Withdrawal
The illustration shows the removal of the 34 liter fuel tank. To reduce weight, the fuel tank must be empty when removed. If necessary, remove fuel from the fuel tank.
Fold down or remove the rear bench seat. Fold back the trim under the rear seat. Turn cover for fuel level indicator sender in -direction of arrow- and remove cover.
Unplug electrical connector -arrow- at blind flange.
Vehicle from 05.2002
Detach fuel supply line -1- from protective flange by pressing release buttons. Pos. -2- ignore.
All cars
Remove the rear right wheel liner. Remove rear axle. Remove bolts and nuts -arrows-. Detach the additional muffler from the right mounting loop -1. Remove heat shield -2-. Reinstall the additional muffler. Fasten the muffler immediately, do not leave it hanging, risk of damage to the connecting element.
Unscrew cover -arrows-.
Unscrew cover for fuel cooler hose outlet -arrow-.
Unscrew nuts -arrows- and remove heat shield -2-. Disconnect the additional muffler from both left-hand mounting loops. Remove heat shield -1-. Reinstall the additional muffler.
Fasten the muffler immediately, do not leave it hanging, risk of damage to the connecting element.
Where present, disconnect fuel return line -arrow- leading to the right-hand fuel changeover valve on the fuel tank by pressing the release buttons.
Disconnect fuel return line -arrow- on right side of fuel cooler. On vehicles with an additional heater, disconnect the fuel line leading to the auxiliary heater metering pump.
Vehicle until 04.2002
Disconnect fuel feed line -arrow-, lead line and fuel filter by pressing release button.
All cars
Open the fuel tank hatch. Clean the area around the fuel filler neck. Unscrew the fuel tank filler cap. Remove screws -arrows- for fuel filler neck.
Loosen screw connections -1- and -3- first. Place a jack -VAG 1383 A- under the fuel tank to support it. Loosen screw connections -2- and -4-. Then lower the fuel tank using the jack -VAG 1383 A-.
Installation
Install in reverse order, taking into account that all hose connections must be fastened with clamps of the appropriate series. Gaskets and seals O-rings must be replaced during assembly work. The arrows marked on the tubing connections must be opposite each other. Check ground wire for signs of oxidation on both connections. If necessary, remove traces of oxidation. Check the installation position of the earth connection. The plug -4- must be firmly seated on the metal ring -3-. The contact tongue -2- must be inserted into the fuel tank -5- and fixed with the spacer sleeve -1-. Position the fuel tank with tie-down strap on the underbody of the vehicle using the hoist -VAG 1383 A-. Screw on fuel tank first at fixing points -2- and -4- and then -1- and -3-. Screw on fuel filler neck to earth in wheel housing -arrows-.
Carefully! After installation, use an ohmmeter to check the electrical connection of the metal ring on the filler neck with the exposed point of the body: specification: approx. 0 ohm.
Install the rear axle. Install the rear right fender liner. Install the rear bench seat.
Tightening torques:
- Tie strap to body: 21 Nm
- Fuel tank to body: 21 Nm
- Fuel filler neck to wheel, niche: 21 Nm
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