Fuel Tank, Removing And Installing, Vehicles With 3.0L (V6)/4.2L (V8) Engines: Installing

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Tightening specifications, refer to OVERVIEW - FUEL TANK, VEHICLES WITH 3.0L (V6);4.2L (V8) ENGINES .

-- Make sure the fuel lines are clipped to the fuel tank.

Vehicles through 10/2006

Fig 1: Fuel Lines Location

Courtesy of AUDI OF AMERICA, LLC

-- Make sure the fuel lines and the wiring harness for the fuel pumps and fuel level sensor are attached to the fuel tank.

-- Push the fuel lines -1 and 3- onto the right locking flange until they click into place.

-- Vehicles with parking heater: Push the fuel supply line -2- onto the auxiliary heater metering pump until it clicks into place.

Continuation for All Vehicles

Fig 2: Fuel Tank, Tightening Specifications and Sequence

Courtesy of AUDI OF AMERICA, LLC

-- Position the fuel tank with mounting straps and support plate on the underbody using Engine/Gearbox JackVAG1383A and the Subframe SupportT10031.

-- Make sure the fuel tank is positioned so that the filler tube can be correctly guided into the opening of the body.

-- Tighten the bolts in the sequence described to secure the fuel tank to the vehicle underbody. Refer to Installing .

-- Mounting plate -9, 10, 11 and 12-.

-- Rear left and right tensioning band -1, 4, 5 and 8-.

-- Front left and right tensioning band -2, 3, 6 and 7-.

-- Tighten the bolts -2 and 3- on the fuel filler tube.

Fig 3: Installation position of Ground (GND) connection

Courtesy of AUDI OF AMERICA, LLC

-- Check if the Ground (GND) wiring -1- and the contact show signs of oxidation. If necessary, remove.

WARNING:

Danger due to electrostatic charge.

After installing, check electrical connection on fuel filler neck metal ring to an empty spot on the body using an Ohm meter.

Specified value: approximately 0 Ω.

-- Tighten the bolts -arrows- on the fuel filler tube.

Fig 4: Identifying Fuel Filler Tube Tightened In Place -Arrows-

Courtesy of AUDI OF AMERICA, LLC

Install in reverse order of removal. Note the following:

-- Install the rubber buffer and the fuel door unit, refer to FUEL FILLER DOOR, REMOVING AND INSTALLING .

-- Install the rear axle, refer to REAR AXLE OVERVIEW .

-- Tighten the left and right floor panel trim in the center, refer to FRONT AND REAR DOOR TRIM MOLDING, REMOVING AND INSTALLING .

-- Install the right rear wheel housing liner, refer to Wheel Housing Liners .

-- On a vehicle with air suspension, deactivate vehicle lift mode, refer to VEHICLE LIFT MODE .

Vehicles from 11/2006:

-- Install the locking flange covers, refer to Figure.

-- Install the left single seat and the left 2/3 seat bench seat cushion in the second row of seats, refer to Seat Frames .

-- Install the right rear single seat in the second row of seats, refer to Seat Frames .

-- Vehicles with parking heater: Bleed the fuel supply line to the metering pump, refer to FUEL SUPPLY LINE TO METERING PUMP, BLEEDING, VEHICLES WITH PARKING HEATER .