Removing and installing front fuel tanks, natural gas, engine code BSX — VW

🧭 Before you start

Release gas pressure, disconnect the battery, remove the exhaust pipe and underbody covers and close all shut-off valves. From inside, remove the bench seat and carpet, unplug the valve wiring and vent and remove the high-pressure lines, plugging the openings. Strap the support to the jack, free the petrol tank, brake cables and fuel lines, unbolt and lower the support with the tanks. Refit in reverse with new strap nuts, then leak test and perform the gas system test.

Fits: VW Touran I (1T, 2003–2015)

• Renewed: as needed

Don't miss

• Release pressure and close every mechanical shut-off valve before opening any gas line.
• Loosen high-pressure unions slowly and counterhold them to let remaining gas escape.
• Plug open gas connections immediately.
• Run the tensioning straps under the fuel lines and do not strap the petrol tank to the support.
• New union nuts: hand-tight plus 180°; refitted ones: hand-tight plus 90°.
• Leak test the natural gas system before the car is handed back.

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

🔧 Engine codes this applies to

📋 Procedure

1. Observe safety precautions .
2. Observe rules for cleanliness .
3. Observe safety precautions when working on natural gas system .
4. ⚠ Release pressure in the system before working on the natural gas system. — Release pressure in high-pressure line .
5. Ensure not to damage the painted surface when working on the fuel tanks.

6. If necessary, protect painted surface with suitable workshop equipment.
7. Disconnect battery Electrical system27Battery; Disconnecting and reconnecting battery.
8. Detach exhaust hanger (1), and loosen clamp (2).
9. Detach exhaust pipe from fuel tank support 26Exhaust pipes/silencers; Assembly overview - silencers.
10. Remove exhaust pipe.
11. Remove protective covers from underbody .
12. Release and unplug connectors (1).
13. Unclip wiring harness from high-pressure line leading to filling connection.
14. Close mechanical shut-off valves on all natural gas tanks.
15. Remove rear bench seat General body repairs, interior72Rear seat; Removing and installing bench seat / individual seats.
16. Release carpet under seats, and fold it to rear General body repairs, interior70Load and luggage compartment trims; Removing and installing load compartment floor.
17. Unscrew nuts to remove cover.
18. Release and unplug connectors (1).
19. Remove wiring harness downwards.
20. Close mechanical shut-off valves (1) and (2) on fuel tanks.
21. Carefully loosen unions (arrows) of high-pressure lines to allow remaining gas to leak out. [Note: When loosening high-pressure lines, counterhold on unions with a suitable tool.]
22. Remove high-pressure lines from connections.
23. Immediately seal open connections with suitable plugs from engine bung setVAS 6122.
24. Unscrew securing nuts (2) for petrol tank (1).
25. Push fuel tank for petrol (1) upwards out of holes in support.
26. Position engine and gearbox jackV.A.G 1383 A under fuel tank support.
27. Unclip high-pressure line from fuel tank support .
28. Secure support to engine and gearbox jack T10523 with tensioning strapsV.A.G 1383 A.
29. Route tensioning straps under fuel lines to prevent them from being damaged.
30. Take care not to secure the fuel tank for petrol as well.
31. Unclip protective caps on bolts (B).
32. Thread brake cables out of support, and place them to one side.
33. Unclip fuel lines for petrol at right from support.
34. Unscrew securing bolts (arrows A) to (arrow C).
35. Push fuel tank for petrol towards right.
36. Lower support with fuel tanks by approx. 3 cm. Guide activated charcoal filter past bracket while doing so.
37. When lowering, make sure that no lines are bent or damaged.
38. Disconnect earth connection (1) from fuel tank.
39. Release connector (2), and pull it off fuel delivery unit.
40. Route tensioning straps under fuel lines to prevent them from being damaged.
41. Push fuel tank for petrol upwards into its installation position.
42. Secure petrol tank to rear axle with tensioning straps T10038(1).
43. Carefully lower fuel tanks with support.
44. Guide brake cable on the left past exhaust system bracket.
45. Remove fuel tanks from support . [Note: If the fuel tanks have to be stored temporarily, do so using bracket T10351.] [Note: Check the protective pads on the bracket for damage and ensure that they are all present. Renew them if necessary.If protective film is fitted on the fuel tank, check it and renew as needed.For allocation of protective film, refer to the parts catalogue.Thoroughly clean adhesive surfaces before fitting new protective film.Bond protective film in the same position.Before a new fuel tank is fitted, the protective film must be bonded in the same position as for the old tank.Adapt new protective film using suitable workshop equipment.Ensure that the handbrake cable is not trapped between fuel tank support and underbody.]
46. ⚠ On fuel lines that are newly installed (initial installation), union nuts should first be tightened hand-tight, then turned 180° further.In case of repair, union nuts are also first tightened hand-tight, then turned 90° further. — Renew nuts (arrows) for securing straps.
47. Check natural gas supply system for leaks 24Checking natural gas supply system for leaks.
48. Perform gas system test 35.1Description of work; Performing visual inspection of natural gas tanks for corrosion and leakage test.

Other VW procedures

• Removing and installing radiator fan V7 and radiator fan 2V177
• Removing and installing catalytic converter – Audi A1
• Removing and installing camshaft oil seal – Audi TT Mk2
• Removing and installing fuel delivery unit, fuel gauge sender
• Bleeding fuel system – Audi A4 Cabriolet B6/B7 / A4 B6/B7
• Removing engine · 41 torque figures
• Removing and installing camshaft – VW Golf Cabriolet · 47 torque figures
• Adjusting valve timing – VW Passat B5 · 83 torque figures
• Removing and installing camshafts – VW Passat B6 · 39 torque figures
• Removing and installing coolant pump · 53 torque figures