Fuel Tank, Removing And Installing, AWD Vehicles: Removing

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

-- Pay attention to all safety precautions. Refer to SAFETY PRECAUTIONS .

-- Follow the guidelines for clean working conditions. Refer to CLEAN WORKING CONDITIONS .

-- Move the front seats all the way forward.

CAUTION:

There is a risk of destroying electronic components when disconnecting the battery.

Follow the steps for disconnecting the battery.

-- Disconnect the ground cable from the battery terminal. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Remove the rear bench seat. Refer to BENCH SEAT/SINGLE SEAT, REMOVING AND INSTALLING .

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 .

-- Unclip the right sealing flange cover -1- at the tabs -arrows- using the :3409 .

Fig 1: Fuel Pump Cover (Under Rear/Bench Seats)

Courtesy of AUDI OF AMERICA, LLC

Version 1:

Courtesy of AUDI OF AMERICA, LLC

-- Release the connector safety catch and disconnect the connector -2- from the sealing flange.

NOTE:

Ignore -1-.

-- Vehicles with parking heater: disconnect the connector for the parking heater metering pump by releasing the connector safety catch.

Version 2:

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect the connectors -1 and 2- on the sealing flange by releasing the connector safety catch.

-- Vehicles with parking heater: disconnect the connector for the parking heater metering pump by releasing the connector safety catch.

-- Lift the tab -2- -arrow A- so that it is possible to reach between the floor panel and the fuel tank.

Fig 2: Fuel Pump Control Module -J538- -1-

Courtesy of AUDI OF AMERICA, LLC

-- At the same time, carefully remove the Fuel Pump Control Module -J538- -1- from the mount -arrow B-.

Version 3:

Courtesy of AUDI OF AMERICA, LLC

-- Release the connector safety catch, and disconnect the connector -1- on the sealing flange.

NOTE:

Ignore -2-.

-- Vehicles with parking heater: disconnect the connector for the parking heater metering pump by releasing the connector safety catch.

Continuation For All Vehicles:

Courtesy of AUDI OF AMERICA, LLC

-- Unclip the left sealing flange cover -1- at the tabs -arrows- using the :3409 .

-- Unlock and disconnect the connector -1- on the All Wheel Drive clutch.

Courtesy of AUDI OF AMERICA, LLC

-- Depending on the version, disconnect the connector -2- on the sealing flange by unlocking the connector safety catch.

-- Open the fuel filler door.

Fig 3: Identifying Cap -2-

Courtesy of AUDI OF AMERICA, LLC

-- Clean the area around the fuel filler neck.

-- Remove the fuel filler cap -2-.

-- Disengage the rubber boot -3- from the fuel filler neck -1-.

NOTE:

Seal the fuel filler neck opening with a clean plug to prevent dirt from entering.

-- Remove The Right Rear Wheel Housing Liner. Refer to REAR WHEEL HOUSING LINER, REMOVING AND INSTALLING .

-- Disconnect the bleeder line -1 and 2- on the EVAP canister. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Courtesy of AUDI OF AMERICA, LLC

-- Unclip the breather line from bracket -arrows-.

-- Unclip the breather lines -1 and 2- from the bracket -arrow- on the subframe.

Courtesy of AUDI OF AMERICA, LLC

-- Remove the fuel filler neck bolts -1 and 2-.

Courtesy of AUDI OF AMERICA, LLC

A3 CABRIOLET:

Courtesy of AUDI OF AMERICA, LLC

-- Remove the fuel filler neck bolts -1 and 2-.

-- Remove the diagonal braces. Refer to OVERVIEW - SUBFRAME .

Market-Specific For North America:

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect the bleeder line -1- on the EVAP canister. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

-- Disconnect the connector -2- to release the connector safety catch.

-- Remove the bolts -3- from the fuel filler neck.

Continuation For All Vehicles:

-- Remove the rear section of the exhaust system. Refer to REAR MUFFLER, REMOVING AND INSTALLING [TDI] / MUFFLER, REMOVING AND INSTALLING [CNSB, CNTC, CYFB] .

-- Remove the driveshaft. Refer to the appropriate service information. .

-- Unlock and disconnect the connector -1- on the All Wheel Drive clutch.

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect the bleeder line -3- and the fuel line -2-. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Courtesy of AUDI OF AMERICA, LLC

WARNING:

Risk of injury due to the fuel being under high pressure.

To reduce the pressure in the fuel system, lay clean cloths around the connection point and carefully loosen the connection point.

-- For vehicles with a parking heater: disconnect the fuel line -1- to the parking heater. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

-- Place the :VAS6931 under the fuel tank to support it as shown.

Courtesy of AUDI OF AMERICA, LLC

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

Courtesy of AUDI OF AMERICA, LLC

WARNING:

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

The fuel tank must be empty when removing it.

-- Remove the bolts -1 to 5-.

NOTE:

For clarity, the fuel tank is shown without the :VAS6931 .

-- Lower the fuel tank using the :VAS6931 .

-- Turn the fuel tank in the corresponding direction to lower it downward at its side and remove it.

-- A second mechanic is required to guide out the fuel filler neck by hand at the longitudinal member.