2022-2024 Audi e-tron GT Charging Flap Difficult to Open TSB

Owners of 2022-2024 Audi e-tron GT and RS e-tron GT models may experience an issue where the Audi e-tron GT charging flap difficult to open or close, or requires excessive force. This Technical Service Bulletin (TSB) 93 24 51 2073892/1, issued on May 9, 2024, addresses this concern by clarifying the proper method for operating the charging flap.

Symptoms

Owners may report that the "Charging flap cannot be opened/closed or that the charging flap is difficult to open." While the charging flap might technically open and close, customers often find that it requires more force than expected. This usually stems from not knowing the precise pressure point required for proper operation.

Cause of the Issue

The pressure needed to open the charging flap varies significantly depending on where it is pressed. The TSB explains that the optimal pressure point on the e-tron GT's charging flap is located directly above the actuator. Pressing on an incorrect area can cause plastic deformation of the flap over time, leading to increased resistance and making the Audi e-tron GT charging flap difficult to operate.

Repair Procedure Summary

This TSB focuses on educating both technicians and owners about the correct way to operate the charging flap to prevent the issue of an Audi e-tron GT charging flap difficult to open. The primary solution involves informing customers about the optimal pressure point.

1. Identify the Optimal Pressure Point: The optimal pressure point is at the rear of the flap, directly above the actuator, and below the design line. For precise measurement, it's approximately 45 mm from the bottom edge and 30 mm from the rear edge of the charging flap (as illustrated in Figure 4 of the TSB). A general guideline suggests it's about one-third of the flap's height from the bottom edge and roughly a thumb's width from the rear edge (Figure 3).
2. Optional Adhesive Dot Application: As an alternative, technicians can place a transparent adhesive dot on the exact pressure point. This involves cutting two circular adhesive dots, each 20 mm in diameter, from protective foil part number AKL44803005 (Figure 5). These dots are then applied directly above the actuators on both sides of the vehicle (Figure 1 shows the charging flap, and Figure 2 details the actuator pin positions). Once the owner becomes accustomed to the correct pressure point, these adhesive dots can be removed.

Required Parts and Tools

For the optional adhesive dot application, the following part is specified:

Tool Number	Tool Description
AKL44803005	Foil

Important Warnings

Audi includes a critical notice for technicians regarding this TSB:

"Try to reproduce the customer complaint (based on the description/cause of the issue), so that it can be clearly assigned to this TSB. The following repair must only be carried out if all the criteria (model/type, chassis number, engine/motor and gearbox code, PR number(s), part number, software version, code etc.) apply exactly. Otherwise, this solution will not eliminate the problem, and repeat repairs may be necessary. In such a case, we may reject the warranty claim and charge back the cost of the parts."

Additionally, this TSB is informational only and is not applicable to any Audi Warranty.

Owner Action

If you are experiencing a charging flap that is difficult to open or close on your 2022-2024 Audi e-tron GT or RS e-tron GT, it is recommended to visit your authorized Audi dealership. They can demonstrate the optimal pressure point for operating the charging flap and, if necessary, apply the temporary adhesive dots to help you learn the correct technique. Be aware that this TSB is informational and the service may not be covered under warranty.

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Source: NHTSA ID 11002169