Removing and installing fuel tank, vehicles with 6.0 ltr. (V12) engine — 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.
• Do not apply force when bending constant velocity joints of the propshaft and bend only as far as stop (not more than approx. 10°).
• 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).
• Mark the installation position of securing straps for fuel tank.

🔧 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. Release the tank flap.
4. Switch off ignition and take out ignition key.
5. Remove individual seat (left-side) or 2/3 section of seat bench (left-side) in 2nd row of seats 72.

6. Remove individual seat (right-side) in 2nd row of seats 72.
7. ⚠ Injury risk!Wear protective gloves. — Use a commercially available carpet knife (1) to cut open floor covering (left and right) along perforation (arrows).
8. Fold back carpet flap to one side (arrow).
9. Remove nuts (1 … 4) on covers for flanges on both sides of vehicle and detach covers. [Note: Lay a clean cloth under the separating points to catch escaping fuel.]
10. ⚠ 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 (2 and 3). Disconnecting plug-in connectors
11. Unplug electrical connector (1) on flange (left-side). [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. Unplug electrical connector (4) on flange (right-side).
14. Vehicles with auxiliary heater: Disconnect fuel line (3) to auxiliary heater. Disconnecting plug-in connectors
15. Open the tank flap.
16. Clean area around fuel filler neck.
17. Remove filler cap (arrow) from fuel filler neck.
18. Seal opening of fuel filler neck with a a clean plug to prevent dirt from dropping into the tank.
19. Remove fuel tank flap unit 55.
20. Lever off rubber cup (1) and take out.
21. Remove bolts (arrows) for fuel filler neck.
22. ⚠ 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.
23. 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°).]
24. Lower propshaft as far as dimension (a).
25. Remove rear right wheel housing liner 66.
26. Disconnect earth wire (1) from fuel filler neck.
27. Unscrew bolts (2) and (3) for fuel filler neck.
28. Unscrew nuts (arrows) and remove protective plate for fuel filler neck.
29. Use punch to knock out pin (1).
30. Remove bracket (2) with breather lines from longitudinal member.
31. Unscrew bolts (left and right) from underbody trim panel (centre) in area of fuel tank 66.
32. Unclip retainers for handbrake cables at fuel tank.
33. 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).
34. Support fuel tank using engine and gearbox jackV.A.G 1383 A and support T10031.
35. In addition, a 2nd mechanic will be required to support the fuel tank by hand.
36. Mark the installation position of securing straps for fuel tank.
37. ⚠ Risk of accident caused by weight of fuel tankFuel tank must be empty when it is removed. — Unscrew bolts (1 ... 12) and remove securing straps and support bracket. [Note: For illustration purposes the fuel tank is shown without engine and gearbox jack.]
38. Initially lower fuel tank at rear until it makes contact with propshaft.
39. In addition, a 2nd mechanic will be required to support the fuel tank at the rear by hand.
40. Carefully guide fuel filler neck out of wheel housing (make sure not to damage paintwork).
41. Unclip fuel lines at fuel tank (arrows).
42. Then lower fuel tank using engine and gearbox jackV.A.G 1383 A; a second mechanic will be required to support fuel tank.
43. Position fuel tank with securing straps and support bracket on underbody, using engine and gearbox jackV.A.G 1383 A and support T10031.
44. When installing fuel tank, make sure that the fuel filler neck is correctly inserted into the opening on the body.
45. Clip fuel lines onto fuel tank.
46. Tighten bolts in specified sequence to secure fuel tank to underbody:
47. Support bracket (9, 10, 11, 12).
48. Securing strap (rear left and right) (1, 4, 5, 8).
49. Securing strap (front left and right) (2, 3, 6, 7).
50. Tighten bolts (2) and (3) for fuel filler neck.
51. Check the earth wiring (1) and connector tab for traces of oxidation. Remove any traces of oxidation if necessary.
52. ⚠ 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 — Tighten bolts (arrows) for fuel filler neck.
53. Install fuel tank flap unit 55.
54. Install rear axle 42.
55. Bolt on underbody trim panel (centre) on left and right 66.
56. Install rear right wheel housing liner 66.
57. Deactivate jacking mode on vehicles with air suspension 43.
58. Install covers for flanges .
59. Install individual seat (left-side) or 2/3 section of seat bench (left-side) in 2nd row of seats 72.
60. Install individual seat (right-side) in 2nd row of seats 72.

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