Volkswagen Workshop Service and Repair Manuals

Removing and installing fuel tank 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. –  Observe rules for cleanliness → Chapter. –  If necessary, empty fuel tank using fuel extractor -VAS 5190-:    Engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CDAA → Chapter.    Engine codes CBFA, CCTA, CCTB → Chapter. –  Remove bench seat → General body repairs, interior; Rep. gr.72.

–  Remove cover -1- with fuel pump control unit -J538--2- 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. –  Unscrew tank flap unit securing bolt and remove tank flap unit → General body repairs, exterior; Rep. gr.55.

Engine codes CAWB, CCZA, CCZB, CDAA: –  Unbolt filler neck from body -1-. –  Unclip electrical wiring -2- from filler neck.

Engine codes CBFA, CCTA: –  Separate hoses -1- and -2-. –  Unbolt filler neck from body -arrows-. –  Unclip electrical wiring from filler neck. All: –  Remove centre and rear silencers. –  Remove heat shields from middle and rear silencers.   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.   Note Press in securing ring to release fuel lines.

–  Disconnect breather line -1- (white) and fuel line -2- (black) at connecting point.   Note t  On vehicles for USA/Canada, the vacuum line for the fuel system diagnosis pump -V144- must be separated in addition. t  Vehicles with auxiliary heater, the fuel line of the metering pump -V54- must also be separated.

–  Unscrew securing strap and securing bolts. 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: Specified torques: Assembly overview - fuel tank.    Engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CDAA → Chapter.    Engine codes CBFA, CCTA, CCTB → Chapter. 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. t  Install breather and fuel lines free of kinks. t  Do not interchange supply line and return line (return line blue or with blue marking, 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.