Fuel Tank, Removing, TFSI Vehicles

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

Special tools and workshop equipment required

Engine and Gearbox Jack:VAS 6931

Fig 1: Engine and Gearbox Jack VAS6931 or VAG1383A
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Gearbox Support:T40173

Fig 2: Gearbox Support T140173
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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 .

CAUTION:

Risk of destroying electronic components when disconnecting the battery.

Follow the steps when disconnecting the battery.

-- Disconnect the ground cable from the battery terminal. Refer to BATTERY, DISCONNECTING AND CONNECTING .

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 .

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

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

Fig 3: Sealing Flange Cover

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-- Disconnect the connectors -1 and 3- on the sealing flange by unlocking the connector safety catch.

Fig 4: Fuel Pump Connectors

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-- Market-specific version/equipment version: release the connector safety catch and disconnect the connector -2-.

Vehicles with Fuel Tank Temperature and Pressure Sensor -GX49- and FWD:

Fig 5: Fuel Tank Temperature and Pressure Sensor -GX49- - FWD Vehicles

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-- Disconnect the connector -1-.

Vehicles with Fuel Tank Temperature and Pressure Sensor -GX49- and AWD:

-- Disconnect the connector -3-.

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Continuation for All Vehicles:

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

-- Remove the fuel filler door unit. Refer to the appropriate Service Information .

A4:

Fig 6: Locating Fuel Filler Neck Bolts -- A4

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-- Remove the fuel filler neck bolts -arrows-.

A5:

Fig 7: Fuel Filler Neck Bolts -- A5

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-- Remove the fuel filler neck bolts -arrows-.

Fig 8: Bleeder Line

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

-- Disengage and free up the bleeder line at the bracket -arrow-.

-- Remove the rear underbody trim panels. Refer to REAR UNDERBODY TRIM PANEL, REMOVING AND INSTALLING .

-- Remove the rear section of the exhaust system. Refer to MUFFLER, REMOVING AND INSTALLING (2.0L) , MUFFLER, REMOVING AND INSTALLING (3.0L) .

-- Rest of World market-specific version/equipment version: loosen the lock washer -2- and remove the fuel hose -3- from the metering pump -1-.

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NOTE:

Place a cloth under the separating point to catch any escaping fuel.

WARNING:

The fuel system is under pressure.

Risk of injury from fuel spraying out.

Wear protective eyewear.
Wear safety gloves.
Reduce the pressure: place clean cloths around the connection point and carefully open the connection point.

-- Disconnect the fuel line -arrow-. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Requirement

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Use the Gearbox Support:T40173 with the mount chromated in yellow and the joint element -B- or with valid CE symbol -A-.

-- Place the Gearbox Support:T40173 on the Engine and Gearbox Jack:VAS 6931 and support as shown on the fuel tank.

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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-.

NOTE:

For reasons of clarity, the fuel tank is shown without the engine and gearbox jack.

-- Lower the fuel tank using the Engine and Gearbox Jack:VAS 6931 .

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NOTE:

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

AWD Vehicles:

-- Equipped on some models: remove the diagonal brace. Refer to DIAGONAL BRACES, REMOVING AND INSTALLING .

-- Remove the driveshaft. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

FWD/AWD Vehicles North American Market-Specific Version and Rest of World AWD Vehicles:

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Requirement

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Use the Gearbox Support:T40173 with the mount chromated in yellow and the joint element -B- or with valid CE symbol -A-.

-- Place the Gearbox Support:T40173 on the Engine and Gearbox Jack:VAS 6931 and support as shown on the fuel tank.

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 through 7-.

NOTE:

For reasons of clarity, the fuel tank is shown without the engine and gearbox jack.

-- Lower the fuel tank using the Engine and Gearbox Jack:VAS 6931 .

Courtesy of AUDI OF AMERICA, LLC

NOTE:

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