Fuel Tank, Removing And Installing, 6.0L (V12) Engine: 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 [For engine(s) BAR, CTWB, BHK, CATA, CNRB, CTWA, CJWE, CJWC, CJWB] Self-Leveling Suspension .

-- Open the fuel filler door.

-- Turn off the ignition and remove the key.

-- 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 1: Cut The Floor Covering Along The Perforation

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-- 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.

NOTE:

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

Fig 3: Fuel Lines Location

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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 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 .

-- Disconnect the connector -1- on the left locking flange.

NOTE:

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

Fig 4: Fuel Lines Location

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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 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 .

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

-- Vehicles with parking heater: Disconnect the fuel line -3- to the parking heater. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

-- Open the fuel tank flap.

Fig 5: Identifying Fuel Filler Cap (Fuel Cap)

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-- 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 Hood, Lids .

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).

-- Remove the rear axle, refer to [For engine(s) BAR, CTWB, BHK, CATA, CNRB, CTWA, CJWE, CJWC, CJWB] Rear Suspension .

-- Hang propshaft -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:

Propshaft 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 propshaft by dimension -a-.

Dimension -a- = 220 mm.

-- Remove the right rear wheel housing liner, refer to Exterior Equipment .

Fig 10: Installation position of Ground (GND) connection

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-- Disconnect the ground 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.

-- 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 parking brake cable bracket from the fuel tank.

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

Fig 12: 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 13: 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 screws -1 to 12- and remove securing bands and carrier plate.

NOTE:

To improve clarity, the fuel tank is shown without the Engine/Transmission Jack.

-- Next lower back of fuel tank to propshaft.

-- 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.

-- Unclip the fuel lines from the fuel tank -arrows-.

Fig 14: Fuel Lines Location

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