Removing and installing fuel tank, engine codes CJKA, CJKB — VW

Removing and installing fuel tank, engine codes CJKA, CJKB
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
Fuel extractor
VAS 5190
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 emptied with the
fuel suction device
VAS 5190
via the filler neck, the non-return valve
arrow
will be damaged.
Non-return valve
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in filler neck
Note
Fuel tank must be drained. Use the
fuel extractor
VAS 5190
to do this.
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.
Note safety precautions before starting installation work
Chapter
.
Observe rules for cleanliness
Chapter
.
Open fuel filler flap and unscrew cap.
Clean area around fuel filler neck.
Remove bolt, pull rubber cup off filler neck and remove.
Remove earth wire.
Unscrew bolt of filler neck.
Remove front left underbody cladding
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.
Remove left middle underbody cladding
arrow
.
Disconnect fuel supply line (black) from fuel filter.
Detach flushing line (white) from activated charcoal filter.
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.
Pull connector off
fuel pump control unit
J538
and unclip line.
Lower fuel tank.
If necessary:
Remove fuel delivery unit
Chapter
.
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. When installing, 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.
Fit connector on to
fuel pump control unit
J538
.
Clip all lines into retainers again.
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
.
Fit left underbody cladding
General body repairs, exterior
Rep. gr.
66
Underbody trim
.
Specified torques
Chapter
“
Assembly overview - fuel tank
”