Removing and installing fuel filler neck with expansion chamber — AUDI

🧭 Before you start

At the filler opening the retaining ring is levered out of the rubber cup and the cup pushed through to the inside, with the filler cap left on. From the wheel arch side the rear right wheel, the heat shield above the silencer and the wheel housing liner come off, then the cable tie, breather pipes, filler pipe hose clip and guard plate are released and the bolts removed so the neck and expansion chamber can be lifted out. On refitting the earth connection is positioned with its contact tab under the filler neck bolt, the connection is checked with an ohmmeter, and the liner goes back.

Fits: Audi A6 C5 (4B)

Don't miss

• Tank no more than half full before the filler pipe comes off; fuel still escapes.
• Leave the filler cap on; open only the tank flap.
• Drop the rear right silencer off its rubber mounting if it blocks the heat shield.
• Earth contact tab goes under the filler neck securing bolt, positioned as illustrated.
• After installation, check filler neck metal ring to body with an ohmmeter: approximately 0 Ω.
• Use hose clips of the original equipment type on every connection.

Written for this job from the workshop steps below · TorqFix editorial.

🔧 Engine codes this applies to

📐 60 workshop diagrams for AFB

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Open the tank flap. [Note: Do not remove filler cap.]
2. Clean area around fuel filler neck.
3. Lever off retaining ring (arrow) in rubber cup and press rubber cup through to inside.
4. Remove rear right wheel.
5. Detach heat shield for fuel filler neck above rear silencer (right side) (arrows). [Note: Detach rear silencer (right-side) from rubber mounting if silencer is preventing access.]

6. Remove rear right wheel housing liner 66.
7. ⚠ The fuel tank must not be more than 1/2 full when removing fuel filler neck with expansion chamber. Otherwise a large amount of fuel will escape.However, a small amount of fuel can still escape when the fuel filler pipe is disconnected. — Cut through cable tie (1).
8. Detach breather pipe (2).
9. Slacken hose clip (3) for filler pipe and detach filler pipe.
10. Press off guard plate .
11. Detach breather pipe from fuel filler neck at the location marked with an (arrow).
12. Unscrew bolts (1) and (2) for fuel filler neck.
13. Guide breather pipe upwards over fuel filler neck.
14. Take out filler neck with expansion chamber. [Note: Secure all hose connections with the correct type of hose clips (same as original equipment) Parts catalogue.]
15. Check installation position of earth connection with fuel tank or fuel filler neck removed.
16. Position the earth connection as illustrated (arrow).
17. Secure the contact tab (1) of earth connection with securing bolt (2) for fuel filler neck.
18. ⚠ After installation, use an ohmmeter to check the electrical connection between the metal ring on the fuel filler neck and a bare metal part on the body:Specification: approx. 0 Ω. — Install rear right wheel housing liner 66.

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