Removing and installing fuel tank, vehicles with 3.0 ltr. (V6) engine and reducing agent metering system — AUDI

🧭 Before you start

Fits: Audi Q7 (4L, 2005–2015)

• 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 .
• Lay a clean cloth under the separating points to catch escaping fuel.
• Seal off filler neck openings with clean plugs to prevent dirt from dropping into the tanks.
• Do not apply force when bending constant velocity joints of the propshaft and bend only as far as stop (not more than approx. 10°).
• Lay a clean cloth under the separating point to catch escaping reducing agent.

🔧 Engine codes this applies to

📋 Procedure

1. ⚠ Risk of accident caused by weight of fuel tankFuel tank must be empty when it is removed. — Drain fuel tank .
2. Activate jacking mode on vehicles with air suspension 43.
3. Switch off ignition and take out ignition key.
4. ⚠ Safety risk due to escaping reducing agent.To prevent large amounts of reducing agent from escaping when the metering line is opened, wait until the reducing agent has been drawn back automatically . — Remove individual seat (left-side) or 2/3 section of seat bench (left-side) in 2nd row of seats 72.
5. Remove individual seat (right-side) in 2nd row of seats 72.

6. ⚠ Injury risk!Wear protective gloves. — Use a commercially available carpet knife (1) to cut open floor covering (left and right) along perforation (arrows).
7. Fold back carpet flap to one side (arrow).
8. Remove nuts (1 … 4) on covers for flanges on both sides of vehicle and detach covers.
9. Unplug electrical connector (arrow) on flange (left-side).
10. Unplug electrical connector (4) on flange (right-side).
11. If fitted, unplug electrical connector (3) on flange. [Note: Lay a clean cloth under the separating points to catch escaping fuel.]
12. ⚠ 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 on vehicles with common rail engine, even after the engine is switched off. 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. — Disconnect fuel lines (1 and 2). Disconnecting plug-in connectors
13. Open the tank flap.
14. Clean area around filler neck.
15. Remove filler cap (1) from fuel filler neck.
16. Remove filler cap (2) from filler neck for reducing agent. [Note: Seal off filler neck openings with clean plugs to prevent dirt from dropping into the tanks.]
17. Remove tank flap unit and rubber cup 55.
18. Remove bolts (arrows) for fuel filler neck.
19. ⚠ 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 (e.g. put a weight of about 50 kg in the luggage compartment). — Remove rear axle 42.
20. Tie propshaft (1) to body using a suitable chain or welding wire, as shown in illustration (arrows). [Note: Do not apply force when bending constant velocity joints of the propshaft and bend only as far as stop (not more than approx. 10°).]
21. Lower propshaft as far as dimension (a).
22. Remove rear right wheel housing liner 66.
23. Remove active tank for reducing agent 26.
24. Disconnect earth wire (1) from fuel filler neck.
25. Unscrew bolt (2) for fuel filler neck.
26. Remove nuts (arrows) and detach guard plate (3) for fuel filler neck.
27. Use punch to knock out pin (1).
28. Remove bracket (2) with pipes from longitudinal member.
29. Unscrew bolts (left and right) from underbody trim panel (centre) in area of fuel tank 66.
30. Remove passive tank for reducing agent 26. [Note: Lay a clean cloth under the separating point to catch escaping reducing agent.]
31. ⚠ Reducing agent can cause skin irritation.Avoid contact with the skin and eyes. Wear gloves and safety goggles.If your skin has come into contact with reducing agent, rinse it off with soap and water.If reducing agent gets into your eyes, rinse them out with water for several minutes.Do not breathe in or swallow reducing agent.If you have swallowed reducing agent, rinse your mouth, drink lots of water and consult a paramedic or doctor immediately. — Disconnect metering line (2). Disconnecting plug-in connectors
32. Unplug electrical connector (1).
33. Unclip fuel supply line (1) and fuel return line (2) at fuel tank (arrows).
34. Unclip retainers (3) for handbrake cables at fuel tank.
35. 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).
36. Support fuel tank using engine and gearbox jackV.A.G 1383 A and support T10031.
37. In addition, a 2nd mechanic will be required to support the fuel tank by hand.
38. Mark the installation position of securing straps for fuel tank.
39. ⚠ Risk of accident caused by weight of fuel tankFuel tank must be empty when it is removed. — Unscrew bolts (1 ... 10) and remove securing straps and support bracket. [Note: For illustration purposes the fuel tank is shown without engine and gearbox jack.]
40. Initially lower fuel tank at rear until it makes contact with propshaft.
41. In addition, a 2nd mechanic will be required to support the fuel tank at the rear by hand.
42. Carefully guide fuel filler neck out of wheel housing (make sure not to damage paintwork).
43. Then lower fuel tank using engine and gearbox jackV.A.G 1383 A; a second mechanic will be required to support fuel tank.
44. Check that lines are clipped onto fuel tank.
45. Position fuel tank with securing straps and support bracket on underbody, using engine and gearbox jackV.A.G 1383 A and support T10031.
46. When installing fuel tank, make sure that the fuel filler neck is correctly inserted into the opening on the body.
47. Tighten bolts in specified sequence to secure fuel tank to underbody:
48. Support bracket (7, 8, 9, 10).
49. Securing strap (rear left and right) (1, 4, 5, 6).
50. Securing strap (front right) (2, 3).
51. Tighten bolt (2) for fuel filler neck.
52. Check the earth wiring (1) and connector tab for traces of oxidation. Remove any traces of oxidation if necessary.
53. ⚠ 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 — Secure fuel filler neck (arrows).
54. Install rubber cup and tank flap unit 55.
55. Install rear axle 42.
56. Bolt on underbody trim panel (centre) on left and right 66.
57. Install rear right wheel housing liner 66.
58. Deactivate jacking mode on vehicles with air suspension 43.
59. Install covers for flanges .
60. Install individual seat (left-side) or 2/3 section of seat bench (left-side) in 2nd row of seats 72.

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