Release connector -arrow- on fuel pump control unit -J538- with tool -T10118- and unplug connector.
Disconnect connectors -1- from left (looking in the direction of travel) flange. Remove rear exhaust system with middle and rear muffler.
Unbolt lower power unit support -arrows-. Remove cardan shaft.
WARNING: The fuel in the pressure line is under pressure!
Disconnect fuel line -1- (black) and ventilation line -2- (white) at the junction. If an auxiliary heater is fitted, also remove the fuel line -3-.
Instructions: To unlock the fuel lines, compress the retaining ring.
Unscrew the right rear wheel. Remove the rear right fender liner.
CAWA, CAWB
Detach vent lines -1- from activated charcoal filter and filler neck -3-. Unclip ABS sensor cable from retainers -2- on filler pipe.
CCTA, CCTB
Detach vent and vacuum lines from canister -arrows-.
Unclip ABS sensor cable from retainers -arrows- on filler neck.
All
Remove the hatch and the filler cap of the fuel tank. Disconnect the ground wire at the filler neck. Unbolt fuel filler neck from body -arrows-.
Unscrew securing bolt -1-. Unscrew band and securing bolts -arrows-. While doing this, support the fuel tank on the engine and gearbox jack -VAG 1383 A-.
Installation
Together with an assistant, guide the filler pipe between the rear axle and the body. Then place fuel tank on jack -VAG 1383 A-. Slowly raise fuel tank to installation position and secure.
Instruction: Only bolts with washers turning on them may be used to fix the clamps of the fuel tank. When using other bolts, the clamps may warp when tightened. Tighten new securing bolts for tie-down straps -arrows- and new bolt -1- to 25 Nm. Tighten securing bolts -arrows- for coolant pump to 8 Nm + turn 90°further. Further installation is carried out, respectively, in the reverse order of removahp an atom, the following must be taken into account. Ventilation and fuel lines should be laid without kinks. Check the fuel tank ground connection on the filler pipe. Make sure fuel hoses are properly secured. After installing the fuel tank, check whether the supply and ventilation lines are still attached to the fuel tank.
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