap gap?

The issue is caused by moisture entering the tank flap bracket, leading to its expansion and subsequent misalignment of the fuel flap.

Will this repair be covered under warranty?

If your vehicle is still under warranty, the repair described in TSB 2071697/2, using Service Number 5537 and Damage Code 0010, may be covered. It's best to consult your Audi service center for specific warranty eligibility.

Audi Q8 Fuel Flap Gap TSB 2071697/2

Owners of 2021-2025 Audi Q8, SQ8, and RS Q8 models may notice an issue with the fuel filler door, specifically an insufficient gap width between the tank flap and the adjacent body panel. This can manifest as the tank flap overlapping the side panel, or issues with its dimensional accuracy, including incorrect gap and flush dimensions, or a crooked appearance. Audi has released Technical Service Bulletin (TSB) 2071697/2 to address this concern, providing a detailed repair procedure for technicians. This TSB was initially published on October 24, 2023, and revised on March 6, 2025.

The primary symptom reported by customers and confirmed by workshops is an "insufficient gap width between the tank flap and the side panel," often leading to the "tank flap overlaps with the side panel." Technicians may also identify issues such as "dimensional accuracy -> gap dimension incorrect," "dimensional accuracy -> flush dimension incorrect," or a "deviation in contour pattern dimensions" of the fuel filler door. These conditions can make the fuel flap appear "crooked" or misaligned. If you observe an Audi Q8 fuel flap gap issue, your vehicle may be affected by this TSB.

Technical Background

According to Audi, the root cause of the insufficient gap width is moisture ingress into the tank flap bracket. This moisture can cause the bracket material to expand, altering the precise dimensions and alignment of the fuel flap relative to the vehicle's side panel. This expansion leads to the observed gap and flush dimension inaccuracies.

Repair Procedure Summary

To resolve the Audi Q8 fuel flap gap issue, Audi TSB 2071697/2 outlines a specific repair procedure. The process involves replacing the existing tank flap unit. After removal, the original painted tank flap is reinstalled onto a new bracket. Crucially, the painted tank flap must be additionally bonded and sealed to the tank flap unit using a specified adhesive.

Furthermore, the repair requires modifying the tank flap unit to improve drainage. This involves creating two new water drains at specific positions (2 and 3), in addition to the existing drain at position 1. Technicians are instructed to use a belt grinder to make these additional drains, as detailed in the TSB's figures. The area where the tank flap contacts the bracket and the reverse side of the tank flap must be thoroughly cleaned using an all-purpose cleaner before adhesive application. Care must be taken to avoid applying adhesive near the tank flap closing actuator. Any excess adhesive must be removed immediately after installation.

Required Parts and Tools

The following parts and materials are specified in TSB 2071697/2 for this repair:

Insert: Part Number 4M8809906 (Quantity: 1)
All purpose cleaner: Part Number D 00940104 (Quantity: 0.1)
1-pack adhesive: Part Number D 190MKDA3 (Quantity: 0.3)
Alternatively, 1-pack MS adhesive: Part Number D 172090M2 (Quantity: 0.3)
Fasteners, Bolts, Nuts, and Screws: As needed per the repair manual (See ETKA/ELSA)

Technicians will also utilize a belt grinder for creating the additional water drains.

Warranty Information

For warranty claims related to TSB 2071697/2, the following codes apply:

Service Number: 5537
Damage Code: 0010
Labor Operations:
- Fuel filler door replace: 5537 5500 (See SRT with associated operations)
- Fuel filler door modify: 5537 4999 (20 TU)
Claim Comment: As per TSB 2071697/2

Audi states that all warranty claims must adhere to the Audi Warranty Policies and Procedures Manual and are subject to review or audit. If the vehicle is outside of warranty, this Technical Service Bulletin serves as informational guidance.

Important Revision History

This Technical Service Bulletin, Transaction No. 2071697/2, has undergone revisions since its initial publication. The first version was released on October 24, 2023. Revision 2, released on March 6, 2025, included updates to the title, header, condition description, technical background, production solution, service procedure, warranty information, and the required parts and tools list. Owners searching for information on earlier versions of this bulletin should refer to the current document.

What Owners Should Do

If you own a 2021-2025 Audi Q8, SQ8, or RS Q8 and notice an issue with your fuel filler door's alignment or an insufficient gap, it is recommended to contact your authorized Audi service center. Describe the symptoms you are experiencing, such as the Audi Q8 fuel flap gap being incorrect or the flap overlapping the body panel. Referencing TSB 2071697/2 can help ensure your service center is aware of the specific repair procedure for this known issue.

Source: NHTSA ID: 11016524