CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– Release connector -1- and fuel line -2- and pull them off flange
-3-.
Note
♦ Press in securing ring to release fuel line.
♦ On vehicles with auxiliary heater, the connector and the fuel
line of the metering pump - V54- must also be disconnected.
– Open locking ring using key - T10202- .
Caution
Do not cant key - T10202- and press against locking ring firmly.
If the key slips off, the fuel delivery unit can be damaged.
– Lift sender flange.
– Insert extraction hose of fuel extractor - VAS 5190- as deeply
as possible into fuel tank and extract fuel.
If fuel tank needed only to be emptied, reinstall sender flange
⇒ page 326 .
3.4
Removing and installing fuel tank
Special tools and workshop equipment required
♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-
Install fuel tank ⇒ page 290 .
3.4.1
Removing fuel tank
Note
♦ The rear axle must be lowered to remove the fuel tank.
♦ Note safety precautions before beginning work ⇒ page 278 .
♦ Observe rules for cleanliness ⇒ page 280 .
♦ Assembly overview - fuel tank ⇒ page 281 .
3. Fuel tank (Passat, CC)
287
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– If necessary, empty fuel tank using fuel extractor - VAS 5190-
⇒ page 283 .
– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
72 ; Removing and installing bench seat .
– Remove cover -1- with fuel pump control unit - J538- -2- from
fuel delivery unit.
– Pull 5-pin connector -arrow- off flange.
Note
For vehicles with auxiliary heater the metering pump - V54- con‐
nector must be separated additionally.
– Remove rear right wheel.
– Remove rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner .
Engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CDAA,
CDAB:
– Pull breather line and pressure retention valve -arrows- off ac‐
tivated charcoal filter.
Note
Grasp securing ring (grey) on pressure retention valve and pull
valve off upwards.
Engine codes CBFA, CCTA, CCTB:
– Pull breather lines and vacuum line -arrows- off activated
charcoal filter.
288
Rep. gr.20 - Fuel supply system
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
All:
– Unclip wire from filler neck -arrows-.
– Unscrew tank flap unit securing bolt and remove tank flap unit
⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit;
Removing and installing tank flap unit .
– Unbolt filler neck from body -arrows-.
WARNING
Fuel supply line is pressurised. Wear protective goggles and
protective clothing to avoid injury and contact with the skin.
Wrap a cloth around the connection before loosening hose
connections. Then release pressure by carefully pulling hose
off connection.
– Separate breather line (white) -1- and fuel line (black) -2- at
connections.
Note
♦ Press in securing ring to release fuel line.
♦ Vehicles with auxiliary heater, the fuel line of the metering
pump - V54- must also be separated.
– Lower rear axle ⇒ Running gear, axles, steering; Rep. gr. 42 ;
Lowering rear axle .
Note
♦ When lowering, ensure sufficient clearance to brake lines and
electrical wiring.
♦ Take the help of another mechanic while unbolting and low‐
ering fuel tank.
– Hold fuel tank and unscrew bolts securing the tensioning
straps -arrows-.
– Remove tensioning straps.
– With the aid of a 2nd mechanic, lower the tank slowly and take
it out through the space between rear axle and body.
3. Fuel tank (Passat, CC)
289
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
3.4.2
Installing fuel tank
– With the aid of a second mechanic, guide the filler neck in be‐
tween rear axle and body.
– Place fuel tank in mounting position and fit new securing bolts
-arrows-.
Note
To secure the securing straps for the fuel tank, only bolts with
loose washers must be used. If different bolts are used, the se‐
curing straps might twist during tightening. Bolts ⇒ ETKA (Elec‐
tronic parts catalogue) .
– Secure rear axle to body again ⇒ Running gear, axles, steer‐
ing; Rep. gr. 42 .
The remaining installation steps are carried out in the reverse se‐
quence of removal. During this procedure, observe the following:
♦ Install breather lines and fuel lines free of kinks.
♦ Ensure that line connections are tight.
♦ Check fuel tank/body earth connection on filler neck.
– Fill fuel tank with at least 5 litres of fuel.
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.
Specified torques:
Component
Specified torque
25 Nm
Tensioning straps to body
♦ Use new bolts!
♦ 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.
Filler neck to body
8 Nm + 90°
Subframe/rear axle to body
⇒ Running gear, axles,
steering; Rep. gr. 42 ; Re‐
moving and installing rear
axle .
♦ Use new bolts!
Fitting wheels
⇒ Running gear; Rep. gr.
44 ; Specified torque for
mounting wheels
290
Rep. gr.20 - Fuel supply system
2024 VW Passat Owner's Manual
VW Passat B7 Service & Repair Manual
VW Passat B6 Service & Repair Manual
