Liquid Vapor Separator: Service and Repair

Fuel Filler Neck With Expansion Tank, Removing And Installing - Vehicles With 6-cylinder Engine And A6 Allroad

Removing
- For removing the filler neck with expansion tank, the fuel tank should not be over 1/2 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 Owner's Manual if necessary.







- Remove cover above battery -arrow-.

NOTE: On vehicles without battery cover: Remove plenum cover







- With ignition switched off disconnect battery Ground strap -arrow-.
- 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 wheel.
- Remove right-rear wheelhousing liner.

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 -1-.
- Disconnect vent line -2-.
- Loosen hose clamp -3- for filler pipe and pull off filler pipe.
- Press protection cover away -arrow-.







- Disconnect vent lines -arrows- at fuel filler neck.
- Remove bolts -1- and -2- for fuel filler neck.
- Guide vent line -3- to top above 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.

- Check installation position of Ground connection while fuel tank and/or fuel filler neck is removed.







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







- 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

- After reconnecting battery, insert anti-theft radio code again.
- 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 23 Nm (17 ft lb)
Heat shield for fuel filler neck 2 Nm (18 in. lb)
Battery Ground strap to battery 5 Nm (44 in. lb)
EVAP canister cover 10 Nm (7 ft lb)