Fuel Tank, Removing And Installing, Fwd Vehicles And Torsion Beam Axle: Removing

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

-- Observe the safety instructions. 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 sealing flange cover -1- at the tabs -arrows- using the Trim Removal Wedge:3409 .

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

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

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-- Vehicles with parking heater: disconnect the connector -2- 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-

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

-- Remove the Fuel Pump Control Module -J538- toward the inside between the fuel tank and the floor panel.

-- Open the fuel filler door.

Fig 3: Identifying Cap -2-

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-- 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 .

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

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

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

-- If installed, remove the left rear underbody trim panel. Refer to UNDERBODY TRIM PANELS, REMOVING AND INSTALLING .

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

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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.

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

-- 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.

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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 .

-- 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.