Fuel Tank With Attachments
Fuel Tank with Attachments
Special tools, testers and auxiliary items required
• Engine/Transmission Jack (V.A.G 1383 A )
Removing
Observe safety precautions. Refer to => [ Safety Precautions ] Fuel Supply System.
Observe rules for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply System.
CAUTION!
• For removal, fuel tank must be empty for weight reasons. Empty fuel tank if necessary. Refer to => [ Fuel Tank, Draining ] Description and Operation.
CAUTION!
• Observe safety precautions when disconnecting the battery.
All except Audi RS4:
- Push the cover over the battery toward the right - arrow 1 - and remove it upward - arrow 2 -.
- With ignition switched off, disconnect Battery Ground (GND) cable - arrow -.
Audi RS4:
- Remove carpeting in luggage compartment.
- With ignition switched off, disconnect Battery Ground (GND) cable - arrow -.
All:
- Open fuel filler flap briefly and then close again.
Sedan:
- Remove carpeting in luggage compartment.
- Fold forward the right backrest of rear seat, if necessary.
Wagon:
- Remove left 1/3 backrest.
- Remove left side trim in luggage compartment and dirt tray.
All:
- Remove cover - arrows - for locking flange in luggage compartment.
- Disconnect ventilation line - 1 -. Do this by pressing the releasing ring - 2 - approximately 2 mm in direction - arrow A - and simultaneously pulling the vent line off - arrow B -.
- Remove rear seat bench.
- Remove cover - arrows - for locking flange, left and right.
Audi RS4:
- Remove electrical wires with connector - arrow - from locking flange opening and lay them aside.
All:
- Disconnect electrical harness connector - arrow - at right locking flange.
- Disconnect electrical harness connector - arrow - at left locking flange.
- Open the tank flap and clean the area around the fuel filler tube.
• Do not remove fuel cap.
- Pry the tensioning ring - arrow - out from rubber gasket and press the rubber gasket through toward the inside.
- Remove right rear wheel.
- Remove right rear wheel housing liner.
- Pull vent line - 2 - off from fuel filler tube by pressing the release buttons.
- Unfasten bolt - 1 - for fuel filler tube.
- Remove EVAP canister cover - arrows - at bottom of spare wheel well.
- Separate the vent lines - 1 - and - 2 -. Do this by pressing the releasing ring - 3 - in direction of - arrow A - and simultaneously pulling the vent line off - arrow B -.
- Unclip the vent lines at top from the bracket - arrow -.
Audi RS4:
- Remove bolts - 1 -.
- Remove EVAP canister cover at bottom of spare wheel well - arrows -.
- Disconnect purge lines - 1 - and ventilation lines - 2 - by pressing the release button.
- Unclip lines from bracket - arrow -.
All:
- Remove rear part of exhaust system.
- Remove driveshaft.
CAUTION!
Before removing the subframe bolts, secure the vehicle against tipping over (e.g. load the luggage compartment with approximately 50 kg).
- Remove rear axle.
- Remove heat shields - 1 - and - 2 -.
- Disconnect parking brake cables at positions indicated by - arrows -.
CAUTION!
Fuel system is under pressure! Before opening system, place clean rags around the connection. Then release pressure by carefully loosening the connection.
- Separate fuel line - 2 - and vent line - 1 - at right front from fuel tank, by pressing the release buttons.
- Place the Engine/Transmission Jack (V.A.G 1383 A ) under the fuel tank for support.
CAUTION!
• For weight reasons, fuel tank must be empty for removal.
- Remove bolts - 1 to 10 -.
- Lower the fuel tank with the Engine/Transmission Jack (V.A.G 1383 A), thereby guiding it by hand.
Installing
Installation is in reverse order of removal, note the following:
- Make sure the fuel and vent lines are properly clipped to the fuel tank.
- Check if the Ground (GND) wiring on both connections show signs of oxidation. If necessary, remove.
- Check the installation position of the Ground (GND) connection:
• The connector - 4 - must be securely attached to the metal ring - 3 -.
• The contact - 1 - must be attached into the fuel tank - 5 - and be secured with the spacer bushing - 2 -.
- Position the fuel tank with mounting straps and carrier plate to vehicle floor using the Engine/Transmission Jack (V.A.G 1383 A ).
- Make sure the fuel tank is positioned so that the filler tube can be correctly guided into the opening of the body.
- Fasten mounting straps and carrier plate - 1 to 10 -.
- Fasten the fuel filler tube.
CAUTION!
After installing, check electrical connection of metal ring at fuel filler tube to a blank portion of chassis using Ohm meter:
• Specified value: Approximately 0 Ohm.
- Install rear axle.
- Install driveshaft.
- Install rear part of exhaust system.
- Install right rear wheel housing liner by tightening fuel filler neck screws.
- Connect battery. Observe safety precautions after connecting battery.
Tightening Specifications
