Fuel Tank, Draining

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Wrench - Fuel Sending UnitT10202
Fuel FunnelT40256 for equipment levels with misfueling guard
Fuel Extraction DeviceVAS5190A
Carpet knife, commercially available

Procedure

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

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

-- Turn off the ignition and remove the key.

-- Open the fuel filler door.

NOTE:

The adapter -1- and cone piece -2- from the Fuel Extraction DeviceVAS5190A will not be used.

Fig 1: Fuel Extracting Unit VAS5190 Demension -a-

Courtesy of AUDI OF AMERICA, LLC

Push the adapter -1- on the hose slightly reward.

-- Attach the insulating tape -arrow- to the hose at a distance -a- from the end of the suction hose.

-a- = 1400 mm (55 in)

-- Remove the cap from the fuel filler tube.

Fig 2: Fuel Extraction Device VAS5190A Components Location

Courtesy of AUDI OF AMERICA, LLC

-- Vehicles with misfueling guard: Install the Fuel FunnelT40256 all the way into the fuel filler tube.

-- Slide the suction hose of the Fuel Extraction DeviceVAS5190A far enough into the fuel tank until the marking applied earlier -arrow- is on the edge of the fuel filler tube.

NOTE:

A flap -1- is located in the fuel tank on the lower end of the filler neck -2-. It must not be damaged by the suction hose of the Fuel Extraction DeviceVAS5190A. Therefore slide in hose only up to the marking -arrow- applied earlier.

Fig 3: Identifying Filler Tube

Courtesy of AUDI OF AMERICA, LLC

-- Slide the suction hose of the Fuel Extraction DeviceVAS5190A far enough into the fuel tank until the marking applied earlier -arrow- is on the edge of the fuel filler tube.

-- Empty the fuel tank through the fuel filler tube.

-- Remove the extracting hose carefully.

NOTE:

When no more fuel can be extracted, the tank is emptied only enough for the locking flange to be opened without danger.

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

Fig 4: Cut The Floor Covering Along The Perforation

Courtesy of AUDI OF AMERICA, LLC

WARNING:

Risk of injury.

Wear safety gloves

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

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

Fig 5: Identifying Locking Flange Cover - Tightening Specifications

Courtesy of AUDI OF AMERICA, LLC

-- Remove the nuts -1 to 4- and remove left locking flange cover.

For vehicles with 3.0L (V6)/4.2L (V8) engines:

Fig 6: Connecting Connector -Arrow- At Left Locking Flange

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect electrical harness connector -arrow- at left 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 -2 and 3-. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

Continuation for All Vehicles

Fig 7: Identifying Removal Of Locking Ring With T10202

Courtesy of AUDI OF AMERICA, LLC

-- Remove locking ring using the Wrench - Fuel Sending UnitT10202.

-- Pull the left locking flange just a little out of the opening in the fuel tank and remove the seal.

Fig 8: Identifying Fuel Extraction Unit

Courtesy of AUDI OF AMERICA, LLC

-- Extract the fuel from both chambers in the fuel tank through the opening for the fuel level sensor using the Fuel ExtractorVAS5190.

Assemble in reverse order of disassembling. Note the following:

Tightening Specifications

Refer to OVERVIEW - FUEL DELIVERY UNIT/FUEL LEVEL SENSOR .

NOTE:

Replace the seal.

-- Install the new seal for the left locking flange dry.

-- Bring the left locking flange into the installation position:

Fig 9: Fuel Tank

Courtesy of AUDI OF AMERICA, LLC

The tab -2- on left locking flange faces toward the arrow marking and must lie between tabs -1 and 3- on fuel tank.

-- Install the left locking flange cover, refer to Figure.

-- Insert the frame into the floor covering. Refer to INSTALLATION FRAME, REMOVING AND INSTALLING .

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