Removing and installing the fuel tank (CAYA, CAYB, CAYC) — VW

🧭 Before you start

Disconnect the battery, unplug the delivery unit, drain the tank and seal the filler neck. Secure the car on the hoist, remove the rear axle, wheel housing liner, silencer and heat shield, disconnect the fuel lines and filler neck bolts, support the tank and remove bolts 1 to 5. Lower it while guiding by hand. Refit with the filler neck correctly located, tighten the bolts, refit the axle and check the lines are clipped on.

Fits: VW Polo 6R (2009–2014)

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• Secure the vehicle on the hoist before undoing subframe bolts; it can tip with the axle out.
• Check the delivery unit connector by pulling it without pressing the catch before removal.
• Seal the filler neck opening with a clean plug to keep dirt out.
• After fitting, confirm supply, return and breather lines are still clipped to the tank.
• Obtain the radio anti-theft code before disconnecting the battery if one is fitted.

Written for this job from the workshop steps below · TorqFix editorial.

🔧 Engine codes this applies to

📋 Procedure

1. Note safety precautions before beginning work . [Note: Before carrying out further work, disconnect battery earth strap. Check whether a coded radio is fitted. Obtain anti-theft coding first if necessary.]
2. With the ignition switched off, disconnect battery earth strap.
3. Fold rear seat bench forwards.
4. Remove cover from fuel delivery unit .
5. First check that the connector (arrow) is fitted securely by pulling the connector without pressing the catch. The connector can cause a fault if it has not been fitted correctly.

6. Now pull off connector.
7. Drain fuel tank .
8. Open tank flap.
9. Clean area around fuel filler neck.
10. Unscrew cap from fuel filler neck (arrow). [Note: In order to prevent the ingress of dirt, seal the opening of the fuel filler neck with a clean plug.]
11. ⚠ Risk of the vehicle tipping on hoist when rear axle has been removed.Before undoing the bolts for subframe, secure vehicle on hoist 42. — Remove rear axle: Running gear, Axles, Steering42Repairing rear axle; Removing and installing rear axle
12. Remove rear right wheel housing liner General body repairs, exterior50Removing and installing wheel housing liner.
13. Fuel supply line (1). Disconnect push-on connector .
14. Disconnect fuel return line (2). Disconnect push-on connector .
15. Remove rear silencer.
16. Remove left heat shield.
17. Remove bolts from filler neck (arrows).
18. Support fuel tank using engine and gearbox jackV.A.G 1383/A.
19. Remove fuel tank securing bolts (1 ... 5).
20. Pull filler neck out of rubber cup of tank flap unit.
21. Lower fuel tank using engine and gearbox jackV.A.G 1383 A, simultaneously guiding fuel tank down by hand.
22. Position the fuel tank with securing strap on underbody, using the engine and gearbox jackV.A.G 1383 A.
23. When installing fuel tank, make sure that the fuel filler neck is correctly inserted into the opening on the body.
24. Tighten bolts (1 … 5).
25. Subframe with attachments 42. [Note: After installing fuel tank, check that the supply, return and breather lines are still clipped onto the fuel tank.]

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