Fuel Tank With Attachments, Removing and Installing
Fuel Tank With Attachments, Removing And Installing
Special Tools and Equipment
- V.A.G1383A engine/transmission jack
- T10031 mount
Removing
Observe safety precautions.
Observe rules for cleanliness.
- For removal, fuel tank must be empty for weight reasons. Empty fuel tank if necessary.
- Release fuel filler flap.
CAUTION:
- On vehicles equipped with Audi Telematics by OnStar(R), switch-off the emergency (backup) battery for the Telematic/Telephone Control Module prior to disconnecting vehicle battery. Use must use the VAS 5051 or VAS 5052.
- The battery must only be disconnected and connected with the ignition switched off, since the Engine Control Module (ECM) can otherwise be damaged.
- Disconnect battery Ground (GND) strap with the ignition switched off.
- Remove luggage compartment floor lining.
- Remove cover for right connector flange (arrows).
- Disconnect ventilation line (arrow), to do so press release mechanisms and disconnect.
WARNING: Before LOOSENING subframe bolts, secure vehicle against tipping (e.g. load luggage compartment with approx. 50 kg).
- Removing rear axle.
- Rear right wheelhousing liner, removing.
- Disconnect Ground (GND) wire -3- from fuel filler tube.
- Disconnect electrical harness connector -1- for Fuel Tank Lock Switch -F314-
- Disconnect ventilation line -5- from fuel filler tube.
- Unscrew bolts -2- and -4- for fuel filler tube.
- Check whether driveshaft has been secured against falling down.
- Driveshaft must be supported on a wood block -1- and secured with wire or cable tie (arrow).
- Make sure that driveshaft is tilted downward slightly so that fuel tank can later be guided over it.
NOTE: The maximum permissible bending angle on driveshaft must not exceed 8 degree.
- Remove heat shield for driveshaft -arrows-.
NOTE: Heat shield is also clipped in on ventilation line at top.
- Remove cover -1-, left, bottom at vehicle floor.
- Remove cover -1-, right, bottom at vehicle floor.
- Disconnect electrical harness connectors:
2 to fuel pumps
3 to fuel level sensors
- Disconnect fuel lines (press release buttons):
1 Fuel return line
4 Fuel supply line
- Disconnect rear right ventilation line (arrow) from fuel tank (press release button).
- Hang brake calipers, previously hung on fuel tank retainers, of removed rear axle on suspension struts using wire (arrow).
- Place V.A.G 1383 A engine/transmission jack with T10031 mount (without threaded rods) under fuel tank to support.
- Support fuel tank using V.A.G 1383 A and T10031 mount.
- In addition, a second mechanic must support fuel tank at rear edge by hand.
WARNING: For weight reasons, fuel tank must be emptied for removal.
- Remove bolts -1- to -6-, if necessary swivel retainer for fuel tank toward front.
- Next, lower fuel tank slightly at rear so that filler tube can be guided out from body.
- Then lower fuel tank using engine/transmission support V.A.G 1383 A, in addition guide fuel tank by hand while doing so.
NOTE: Fuel tank is depicted without engine/transmission jack V.A.G 1383 A in the illustration.
Installing
NOTE: Secure all hose connections using hose clamps appropriate for the model type.
- Check whether fuel supply and fuel return lines, as well as wiring harness to fuel pumps and fuel level sensors are clipped in on fuel tank at retainers -1-.
- When installing a new fuel tank, affix pads -2- onto fuel tank as shown in illustration.
- Position fuel tank with tension straps and retainers to vehicle floor using engine/transmission jack V.A.G 1383 A and mount T10031.
- When positioning the fuel tank, make sure that the filler tube is guided correctly into opening on body.
- Tighten fuel tank first at mounting points -1-, -2-, -5-, -6- and then at mounting points -3- and -4- (22 Nm).
- Make sure that spacers of tensions straps are seated directly under fuel tank seam (arrow).
- Tighten fuel filler tube with bolts -2- and -4- (22 Nm).
- Connect ventilation line -5- until it engages audibly.
- Connect electrical harness connector -1- for Fuel Tank Lock Switch -F314-.
- Check whether Ground (GND) wire -3- and connector tab show traces of oxidation. Remove them if necessary.
WARNING: After installing, check electrical connection of metal ring at fuel filler tube to a blank portion of chassis using Ohm meter
Specified value: approx. 0 Ohm.
Rest of installation is performed in the reverse order of removal.
- Install rear axle:
- Install rear right wheelhousing liner.
- Install rear part of exhaust system:
- Connect battery. Observe safety precautions after connecting the battery.
Tightening torques
Component Nm
Tension strap/bracket for fuel tank to chassis 22
Fuel filler tube to chassis 22