Volkswagen Workshop Service and Repair Manuals

Removing fuel tank –  Note safety precautions before beginning work → Chapter. If necessary, empty fuel tank using fuel extractor -VAS 5190- → Chapter. –  Remove right rear wheel. –  Remove rear right wheel housing liner → General body repairs, exterior; Rep. Gr.66 –  Unscrew tank flap unit securing bolt and remove tank flap unit → General body repairs, exterior; Rep. Gr.55.

–  Unbolt filler neck from body -1-. –  Unclip electrical wiring -2- from filler neck. –  Remove seat bench → General body repairs, interior; Rep. Gr.72.

–  Remove covers and separate electrical connectors -arrows-.   Note For vehicles with auxiliary heater the metering pump -V54- connector must be separated additionally. Vehicles up to 06/2007 (two-part propshaft): –  Remove centre and rear silencers.

–  Secure exhaust system to underbody using wire. –  Remove rear propshaft → Propshaft and rear final drive; Rep. Gr.39. Vehicles from 06/2007 (single part propshaft): –  Remove centre and rear silencers. –  Remove front exhaust pipe with catalytic converters → Chapter. –  Remove complete propshaft → Propshaft and rear final drive; Rep. Gr.39. Continuation for all vehicles:   WARNING The fuel system is pressurised! Wear eye protection and protective clothing to avoid possible injury and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

–  Disconnect breather line -1- (white) and fuel line -2- (black) at connecting point.   Note On vehicles with auxiliary heater the fuel line of the metering pump -V54- must also be separated.

–  Pull off adapter cable on four-wheel drive control unit -J492-.

–  Unscrew securing straps and securing bolts. First support fuel tank with engine and gearbox jack -V.A.G 1383 A-. –  Slowly lower fuel tank.   Note The filler neck must be “guided out” between body and rear axle. To do this, take the fuel tank off engine and gearbox jack -V.A.G 1383 A- with the assistance of a 2nd mechanic.