Audi Workshop Service and Repair Manuals

Draining fuel tank Special tools and workshop equipment required

t  Wrench -T10202-

t  Fuel extractor -VAS 5190-

Procedure Observe safety precautions → Chapter. Observe rules for cleanliness → 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.

Audi RS4: –  Lift luggage compartment floor mat and make sure it remains in position. –  With ignition switched off, disconnect earth strap -arrow- at battery.

All models:   Caution Secure earth wire of fuel extractor -VAS 5190- to a bare metal part on the body. –  Detach tapered adapter -2- from shaft end -1- of fuel extractor -VAS 5190-. –  Use insulating tape to mark the extraction hose -arrow- at a distance of -a- = 1865 mm from the end of the hose.

–  Remove filler cap from fuel filler neck. –  Screw shaft end -1- of fuel extractor -VAS 5190- onto fuel filler neck. –  Push extraction hose into fuel tank until marking on extraction hose -arrow- coincides with shaft end.   Note

t  The procedure when using a fuel extractor without shaft end is basically the same. t  In this case, make a mark -arrow- on the extraction hose at distance -a- = 1800 mm from the end of the hose using insulating tape. The extraction hose has been properly inserted when the affixed mark is level with the edge of the filler neck. t  If hose is difficult to insert, apply a thin coat of engine oil. DO NOT use silicone-based lubricant. –  Drain fuel tank as far as possible via fuel filler neck. –  Carefully remove extraction hose.

–  Remove rear seat bench → Rep. Gr.72. –  Unscrew cover for flange (right-side) -arrows-.

Audi RS4: –  Pull wiring with connector -arrow- out of opening for flange and move to one side.

All models: –  Unplug electrical connector -arrow- at flange (right side of vehicle).

–  Mark fuel return pipe -1- and fuel supply pipe -2-.   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 both pipes from flange (press release tabs). –  On vehicles with auxiliary heater, also disconnect fuel line leading to metering pump for auxiliary heater (press release tab).

–  Unscrew locking ring using wrench -T10202-. –  Remove flange with seal from fuel tank opening.

–  Insert extraction hose to marking -x- = 800 mm through right opening in fuel tank and into left fuel chamber. –  Draw off fuel in left chamber of fuel tank. –  Re-install flange (right-side) → Anchor; observe notes on procedure for connecting battery → Rep. Gr.27.