Fuel Tank, Removing and Installing

REMOVING





- remove four bolts securing tank cover plate (arrows)
- remove fuel pump relay from fuse/relay panel
- insert remote control VW 1348/3A
- drape remote control along side of vehicle





- remove fuel line from intake on accumulator (arrow)
- activate fuel pump with VW 1348/3A remote control
- after fuel has been transferred to a suitable container, disconnect battery ground strap





- remove cover for fuel gauge and fuel pump (under luggage compartment cover)
- disconnect plug connection for fuel pump and fuel gauge

WARNING: Never smoke when working with fuel or have anything in area that can ignite it. Always replace seals and fuel hose clamps, Always clean fuel lines before loosening





- detach fuel supply hose (A), fuel return hose (B) and vent hose (C)





- detach vent hose and overflow hose from tank filler cap (arrows)





- remove screw securing filler neck splash shield (arrow)
- remove filler pipe





- detach filler pipe from fuel tank hose (arrow)





- disconnect and remove exhaust system from header pipe back, 3 bolt flange (arrows)





- remove heat shield, 4 bolts (arrows)





- loosen adjusting nut for parking brake cable (arrow)





- unhook parking brake cable from brake lever (arrows)





- slide parking brake cable through guides (arrows)





- lock rear axle differential and hold one wheel stationary by hand
- detach drive shaft 6 bolts (arrow) and tie up





- remove cover plate for left axle shaft (A)
- loosen lock nut (B)
- remove holder for adjusting element (C) and tie up





- unfasten left and right axle shafts (arrow) and tie up





- support final drive using a suitable support fixture.





- unfasten and plug, left and right brake lines (left line is shown by arrow A)
- unclip brake line clips (shown by arrow B)





- unscrew lock nuts from diagonal arm and final drive (arrows)





- pull parking brake lines through eyes and tie up in back
- detach cross member II from cross member I (arrows)
- slightly lower final drive unit
- disconnect wiring from switch for differential lock, warning lamp





- carefully lower final drive





- loosen fuel tank locknuts (arrows) and remove fuel tank

Installation

- Install in the reverse order of removal. Torque to proper specification. [1][2]Fuel Tank