Volkswagen Workshop Service and Repair Manuals

Removing and installing fuel tank (engine codes CBFA, CCTA, CBTA, CBUA) Special tools and workshop equipment required

t  Torque wrench -V.A.G 1331- Removing l  Fuel tank must not be more than 1/4 full.   Note t  If necessary, empty fuel tank using fuel extractor -VAS 5190- → Chapter. t  Note safety precautions before beginning work → Chapter. t  Observe rules for cleanliness → Chapter. –  Remove coded rim bolt from luggage compartment if necessary. –  Open fuel tank flap and remove fuel tank cap. –  Unscrew tank flap unit securing bolt and remove tank flap unit → General body repairs, exterior; Rep. gr.55. –  Remove bench seat → General body repairs, interior; Rep. gr.72.

–  Unclip cover -1- for fuel delivery unit. Arrow -2- points in direction of travel.   Note For vehicles with auxiliary heater the metering pump -V54- connector must be separated additionally.

–  Disconnect connector -1- from fuel delivery unit → Chapter. –  Remove rear right wheel housing liner → General body repairs, exterior; Rep. gr.66.

–  Detach connectors -1- and -2-. –  Unbolt filler neck from body -arrows-.

–  Unclip the ABS line -A- out of the bracket -arrows-. –  Remove exhaust system.   WARNING Fuel supply line is pressurised. Wear eye protection and protective clothing to avoid possible injury and skin contact. Before loosening fuel lines, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

–  Disconnect white breather line -1-, black supply line -2- and green vacuum line for fuel system diagnostic pump -V144--3- at connection. Separate push-on couplings → Chapter.   Note During the further procedure, a second mechanic is required to support the fuel tank.

–  Remove securing strap and securing bolts -arrows-. –  Turn fuel tank out to side. Installing Installation is performed in the reverse order of removal. In the process, note the following: t  Install breather and fuel lines free of kinks. t  Do not interchange supply and return lines (supply line black, return line blue). t  Ensure that line connections are tight. t  Check earth connection on fuel tank and body to filler neck. t  After installing fuel tank, check that lines are still clipped onto the fuel tank. –  Bleed fuel system → Rep. gr.23. –  Connect battery → Electrical system; Rep. gr.27. Specified torque:

Component		Nm
Fuel tank to body - M6		10
Fuel tank to body - M8 t  Renew bolts.		25