Removing and installing fuel tank, front-wheel drive, engine codes CAYD, CAYE, CFHC, CFHE, CFHF, CLCA, CLCB, CFJA — VW

Removing and installing fuel tank, front-wheel drive, engine codes CAYD, CAYE, CFHC, CFHE, CFHF, CLCA, CLCB, CFJA
Special tools and workshop equipment required
Torque wrench (5…50 Nm)
V.A.G 1331
Torque wrench
V.A.G 1332
Engine and gearbox jack
V.A.G 1383 A
Removing
Carry out the following work:
Observe safety precautions
Chapter
.
Observe rules for cleanliness
Chapter
.
Note
Before carrying out further work, disconnect the battery. For this reason, first check whether a coded radio is fitted. Obtain anti-theft coding beforehand if necessary.
When lowering fuel tank, guide it carefully to prevent damage.
Disconnect battery earth strap with ignition switched off
Rep. gr.
27
Battery; Disconnecting and reconnecting battery
.
Empty fuel tank as far as possible via fuel filler neck using
fuel extractor
VAS 5190
Chapter
.
Unclip rubber cup from filler neck.
Unscrew bolts
1
on filler neck.
Push back lug
2
using a screwdriver.
Remove rear left wheel.
Remove rear left wheel housing liner
Rep. gr.
66
Removing and installing wheel housing liner
.
If fitted, unscrew bolt
arrow
for filler neck on side member.
WARNING
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.
On vehicles with auxiliary heater, detach fuel line
1
from hose
2
on metering pump
Rep. gr.
82
Fuel supply;
Removing and installing metering pump
V54
Loosen nuts
1
and push clip forwards
arrow
.
Unscrew nuts and remove rear tunnel bridge
3
.
Only unscrew front mounting on rear part of exhaust system
1
.
Unscrew bolts and remove heat shield
2
for fuel tank.
Support fuel tank with
engine and gearbox jack
V.A.G 1383 A
.
Unscrew bolts
arrows
and remove tensioning straps.
Lower fuel tank just enough to enable connector
1
on flange to be pulled off.
Then slowly lower fuel tank. In the process, pull fuel tank forwards, turn and guide filler pipe between rear axle and body.
Installing
Carry out the following work:
Install in reverse order. In the process, note the following:
Caution
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.
Install breather and fuel hoses free of kinks.
Ensure that fuel hose connections are tight.
Do not interchange supply and return lines (return line blue or with blue markings, supply line black).
Supply and return lines must be clipped in on fuel tank.
On vehicles with auxiliary heater, fit fuel line to metering pump
Rep. gr.
82
Fuel supply;
Removing and installing metering pump
V54
.
Torque settings for fuel tank
Chapter
Torque settings for silencer with mountings and tunnel bridge
Rep. gr.
26
Exhaust pipes and silencers; Assembly overview - silencers