Audi Workshop Service and Repair Manuals

Observe safety precautions

Observe rules for cleanliness
=> Page 20-5

Special tools, testers and auxiliary items

• ◆ Universal support V.A.G 1359/2
• ◆ Engine/gearbox jack V.A.G 1383 A

Removing

• ‒ Obtain radio code on vehicles with coded radio.
• ‒ With ignition switched off disconnect battery earth strap.
• ‒ Open fuel filler cap briefly, then close it again.
• ‒ Drain fuel tank if necessary using fuel extractor V.A.G 1433 A => Page 20-53.

Note:

The fuel tank must be empty when it is removed from the vehicle in order to reduce weight.

• ‒ Remove rear axle:

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

• ‒ Detach trim in luggage compartment.
• ‒ Detach cover for flange on fuel tank under floor trim in luggage compartment.
• ‒ → Release and unplug 4-pin connector -1-.

Note:

Do not disconnect return pipe -2- and supply pipe -3-.

• ‒ Clean area around tank filler neck.
• ‒ Open tank flap and lever out clamping ring in rubber cup (on filler neck).

• ‒ Press rubber cup through to the inside.
• ‒ Take off rear right wheel.
• ‒ Remove rear right wheel housing liner.
• ‒ → Remove bolt -1- for fuel filler neck, earth connection -2- and protective plate -3- below wheel housing liner.

• ‒ → Mark the supply pipe -1-, return pipe -3- and breather pipe to activated charcoal filter -2- on vehicle floor. Then pull pipes off.
• ‒ Position engine/gearbox hoist V.A.G 1383 A below vehicle to support tank.

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

Installing

Installation is carried out in the reverse order, when doing this note the following:

Notes:

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

=> Parts catalogue

• ◆ Hose clip pliers V.A.G 1921 are recommended when installing spring-type clips.
• ◆ Always renew sealing rings and gaskets when assembling.

• ‒ → Ensure that connector for earth connection -arrow- is properly seated on metal ring on fuel filler neck. Check that the earth wire is routed correctly.

• ‒ 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 pipes as previously marked:

•     1 -    Supply pipe
•     3 -    Breather pipe to activated charcoal filter
•     2 -    Return pipe

• ‒ Plug in connector for fuel pump and fuel gauge sender.

• ‒ After connecting battery, enter anti-theft code for radio

=> Radio operating instructions

• ‒ Close windows fully using electric window switches.
• ‒ Then operate all electric window switches again for at least one second in the "close" direction to activate the automatic one-touch function.
• ‒ Set clock to correct time.

Tightening torques