Fuel Tank, Removing And Installing, Vehicles With Front Wheel Drive (Fwd) And Torsion Beam Axle: Removing

WARNING: This page is about a different car, the 2015 Audi A3. However, it is still accessible from the selected car via links, so may be relevant.

-- Observe 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.

-- Turn off the ignition.

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

Fig 1: Rear/Bench Seats

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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.

-- Drain the fuel tank. Refer to FUEL TANK, DRAINING .

-- Unclip the locking flange cover -1- at the tabs -arrows- using the Trim Removal Wedge:3409 .

Fig 2: Fuel Pump Cover (Under Rear/Bench Seat)

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

Fig 3: Top View Of Fuel Pump

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-- Equipment levels with parking heater: Disconnect the connector -3- 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 4: 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 5: Identifying Fuel Filler Cap (Fuel Cap)

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-- Clean the area around the fuel filler tube.

-- Remove the fuel filler cap -arrow-.

NOTE:

Seal the fuel filler tube opening with a clean plug to prevent dirt from getting into the tube.

-- Remove the right rear wheel housing liner. Refer to REAR WHEEL HOUSING LINER, REMOVING AND INSTALLING .

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

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Vehicles With An SCR System:

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-- Remove the fuel filler tube bolts -1 and 3-.

-- Remove the bolts -4 and 5- and remove the reducing agent tank filler neck -2- on the fuel filler tube.

Continuation For All Vehicles:

-- Remove the rear section of the exhaust system. Refer to OVERVIEW - MUFFLER .

WARNING:

There is a risk of burns due to hot fuel.

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.

-- Equipment levels with parking heater: Disconnect the fuel line -1- to the parking heater by pressing the release button.

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-- Press the release button and disconnect the fuel supply line -2- and the fuel return line -3-.

-- Place the Engine and Gearbox Jack:VAS6931 under the fuel tank to support it as illustrated.

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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-.

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NOTE:

To improve clarity, the fuel tank is shown without the Engine and Gearbox Jack:VAS6931 .

-- Lower the fuel tank using Engine and Gearbox Jack:VAS6931 .

-- By turning it accordingly, lower the fuel tank sideways and remove it.

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