CHARGEPORT ACTUATOR REPLACEMENT. (And possible boot cubby leak fix) by Max Berman
Hi folks. You'll probably find that after your warranty goes, so does your charge port actuator. This means you'll come to your car and find that the charge flap won't unlock. Here's a quick guide to replacing it. Takes about 30 minutes with the right tools. The genuine part costs around £33.
1. Don't do what I did and lever the port open, you'll snap off the lugs that hold the charge flap to the charge door. Slide the flap towards the front of the car then hinge outwards from the back. Refer to the tech manual I've posted for clearer instructions.
2. Spray around the rim of your charge port (where the car meets the plastic charge port) with soapy water. This aids removal without scratching paint.
3. Using a smallish pointy trim tool ( I got a generic set off Amazon), lever the charge port from the bottom left. Once you've got it far enough, pull the whole assembly out with your fingers. Be careful not to snap any lugs!
4. Carefully remove the wee drainage tube (pictured) and the two sets of wired plugs going to the charge port. The charge port should now be free of the car. My Drainage tube was loose which I realised was causing the leak in my boot cubby!
5. If you need to, you can now charge your car at this point.
6. Looking at the back of the charge port, you'll see the actuator, held in with two Torx 20mm screws. Carefully undo and set aside.
7. You should be able to gently twist the entire actuator to unlock the port and remove the actuator from the assembly.
8. I went for a genuine part from VW. It was £33. It's part 8V0.862.159.A You can get this from either a VW or Audi parts department. Shop around. There was a £10 difference between highest and lowest price local to me.
9. To reassemble, do everything in reverse.
10. Important note: I reassembled but left the actuator lead unplugged and in the open position. Hopefully this will slow down this problem reoccurring. It's not like anyone is going to steal your charge! The flap opens and closes like normal but doesn't lock with the central locking. Be sure to tape up or make the plug terminal watertight if you choose to do this. I just covered the plug socket with some polythene before partially plugging the plug back in. This held the plug firmly in place and kept the terminals dry.