Removing and installing fuel tank - vehicles up to model year 2013 — AUDI

🧭 Before you start

Fits: Audi A8 D4 (4H, 2010–2017)

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• Risk of accident caused by weight of fuel tankFuel tank must be empty when it is removed. — Drain fuel tank .
• Seal off opening of fuel filler neck with a clean plug to prevent dirt from entering.
• Position engine and gearbox jackV.A.G 1383 A with support T10031 under vehicle to support tank, as shown in illustration (do not use threaded rods of support).
• Risk of accident caused by weight of fuel tankFuel tank must be empty when it is removed. — Remove bolts (1 ... 7).
• For illustration purposes the fuel tank is shown without engine and gearbox jack.

🔧 Engine codes this applies to

📋 Procedure

1. Observe safety precautions .
2. Observe rules for cleanliness .
3. ⚠ Risk of accident caused by weight of fuel tankFuel tank must be empty when it is removed. — Drain fuel tank .
4. Open tank flap.
5. Clean area around fuel filler neck.

6. Remove filler cap (arrow) for fuel filler neck. [Note: Seal off opening of fuel filler neck with a clean plug to prevent dirt from entering.]
7. Remove tank flap unit General body repairs, exterior55Tank flap unit; Exploded view - tank flap unit.
8. Disconnect earth wires (1 and 2) from guard plate and metal ring on fuel filler neck.
9. Remove bolts (3) for fuel filler neck.
10. Remove rear wheel housing liner (right-side) General body repairs, exterior66Wheel housing liners; Removing and installing wheel housing liner (rear).
11. Remove nut (1).
12. Detach protective sleeve (3).
13. Detach breather line (2) from connection; to do so, apply removal tool T40225 to release ring (4) and press it in (arrow).
14. Remove rear section of exhaust system 26Exhaust pipes/silencer; Exploded view - silencer.
15. ⚠ The vehicle can tip over on the lifting platform when the rear axle is removed.BEFORE loosening the subframe bolts, take steps to ensure that the vehicle does not tip forwards on the lifting platform Running gear, axles, steering42Subframe; Exploded view - subframe. — Remove subframe Running gear, axles, steering42Subframe; Exploded view - subframe.
16. Release retainer catches and unplug electrical connectors (1 and 2) on right side of fuel tank.
17. If fitted, unplug electrical connector (3) at metering pump.
18. ⚠ The fuel can become extremely hot. This can cause injuries.In extreme cases the fuel lines and the fuel can reach a temperature of 100 °C. Allow the fuel to cool down before disconnecting the lines - danger of scalding.Wear protective gloves.Wear safety goggles.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 return line (2).
19. Press release tab and disconnect fuel supply line (1).
20. If fitted, disconnect fuel supply line (3) for auxiliary heater.
21. Position engine and gearbox jackV.A.G 1383 A with support T10031 under vehicle to support tank, as shown in illustration (do not use threaded rods of support).
22. In addition, a 2nd mechanic will be required to support the fuel tank at the rear by hand.
23. ⚠ Risk of accident caused by weight of fuel tankFuel tank must be empty when it is removed. — Remove bolts (1 ... 7).
24. Then lower fuel tank using engine and gearbox jackV.A.G 1383 A, simultaneously guiding fuel tank down by hand. [Note: For illustration purposes the fuel tank is shown without engine and gearbox jack.]
25. Check that fuel and breather lines as well as wiring harness for fuel pump and fuel gauge senders are clipped onto fuel tank.
26. Check that electrical connectors are attached at flanges and are properly secured.
27. Position fuel tank with securing straps and support bracket on underbody using engine and gearbox jackV.A.G 1383 A and support T10031.
28. When installing fuel tank, make sure that fuel filler neck is correctly inserted into opening on body.
29. Tighten bolts (1 ... 7) for securing straps and support bracket.
30. Tighten bolts (3) for fuel filler neck.
31. Check earth wires (1 and 2) for traces of oxidation at connectors; remove any oxidation.
32. Connect earth wires at guard plate and on metal ring at fuel filler neck, ensuring that connector is securely fitted.
33. ⚠ Safety risk due to 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 — Vehicles with auxiliary heater: Bleed fuel supply line leading to metering pump 23Injection system; Filling and bleeding fuel system.

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