Engine Code CDVB

Fuel Tank

Special tools, testers and auxiliary items required

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

• Trim Removal Wedge (3409)

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

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

- 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 fuel pump control module - 2 - from the cover - 1 -.






- Remove the cover - 1 - from the fuel delivery unit using the trim removal wedge (3409) at the tabs - arrows -.






- Disconnect the connector - 1 - from the fuel delivery unit.






- Remove the right rear wheel housing liner..

- Disconnect the lines - 3 and 4 - from the Evaporative Emission (EVAP) canister - 1 -. Refer to => [ Coupling, Disconnecting ] Coupling, Disconnecting.






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






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

- Loosen and lower the right rear underbody panel.

The fuel lines are under pressure.

Danger of personal injury to eyes and skin.

Wear protective eyewear 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 black supply line - 1 - and the white vent line - 2 -. Refer to => [ Coupling, Disconnecting ] Coupling, Disconnecting.






- Remove the underbody tunnel brace - A -.






- Separate the exhaust system at the clamping sleeve - 1 -.

- Remove the bolts - 1 - from the suspended mount - 2 -.






The mount - 2 - is installed on the underbody in connection with the heat shield - 3 - and fuel tank tensioning strap - 4 -.

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

- Remove the left and right bolts from the rear exhaust system suspended mount and then remove it with a second technician.

- Lower the rear subframe.

- Remove the nuts - arrows - from the heat shield - 1 - and then remove the heat shield.






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






• Pay attention to the installed position of the fuel tank tensioning straps - 2 -.

• Mark them if necessary.

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

- Swivel the fuel tank downward and pull it as far as possible away from the rear subframe. Pay attention to the parking brake cable while doing this.

- Move the fuel tank to the right and downward and then pull it forward.

- 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

Install in the reverse order of removal. 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. Refer to => [ Coupling, Disconnecting ] Coupling, Disconnecting.

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

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

- Attach the heat shield - 1 - to the fuel tank with the nuts - arrow -.






• Tightening specification for the heat shield nuts: 2.5 Nm

• Pay attention to the installed position of the fuel tank tensioning straps - 2 -.






- Raise the rear subframe.

Tightening Specifications