Fuel Tank

Fuel Tank

Special tools, testers and auxiliary items required

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• The fuel tank may be a maximum of 1/4 full.

• Drain the fuel tank using the fuel extracting device (VAS 5190). Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.

- Turn off the ignition and all electric consumers and remove the key.

- Open the fuel filler door and the fuel cap.

- Remove the rear seat bench.

- Remove the cover - 1 - from the fuel delivery unit. The arrow - 2 - points in the direction of travel.






- Disconnect the connector - arrow - from the fuel delivery unit.






- Remove the right rear wheel housing liner..

The fuel lines are under pressure.

Danger of personal injury to eyes and skin.

Wear protective goggles and protective clothing in order to avoid injury and contact with the skin. Wrap a cloth around the connection before removing a fuel hose. Open the connection carefully and release the pressure.

- Disconnect both of the lines on the filler tube from the Evaporative Emission (EVAP) canister. Disconnecting, couplings, refer to => [ Coupling, Disconnecting ] Service and Repair.

- Remove the bolts - 1 and 2 - from the filler tube.






- Remove the Anti-lock Brake System (ABS) wire - arrows - from the retainers.

The fuel lines are under pressure.

Danger of personal injury to eyes and skin.

Wear protective goggles and protective clothing in order to avoid injury and contact with the skin. Wrap a cloth around the connection before removing a fuel hose. Open the connection carefully and release the pressure.

- Disconnect the vent line - 1 - (white) and the supply line - 2 - (black) at the connecting points. Disconnecting the couplings, refer to => [ Coupling, Disconnecting ] Service and Repair.






Engine Codes CBTA and CBUA






- Loosen the front clamping sleeve - 1 -.

• A second technician is required for the remainder of the procedure to help support the exhaust system.

- Push the rear section of the exhaust system out of the retaining straps - arrows -.

The exhaust system is then hanging by the rear subframe and the rear tunnel brace.

- Push the exhaust system as far as possible to the left.

Engine Codes CBFA and CCTA






• The illustration shows the vehicle with twist beam suspension.

- Loosen the front clamping sleeve - 1 -.

• A second technician is required for the remainder of the procedure to help support the exhaust system.

- Push the rear section of the exhaust system out of the retaining straps - arrows -.

- Remove the rear section of the exhaust system.

• A second technician is required for the remainder of the procedure to help support the fuel tank.

Continuation for all Vehicles

- Remove the fuel tank and tensioning strap bolts - arrows -. Have a second technician hold the fuel tank - 1 - while doing this.






Always make sure there is enough clearance for the filler tube to prevent damaging the fuel tank while removing it.

- Move the fuel tank downward once it is removed from the rear subframe. While doing this turn the fuel tank to the left.

- Remove the fuel tank downward. While doing this turn the fuel tank slightly to the left. The filler tube can then be guided past the rear subframe.

Installing

Installation is performed in the reverse order of removal. When doing this note the following:

• Make sure the vent and fuel lines are not kinked.

• Be careful not to confuse the supply line and the vent line (the supply line is black and the vent line is white).

• Make sure the line connections are securely fastened.

• Make sure the ground connection on the filler tube is tight.

• Make sure the lines are still attached to the fuel tank after installing the fuel tank.

- Bleed the fuel system.

Tightening Specifications






• 1 Always replace