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 Observe notes on procedure for disconnecting the battery → Rep. Gr.27. –  Slide cover above battery to the right -arrow 1- and lift off -arrow 2-.

–  With ignition switched off, disconnect earth strap -arrow- at battery. –  Briefly open filler cap for fuel tank and close again. Saloon: –  Detach trim in luggage compartment. –  If necessary, fold forward right backrest of rear seat bench. Avant: –  Remove left-side section of backrest (1/3 section) → Rep. Gr.72. –  Remove left-side trim in luggage compartment and anti-soiling tray → Rep. Gr.70.

All models: –  Unscrew cover for flange -arrows-.

–  Unplug electrical connector -arrow- at flange.

Vehicles with hose connection: –  Detach breather pipe -1-.

Vehicles with plug-in connector: –  Disconnect breather pipe -arrow- (press release tab).

All models: –  Open tank flap and detach loop -1- on tank flap.   Note Do not remove filler cap. –  Clean area around fuel filler neck. –  Lever off retaining ring -arrow- in rubber cup and press rubber cup through to inside.

–  Remove rear wheel (right-side). –  Remove rear right wheel housing liner → Rep. Gr.66. –  Disconnect breather pipe -2- from fuel filler neck. –  Unscrew bolt -1- for fuel filler neck.

–  Remove trim panel on underbody -arrows-.

–  Remove underbody covers -1- and -2-. –  Remove rear section of exhaust system → Rep. Gr.26.   WARNING BEFORE loosening subframe bolts, take steps to ensure that vehicle does not tip forwards (e.g. put a weight of about 50 kg in luggage compartment). –  Remove rear axle → Rep. Gr.42.

–  Disengage handbrake cable from the front right of the fuel tank at the points marked by -arrows-.

WARNING The fuel system is pressurised. Before opening the system place a clean cloth around the connection. Then release pressure by carefully loosening the connection. –  Detach fuel supply pipe -1- from fuel filter (press release tab). Catch escaping fuel. –  Disconnect fuel return pipe -3- and breather pipe -2- at connection (press release tab). –  On vehicles with auxiliary heater, also disconnect fuel line leading to metering pump for auxiliary heater.

Vehicles with 1.8 ltr. turbo engine:   WARNING The fuel system is pressurised. Before opening the system place a clean cloth around the connection. Then release pressure by carefully loosening the connection. –  Disconnect fuel pipe -1- and breather pipe -2- from front right of fuel tank by pressing release tabs. –  On vehicles with auxiliary heater, also disconnect fuel line leading to metering pump for auxiliary heater.

All models: –  Position engine and gearbox jack -V.A.G 1383 A- below vehicle to support tank.   WARNING To reduce weight, fuel tank must be empty upon removal. –  Remove bolts -1 ... 7-. –  Then lower fuel tank using engine and gearbox jack -V.A.G 1383 A-.

Installing Installation is carried out in the reverse order; note the following:   Note Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. –  Check that fuel pipes and breather pipes are clipped onto brackets and fuel tank -arrows-.

–  Check the earth wiring at both ends for traces of oxidation. Remove any traces of oxidation if necessary. –  Check installation position of earth connection: l  Connector -3- must be seated properly on metal ring -2-. l  The contact tab -1- must be hooked onto the fuel tank -4-.

–  Position the fuel tank with securing straps on underbody, using the engine and gearbox jack -V.A.G 1383 A-. –  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 -2, 5, 3, 4-, then at points -1, 6, 7-. –  Secure 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 Ω. –  Install rear axle → Rep. Gr.42. –  Install rear section of exhaust system → Rep. Gr.26. –  Install rear right wheel housing liner and tighten securing bolt for fuel filler neck → Rep. Gr.66. –  Connect battery. Observe notes on procedures required after connecting battery → Rep. Gr.27. Tightening torques

Component	Nm
Securing straps to body	23
Fuel filler neck to wheel housing	23