Fuel Fill Neck W/Expansion Tank, Removing and Installing (AWD)

Fuel Filler Neck With Expansion Tank, Removing And Installing - Vehicles With 8-cylinder Engine Except A6 Allroad

Removing
- For removing the filler neck with expansion tank, the fuel tank should not be over 1 P@ full. 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.

- Vehicles with coded radio/navigation system (RNS) coding, refer to the Owner's Manual, if necessary.

Audi A6:







- Remove cover above battery -arrow-.

NOTE: On vehicles without battery cover: Remove plenum cover







- With ignition switched off disconnect battery Ground strap -arrow-.

WARNING: Fire Hazard. Do not smoke, work near heaters or have anything in the area that could ignite the fuel or fumes.

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:
- 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 heat shield for fuel filler neck above rear muffler -arrows-.

NOTE: For easy access lift rear muffler out of hanger.

- Remove right-rear wheelhousing liner.
- Remove right rear wheel

NOTE: To ease repair process, remove muffler from muffler hangers.

- Remove cover for EVAP canister below spare wheel molding.







- Remove vent line -arrow- from EVAP canister.

WARNING:
- When removing fuel filler neck with expansion tank the fuel tank should only be 1/2 full. Drain fuel tank if necessary.
- However, when loosening hose for filler pipe some fuel may escape.







- Cut cable tie -2-.
- Remove vent line -3-.
- Loosen hose clamp -1- for filler pipe and detach filler pipe.







- Remove bolts -1- and -2- as well as nut -3- for fuel filler neck.
- Swing fuel filler neck little toward front of vehicle.

CAUTION: DO NOT kink lines.







- Disconnect vent lines -arrows- at back side of fuel filler neck.
- Remove fuel filler neck together with expansion tank.

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 Parts catalog.







- Check installation position of Ground connection while fuel tank and/or fuel filler neck is removed. If necessary unbolt expansion tank -1- -arrow-.







- Route and connect Ground (GND) wire as shown in Fig. -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.







- Hold terminal tongue -1- with bolt -2- for fuel filler neck.

CAUTION:
After installing the expansion tank, use ohmmeter to check the electrical connection between metal (Ground clamp) ring on the fuel filler neck and bare metal part (Ground (GND) on Body.
- Specification: approx. 0 ohm

- Install right rear wheelhousing liner.
- Install center and rear muffler stress free.

NOTE: With Battery re-connected, remember to activate electrical equipment (radio, clock, window switches) according to operating instructions.

- Generate readiness code.

Tightening torque

Component Tightening torque
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 2 Nm (in. lb)
Battery pole 5 Nm (44 in. lb)
Cover for EVAP canisters 10 Nm ( 7 ft lb)