2021-2025 Audi Q8 Fuel Filler Door Fitment TSB 2071697/1

Owners of 2021-2025 Audi Q8, SQ8, and RS Q8 vehicles may notice an issue with the Audi Q8 fuel filler door fitment. This problem, identified in Technical Service Bulletin (TSB) 2071697/1, describes situations where the fuel filler door does not sit correctly against the side panel of the vehicle. This TSB was released on October 24, 2023, to provide a repair procedure for affected vehicles with internal combustion engines.

Symptoms

If you own a 2021-2025 Audi Q8, SQ8, or RS Q8, you might observe the following issues related to the Audi Q8 fuel filler door fitment:

• The gap between the fuel filler door and the vehicle's side panel appears insufficient.
• The fuel filler door sits over-flush with the side panel, meaning it protrudes slightly.

These symptoms indicate an incorrect fitment that can be reproduced and confirmed by a technician.

Technical Background

Audi has determined that the root cause of the incorrect Audi Q8 fuel filler door fitment is the expansion of the fuel filler door insert. This expansion is attributed to moisture adsorption, where the material of the insert absorbs moisture, causing it to swell and alter the fitment with the side panel.

Important Warnings

During the repair process, it is crucial to follow specific instructions to ensure proper function and avoid damage. Technicians are explicitly warned:

• Do not apply any adhesive in the area of the fuel filler door actuator bracket! Applying adhesive in this specific area could interfere with the proper operation of the fuel filler door actuator.
• The original fuel filler door (with its original paint finish) must not be discarded. It needs to be reinstalled after the insert modification.

Repair Procedure Summary

To correct the fuel filler door fitment issue, Audi TSB 2071697/1 outlines a multi-step repair process for technicians:

1. The fuel filler door insert must be replaced. This involves following the detailed instructions provided in the Elsa repair manual for removing and installing the fuel filler door unit.
2. The original painted fuel filler door must be retained and reinstalled, not replaced.
3. The painted fuel filler door must be bonded and sealed to the new fuel filler door insert.
4. The new fuel filler door insert comes with one water drain. Technicians must create two additional water drains in specific positions (#2 and #3) as illustrated in Figure 1 of the TSB.
5. A belt sander is used to create these additional water drains, as shown in Figures 2-4.
6. The fuel filler door insert's contact areas and the backside of the fuel filler door are cleaned using all-purpose cleaner D00940104. Proper flash-off and drying times must be observed (Figure 5).
7. Adhesive (D190MKDA3 or D172090M2) is applied to the inside area of the bracket, carefully avoiding the fuel filler door actuator bracket area (Figure 6).
8. The original fuel filler door is immediately reinstalled onto the modified insert, and any excess adhesive is removed promptly (Figure 7).

Required Parts and Tools

For this repair, the following parts and materials are specified:

• Insert: Part Number 4M8809906 (Quantity: 01)
• All purpose cleaner: Part Number D00940104 or equivalent (Quantity: 0.1)
• 1-pack adhesive: Part Number D190MKDA3 or D172090M2 (Quantity: 0.3)
• Fasteners, Bolts, Nuts, and Screws: As needed per the repair manual (Refer to ETKA/ELSA)

Warranty Information

This repair is covered under warranty for vehicles up to 48 months or 50,000 miles. For Certified Pre-Owned (CPO) vehicles, ownership verification (G10) is required. If the vehicle is outside of warranty, this Technical Service Bulletin serves as informational guidance only.

• Service Number: 5537
• Damage Code: 0010
• Labor Operations:
  • Fuel filler door replace: 5537 5500 (Time Units: See SRT with associated operations)
  • Fuel filler door modify: 5537 4999 (Time Units: 20 TU)
• Diagnostic Time (GFF) and Road Test Time: No allowance (0 TU) for both prior to and after the service procedure.
• Claim Comment: As per TSB 2071697/1

Source: NHTSA ID 10244486