Removing and installing fuel tank (four-wheel drive, USA vehicles) — AUDI

🧭 Before you start

Fits: Audi TT Mk2 (8J, 2006–2014)

• Opens: fuel

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• Risk of accident caused by weight of fuel tankFuel tank must be empty when it is removed. — Drain fuel tank .
• A second person will be required for detaching rear section of exhaust system.
• Risk of accident caused by weight of fuel tankFuel tank must be empty when it is removed. — First remove bolts (2, 5, 6).
• The following two illustrations show the electrical connectors on the flanges in their installation position.
• When installing fuel tank, make sure that the fuel filler neck is correctly inserted into the opening on the body.

🔧 Engine codes this applies to

📋 Procedure

1. Release the tank flap.
2. ⚠ To prevent irreparable damage to the electronic components when disconnecting the battery:Observe notes on procedure for disconnecting the battery. — Disconnect battery Electrical system27Battery; Disconnecting and connecting battery.
3. ⚠ Risk of accident caused by weight of fuel tankFuel tank must be empty when it is removed. — Drain fuel tank .
4. Clean area around fuel filler neck.
5. Remove filler cap (arrow) from fuel filler neck.

6. Seal opening of fuel filler neck with a piece of clean foam or similar to prevent dirt from dropping into the tank.
7. Remove rear right wheel housing liner General body repairs, exterior66Wheel housing liner; Exploded view - wheel housing liner (rear).
8. Remove bolts (3) and (4) for fuel filler neck.
9. Remove breather line (2) going to activated charcoal filter (press release tab).
10. Detach electrical wire (1) for ABS speed sensor from bracket on fuel filler neck.
11. Move overflow hose (5) on fuel filler neck clear.
12. Remove diagonal struts Running gear, axles, steering42Subframe; Exploded view - subframe.
13. Press release tab and disconnect breather line (arrow) leading to activated charcoal filter.
14. ⚠ Risk of damage to flexible joints in front exhaust pipeThe flexible joints in the front exhaust pipe must not be bent more than 10°.Before slackening clamp on exhaust pipe, secure front section of exhaust system to underbody of vehicle with a chain. — Disconnect exhaust system at clamp (1).
15. Secure front section of exhaust system with a chain. To do so, engage hooks3004 into openings on underside of vehicle (remove plugs if fitted).
16. Push the clamp back in order to separate the exhaust system. [Note: A second person will be required for detaching rear section of exhaust system.]
17. Disengage rear silencer at the rubber mountings and remove rear section of exhaust system.
18. Remove propshaft Rear final drive39Propshaft.
19. Press release tab and disconnect breather line (2) at front right of fuel tank.
20. ⚠ Risk of injury - fuel system operates under high pressure.To reduce the pressure in the fuel system, wrap a clean cloth around the connection and carefully loosen the connection. — Press release tab and disconnect fuel line (1) at front right of fuel tank.
21. ⚠ Risk of accident caused by weight of fuel tankFuel tank must be empty when it is removed. — First remove bolts (2, 5, 6).
22. Disengage wiring harness (arrows) and move clear.
23. Position engine and gearbox jackV.A.G 1383 A below vehicle to support tank.
24. Remove bolts (1, 3, 4, and 7).
25. ⚠ Risk of overstretching electrical wiring.Subsequently, when lowering fuel tank, make sure that electrical wiring is not under tension. — Lower fuel tank using engine and gearbox jackV.A.G 1383 A only until you can reach electrical connectors on flanges with your hand. [Note: The following two illustrations show the electrical connectors on the flanges in their installation position.]
26. Unplug electrical connector (1) on flange (left-side).
27. Disengage electrical connector (2) for Haldex coupling.
28. Unplug electrical connector (arrow) at flange (right-side).
29. Then lower fuel tank using engine and gearbox jackV.A.G 1383 A, simultaneously guiding fuel tank down by hand.
30. Remove fuel tank downwards (turning it sideways as required).
31. In addition, a 2nd mechanic will be required to guide the fuel filler neck on trailing arm out by hand.
32. Position fuel tank with securing straps on underbody, using engine and gearbox jackV.A.G 1383 A.
33. Attach wiring harness at top of fuel tank.
34. When installing fuel tank, make sure that the fuel filler neck is correctly inserted into the opening on the body.
35. Secure fuel tank by first tightening bolts at points (1, 3, 4, 7), then at points (2, 5, 6).
36. The connections (2) and (4) on filler neck must be free from corrosion to ensure earth connection to body is not impaired.
37. Tighten bolts (2) and (4) for fuel filler neck.
38. Check the earth wiring at both ends for traces of oxidation and remove oxidation if necessary.
39. Position the earth connection as illustrated (1).
40. Ensure that connectors (arrows) for earth connection are properly seated on protective plate (5) and on fuel filler neck (3).
41. ⚠ Risk of explosion caused by electrostatic discharge.After installation, use an ohmmeter to check the electrical connection between the metal ring on the fuel filler neck and a bare metal part on the body:Specification: approx. 0 Ω. — Attach electrical wire for ABS speed sensor to bracket on fuel filler neck.
42. Install breather line (leading to activated charcoal filter) at filler neck.
43. Install rear right wheel housing liner General body repairs, exterior66Wheel housing liner; Exploded view - wheel housing liner (rear).
44. Install propshaft Rear final drive39Propshaft.
45. Install rear section of exhaust system 26Exhaust pipes/silencer; Exploded view - silencer.
46. Install diagonal struts Running gear, axles, steering42Subframe; Exploded view - subframe.
47. Connect battery. Observe notes on procedure after disconnecting the battery Electrical system27Battery; Disconnecting and connecting battery.

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