Engine Code BBW

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Special tools, testers and auxiliary items required

Fig 1: Torque Wrench V.A.G. 1331 (5 To 50 Nm)

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Torque wrench (5 to 50 Nm) VAG 1331

Fig 2: Engine & Transmission Jack VAG 1383 A

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Engine/transmission jack VAG 1383 A
Textile or rubber mat

Requirement

Fuel tank must be empty

Removing

NOTE:

Observe safety precautions before starting work. Refer to Safety Precautions When Working on the Fuel Supply System under Safety precautions when working on fuel supply system .
The fuel extraction unit VAS 5190 is recommended for emptying the fuel tank. Contrary to the operating instructions the draining must not occur via the filler neck in this engine/vehicle or inner components will be damaged. Empty fuel tank only via the open flange. Refer to Fuel Delivery Unit, Removing and Installing under Fuel delivery unit, removing and installing .

Open fuel flap.
Check whether a coded radio is installed. If so, obtain anti-theft coding.
With ignition switched off disconnect battery Ground strap.
Fold rear seat bench forward.

Remove cover from fuel delivery unit.

Fig 3: Installed Position Of Flange Of Fuel Delivery Unit

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Disconnect 4-pin connector - 1 -.
Unscrew nuts - 2 - and take flange - 3 - off.
Drain fuel tank via flange opening, e.g. with VAS 5190.
Bolt on flange again .

Remove rear axle: Refer to 42 REAR SUSPENSION
Remove rear part of exhaust system. .
Remove right rear wheelhousing liner: Refer to 66 EXTERIOR EQUIPMENT
Clean fuel filler neck and EVAP canister area.

Fig 4: Tank Flap, Leak Detection Pump, Vacuum Hose, Pressure Hose & Connector

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Remove tank flap unit with rubber cup - 1 -. Refer to TANK FLAP UNIT
Pull vacuum hose for fuel system leak detection pump - 2 - off union.
Remove 3-pin connector - 3 - and disconnect wiring.
Pull pressure hose - 5 - off.

NOTE:

To unlock, press the safety ring - arrow - into the EVAP canister.

Remove fuel system leak detection pump - 4 - with detection pump air filter and bracket by pulling from center forward and then sliding downward.

Fig 5: EVAP Canister Breather Lines & Clips

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Pull breather lines - 3 - and - 4 - off by pressing safety rings at EVAP canister - arrows - on upper and lower part together and unclipping breather line - 3 - out of clip - 1 -.
Remove bolts - 2 -.

Fig 6: Fuel Line, Vacuum Line, Breather Line & Clips

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Unclip vacuum line - 1 - at fuel tank.
Disconnect breather line - 2 -.

CAUTION:

The fuel system is under pressure! Before opening the system place a cloth around the connection. Then release the pressure by carefully loosening the connection.
Always wear eye protection and wear fuel-resistant gloves when disconnecting system connections.

Loosen spring-type clamp - 3 - and pull supply hose off fuel line. Collect leaking oil.
Seal lines to avoid contamination of fuel system.

Fig 7: Locating Fuel Tank Bolts

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Support fuel tank with engine/transmission jack VAG 1383 A and unscrew bolts - arrows -.

NOTE:

To prevent paintwork being damaged place a textile or rubber mat between fuel tank and jack.

Lower fuel tank.

Installing

Installation is performed in reverse order to removal, considering the following:

Tensioning strap rubber profile must not be damaged.

Fig 8: Locating Fuel Tank Bolts

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Replace bolts - arrows -.
Guide wirings on EVAP canister must be securely connected. Check for correct seat by tightening.

Adapt (match) engine control module to throttle valve control module. Refer to Adapting Components and Functions under Components, checking .
Generate readiness code again if DTC memory has been erased, refer to Adapting Components and Functions under Components, checking .