Contents: Cars with torsion beam suspension ⬇ All ⬇ Car with independent heater ⬇ Cars with multi-link suspension ⬇ Cars with torsion beam suspension ⬇ Installation ⬇
Note: Empty the fuel tank.
Move the front seats all the way forward. Switch off the ignition and remove the ignition key from the lock. Remove the rear seat. Unlock the cover locks "1" using the wedge "3409" "arrows".
Remove the sealing sleeve "1" from the cover "2" with a downward movement. Move the cover "2" back along the electrical wiring "3".
Disconnect connectors -1, 2- from the connecting flange, unlocking the connector locks. If available, disconnect connector "3" of the metering pump of the independent heater "V54", while unlocking the connector locks.
Press the locking tab "2" upwards "arrow A", grasping it with your finger between the body bottom and the fuel tank. At the same time, carefully remove the fuel pump control unit "J538" "pos. 1" along the wiring harness "3" from the mount "arrow B". Remove the fuel pump control unit "J538" between the fuel tank and the supporting base. Clean the area around the filler neck. Unscrew the filler neck plug.
Note: To prevent dirt from entering, cover the filler neck opening with a clean cloth.
Remove the filler cap. Remove the rear right wheel. Remove the rear right fender liner.
Cars with torsion beam suspension
Remove the right rear brake caliper and set it aside. Disconnect the rear right ABS sensor connector and remove the wire from the mountings on the rear axle.
All
Unscrew the screws -1, 2- of the filler neck. Remove the rear muffler.
Disconnect the fuel supply line "1" and the fuel return line "2". Unlock and disconnect the quick-release coupling.
Car with independent heater
Disconnect fuel line "1" to the independent heater. Unlock and disconnect the quick-release coupling.
Cars with multi-link suspension
Mark the direction of travel of the car on the clamp. Unscrew screw "4". Remove the exhaust system hanger. Unscrew screw "2" and remove the clamp.
To avoid hanging, place the engine and transmission jack "VAG 1383 A" under the car and support the fuel tank on it, as shown in the figure.
Unscrew screws "1" and "3".
Note: For clarity, the fuel tank is shown in the figure without a jack for engines and transmission units "VAG 1383A". To remove the fuel tank, you will need the help of a 2nd mechanic.
Lower the fuel tank using the engine and transmission jack "VAG 1383 A". Tilt the fuel tank appropriately to the side and lower it. Pass the filler nipple between the rear suspension and the body.
Cars with torsion beam suspension
Mark the direction of travel of the vehicle on the clamp. Unscrew screw "5". Remove the exhaust system hanger "arrow". Unscrew screws "3" and remove clamp "7".
To avoid hanging, place the engine and transmission jack "VAG 1383 A" under the car and support the fuel tank "1" on it, as shown in the figure.
Unscrew screws "2", "4" and "6". Lower the fuel tank using the jack for engines and transmission units "VAG 1383 A". Tilt the fuel tank to the side accordingly and lower it. Pass the filler nipple between the rear suspension and the body.
Installation
Note: Replace the sealing rings. When connecting electrical connectors, make sure that they are securely locked.
Check the installation position of the tank exhaust ventilation line tip. Check the ground wire connector for corrosion, clean if necessary. Check the reliability of the connector fastening. Connector "2" should fit tightly on the metal ring "3". Contact tongue "1" should be attached to the fuel tank "4" and secured with a spacer sleeve "5".
Warning! Danger of electrostatic discharge. After installation, use an ohmmeter to check the electrical connection between the metal ring on the filler neck and the cleaned metal surface on the body. Nominal resistance value: approximately 0 Ohm.
Check whether the fuel lines are secured to the fuel tank with clamps. Using the jack for engines and transmission units "VAG 1383 A", place the fuel tank with the fastening clamps under the bottom of the car. When placing the fuel tank, make sure that the filler neck fits correctly into the hole in the body.
Note: The new clamp mounting screws are longer, observe the part number.
Installation in reverse order.