Removing and installing fuel tank, engine codes CAAA, CAAB, CAAC, CAAD, CAAE, CCHA, CCHB, CFCA — VW

Removing and installing fuel tank, engine codes CAAA, CAAB, CAAC, CAAD, CAAE, CCHA, CCHB, CFCA
WARNING
Risk of explosion of fuel tank. If a new or completely empty fuel tank has been installed, it must be filled immediately with at least 5 litres of fuel. The fuel pump must not be allowed to run when the fuel tank is empty.
Special tools and workshop equipment required
Union nut tool
3217
Torque wrench
V.A.G 1331
Torque wrench
V.A.G 1332
Engine and gearbox jack
V.A.G 1383 A
Removing
Caution
It is not permissible to empty the fuel tank with the fuel suction device
VAS 5190 via the filler neck.
If the fuel tank is to be emptied, the fuel system pressurisation pump
G6 together with fuel gauge sender (G) must first be removed, after which the fuel tank can be emptied via the resulting opening.
If the fuel tank is emptied with the fuel suction device
VAS 5190 via the filler neck, the non-return valve (arrow) will be damaged.
Non-return valve (arrow) in filler neck
Note safety precautions before starting installation work (see the separate procedure).
Observe rules for cleanliness (see the separate procedure).
Note
Before carrying out further work, disconnect battery earth strap. For this reason, first check whether a coded radio is fitted. Obtain anti-theft coding first if necessary.
Open fuel filler flap and unscrew cap.
Clean area around fuel filler neck.
Loosen bolt, then pull rubber cup off filler neck to remove.
Remove earth wire.
Unscrew bolt of filler neck.
Remove front left underbody cover (arrow).
Remove left middle underbody cover (arrow).
Press securing ring to release fuel lines, and detach fuel supply line (1) and return line (2).
Vehicles with auxiliary heater
Remove clip (5).
Pull hose (6) off fuel line (3).
Continuation for all vehicles
Remove securing straps. When doing this, support fuel tank with engine and gearbox jack
V.A.G 1383 A.
Lower engine and gearbox jack
V.A.G 1383 A just enough to allow connector to be pulled off fuel pump flange.
Pull connector off fuel pump flange and unclip wire from fuel tank.
Unclip wiring harness (1) from fuel tank.
Lower fuel tank.
If fuel tank is to be renewed:
Unclip and remove supply line (2) and return line (3) from fuel tank.
If vehicle has an auxiliary heater, unclip and remove fuel line (4) from fuel tank.
If necessary:
Remove fuel delivery unit (see the separate procedure).
Use the fuel suction device
VAS 5190 to completely empty the fuel tank via the fuel delivery unit.
Installing
Installation is carried out in the reverse order; note the following:
WARNING
Risk of explosion of fuel tank. If a new or completely empty fuel tank has been installed, it must be filled immediately with at least 5 litres of fuel. The fuel pump must not be allowed to run when the fuel tank is empty.
Push connector onto fuel pump flange and clip wire onto fuel tank.
Clip fuel lines (2) to (4) onto fuel tank.
Clip wiring harness (1) onto fuel tank.
Connect fuel supply line (1) and return line (2)
. Connections for fuel lines must engage audibly when joined.
Push hose (6) onto fuel line (3) as far as mark (4).
Remove underbody covers on left (repair group 66: Underbody cover).
Specified torques (see “Assembly overview – fuel tank, engine codes CAAA, CAAB, CAAC, CAAD, CAAE, CCHA, CCHB, CFCA”)