Fuel Tank With Attachments, Removing and Installing
Fuel Tank With Attachments, Removing And Installing - Vehicles With 8-cylinder Engine Except A6 Allroad
WARNING: Fire hazard. When working on the fuel system DO NOT smoke, work near heaters or have anything in the area that can ignite the fuel or fumes.
Special tools, testers and auxiliary items
- VAG 1383 A Engine/transmission jack with VAG1359/2 Universal support
Removing
- For weight reasons the fuel tank must be empty. If necessary empty fuel tank.
CAUTION: After reconnecting vehicle battery on vehicles equipped with Audi Telematics by OnStar(R), switch-on the emergency (back-up) battery for the Telematic/Telephone Control Module.
Audi A6:
- Remove cover above battery -arrow-.
NOTE: On vehicles without separate battery cover: Remove plenum cover.
- With ignition switched off, disconnect battery Ground (GND) cable -arrow-.
Audi RS6:
- Turn locks -arrow- counterclockwise and remove cover -1-
- Remove cover -1- off upward.
- With ignition switched off, disconnect battery Ground (GND) cable -arrow-.
All:
WARNING: The fuel tank must be empty when removing in order to reduce weight. If necessary empty fuel tank.
- Remove rear seat bench.
- Remove cover for flange on fuel tank under rear seat bench (right side).
- Carefully release 4-pin connector -arrow- and disconnect.
- Thoroughly clean area around fuel filler neck.
- With the fuel filler flap open, loop -1- where available.
- Pry locking collar -arrow- in the rubber cup (around the filler neck) out
- Push rubber cup inward.
- Open fuel filler cap briefly and close again
NOTE: Do not remove caps.
- Remove center and rear muffler
- Remove heat shield for fuel filler neck above rear silencer (right side) -arrow-.
- Remove rear axle.
- Remove rear right wheel housing liner.
- Remove bolts -1- and -2- as well as nut -3- for fuel filler neck beneath wheelhousing liner.
- Remove cover for EVAP canister under spare wheel molding.
- Remove vent lines -arrows- on EVAP canister.
WARNING:
- Fire Hazard. Do not smoke, work near heaters or have anything in the area that could ignite the fuel or fumes.
- Fuel supply lines are under pressure. Before loosening any lines, cover the connection with a rag. Release the pressure by slowly separating the connection.
Vehicles with 8 - cylinder (Naturally aspirated engine):
- Mark supply line -3-, return line -2- and vent line -1- and disconnect.
Vehicles with 8 - cylinder (Turbo engine):
- Disconnect the fuel advance line -3- from junction point.
- Disconnect the fuel return pipe -2- and the breather pipe -1-.
All:
NOTE: The vent line remains attached during removal of fuel tank.
WARNING: For weight reason the fuel tank must be empty when removing.
- Remove heat shields at left and right of fuel tank.
- Support fuel tank using VAG1383A engine/transmission jack.
WARNING: For weight reasons the fuel tank must be empty before removal of the tank is started.
- Remove fasteners -1- through -8- for support straps and carrier panel.
- Lower fuel tank together with carrier panel -9-.
NOTE: -Arrow- points toward the front of the vehicle.
Installing
Installation is the reverse of removal, however note the following:
NOTE:
- Fasten all hose clamps with the same type of clamp that was used in production.
- Use VAG1921 pliers or similar tool to install spring clamps.
- Always replace seals and O-rings.
- Check installation position of Ground (GND) connection while fuel tank and/or fuel filler neck is removed. If necessary unbolt expansion tank -1- -arrows-.
- Route and connect Ground wire as shown -arrow-.
- Make sure that harness connector for Ground (GND) connection is properly seated on metal ring (Ground clamp) on fuel filler neck.
- Check if contact terminal (tongue) at fastening hole is properly locked in.
- Mount terminal tongue -1- with the bolt -2- for fuel filler neck.
WARNING:
After installing, measure the resistance using a multimeter (Fluke 83 or equivalent) between the metal ring of the fuel filler neck and a bare metal part of the body.
- Specified value: approx. 0 Ohms
- Make sure that fuel supply, return and vent lines at right-front of fuel tank are properly installed in retainers.
- Carefully install cover for closing flange with indentation positioned on top of connector.
- With ignition switched off, reconnect battery Ground (GND) strap.
- After reconnecting battery, insert anti-theft radio code again.
- Using switches, fully close power windows up to stop.
- Then, operate all power windows for at least 1 second in "close" position to activate "one touch" opening/closing function.
- Set time display on clock.
- Install right rear wheelhousing liner.
- Install center and rear muffler stress free.
- Install rear axle.
- Generate readiness code.
Tightening torque
Component Nm
Tank strap to body 23 Nm (17 ft lb)
Fuel filler neck to body
M8 23 Nm (17 ft lb)
Spring nut 1.3 Nm (11.5 in. lb)
Heat shield for fuel filler neck at fuel filler neck 2 Nm (18 in. lb)
Battery pole 5 Nm (44 lbf -in)
EVAP cover 10 Nm (7 ft lb)