Technical Service Bulletin
55 Fuel filler door to side panel incorrect fitment
55 23 81 2071697/1 October 24, 2023.
Model(s)

Year

VIN Range

Vehicle-Specific Equipment

Q8, SQ8, and
RS Q8

2021 – 2025

All

Internal Combustion Engine

Condition
Customer states:
• The gap between the fuel filler door and the side panel is insufficient.
and/or
• The fuel filler door is over flush to the side panel.
Workshop findings:
• The customer complaint can be reproduced.

Technical Background
The fuel filler door insert may have expanded due to moisture adsorption. This causes the gap between the fuel
filler door and the side panel to change.

Production Solution
Optimized process.

Service
1.

Replace the fuel filler door insert according to: Elsa>>Repair manual>>Body>>Body Exterior>>55
Hood, Lids>>Fuel Filler Door Unit>> Fuel Filler Door Unit, Removing and Installing.

2.

Do not discard the original fuel filler door! The original fuel filler door (with original paint finish) must
be reinstalled.

3.

The painted fuel filler door must be bonded/sealed additionally to the fuel filler door insert.

4.

The new fuel filler door insert is equipped with one water drain in position #1. Two additional water
drains must be created in positions #2 and #3 (Figure 1).

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intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this
document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may
these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Technical Service Bulletin

Figure 1. Adding two water drains in positions #2 & #3.
5.

Make two additional water drains using a belt sander (Figures 2 – 4).

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All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this
document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may
these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Technical Service Bulletin

Figure 2. Use a belt sander to make additional drains.

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All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this
document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may
these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Technical Service Bulletin

Figure 3. One of the new water drains.

© 2023 Audi of America, Inc.

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All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this
document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may
these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Technical Service Bulletin

Figure 4. Both newly added water drains.
6.

Clean the fuel filler door insert where it contacts the fuel filler door as well as the backside of the fuel
filler door with all purpose cleaner D00940104. Observe flash-off/drying time (Figure 5).

© 2023 Audi of America, Inc.

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All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this
document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may
these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Technical Service Bulletin

Figure 5. Clean the fuel filler door and insert with all purpose cleaner.
7.

Apply a bead of adhesive (D190MKDA3 or D172090M2) on the inside area of the bracket.
Do not apply any adhesive in the area of the fuel filler door actuator bracket (Figure 6)!

© 2023 Audi of America, Inc.

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All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this
document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may
these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Technical Service Bulletin

Figure 6. Adhesive applied to the fuel filler door insert.
8.

Reinstall the original fuel filler door on the modified fuel filler door insert immediately.
Remove any excess adhesive as quickly as possible (Figure 7)!

© 2023 Audi of America, Inc.

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All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this
document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may
these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Technical Service Bulletin

Figure 7. Original fuel filler door installed with excess adhesive removed.

Warranty
Claim Type:

• 110 up to 48 Months/50,000 Miles.
• G10 for CPO Covered Vehicles – Verify Owner.
• If the vehicle is outside any warranty, this Technical Service Bulletin is
informational only.

Service Number:

5537

Damage Code:

0010

Labor Operations: Fuel filler door replace

Diagnostic Time:

5537 5500

See SRT with
associated operations

Fuel filler door modify

5537 4999

20 TU

GFF

No allowance

0 TU

Road test prior to the service
procedure

No allowance

0 TU

© 2023 Audi of America, Inc.

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All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this
document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may
these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Technical Service Bulletin
Road test after the service procedure
Claim Comment:

No allowance

0 TU

As per TSB 2071697/1

All warranty claims submitted for payment must be in accordance with the Audi Warranty Policies and Procedures
Manual. Claims are subject to review or audit by Audi Warranty.

Required Parts and Tools
Always check with your Parts Department and/or ETKA for the latest information and parts bulletins.
Part Number

Part Description

Quantity

See ETKA

Fasteners, Bolts, Nuts, and Screws as needed per the Repair Manual

See ETKA/ELSA

4M8809906

Insert

01

D 00940104

All purpose cleaner

0.1

or equivalent

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All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this
document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may
these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Technical Service Bulletin

D 190MKDA3 1-pack adhesive

0.3

or
D 172090M2

1-pack ms adhesive

© 2023 Audi of America, Inc.

0.3

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All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this
document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may
these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Technical Service Bulletin

Additional Information
All parts and service references provided in this TSB (2071697) are subject to change and/or removal.
©2023 Audi of America, Inc. All rights reserved. The information contained in this document is based on the
latest information available at the time of printing and is subject to the copyright and other intellectual property
rights of Audi of America, Inc., its affiliated companies, and its licensors. All rights are reserved to make changes
at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may
these materials be modified or reposted to other sites without the prior expressed written permission of the
publisher.

© 2023 Audi of America, Inc.

Page 11 of 11

All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this
document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may
these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.