Audi Workshop Service and Repair Manuals

Observe safety precautions.

Observe rules for cleanliness => Page 20-3.

Special tools and workshop equipment required

• ◆ V.A.G 1383 A and V.A.G 1359/2

Removing

• ● To avoid unnecessary weight, the fuel tank must be empty when it is removed. Drain the tank if necessary. Procedure for draining fuel tank => Page 20-45.

• ‒ 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-.

• ‒ Clean area around tank filler neck.
• ‒ → Open tank flap and (if fitted) detach loop -1- on tank flap.
• ‒ Lever out clamping ring -arrow- in rubber cup (on filler neck).

Note:

Do not remove filler cap.

• ‒ Press rubber cup through to the inside.

• ‒ Remove rear right wheel.
• ‒ Remove rear right wheel housing liner:

=> General body repairs, Exterior; Repair group 66; Removing and installing rear wheel housing liner

• ‒ → Unscrew bolts -arrows- securing fuel filler neck.
• ‒ Remove rear section of exhaust system:

=> Engine Mechanics; Repair group 26

• ‒ Remove propshaft:

=> Manual gearbox; Repair group 39

=> Automatic gearbox; Repair group 39

• ‒ Remove rear axle:

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 42; Servicing rear axle (four-wheel drive vehicles)

• ‒ → Press release catches -arrows- and disconnect black fuel supply line and blue fuel return line at front of fuel tank (right side).

Vehicles with auxiliary heater

• ‒ In addition, disconnect supply hose for auxiliary heater.

• ‒ Position engine/gearbox hoist V.A.G 1383 A below vehicle to support tank.

• ‒ → Slacken bolted connections in following order:
• ‒ Retaining lugs: -1- and -5-
• ‒ Reinforcement panel: -3- and -7-
• ‒ Securing straps: -2-, -4-, -6- and -8-
• ‒ Lower fuel tank with V.A.G 1383 A.

Installing

Install in reverse sequence; note the following points:

• ‒ → Check position of earth connection:
• ‒ Ensure connector -2- is seated properly on metal ring -1-
• ‒ Make sure earth wire is in retainer -3-
• ‒ The contact -4- must be hooked into the fuel tank -6- and secured with the spacer bush -5-
• ‒ Check that supply pipe and return pipe are clipped onto front right of fuel tank.

• ‒ Position fuel tank with securing straps and carrier plate on underside of vehicle using engine/gearbox jack V.A.G 1383 A.
• ‒ → Secure fuel tank by tightening bolted connections to 26 Nm in following order:
• ‒ Securing straps: -2-, -4-, -6- and -8-
• ‒ Reinforcement panel: -3- and -7-
• ‒ Retaining lugs: -1- and -5-

• ‒ → Tighten bolts -arrows- to 11 Nm.

• ‒ → Connect black fuel supply line and blue fuel return line at front of fuel tank (right side -arrows-).

• ‒ Install rear axle:

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 42; Servicing rear axle (four-wheel drive vehicles)

• ‒ Install rear right wheel housing liner:

=> General body repairs, Exterior; Repair group 66; Removing and installing rear wheel housing liner

• ‒ Install propshaft:

=> Manual gearbox; Repair group 39

=> Automatic gearbox; Repair group 39

• ‒ Install rear section of exhaust system:

=> Engine Mechanics; Repair group 26

• ‒ Plug in electrical connectors.
• ‒ Install cover for flange on fuel tank under rear seat bench (right side).

Tightening torques