Removing and installing fuel tank, engine codes CDLG, CAVB, CAVC, CAVD, CBZA, CBZB, CTHD, CTKA — VW

🧭 Before you start

Fits: VW Golf VI (5K, 2008–2013); platform code 521

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• For vehicles with auxiliary heater the metering pump V54 connector must be separated additionally.
• The aid of a 2nd mechanic is required to remove the rear part of the exhaust system.
• Vehicles with auxiliary heater, the fuel line of the metering pump V54 must also be separated.
• The aid of a 2nd mechanic is required to remove the fuel tank.

🔧 Engine codes this applies to

📐 38 workshop diagrams for CAVB

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Observe safety precautions .
2. Observe rules for cleanliness .
3. Unscrew tank flap unit securing bolt and remove tank flap unit General body repairs, exterior55Tank flap unit.
4. Drain fuel tank and clean fuel filler neck and surrounding area .
5. Remove bench seat General body repairs, interior72Rear seat; Removing and installing bench seat / individual seats.

6. Remove cover (1) with fuel pump control unit J538(2) from fuel delivery unit.
7. Unclip cover (1) at retaining tabs (arrows), using removal wedge3409.
8. Pull off connector (arrow). [Note: For vehicles with auxiliary heater the metering pump V54 connector must be separated additionally.]
9. Remove rear right wheel Running gear, axles, steering44Wheels, tyres and alignment.
10. Remove rear right wheel housing liner General body repairs, exterior66Wheel housing liner; Removing and installing wheel housing liner.
11. Undo and remove bolts (1) from filler neck in body structure.
12. Unclip and remove wire from filler neck (2).
13. Loosen clamping sleeve (arrows).
14. Remove rear cross member for underbody. To do this, unscrew nuts (1) and (2). [Note: The aid of a 2nd mechanic is required to remove the rear part of the exhaust system.]
15. Remove centre silencer and rear silencer 26Exhaust system/silencer; Assembly overview - silencers.
16. ⚠ Fuel supply lines are under pressure! Wear eye protection and protective gloves to avoid injuries and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection. — Disconnect breather line (1) (white) and supply line (2) (black) at connecting point. Separate push-on couplings . [Note: Vehicles with auxiliary heater, the fuel line of the metering pump V54 must also be separated.]
17. Unscrew bolts (1) and (3).
18. Place engine and gearbox jackV.A.G 1383 A under fuel tank to support it.
19. Unscrew bolts (2) and (4). [Note: The aid of a 2nd mechanic is required to remove the fuel tank.]
20. Lower fuel tank and guide it out of the body structure.
21. With the aid of a 2nd mechanic, guide the filler neck in between rear axle and body.
22. Slowly raise fuel tank into installation position.
23. Secure fuel tank with bolts (1) through (4). [Note: To secure the securing straps for the fuel tank, only bolts with loose washers must be used. This will stop the securing straps from being twisted out of position when tightening the bolts.Plug-in connectors for fuel lines must engage »audibly« when joined.Note colour assignment when installing the plug-in connectors Ensure plug-in connector is secured properly by pulling.Separate plug-in connectors .]
24. Note installation position of earth connection.
25. Check whether there are signs of oxidation on the earth wire of the connectors, remove if necessary.
26. ⚠ Risk of explosion due to electrostatic discharge.After installation, check electrical connection using an Ohmmeter.Check connection of metal ring on fuel filler neck by measuring between ring and a bare metal part of the body.Specification: approx. 0 ohm. — Fill fuel tank with at least 5 litres of fuel.

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