Fuel Tank, Removing And Installing, Vehicles With 3.0L (V6)/4.2L (V8) Engines: Removing

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2015 Audi Q7, 2014 Audi Q7, 2013 Audi Q7, 2011 Audi Q7, and 2010 Audi Q7. However, it is still accessible from the selected car via links, so may be relevant.

Follow all safety precautions, refer to WORKING ON FUEL SYSTEM .

Follow the guidelines for clean working conditions, refer to CLEAN WORKING CONDITIONS .

WARNING:

Risk of accident due to the weight of the fuel tank.

The fuel tank must be empty when removing it.

-- Drain the fuel tank, refer to FUEL TANK, DRAINING .

-- On a vehicle with air suspension, activate vehicle lift mode, refer to VEHICLE LIFT MODE .

-- Open the fuel filler door.

-- Turn off the ignition and remove the key.

Vehicles from 11/2006:

Fig 1: Cut The Floor Covering Along The Perforation

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-- Remove the left single seat and the left 2/3 seat bench seat cushion in the second row of seats, refer to Seat Frames .

-- Remove the right rear single seat in the second row of seats, refer to Seat Frames .

WARNING:

Risk of injury.

Wear safety gloves

-- Cut the floor covering along the perforation -arrows- on the left and right sides with a carpet knife -1-.

-- Fold carpet cut-out to side -arrow-.

Fig 2: Identifying Locking Flange Cover - Tightening Specifications

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-- Remove the left and right nuts on the locking flange cover -1 ••• 4- and then remove the cover.

-- Disconnect the connector -arrow- on the left locking flange.

Fig 3: Connecting Connector -Arrow- At Left Locking Flange

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-- Disconnect the connector -4- on the right locking flange.

Fig 4: Locking Flange Cover

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-- If equipped, disconnect the connector -3- on the right locking flange.

NOTE:

Place a clean cloth under the separating location to catch any fuel that may leak out.

WARNING:

Very hot fuel can burn your skin.

In extreme cases, the fuel lines and the fuel itself in vehicles with a common rail engine can be as hot as 100 °C (212 °F) after the engine has been turned off. Let the fuel cool down before opening any line connections otherwise there is a danger of scalding.
Wear safety gloves
Wear protective eyewear.

There is a risk of injury because the fuel is under pressure.

To reduce pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.

-- Disconnect fuel lines -1 and 2-. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

-- Vehicles with parking heater: Disconnect the fuel line to the parking heater. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

Continuation for All Vehicles

Fig 5: Identifying Fuel Filler Cap (Fuel Cap)

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-- Open the fuel tank flap.

-- Clean the area around the fuel filler tube.

-- Remove the fuel cap -arrow-.

-- Seal off the fuel filler tube opening with a clean plug to prevent dirt from getting in.

-- Remove the fuel filler door insert, refer to FUEL FILLER DOOR, REMOVING AND INSTALLING .

Fig 6: Identifying Rubber Gasket -1-

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-- Pry out rubber gasket -1- and remove it outward.

-- Remove the fuel filler tube bolts -arrows-.

Fig 7: Identifying Fuel Filler Tube Tightened In Place -Arrows-

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WARNING:

Risk of vehicle tipping on hoist with rear axle removed.

Secure the vehicle on a hoist before loosening the subframe bolts (for example, load the luggage compartment with about 50 kg (110 lbs)).

-- Remove the rear axle, refer to REAR AXLE OVERVIEW .

-- Hang driveshaft -1- on body with a suitable chain or with welding wire as shown in illustration -arrows-.

Fig 8: Identifying Hanging Driveshaft -1- On Body With Suitable Chain

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NOTE:

Driveshaft CV joints must only be moved without force and only as far as stop which is approximately a 10° angle.

Fig 9: Identifying Dimension -A- To Lower Driveshaft

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-- Lower driveshaft by dimension -a-.

Dimension -a- = 220 mm (7.8 in).

-- Remove the right rear wheel housing liner, refer to Wheel Housing Liners .

Fig 10: Installation position of Ground (GND) connection

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-- Disconnect the Ground (GND) wire -1- from the fuel filler tube.

-- Remove the bolts -2 and 3- from the fuel filler tube.

-- Remove the nuts -arrow- and the fuel filler tube shield.

Fig 11: Identifying Fuel Filler Tube Protective Plate Bolts -Arrows-, Drive Pin -1-, And Bracket -2-

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-- Drive pins -1- through with a punch.

-- Remove bracket -2- with vent lines from longitudinal member.

Vehicles through 10/2006

Fig 12: Identifying Fuel Level Sensor Electrical Connectors -1 And 2-

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-- Disconnect fuel pump and fuel level sensor connectors -1 and 2- on the left longitudinal member.

Continuation for All Vehicles

-- Remove the left and right bolts on the floor panel trim near the fuel tank, refer to FRONT AND REAR DOOR TRIM MOLDING, REMOVING AND INSTALLING .

-- Unclip the fuel supply line -2- and the fuel return line -3- from the fuel tank and from the bracket -arrows-.

Fig 13: T10031

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-- Unclip parking brake cable bracket -4- at fuel tank.

-- Vehicles with parking heater: Also unclip fuel supply line -1- to auxiliary heater metering pump.

-- Place the Engine/Gearbox JackVAG1383A with the Subframe Support T10031 (without threaded rods) under the fuel tank to support it as shown.

Fig 14: Placing V.A.G1383A And T10031 (Without Threaded Rods) Under Fuel Tank

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The Subframe Support T10031 mounting plates must be positioned near the round impressions in the bottom of the fuel tank.

-- Support the fuel tank with the Engine/Gearbox Jack VAG1383A and the Subframe Support T10031.

-- A second technician must also support fuel tank by hand.

-- Identify location of fuel tank securing bands.

Fig 15: Fuel Tank, Tightening Specifications and Sequence

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WARNING:

Risk of accident due to the weight of the fuel tank.

The fuel tank must be empty when removing it.

-- Remove bolts -1 to 12- and remove securing bands and carrier plate.

NOTE:

To improve clarity, the fuel tank is shown without the Engine/Gearbox JackVAG1383A.

-- Next lower back of fuel tank to driveshaft.

-- A second technician is needed to hold the rear edge of the fuel tank.

-- Carefully guide filler tube out of wheel housing so avoid paint damage.

Vehicles through 10/2006:

NOTE:

Place a clean cloth under the separating location to catch any fuel that may leak out.

-- Thread through gap between body and fuel tank.

WARNING:

Very hot fuel can burn your skin.

In extreme cases, the fuel lines and the fuel itself in vehicles with a common rail engine can be as hot as 100 °C (212 °F) after the engine has been turned off. Let the fuel cool down before opening any line connections otherwise there is a danger of scalding.
Wear safety gloves
Wear protective eyewear.

There is a risk of injury because the fuel is under pressure.

To reduce pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.

-- Disconnect the fuel lines -1 and 3-. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

Fig 16: Fuel Lines Location

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-- Vehicles with parking heater: Disconnect the fuel line -2- to the parking heater. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

Continuation for All Vehicles

-- Lower the fuel tank with the Engine/Gearbox JackVAG1383A while a second technician guides it.