Safety rules for working with the power supply system
Caution: When performing installation work, especially in the engine compartment due to its dense layout, the following rules must be observed. All types of lines (for example fuel, hydraulic, activated carbon absorber, cooling system, air conditioning system circuit, brake system, vacuum), and electrical wires must be laid as they were originally laid. To avoid damage to hoses, tubes or wires, it is necessary to provide sufficient space when working with all moving or heated units. When removing and installing the fuel level sensor "G" or fuel pump (fuel delivery module) from full or partially filled fuel tanks, the following should be taken into account: Remove the fuel pump fuse. The fuel in the fuel system is under pressure!
Removal
Strictly observe safety regulations before starting installation work. With the ignition off, disconnect the battery ground wire. Unscrew the filler flap fastening screw and remove it. Pump out the fuel from the tank and clean the surface near the filler pipe. Remove the rear bench seat. Remove the cover from the fuel supply module. Disconnect connector "1" and fuel line "2" from the right (in the direction of movement) flange.
Unlock the "arrow" connector on the fuel pump control unit -J538- using the "T10118" tool and disconnect the connector.
Disconnect connectors "1" from the left (depending on the direction of travel) flange.
Unscrew the nuts of the double clamp "arrow" and move it forward along the exhaust pipe.
Unscrew the nuts "arrows" and pull the exhaust pipe back. Remove the rear part of the exhaust system with the middle and rear muffler.
All-wheel drive vehicles
Unscrew the pendulum support "arrow". Remove the cardan shaft.
Continued for all cars
CAUTION: The fuel in the pressure line is under pressure.
Disconnect the fuel line "1" (black) and the ventilation line "2" (white) at the junction. If an independent heater is installed, also remove the fuel line-3-. -
Instructions: To unlock and remove the line, squeeze the locking ring.
Unscrew the right rear wheel. Remove the rear right mudguard. Disconnect the ventilation pipes "1" from the activated carbon canister and the filler neck "3". Disconnect the cable "2" from the holder. Remove the hatch and the filler cap of the fuel tank. Disconnect the ground wire on the filler neck.
Unscrew the fuel tank neck from the body of the "arrow".
Loosen the mounting bolt "1". Loosen the bandage and mounting bolts "arrows". In doing so, support the fuel tank on the jack for engines and transmission units -VAQ 1383 A-.
Installation
With the help of a second mechanic, pass the filler neck between the rear axle and the body. Then place the fuel tank on the tilting device -VAG 1383 A-. Slowly lift the fuel tank to the installation position and secure it.
Instructions: Only bolts with rotating washers on them are allowed to be used to secure the fuel tank mounting clamps. If other bolts are used, the clamps may become warped when tightened.
Tighten the new fastening bolts of the clamping clamps "arrows" and the new bolt "1" with a torque of 20 Nm + 90° further. Tighten the fastening bolts of the "arrows" of the filler neck with a torque of 8 Nm + 90° further. Further installation is carried out in the reverse order of removal. In this case, it is necessary to take into account the following. The ventilation and fuel lines must be laid without kinks. Check the connection of the fuel tank to the ground on the filler pipe. Ensure proper fastening of the fuel hoses. After installing the fuel tank, check whether the feed and ventilation lines are still secured to the fuel tank.
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