Fuel Tank, Removing And Installing: Removing

WARNING: This page is about a different car, the 2016 Audi Q5, 2015 Audi Q5, and 2014 Audi Q5. However, it is still accessible from the selected car via links, so may be relevant.

-- Follow all safety precautions, refer to FUEL SYSTEM SAFETY PRECAUTIONS .

-- Follow the rules 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. Empty fuel tank if necessary. Procedure, refer to FUEL TANK, DRAINING .

-- Remove 1/3 of the rear seat, refer to SEAT BENCH/SINGLE SEAT, REMOVING AND INSTALLING .

Fig 1: Identifying Locking Flange Cover & Bolts -Arrows-

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-- Remove the bolts -arrows- and remove the sealing flange cover -1-.

4-Cylinder and 6-Cylinder Generation I Engine:

Fig 2: Harness Connector -1- At Sealing Flange

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-- Disconnect the connector -1- on the sealing flange.

-- Push the circlip -1- upward in direction of -arrow A- and squeeze the release in direction of -arrow B-.

Fig 3: Pulling Lock -1- Upward -Arrow A- & Press -Arrow B-

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4-Cylinder and 6-Cylinder Generation II Engine:

Fig 4: Harness Connectors -1- & -2- At Sealing Flange

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-- Open the connector locking mechanism with the Elbow Assembly Tool T10118 and disconnect the connector -1- on the sealing flange.

-- Disconnect the connector -2- on the sealing flange.

-- Push the circlip -1- upward -arrow A- and squeeze the release -arrow B-.

Fig 5: Pulling Lock -1- Upward -Arrow A- & Press -Arrow B-

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Continuation for All Vehicles:

-- Open the fuel filler door.

-- Clean the area around the fuel filler tube.

NOTE:

Seal the opening with a clean piece of foam to prevent dirt from getting into the fuel tank.

-- Remove the locking cap -arrow- from the fuel filler tube.

Fig 6: Identifying Fuel Filler Cap (Fuel Cap)

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-- Remove the right rear wheel.

-- Remove the right rear wheel housing liner, refer to OVERVIEW - REAR WHEEL HOUSING LINER .

NOTE:

Ignore items -3 to 7-.

-- Remove fuel filler tube bolts -1- and -2-.

-- Remove the rear section from the exhaust system, refer to OVERVIEW - MUFFLER .

Fig 7: Fuel Filler Tube Ground Connection

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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 OVERVIEW - REAR AXLE .

-- Remove the right underbody panel, refer to OVERVIEW - UNDERBODY PANELS .

WARNING:

Very hot fuel can burn your skin.

In extreme cases the temperature of the fuel lines and/or the fuel can go up to 100 °C (212 °F). 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 high pressure.

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

-- Remove the bolts -1 and 3-, nuts -4- and bracket -2-.

Fig 8: Bracket - Tightening Sequence

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-- Disconnect the fuel return line -1- and fuel supply line -2-.

Fig 9: Identifying Metering Pump On Vehicles With An Auxiliary Heater

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-- Press the release and disconnect the fuel line -1- on the metering pump on vehicles with an auxiliary heater.

-- Open the latch -2- with a screwdriver and disengage the bracket -3- with the metering pump for the auxiliary heater on the fuel tank in direction of -arrow-.

Fig 10: Fuel Line -1- On Metering Pump On Vehicles With An Auxiliary Heater

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-- Place the Engine and Gearbox Jack VAS6931 under the fuel tank for support.

Fig 11: Placing VAG 1383 A Under Fuel Tank

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-- Support the fuel tank using the Engine and Gearbox Jack VAS6931.

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- and remove the exhaust system bracket -2-.

-- Remove the bolts -3 to 6-.

-- Lower the fuel tank using the Engine and Gearbox Jack VAS6931 while guiding the fuel tank with one hand.

Fig 12: Installing Exhaust System Bracket -2- & Tighten Bolts -1 Through 6-

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