Engine Codes CBTA and CBUA

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 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..

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






- Remove the bolts - 1 and 2 - for 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.






- Lower the rear subframe.






- Loosen the bolts - arrows - for the heat shield - 1 -, if equipped, and then remove the heat shield.

- Loosen the front exhaust clamping sleeve - 1 -.






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

- Remove the bolt - 1 -.






- Remove the bumper cover - 2 - in the - direction of the arrow - and swivel the exhaust system downward.

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.

- Loosen the fuel tank heat shield - 1 - nuts - arrows - and remove the heat shield.






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

- 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.

- Install the heat shield - 1 - and nuts - arrows - to the fuel tank.






• Tightening specification for the nuts: 2.5 Nm

- Attach the heat shield - 1 -, if equipped to the rear subframe.






- Counter-hold the brake line bracket when tightening the bolts - arrows -. Tightening specification: 2.5 Nm.

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






- Raise the rear subframe.

- Bleed the fuel system.

Tightening Specifications