Audi Workshop Service and Repair Manuals

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

t  Hose clamps, up to 25 mm -3094- for vehicles with SCR catalytic converter

t  Engine and gearbox jack -V.A.G 1383 A-

t  Engine bung set -VAS 6122- for vehicles with SCR catalytic converter Removing –  Observe safety precautions → Chapter. –  Observe rules for cleanliness → Chapter.   WARNING Risk of accident caused by weight of fuel tank Fuel tank must be empty when it is removed. –  Drain fuel tank → Chapter. Vehicles with SCR catalytic converter: –  Drain active tank for reducing agent → Rep. gr.26.

All vehicles (continued): –  Remove rear seat bench → Rep. gr.72. –  Unscrew cover for flange -arrows-.

–  Unplug electrical connectors -1- and -2- on flange. Vehicles with auxiliary heater: –  Unplug electrical connector -3- for metering pump for auxiliary heater on flange.

All vehicles (continued): –  Open tank flap. –  Clean area around fuel filler neck. –  Remove filler cap -arrow- from fuel filler neck.   Note Seal off opening of fuel filler neck with a piece of clean foam to prevent dirt from dropping into the tank.

–  Remove rear right wheel. –  Remove rear right wheel housing liner → Rep. gr.66. –  Remove bolts -1- and -2- for fuel filler neck.

Vehicles with SCR catalytic converter: –  Press release tabs and disconnect filler and draining lines -arrows-.

–  Unscrew nut -1- and detach cover -2- for transfer pump for reducing agent -V436-.   WARNING Reducing agent can cause skin irritation. t  Avoid contact with the skin and eyes. Wear gloves and safety goggles. t  If your skin has come into contact with reducing agent, rinse it off with soap and water. t  If reducing agent gets into your eyes, rinse them out with water for several minutes. t  Do not breathe in or swallow reducing agent. t  If you have swallowed reducing agent, rinse your mouth, drink lots of water and consult a paramedic or doctor immediately.

–  Clamp off connecting hose -1- with hose clamp -3094-.   Note Hold a clean cloth under the separating point to catch escaping reducing agent. –  Press release tab to disconnect transfer line -3- and move clear transfer line. –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-.   Note Disregard -item 2-.

–  Unplug electrical connector -3- and move electrical wire clear.   Note Hold a clean cloth under the separating point to catch escaping reducing agent.   WARNING Safety risk due to escaping reducing agent. Observe safety measures for handling reducing agent → Chapter. –  Press release tabs and disconnect transfer line -1- and filler line -4-. –  Disconnect breather line -2-.

–  To disconnect breather line, press release catches in direction of -arrows-. –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-. All vehicles (continued): –  Remove rear section of exhaust system → Rep. gr.26.   WARNING The vehicle can tip over on the lifting platform when the rear axle is removed. BEFORE loosening the subframe bolts, take steps to ensure that the vehicle does not tip forwards on the lifting platform (e.g. put a weight of about 50 kg in the luggage compartment). –  Remove rear axle → Rep. gr.42.   WARNING The fuel can become extremely hot. This can cause injuries. t  In extreme cases the fuel lines and the fuel can reach a temperature of 100 °C. Allow the fuel to cool down before disconnecting the lines - danger of scalding. t  Wear protective gloves. t  Wear safety goggles. Risk of injury - fuel system operates under high pressure. To reduce the pressure in the fuel system, wrap a clean cloth around the connection and carefully loosen the connection.

–  Press release tab and disconnect fuel return line -2-. –  Disconnect fuel supply line -1-. Vehicles with auxiliary heater: –  In addition, disconnect fuel line leading to auxiliary heater at metering pump. –  Unplug electrical connector at metering pump.

All vehicles (continued): –  Position engine and gearbox jack -V.A.G 1383 A- below vehicle to support tank. –  Support fuel tank using engine and gearbox jack -V.A.G 1383 A-.

WARNING Risk of accident caused by weight of fuel tank Fuel tank must be empty when it is removed. –  Remove bolts -1 ... 5- and detach bracket -6- for exhaust system. –  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: l  Tightening torques → Chapter „Fuel tank with attached components - exploded view“ –  Check that fuel lines and breather lines are clipped onto fuel tank.

–  Position fuel tank with securing strap and support bracket on underbody using engine and gearbox jack -V.A.G 1383 A-. –  When installing fuel tank, make sure that fuel filler neck is correctly inserted into opening on body. –  Attach bracket -6- for exhaust system and tighten bolts -1 ... 5- for securing strap and support bracket.

–  Connections -1- and -2- on filler neck must be free of corrosion to ensure proper earth connection to body. –  Tighten bolts -1- and -2- for fuel filler neck.   WARNING Safety risk due to electrostatic discharge. 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 rear section of exhaust system → Rep. gr.26. Vehicles with SCR catalytic converter: –  Install cover for transfer pump for reducing agent -V436- → Rep. gr.26. All vehicles (continued): –  Install rear right wheel housing liner → Rep. gr.66. –  Install cover for flange → Fig.. –  Install rear seat bench → Rep. gr.72. Vehicles with auxiliary heater: –  Bleed fuel supply line leading to metering pump → Chapter.