Audi Workshop Service and Repair Manuals

Removing and installing fuel tank with attached components Special tools and workshop equipment required

t  Engine and gearbox jack -V.A.G 1383 A- Removing Observe safety precautions → Chapter. Observe rules for cleanliness → Chapter. l  To reduce weight, the fuel tank must be empty when it is removed from the vehicle. Drain the tank if necessary. Procedure → Chapter. Saloon: –  Detach trim in luggage compartment. –  If necessary, fold forward right backrest of rear seat bench. Avant: –  Remove left-side section of backrest (1/3 section) → Rep. Gr.72. –  Remove left-side trim in luggage compartment and anti-soiling tray → Rep. Gr.70.

All models: –  Unbolt cover -arrows-.

–  Disconnect breather hose -1- by pressing release tab. –  Detach breather pipe -2-.

–  Remove rear seat bench → Rep. Gr.72. –  Detach cover for flange (left and right side) -arrows-.

–  Unplug electrical connector -arrow- at flange.

–  Unplug electrical connector -arrow- at flange (left side of vehicle).

–  Open tank flap and detach loop -1- on tank flap.   Note Do not remove filler cap. –  Clean area around fuel filler neck. –  Lever off retaining ring -arrow- in rubber cup and press rubber cup through to inside.

–  Remove rear wheel (right-side). –  Remove rear right wheel housing liner → Rep. Gr.66. –  Disconnect breather hoses -2- and -3- from fuel filler neck (press release tabs). –  Unscrew bolt -1- for fuel filler neck. –  Remove rear section of exhaust system → Rep. Gr.26. –  Remove propshaft → Rep. Gr.39.   WARNING BEFORE loosening subframe bolts, take steps to ensure that vehicle does not tip forwards (e.g. put a weight of about 50 kg in luggage compartment). –  Remove rear axle → Rep. Gr.42.

–  Detach heat shields -1- and -2-.

–  Detach handbrake cables from the retainers marked by -arrows-.

WARNING The fuel system is pressurised. Before opening the system place a clean cloth around the connection. Then release pressure by carefully loosening the connection. –  Disconnect fuel lines -1- and -2-. –  Catch escaping fuel. Vehicles with auxiliary heater: –  In addition, disconnect fuel line at metering pump for auxiliary heater.

All models: –  Position engine and gearbox jack -V.A.G 1383 A- below vehicle to support tank.   WARNING To reduce weight, fuel tank must be empty upon removal. –  Remove bolts -1 ... 10-. –  Then lower fuel tank using engine and gearbox jack -V.A.G 1383 A-, simultaneously guiding fuel tank down by hand. Installing Installation is carried out in the reverse order; note the following:   Note Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. –  Check that fuel lines are clipped onto fuel tank.

–  Check the earth wiring at both ends for traces of oxidation. Remove any traces of oxidation if necessary. –  Check installation position of earth connection: l  Connector -3- must be seated properly on metal ring -2-. l  The contact tab -1- must be hooked onto the fuel tank -4-.

–  Position the fuel tank with securing straps and support bracket on underbody, using the engine and gearbox jack -V.A.G 1383 A-. –  When installing fuel tank, make sure that the fuel filler neck is correctly inserted into the opening on the body. –  Tighten bolts for securing straps and support bracket -1 ... 10-. –  Secure fuel filler neck.   Caution After installation, use an ohmmeter to check the electrical connection between the metal ring on the fuel filler neck and a bare metal part on the body: Specification: approx. 0 Ω. –  Install rear axle → Rep. Gr.42. –  Install propshaft → Rep. Gr.39. –  Install rear section of exhaust system → Rep. Gr.26. –  Install rear right wheel housing liner and tighten securing bolt for fuel filler neck → Rep. Gr.66. Vehicles with auxiliary heater: –  Let auxiliary heater run with full load for 10 minutes to bleed fuel supply pipe going to metering pump. Tightening torques

Component	Nm
Securing straps and support bracket for fuel tank to body	23
Fuel filler neck to body	23