Audi Workshop Service and Repair Manuals

Observe safety precautions.

Observe rules for cleanliness => Page 20-3.

A - Procedure if tank is more than 1/3 full => Page 20-46.

B - Procedure if tank is less than 1/3 full => Page 20-51.

Special tools and workshop equipment required

• ◆ VAS 5190

or

• ◆ V.A.G 1433 A

• ◆ Union nut spanner 3217

Work sequence

A - Procedure if fuel tank is more than 1/3 full

• ‒ Remove filler cap from fuel tank filler neck.

• ‒ → Detach tapered adapter -2- from shaft end -1- of VAS 5190.
• ‒ Mark drain hose -arrow- at distance a = 1415 mm from end of hose using insulating tape.

• ‒ → Screw shaft end -1- of fuel extractor VAS 5190 onto fuel filler neck.
• ‒ Push drain hose into fuel tank until marking on drain hose -arrow- coincides with shaft end.

Note:

→ A ball valve -2- is located at the bottom end of the fuel filler neck in the fuel tank -1-. To avoid damaging the ball valve with the drain hose -3-, do not push the hose into the fuel tank further than the mark -arrow- applied earlier.

• ‒ Drain tank as far as possible via fuel filler neck.
• ‒ Carefully pull out drain hose.

Notes:

• ◆ The procedure when using a fuel extractor without shaft end is basically the same.
• ◆ → In this case, mark drain hose -arrow- at distance a = 1350 mm from end of drain hose using insulating tape. The drain hose is fitted properly when the marking on the hose coincides with the rim of the filler neck.
• ◆ If the hose does not go in easily, lubricate lightly with engine oil. Do not use silicone lubricant.

• ‒ Remove rear seat bench.

=> General body repairs, Interior; Repair group 72; Rear seats

• ‒ Fold back floor covering under rear seat bench.
• ‒ Detach cover for flange on fuel tank under rear seat bench (right side).
• ‒ → Release and unplug electrical connector -arrow-.

• ‒ → Press release catches and disconnect black fuel supply line -1- and blue fuel return line -2-.

• ‒ → Remove union nut with spanner 3217.
• ‒ Take flange of fuel delivery unit out of opening in fuel tank and move clear, with hoses connected.
• ‒ Draw off fuel in right chamber of fuel tank.

• ‒ → Insert drain hose to marking x = 800 mm through right opening in fuel tank and into left fuel chamber.
• ‒ Draw off fuel in left chamber of fuel tank.
• ‒ Re-install flange on right side => Page 20-70.

B - Procedure if tank is less than 1/3 full

• ‒ Remove rear seat bench.

=> General body repairs, Interior; Repair group 72; Rear seats

• ‒ Fold back floor covering under rear seat bench.
• ‒ Detach cover for flange on fuel tank under rear seat bench (right side).

• ‒ → Release and unplug electrical connector -arrow-.

• ‒ → Press release catches and disconnect black fuel supply line -1- and blue fuel return line -2-.

• ‒ → Remove union nut with spanner 3217.
• ‒ Take flange of fuel delivery unit out of opening in fuel tank and move clear, with hoses connected.

• ‒ Draw off fuel in right chamber of fuel tank.

• ‒ → Insert drain hose to marking x = 700 mm through right opening in fuel tank and into left fuel chamber.
• ‒ Draw off fuel in left chamber of fuel tank.
• ‒ Re-install flange on right side => Page 20-70.