Fuel Tank With Attachments, Removing And Installing, Rest Of World Vehicles With AWD: Removing

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

-- Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

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

CAUTION:

Risk of destroying electronic components when disconnecting the battery.

Observe the steps for disconnecting the battery.

-- Disconnect the battery. Refer to BATTERY .

WARNING:

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

The fuel tank must be empty when removing it.

-- Fuel Tank, Draining. Refer to FUEL TANK, DRAINING, REST OF WORLD VEHICLES WITH AWD .

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

Fig 1: Identifying Cover Bolts For Locking Flange

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-- Remove the locking flange cover -arrows-.

A5 from MY 2011, A4 from MY 2012:

Fig 2: Disconnect Connectors

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-- Disconnect the connector -3- to the auxiliary heater metering pump at the locking flange, if necessary.

-- Open the connector locking mechanism with the Elbow Assembly Tool:T10118 and disconnect the connector -2- on the locking flange.

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

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

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

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A5 from MY 2012, A4 from MY 2013:

Fig 4: View Of Fuel Delivery Unit Harness Connectors

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-- Disconnect the connector -2- to the auxiliary heater metering pump at the locking flange, if necessary.

-- Open the connector locking mechanism with the Elbow Assembly Tool:T10118 and disconnect the connectors -1 and 3- on the locking flange.

Continuation for all vehicles:

Fig 5: Identifying Cap -2-

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-- Open the fuel filler door.

-- Clean the area around the fuel filler tube -1-.

-- Remove the cap -2- from the fuel filler tube.

NOTE:

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

Ignore -item 3-.

-- Remove the right rear wheel.

Fig 6: Fuel Filler Tube Ground Connection

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-- Remove the right rear wheel housing liner. Refer to Wheel Housing Liner .

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

-- Remove the rear section from the exhaust system. Refer to EXHAUST PIPES/MUFFLERS [For engine(s) CAED, CAEB, CPMB, CPMA] or EXHAUST PIPES/MUFFLERS [For engine(s) CALA] or EXHAUST PIPES/MUFFLERS [For transmission(s) 0B6] [For engine(s) CAUA] or EXHAUST PIPES/MUFFLERS [For engine(s) CFSA] .

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 REAR AXLE, REMOVING AND INSTALLING .

Fig 7: View Of Fuel Line Connector -1- At Front Of Fuel Tank

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WARNING:

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.

-- Disconnect the fuel line -1- on the front of the fuel tank on the right side. Refer to CONNECTOR COUPLINGS, SEPARATING .

-- Disconnect the additional fuel line to the auxiliary heater and the connector on the metering pump, if applicable.

-- Disconnect the ventilation line -1- at the left on the EVAP canister. Refer to CONNECTOR COUPLINGS, SEPARATING .

Fig 8: Disconnecting Vent Line -1- From EVAP Canister

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

Fig 9: Identifying Support Fuel Tank Using V.A.G 1383 A

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-- Support the fuel tank with the Engine and Gearbox Jack.

Fig 10: Position fuel tank with mounting strap and carrier plate on the vehicle underbody using the V.A.G 1383 A

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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 the bolts -1 to 5- and remove the exhaust system bracket -6-.

-- Lower the fuel tank with the Engine and Gearbox Jack while guiding it by hand.