Right Fuel Tank Chamber With Attachments
Right Fuel Tank Chamber with Attachments
Special tools, testers and auxiliary items required
• Pry Lever - Rmv Outside Mirror (80 - 200)
• Hose Clip Pliers (V.A.G 1921)
• Fuel Extracting Device (VAS 5190)
• Wrench (T10202)
Removing
- Observe safety precautions. Refer to => [ Safety Precautions ] Safety Precautions.
- Observe rules for cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
- Slide the driver's seat forward as far as possible. Then fold the backrest forward.
CAUTION!
Risk of destroying electrical components when battery is disconnected.
• Observe measures when disconnecting battery.
- With the ignition switched off, disconnect the battery ground (GND) - arrow -.
- Removing engine.
CAUTION!
Danger due to escaping fuel.
• Fuel tank must be empty.
• The following procedure drains the fuel tank about 90%. Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.
• When removing the right fuel tank chamber, open the right locking flange and drain the remaining fuel through the opening in the fuel tank chamber.
- Fuel Tank, Emptying. Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.
R8 Coupe
- Remove left side trim panel.
- Remove the right rear connector station from the control module bracket and lay it aside.
- Disconnect the control module electrical connectors and remove the control module bracket - arrow - from the vehicle.
- Press the electrical wiring harness off the rear bulkhead using (80 - 200) and free it up.
R8 Spyder
- Remove the cover module.
All Vehicles
- Fold the insulation mat over the connection seal cover.
- Remove the left and right bolts on the locking flange cover - 1 to 4 - and then remove the cover.
- Disconnect the fuel lines - 1, 2, 3 - on the left locking flange by pressing the release buttons.
• Depending on the version, there may be 2 instead of 3 lines.
• Disregard - arrow -.
- Disconnect the electrical connector - arrow - on the right locking flange.
- Disconnect the fuel lines - 1, 2, 3 - on the right locking flange by pressing the release buttons.
• Depending on the version, there may be 2 instead of 3 lines.
CAUTION!
Danger due to escaping fuel.
• To prevent large quantities of fuel from spilling out when removing the right locking flange, empty the fuel tank. Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.
- Disconnect the right locking flange locking rings using (T10202).
- Remove the fuel delivering unit locking flange and sealing ring from the opening in the fuel tank.
- Disconnect the fuel line - 1 - on the inside of the locking flange by pressing the release button.
- Disconnect the electrical connectors - 2, 3, 4 - and remove the locking flange.
• Leave the locking flange out when removing the right fuel tank chamber.
- Drain the fuel in the right fuel tank chamber using (VAS 5190) through the opening in the fuel tank chamber.
• Seal the opening on the locking flange with wide adhesive tape to prevent dirt from falling into the right fuel tank chamber while it is removed.
R8 Coupe
- Loosen bolts - arrows - a few turns.
- Remove the bolt - 2 - and remove the right engine control module bracket - 1 -.
R8 Spyder
- Disconnect the vent line - 6 - from the EVAP canister by pressing the release button.
- Disconnect the bleeder line - 3 - from the EVAP canister.
• Ignore - 4 -.
- Remove bolts - 1, 5, 7 - and remove the EVAP canister - 2 -.
R8 Coupe
- Disconnect the vent line - 1 - from the EVAP canister by pressing the release button.
- Remove bolts - 3, 5, 7 - and remove the EVAP canister - 4 -.
• Ignore - 2 -.
- Disconnect the ground wire - 2 - from the fuel filler tube metal ring - 1 -.
- Remove bolt - 3 - for the fuel filler tube.
- Separate the vent lines - 3 - and - 4 - by pressing the release button.
- Loosen the hose clamp - 1 - and remove the fuel filler tube - 2 -.
• Seal the fuel filler tube opening with a clean plug to prevent dirt from getting into the tube.
R8 Spyder
- Disconnect the ground wire - 2 - from the fuel filler tube metal ring - 1 -.
- Remove bolt - 3 - for the fuel filler tube.
- Press the release button and remove the bleed lines - 1 and 2 -.
- Free up the bleed line on the bracket - arrow -.
- Loosen the clamp and remove the fuel filler tube - 3 -.
• Seal the fuel filler tube opening with a clean plug to prevent dirt from getting into the tube.
All Vehicles
- Disconnect the upper ground (GND) connection connector - arrow - on the fuel tank chamber.
- Disconnect the engine oil cooler coolant hoses and lay them to the side.
- Remove the oil line for the engine oil cooler.
- Remove brake booster vacuum line.
- Remove the power steering hydraulic oil lines.
- Disconnect the refrigerant line leading from the evaporator to the A/C accumulator at the separating point and remove.
- Remove nuts - 1 - and - 2 -.
- Remove the bolts - arrow - and remove the left fuel tank chamber heat shield.
- Disconnect the coolant hose on the rear panel from the bracket and lay it to the side.
- Remove nuts - 1 - and - 2 -.
- Remove the bolts - arrows - and remove the left fuel tank chamber heat shield.
- Remove bolts - 1 through 3 - and the upper right longitudinal member.
- Remove the fuel supply line and suction jet pipe - 1 -.
CAUTION!
Danger due to escaping fuel.
• Remove the connection hose - 2 - only when the fuel tank is empty.
- Loosen the hose clamps and disconnect the connection hose - 2 -.
- Loosen the ATF cooler on the right longitudinal member.
R8 Coupe
- Remove bolts - arrows -, remove tensioning straps - 1 - and - 2 -.
R8 Spyder
- Remove the bolts - 1 and 6 - and remove the mounting strap.
- Remove the bolts - 3 and 5 - and remove the mounting strap.
- Remove the bolts - 2 - and nuts - 4 - and then remove the mounting strap.
All Vehicles
CAUTION!
The fuel line connectors - arrow 3 - could be damaged if the locking flange was not removed.
• When removing the fuel tank chambers with the locking flange installed, make sure the connections do not hang on the body.
- Push the fuel tank chamber as far as possible forward to the left - arrow 1 - and hold it there.
- At the same time, tip the fuel tank chamber on the rear edge toward the center of the vehicle - arrow 2 -.
Installing
• Tightening specifications, refer to => [ Fuel Tank with Attachments Assembly Overview ] Fuel Tank With Attachments Assembly Overview, => [ Locking Flange Cover - Tightening
Specifications ] Fuel Tank With Attachments Assembly Overview.
Installation is in reverse order of removal, note the following:
• Secure all hose connections with hose clamps appropriate for the model.
- Check the backing pieces - 1 to 4 - on the chassis mounts for damage; replace if necessary.
- Coat the backing pieces with a silicone-free lubricant before installing the fuel tank.
CAUTION!
Danger of damaging the fuel line connections
• When removing the fuel tank chambers, make sure the connections hang on the body.
- Replace the right fuel tank chamber and carefully reinstall in reverse order.
- Press the right fuel tank chamber outward until the weld seam touches the sound insulation on the B-pillar.
- Place the wedge - 2 - directly on the right fuel tank chamber weld seam - arrow - and secure with tension strap - 1 -.
R8 Coupe
- First, mount the tension strap - 1 - in the center - arrows -.
- Then mount the left tension strap - 2 - - arrows -.
R8 Spyder
- Tighten the nuts - 4 - and the bolt - 2 - in the center of the mounting strap first.
- Tighten the bolts - 3 and 5 - on the left side of the mounting strap.
- Tighten the bolts - 1 and 6 - on the rear mounting strap.
All Vehicles
- Connect the ground (GND) connection for the right fuel tank chamber - arrow -.
R8 Coupe
- Connect the ground (GND) connection to the metal ring - 1 - on the fuel filler tube. Make sure the connector - 2 - fits securely.
CAUTION!
Risk of explosion due to electrostatic charge.
• After installing, check electrical connection on fuel filler neck metal ring to an empty spot on the body using an Ohm meter.
• Specified value: approximately 0 ohms.
R8 Spyder
- Connect the ground (GND) connection to the metal ring - 1 - on the fuel filler tube. Make sure the connector - 2 - fits securely.
CAUTION!
Risk of explosion due to electrostatic charge.
• After installing, check electrical connection on fuel filler neck metal ring to an empty spot on the body using an Ohm meter.
• Specified value: approximately 0 ohms.
All Vehicles
- Install right locking flange => [ Installing ] Fuel Delivery Unit.
- Check the fuel tank for leaks. Refer to => [ Fuel Tank System, Checking for Leaks ] Fuel Tank System, Checking For Leaks.
- Inspect the seal - 1 - on the locking flange covers for damage.
- If necessary, replace the seal.
- Install ATF cooler.
- Install upper right longitudinal member.
- Install fuel tank chamber heat shield.
- Install the refrigerant line from the evaporator to the A/C accumulator.
- Install the right rear connector station.
- Install engine.
R8 Spyder
- Install the cover module.