Volkswagen Workshop Service and Repair Manuals

Removing and installing fuel tank (engine codes CDLG, CAVB, CAVC, CAVD, CBZA, CBZB) Special tools and workshop equipment required

t  Torque wrench (5…50 Nm) -V.A.G 1331-

t  Engine and gearbox jack -V.A.G 1383 A- Removing fuel tank –  Note safety precautions before beginning work → Chapter. –  Unscrew tank flap unit securing bolt and remove tank flap unit → General body repairs, exterior; Rep. gr.55. –  Drain fuel tank and clean fuel filler neck and surrounding area. –  Remove rear bench seat (Golf Plus: rear right seat) → General body repairs, interior; Rep. gr.72.

–  Remove cover from fuel delivery unit.

–  Pull off connector -arrow-.   Note For vehicles with auxiliary heater the metering pump -V54- connector must be separated additionally. –  Remove rear right wheel. –  Remove rear right wheel housing liner → General body repairs, exterior; Rep. gr.66. –  Remove centre and rear silencers.

–  Unbolt filler neck from body -1-. –  Unclip electrical wire -2-.   WARNING Fuel supply line 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 supply line -2- (black) at connecting point. Separate push-on couplings → Chapter.   Note Vehicles with auxiliary heater, the fuel line of the metering pump -V54- must also be separated.

–  Unscrew securing strap and securing bolts -arrows-. When doing this, support fuel tank with engine and gearbox jack -V.A.G 1383 A-. –  Lower fuel tank. Installing fuel tank: Installation is performed in the reverse sequence. In the process, note the following: t  To secure the securing straps for the fuel tank, only bolts with loose washers must be used. If different bolts are used, the securing straps might twist during tightening. Bolts → ETKA (electronic parts catalogue). t  Install breather and fuel lines free of kinks. t  Do not interchange supply and return lines (return line blue or with blue markings, supply line black). t  Ensure wiring/line connections are secured properly by pulling back. t  Check earth connection on fuel tank and body to filler neck. t  After installing fuel tank, check that the supply, return and breather lines are still clipped onto the fuel tank. Specified torque

Component	Specified torque
Filler neck of fuel tank to body	10 Nm
Fuel tank to underbody	25 Nm
Bench seat	→ General body repairs, interior; Rep. gr.72.
Exhaust system	→ Rep. gr.26
Tank flap unit	→ General body repairs, exterior; Rep. gr.55