Audi Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ Hose clamp pliers V.A.G 1275

• ◆ V.A.G 1383 A and V.A.G 1359/2

Observe safety precautions.

Observe rules for cleanliness => Page 20-3.

Removing

• ‒ The fuel tank must be empty when it is removed from the vehicle in order to reduce weight. Drain fuel tank if necessary. Procedure => Page 20-107.
• ‒ Remove rear axle:

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 42; Removing and installing rear axle

• ‒ Detach floor trim in luggage compartment.
• ‒ Unbolt cover for flange.

• ‒ → Release and unplug connectors -1- and -2-.

Note:

Connector -1- is only fitted on vehicles with 6-cylinder engine.

• ‒ Clean area around tank filler neck.
• ‒ → Open tank flap and lever out clamping ring -arrow- in rubber cup (on filler neck).
• ‒ Press rubber cup through to the inside.

• ‒ → Remove bolt -1- for fuel filler neck, earth connection -2- and protective plate -3- below wheel housing liner.

• ‒ → Disconnect fuel supply pipe and fuel return pipe -arrows- on underside of vehicle.

Vehicles with auxiliary heater

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

All models

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

• ‒ Mark the correct positions of the securing straps.
• ‒ → Remove securing straps and carrier plate -arrows-.
• ‒ Lower fuel tank out of vehicle.

Installing

Install in reverse sequence; note the following points:

Notes:

• ◆ Secure all hose connections with the correct hose clips (same as original equipment)

=> Parts catalogue

• ◆ Always renew sealing rings and gaskets when assembling.

• ‒ Check the earth wiring at both ends for traces of oxidation. Remove any traces of oxidation if necessary.

• ‒ → Route earth connection as shown in illustration.
• ‒ Ensure that connector for earth connection -arrow- is properly seated on metal ring on fuel filler neck.
• ‒ Loosely attach securing straps and carrier plate on fuel tank.
• ‒ Position fuel tank with securing straps and carrier plate on underside of vehicle using engine/gearbox jack V.A.G 1383 A.

• ‒ → First tighten bolt -1- securing protective plate -3-, earth connection -2- and fuel filler neck.

• ‒ → Tighten bolts for securing straps and carrier plate -arrows-.
• ‒ Tighten plastic nuts on securing straps and carrier plate.

• ‒ → Connect fuel pipes -arrows-.
• ‒ Plug in connector for fuel pump and fuel gauge sender.

Tightening torques