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.   Caution To prevent irreparable damage to the electronic components when disconnecting the battery: Observe notes on procedure for disconnecting the battery. –  Disconnect battery → Electrical system; Rep. gr.27.   WARNING Risk of accident caused by weight of fuel tank Fuel tank must be empty when it is removed. –  Drain fuel tank → Chapter.

–  Remove rear seat bench → Rep. gr.72. –  Unscrew cover for flange -arrows-.

–  Unplug electrical connector -1- on flange. –  If fitted, unplug electrical connector -2- for metering pump for auxiliary heater on flange.

–  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 → Rep. gr.44. –  Remove rear right wheel housing liner → Rep. gr.66. –  Remove bolts -1- and -2- for fuel filler neck. –  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 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 line -1- at front of fuel tank (right-side). –  If fitted, disconnect fuel line leading to auxiliary heater and unplug electrical connector at metering pump.

–  Disconnect breather line -1- on left of activated charcoal filter (press release tab).

–  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 ... 4- and detach bracket -5- 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 l  Tightening torque → Chapter Installation is carried out in the reverse order; note the following: –  Check that fuel lines are clipped onto fuel tank.

–  Position fuel tank and securing straps 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 -5- for exhaust system and tighten securing strap bolts -1 ... 4-.

–  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 Risk of explosion caused by 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. –  Install rear right wheel housing liner → Rep. gr.66. –  Fit rear wheel → Rep. gr.44. –  Install cover for flange → Fig.. –  Install rear seat bench → Rep. gr.72. –  Connect battery (observe notes on procedure for connecting the battery → Electrical system; Rep. gr.27). –  Vehicles with auxiliary heater: Bleed fuel supply line leading to metering pump → Chapter.