Fuel Tank With Attachments, Removing and Installing

Fuel Tank With Attachments, Removing And Installing - Vehicles With 6-cylinder Engine And A6 Allroad

Special tools, testers and auxiliary items







- Engine/transmission jack VAG 1383 A with universal support VAG1359/2

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.

Removing
- Obtain radio code on vehicles with coded radio.







- Remove cover above battery -arrow-.

NOTE: On vehicles without separate battery cover: Remove plenum cover.







- With ignition switched off disconnect battery Ground strap.

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.
- Remove center and rear silencers







- Remove heat shield for fuel filler neck above rear silencer (right side).
- Remove rear axle.
- 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
- Remove right rear wheel housing unit.







- Remove 2 bolts -arrows- for fuel filler neck underneath wheelhousing liner.
- Disconnect line -1- to 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.







- Mark supply line -3-, return line -2- and vent line -1- and disconnect.







- Disconnect vent line for EVAP canister -arrow- at rear of fuel tank.

NOTE: The vent line remains attached when the fuel tank is removed.

- Remove heat shields at left and right of fuel tank.
- Support fuel tank using VAG1383A engine/transmission jack.

WARNING: For weight reason the fuel tank must be empty when removing.







- Remove fasteners -1- through -8- for support straps and carrier panel.
- Lower fuel tank together with carrier panel -9-.

NOTE: The -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.







- Route and connect Ground wire as shown -arrow-.
- Ensure 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 the terminal -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 Ohm

- Ensure that fuel supply and return 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.
- Install right rear wheelhousing liner.
- Install center and rear muffler stress free.
- Install rear axle.
- Generate readiness code.

Tightening torque

Component Nm
Filler neck at body 23 (17 ft lb)
Fuel filler neck heat shield at filler neck 2 (18 in lb)
Cover for EVAP canisters 10 (7 ft lb)
Battery connector 5 (44 in lb)