Fuel Tank, Removing, TFSI Vehicles

Special tools and workshop equipment required

Scraper no. 1 from the Scraper Set: VAS6845

Fig 1: Identifying Clip release lever no. 4 from the Scraper Set VAS6845
Courtesy of AUDI OF AMERICA, LLC
Engine and Gearbox Jack: VAS6931

Fig 2: Engine and Gearbox Jack VAS6931 or VAG1383A
Courtesy of AUDI OF AMERICA, LLC
Gearbox Support: T40173

Fig 3: Gearbox Support T140173
Courtesy of AUDI OF AMERICA, LLC

Removing

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

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

-- Move the front seats all the way forward into the highest position.

-- Disconnect the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

CAUTION:

There is a risk of accident due to the heavy weight of the fuel tank.

- Drain the fuel tank before removing it.

FWD Vehicles:

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

-- Remove the luggage compartment floor.

-- Remove the storage compartment for the vehicle tool kit.

-- Q3 Sportback: pull and disengage and remove the cover -3- for the left support upward in direction of -arrow A-.

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts -2- for the left support -1- and disengage the carrier upward in direction of -arrow B- and remove.

-- Remove the button -2-.

Courtesy of AUDI OF AMERICA, LLC

-- Disengage the trim -1- under the C-pillar trim panel and remove it in direction of -arrows-.

-- Fold the trim over the sealing flange cover toward the right to the side.

-- Unclip the sealing flange cover -1- with the scraper from the : VAS6845 at the frame in direction of -arrows-.

Courtesy of AUDI OF AMERICA, LLC

-- Drain the fuel tank. Refer to FUEL TANK MORE THAN .

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

Courtesy of AUDI OF AMERICA, LLC

-- Rest of World equipment and market-specific versions: disconnect the connector -2- for the metering pump for the parking/auxiliary heater by releasing the connector safety catch.

-- Press up the tab in direction of -arrow A-.

Courtesy of AUDI OF AMERICA, LLC

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

-- Remove the control module toward the inside and move it to the side with the wires attached.

AWD Vehicles:

Courtesy of AUDI OF AMERICA, LLC

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

-- Remove the buttons -1-.

-- Disengage the trim -2- from under the C-pillar trim panel and remove in direction of -arrows-.

-- Fold the trim over the sealing flange covers toward the rear to the side.

-- Unclip the right sealing flange cover -1- with the scraper from the : VAS6845 at the frame in direction of -arrows-.

Courtesy of AUDI OF AMERICA, LLC

-- Drain the fuel tank. Refer to FUEL TANK MORE THAN .

-- Unlock the connector safety catch and disconnect the connectors -2 and 3- on the right sealing flange.

Courtesy of AUDI OF AMERICA, LLC

-- Rest of World equipment and market-specific versions: disconnect the connector -1- for the Metering Pump -V54- for the parking/auxiliary heater by releasing the connector safety catch.

AWD Vehicles, Excluding RS Q3:

Courtesy of AUDI OF AMERICA, LLC

-- Press up the tab in direction of -arrow A-.

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

-- Remove the control module toward the inside and move it to the side with the wires attached.

All AWD Vehicles:

Courtesy of AUDI OF AMERICA, LLC

-- Unclip the left sealing flange cover -1- with the scraper from the : VAS6845 at the frame in direction of -arrows-.

-- Rest of World market versions: disconnect the connectors -1 and 2- on the left sealing flange by releasing the connector safety catch.

Courtesy of AUDI OF AMERICA, LLC

-- China/NAR market versions: disconnect the left connector -arrow- on the fuel tank by releasing the connector safety catch.

Courtesy of AUDI OF AMERICA, LLC

Continuation for All Vehicles:

Fig 4: The Fuel Filler Cap

Courtesy of AUDI OF AMERICA, LLC

-- Open the fuel filler door.

-- Clean the area around the fuel filler neck.

-- Remove the fuel filler neck cap -arrow-.

-- Seal the fuel filler neck opening with a clean plug to prevent any dirt from getting in.

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

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

Courtesy of AUDI OF AMERICA, LLC

EVAP Canister Version 1:

Courtesy of AUDI OF AMERICA, LLC

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

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

EVAP Canister Version 2:

Courtesy of AUDI OF AMERICA, LLC

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

EVAP Canister Version 3:

Courtesy of AUDI OF AMERICA, LLC

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

Continuation for All:

-- Remove the left and right center underbody trim panel. Refer to OVERVIEW - UNDERBODY TRIM PANELS .

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

-- Rest of World Equipment and market-specific versions: disconnect the fuel line -3- for the parking/auxiliary heater. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Courtesy of AUDI OF AMERICA, LLC

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

FWD Vehicles:

Courtesy of AUDI OF AMERICA, LLC

-- Remove the rear axle underbody trim panels. Refer to OVERVIEW - UNDERBODY TRIM PANELS .

-- Remove the right rear trailing arm. Refer to TRAILING ARM WITH MOUNTING BRACKET, REMOVING AND INSTALLING .

-- Place the Gearbox Support: T40173 on the Engine and Gearbox Jack: VAS6931 and support on the fuel tank.

The fuel tank must be empty when removing it.

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts -1 to 4-. (Shown without the engine and transmission jack.)

-- Lower the fuel tank using the engine and gearbox jack.

Courtesy of AUDI OF AMERICA, LLC

When guiding out the fuel tank, pay attention to the clearance to the fuel filler neck.

-- 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.

AWD Vehicles:

Courtesy of AUDI OF AMERICA, LLC

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

-- Remove the driveshaft. Refer to DRIVESHAFT, REMOVING AND INSTALLING .

-- Disconnect and free up the connector -arrow- for the All-Wheel Drive Control Module -J492- to do so release the connector safety catch.

Courtesy of AUDI OF AMERICA, LLC

-- Remove the right rear trailing arm. Refer to TRAILING ARM WITH MOUNTING BRACKET, REMOVING AND INSTALLING .

-- Place the Gearbox Support: T40173 on the Engine and Gearbox Jack: VAS6931 and support on the fuel tank.

Courtesy of AUDI OF AMERICA, LLC

The fuel tank must be empty when removing it.

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts -1 to 5-. (Shown without the engine and transmission jack.)

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

Courtesy of AUDI OF AMERICA, LLC

When guiding out the fuel tank, pay attention to the clearance to the fuel filler neck.

-- 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.