Fuel Tank, Installing, All Vehicles

WARNING: This page is about a different car, the 2024 Audi S6 and 2024 Audi A6 Quattro. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Analog/Digital Multimeter:FLU83III

Fig 1: Analog/Digital Multimeter FLU83III
Courtesy of AUDI OF AMERICA, LLC

Procedure

Install in the reverse order of removal while noting the following:

The fuel lines as well as the wiring harness to the fuel delivery unit must be clipped onto the fuel tank.

-- Position the fuel tank with mounting straps and support plate on the underbody using the Engine and Gearbox Jack:VAS6931 .

-- When positioning the fuel tank, make sure that the fuel filler neck is guided correctly into the opening of the body.

Vehicles with High-Voltage System:

-- Route the high-voltage cables on the fuel tank. Refer to appropriate Service Information .

Continuation for All Vehicles:

Courtesy of AUDI OF AMERICA, LLC

-- Tighten the bolts -arrows- on the mounting strap and the support plate.

Vehicles with High-Voltage System:

-- Install the Electric Drive Power and Control Electronics -JX1-. Refer to appropriate Service Information .

TSI Vehicles:

Courtesy of AUDI OF AMERICA, LLC

-- Install the reducing agent filler neck -1-. Refer to appropriate Service Information .

-- Tighten the bolts -arrows-. (Shown on the A6 TDI).

Continuation for All Vehicles:

Fig 2: Ground Connection Routing - North American Vehicles

Courtesy of AUDI OF AMERICA, LLC

-- Attach the ground wire -arrow A- to the fuel filler neck metal ring.

-- North American version: connect the ground wire -arrow B- to the fuel filler neck protective plate.

-- Make sure the connector is securely fastened.

CAUTION:

There is a risk of the fuel tank exploding due to electrostatic discharge.

Severe injuries and burns are possible.

- Check the electrical connector using an Ohm meter after installing the fuel tank.

-- Check the electrical connection of the threaded ring on the fuel filler neck to a bare area of the vehicle body using the Analog/Digital Multimeter:FLU83III .

Specified value: approximately 0 Ω.

-- Install the driveshaft. Refer to DRIVESHAFT, REMOVING AND INSTALLING .

-- Install the fuel filler door unit. Refer to appropriate Service Information .

-- Install the subframe. Refer to appropriate Service Information .

Vehicles with High-Voltage System:

CAUTION:

There is a risk of fatal injury due to high voltage.

Electrocution by direct contact or electric arc can cause severe bodily injury or fatal injury.

- Have an Audi high-voltage technician or an Audi high-voltage expert bring the high-voltage system back into service.

-- Re-energize the high-voltage system. Refer to [For engine(s) DPAA] High-Voltage System, Re-Energizing .

Continuation for All Vehicles:

-- TFSI vehicles: connect the battery. At the same time, follow all steps after connecting the battery. Refer to BATTERY A, DISCONNECTING AND CONNECTING, VEHICLES WITH HIGH-VOLTAGE SYSTEM, (0K3) .

CAUTION:

Risk of the fuel tank exploding when starting the fuel pump.

Severe injuries and burns are possible.

- After installing a new or completely empty fuel tank, immediately fill with at least 5 liters of fuel.

-- After installing a new or completely empty fuel tank, at least five liters of fuel must be added before starting the engine.

-- Equipped on some models: bleed the fuel line to the parking/auxiliary heater metering pump. Refer to FUEL LINE TO METERING PUMP, BLEEDING .

Tightening Specifications

Refer to OVERVIEW - FUEL TANK
Refer to OVERVIEW - EVAP SYSTEM, VEHICLES WITH Fuel Tank Leak Detection Module -GX36- OR WITH HIGH-VOLTAGE SYSTEM
Refer to OVERVIEW - MUFFLER .
Refer to appropriate Service Information .
Refer to OVERVIEW - REAR WHEEL HOUSING LINER .
Refer to OVERVIEW - UNDERBODY TRIM PANELS .