Carefully! To reduce weight, the fuel tank must be empty when removed. If necessary, pump out the fuel from the tank.
Switch off the ignition and all electrical consumers and remove the ignition key from the lock. Remove rear seat. Unclip flange cover -1- at fixing points -arrows- using wedge -3409-. Disconnect connector -1- for fuel pump.
Vehicles with auxiliary heater
Unplug connector -2- for auxiliary heater metering pump.
All
Press mounting -2- upwards in -direction of arrow A- by placing your finger between the body support and fuel tank. At the same time, carefully pull the fuel pump control unit -J538- -1- out of the clip using the wiring harness -3- -arrow B-. Remove fuel pump control unit -J53B- between fuel tank and support. Open the fuel tank door. Clean the area around the filler neck.
Unscrew filler cap -1-.
Note: Cover the filler opening with a clean cloth to prevent dirt from entering.
Remove the right rear wheel. Remove the rear right fender liner. Remove the brake caliper for the right rear wheel and set aside. Disconnect the rear right wheel ABS sensor connector and remove the wire from the mountings on the rear axle. Disconnect the vent hoses -1 and 2- of the canister, to do this, disconnect the quick-release couplings. Disconnect ventilation hoses from bracket -arrows-.
Detach vent hose -1 -from bracket -arrow-. Separate the exhaust pipe with a body saw, eg -VAG 1523 A- or cut-off machine, and remove central and rear section of exhaust system separately.
Remove screws -1- and -2- for filler neck.
Attention! Risk of injury from high pressure fuel. To relieve pressure in the fuel system, cover the connector area with a clean rag and carefully loosen the connection.
Unlock the parking brake cable from the fasteners.
Detach breather hose -3- and fuel line -2-.
Note: On vehicles with auxiliary or auxiliary heater, the fuel line -1- of the metering pump -V54- must also be disconnected. The fuel tank is heavy - risk of accident. The fuel tank must be empty when removed.
Remove bolt -5-. Remove suspension bracket for exhaust system -arrow-. Unscrew screw -3- and remove tensioning strap -7-.
Support fuel tank with engine and gearbox jack -VAG 1383A-.
Release fixing screws -2-, -4- and -6-. Loosen the fuel tank heat shield nuts and remove the shield. Lower fuel tank slightly using engine and gearbox jack -VAG 1383A-.
Note: The assistance of a 2nd mechanic is required to remove the fuel tank. Be careful not to damage individual wires.
With the help of a second mechanic, move the fuel tank aside and lower it. Route the filler plug between the rear suspension and the body.
Installation
Note: On vehicles with auxiliary or auxiliary heater, check that the metering pump -V54- is securely fastened to the bracket.
Check both earth connections for corrosion and clean if necessary. Check the mounting position of the ground wire.
Note: The assistance of a 2nd mechanic is required to install the fuel tank. Be careful not to damage individual wires.
Using a second mechanic, guide fuel filler neck between rear axle and body and support fuel tank with engine and gearbox jack -VAG 1383A-. Install in reverse order. Ventilation and fuel lines should be laid without kinks. Do not confuse supply and ventilation pipes (ventilation - white, supply - black). Ensure reliable connection of pipelines. After installing the fuel tank, check whether the pipes are fixed to it.