Removing and installing fuel tank, four-wheel drive, engine codes CFHC, CFHE, CFHF, CLCA, CLCB, CFJA — AUDI

🧭 Before you start

Fits: VW Caddy III (2K, 2004–2015); platform code 2C0

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• The fuel pump must not be allowed to run when the fuel tank is empty, as this may cause deflagrations.The fuel tank must contain at least 5 litres of fuel. — Observe safety precautions .
• Fuel tank is tilted to side during further work. To do this, fuel tank must be completely drained. — Open locking ring using tank sender wrench T10202.
• When lowering fuel tank, guide it carefully to prevent damage.
• After installing fuel delivery unit, check that supply and return lines are still clipped onto fuel tank.

🔧 Engine codes this applies to

📋 Procedure

1. ⚠ The fuel pump must not be allowed to run when the fuel tank is empty, as this may cause deflagrations.The fuel tank must contain at least 5 litres of fuel. — Observe safety precautions .
2. Observe rules for cleanliness .
3. Check whether a coded radio is fitted. If so, obtain anti-theft coding:
4. Disconnect earth cable at battery with ignition switched off 27Disconnecting and connecting battery.
5. Drain fuel tank with fuel extractorVAS 5190.

6. Unclip rubber cup from filler neck.
7. Unscrew bolts (1) on filler neck.
8. Push back lug (2) using a screwdriver.
9. Remove rear left wheel.
10. Remove rear left wheel housing liner 66Removing and installing wheel housing liner.
11. If fitted, unscrew bolt (arrow) for filler neck on side member.
12. ⚠ The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)!The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure!Wear eye and hand protection when performing any type of repair work on the fuel system! — Separate fuel supply lines (1) and (2) at front right of fuel tank. Press buttons on hose couplings to do this.
13. On vehicles with auxiliary heater, detach fuel line (1) from hose (2) on metering pump 82Fuel supply; Removing and installing metering pump V54
14. Loosen nuts (1) and push clip forwards (arrow).
15. Unscrew nuts and remove rear tunnel bridge (3).
16. Only unscrew front mounting on rear part of exhaust system (1).
17. Unscrew bolts and remove heat shield (2) for fuel tank.
18. Unbolt both shock absorbers on rear axle (arrow).
19. Unhook breather lines (2) and (3) from rear final drive out of carrier plate (1).
20. Remove carrier plate (1).
21. Unscrew bolts (arrows) and lower fuel tank as far as propshaft.
22. Pull off both connectors on flanges.
23. ⚠ The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)!The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure!Wear eye and hand protection when performing any type of repair work on the fuel system! — Remove fuel lines on both flanges. To do this, press release buttons.
24. ⚠ Fuel tank is tilted to side during further work. To do this, fuel tank must be completely drained. — Open locking ring using tank sender wrench T10202.
25. Lift up fuel gauge sender 2G169.
26. Insert suction hose of fuel extractorVAS 5190 as far as possible into fuel tank and extract remaining fuel.
27. Pull off breather line on fuel tank and unclip from fuel tank.
28. Open screw-type clip (2) and pull off connecting hose (1) from fuel tank.
29. Lower rear axle approximately 20 mm. [Note: When lowering fuel tank, guide it carefully to prevent damage.]
30. With fuel tank in position shown remove on left-hand side.
31. ⚠ The fuel pump must not be allowed to run when the fuel tank is empty, as this may cause deflagrations.The fuel tank must contain at least 5 litres of fuel. — Observe installation position of fuel feed line to auxiliary heater 82Fuel supply; Fuel feed.
32. After installing fuel delivery unit, check that supply and return lines are still clipped onto fuel tank.

Other AUDI procedures

• Checking fuel pressure of fuel pump, vehicles with 6.0 bar low pressure fuel system
• Emptying fuel tank, front-wheel drive, engine codes CAYD, CAYE, CFHC, CFHE, CFHF, CLCA, CLCB, CFJA
• Emptying fuel tank, four-wheel drive, engine codes CFHC, CFHE, CFHF, CLCA, CLCB, CFJA
• Removing and installing fuel tank, four-wheel drive, engine codes CFHC, CFHE, CFHF, CLCA, CLCB, CFJA
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