Removal and installation of the fuel tank

Removing

Instructions: Before disconnecting the battery, open the filler flap and, if necessary, remove the adapter for wheel lock bolts from the luggage compartment.

With the ignition off, disconnect the battery ground wire. If necessary, pump out the fuel from the tank. Remove the right rear wheel. Remove the rear right fender liner. Loosen the filler cap screw and remove it. Unscrew filler pipe from body -arrows- and, if necessary, detach cable from filler pipe.



Unclip ABS sensor cable from retainers -arrows- on filler neck. Remove the rear bench seat.



Remove covers and unplug electrical connectors -arrows-. Remove the rear of the exhaust system. Securely fasten the front of the exhaust system to the bottom. Remove cardan shaft.




Unplug connectors -arrow- from all-wheel drive control unit -J492-.

WARNING: The fuel pressure line is under pressure!

Disconnect quick couplings -1- and -2- for fuel lines between tank and body.

Instruction: To unlock and remove the fuel lines, compress the retaining ring.

Unscrew securing bolt -1-.




Support fuel tank with jack -VAG 1383 A-, then unscrew securing bolts -arrows- and clamps. Lower tank slowly. If necessary, disconnect the wires and pipelines attached to the upper part of the tank.

Instructions: The filler pipe must be" between body and rear axle. To do this, with the help of a second person, lift the fuel tank downwards from the jack -VAG 1383 A-.

Installation

Attach cable from four-wheel drive control unit -J492- to fuel tank. Together with an assistant, guide the filler pipe between the rear axle and the body. Then place fuel tank on jack -VAG 1383 A-.



Raise fuel tank slowly to installation position and secure. Connect adapter cable to all-wheel drive control unit -J492-. Further installation is carried out in the reverse order. In doing so, the following must be taken into account. Ventilation and fuel lines should be laid without kinks. Do not confuse pressure and return lines (return line blue or with blue mark, pressure line black). Ensure reliable connection of pipelines. Check the tank ground connection on the filler pipe.