Removing
With the ignition off, disconnect the battery ground wire. Unscrew the fixing bolt of the filler hatch assembly and remove it. Drain the fuel from the tank and clean the area around the filler pipe. Remove bench seat. Remove the cover from the fuel delivery module. Remove connector -1- and fuel line -2- from right (looking in the direction of travel) flange.
Lever out connector -arrow- on fuel pump control unit -J538- with assembly tool -T10118- and remove connector.
Remove connector -1- from left (looking in the direction of travel) flange.
Unscrew the nuts of the double clamp -arrows- and move it forwards along the exhaust pipe -1-.
Unscrew nuts -arrows- and pull exhaust pipe back. Remove rear exhaust system with middle and rear muffler.
Unscrew rocker 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 independent heating is installed, also remove fuel line -3-.
Instructions: To disconnect the fuel lines, press the retaining ring.
Unscrew the right rear wheel. Remove the rear right fender liner. Detach vent lines -1- from activated charcoal filter and filler neck -3-. Detach cable -2- from holder. 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 so, support the fuel tank with the jack -VAG 1383 A-.
Installation
Using a second mechanic, guide the filler neck 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.
Note: Only bolts with loose washers may be used to fasten the fuel tank clamps. If other screws are used, the tie-down straps may become twisted when tightened.
Tighten new retaining bolts for clamping collars -arrows- and new bolt -1- to 20 Nm + turn 90°further. Tighten retaining bolts -arrows- for coolant pump to 8 Nm + turn 90°further. Further installation is carried out, respectively, in the reverse order of removal. In doing so, the following must be taken into account. Ventilation and fuel lines should be laid without kinks. Check for a tank/body 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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