Removing and installing fuel filler neck with expansion chamber - Vehicles with 8-cylinder engine except for A6 allroad — AUDI

AEB AFY AGA AGE AJG AJK AJL AJP ALF ALG ALT ALW AML AMM AMX ANB ANK APC APR APS APU APZ AQD AQE AQJ ARE ARH ARJ ARK ARN ARS ART ASG ASM ASN ATX AWT AZA BAS BBJ BCY BDV BES
Removing

Observe safety precautions=> Page
20-1
.

Observe rules for cleanliness => Page
20-4
.

The fuel tank must not be more than1/2full when removing the fuel filler neck with expansion chamber. Drain the fuel tank if necessary=>Page
20-119
.

Obtain code on vehicles with coded radio/integrated radio and navigation system.
With ignition switched off disconnect battery earth strap.

Clean area around tank filler neck.
Open tank flap and lever out clamping ring -arrow- in rubber cup (on filler neck).
Press rubber cup through to the inside.
Remove rear right wheel.

Detach heat shield for fuel filler neck above rear silencer (right side) -arrows-.

Note:

If necessary detach rear silencer (right side) from exhaust mounting.

Remove rear right wheel housing liner:

=> General body repairs, exterior; Repair group 66; Removing and installing wheel housing liner
General body repairs, exterior
Removing and installing wheel housing liner

Cut cable tie -2- open.
Disconnect vent pipe -3-.
Slacken filler pipe hose clamp -1- and disconnect filler pipe.

Carefully disconnect vent pipe -arrow at vent valve.
Unscrew bolts -1- and -2- as well as nut -3- for fuel filler neck.
Swivel fuel filler neck slightly forward in direction of travel.

Note:

Do not kink the pipes!

Disconnect vent pipes -arrows- at rear of fuel filler neck.
Take out filler neck with expansion chamber.

Installing

Install in reverse sequence; note the following points:

Note:

Secure all hose connections with the correct hose clips (same as original equipment)

=> Parts catalogue

Check fitting position of earth wire with fuel tank or filler neck removed.If necessary, unbolt expansion chamber -1- -arrows-.

Position the earth connection as illustrated -arrow-.
Ensure that plug connector for earth connection is properly seated on metal ring on fuel filler neck.
Ensure that contact tab is properly clipped onto contact at mounting hole.

Secure the contact tab -1- of earth wire with bolt -2- for fuel filler neck.

Caution
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

Install rear right wheel housing liner:

=> General body repairs, exterior; Repair group 66; Removing and installing wheel housing liner
General body repairs, exterior
Removing and installing wheel housing liner

Install centre and rear silencers of exhaust system and align free of stress

=> Engine, Mechanics; Repair group 26
Engine, Mechanics

Tightening torques

Component · Nm
Fuel filler neck · M8 · 23
to body · Speed nut · 1.3
Heat shield for filler neck to filler neck · 2
Battery terminal to terminal post · 5