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.   Caution To prevent irreparable damage to the electronic components when disconnecting the battery: Observe notes on procedure for disconnecting the battery. –  Disconnect battery → Rep. gr.27.

–  Remove rear seat bench → Rep. gr.72. –  Unclip the retaining tabs -arrows- for the flange cover (right-side).

–  Unplug electrical connector -arrow- at flange.

–  Unclip the retaining tabs -arrows- for the flange cover (left-side).

–  Unplug electrical connector -1- at flange. –  Unplug electrical connector -2- for Haldex coupling.

–  Open the tank flap. –  Clean area around fuel filler neck. –  Remove filler cap -arrow- from fuel filler neck. –  Seal opening of fuel filler neck with a piece of clean foam or similar to prevent dirt from dropping into the tank.

–  Remove rear right wheel housing liner → Rep. gr.66. –  Unscrew bolts -1- for fuel filler neck. –  Detach electrical wire -2- for ABS speed sensor from bracket on fuel filler neck.

–  Remove rear cross member for underbody; to do so, unscrew nuts -1- and -2-.   Caution To protect flexible joints, secure front section of exhaust system to underbody with wire before you loosen bolt connections on clamp -3-. –  Disconnect exhaust system at clamp -3-. –  Unhook rear silencer at rubber mountings -arrow- and remove rear section of exhaust system.   Note A second person will be required for detaching rear section of exhaust system.

–  Remove heat shield for propshaft -arrows-. –  Remove propshaft → Rep. gr.39.   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.

–  Disconnect fuel pipe -2- (black) and breather pipe -1- (white) at front right of fuel tank (press release tabs). Vehicles with auxiliary heater: –  In addition, disconnect fuel line leading to auxiliary heater at metering pump.

All vehicles (continued):   WARNING To reduce weight, fuel tank must be empty upon removal. –  First remove bolts -2, 5- and -6-. –  Disengage wiring harness -arrows- and move clear. –  Position engine and gearbox jack -V.A.G 1383 A- below vehicle to support tank. –  Unscrew bolts -1, 3, 4- and -7-.

–  Then lower fuel tank using engine and gearbox jack -V.A.G 1383 A-, simultaneously guiding fuel tank down by hand. –  Remove fuel tank downwards (turning it sideways as required). –  In addition, a 2nd mechanic will be required to guide the fuel filler neck on trailing arm out by hand. Installing l  Tightening torques → Chapter Installation is carried out in the reverse order; note the following:

–  Check the earth wiring at both ends for traces of oxidation and remove oxidation if necessary. –  Check installation position of earth connection: l  Connector -1- must be seated securely on metal ring -2-. l  Contact tab -4- must be attached to fuel tank -3- and secured with spacer bush -5-.

–  Position fuel tank with securing straps on underbody, using engine and gearbox jack -V.A.G 1383 A-. –  Attach wiring harness at top of fuel tank. –  When installing fuel tank, make sure that the fuel filler neck is correctly inserted into the opening on the body.

–  Secure fuel tank by first tightening bolts at points -1, 3, 4- and -7-, then at points -2, 5- and -6-.

–  Secure contact tab for earth connection with securing bolt -arrow- for 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 Ohm –  Attach electrical wire for ABS speed sensor to bracket on fuel filler neck. –  Install rear right wheel housing liner → Rep. gr.66. –  Install propshaft → Rep. gr.39. –  Install rear section of exhaust system → Rep. gr.26. –  Install rear seat bench → Rep. gr.72. –  Connect battery. Observe notes on procedures required after connecting battery → Rep. gr.27.