Removing and installing fuel tank 1: VW (CPGA)

🧭 Before you start

Fits: platform code 121

• Renewed: gearbox support, if necessary, rubber pads

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• Mark installation position of protective pads using a felt-tip pen.
• To do this, mark horizontal and vertical alignment (arrows) on fuel tank (1) and on securing straps (2).
• Any point on bracket (1) can be used as a reference. However, it is essential to use the same point for the measurement after reinstalling.
• When loosening, counterhold on union with a suitable tool.
• Ensure that the ratchets of the tensioning straps are offset, as shown in illustration.

🔧 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. ⚠ Before using the gearbox support T40173, always check if it is the latest version.Older versions of the gearbox support must not be used and are to be replaced by the latest version.Identification of latest version:On the latest version, the components highlighted in (red) in the illustration (arrows) are yellow chromated.If the gearbox support does not comply with the requirements, proceed as follows:German market: Contact the manufacturer Matra in order to replace the gearbox support.All other markets: Contact your importer in order to replace the gearbox support. — Use suitable workshop equipment to adapt support padsVAS 6131/14-1 to shape of fuel tank.
5. Extend gearbox support T40173 with gearbox support T40173/1.

6. To do this, install gearbox support T40173/1 between rigid carrier (1) and bars (arrows).
7. If necessary install mountings for support padsVAS 6131/14-1 to gearbox support T40173/1.
8. Take care not to damage painted surfaces when working on fuel tanks.
9. If necessary, protect painted surface with suitable workshop equipment.
10. Remove underbody cladding General body repairs, exterior66Underbody cladding.
11. Release pressure in high-pressure line .
12. Disconnect battery Electrical system27Battery; Disconnecting and reconnecting battery.
13. Mark installation position of protective pads using a felt-tip pen.
14. To do this, mark horizontal and vertical alignment (arrows) on fuel tank (1) and on securing straps (2).
15. Measure dimension (a) between securing strap (2) and mounting (1).
16. Dimension (a) must be measured between centre line of barrel (3) and mounting (1). [Note: Any point on bracket (1) can be used as a reference. However, it is essential to use the same point for the measurement after reinstalling.]
17. Release and pull off connector (1) on fuel tank shut-off valve 1N361(2).
18. Carefully loosen union nuts (arrows) to allow remaining gas to escape.
19. When loosening, counterhold on union with a suitable tool.
20. Unscrew union nuts (arrows).
21. Remove high-pressure lines (3) from connections.
22. ⚠ Take care not to bend or deform the lines (3). — Immediately seal open connections using suitable plugs from engine bung setVAS 6122.
23. Position engine and gearbox jackV.A.G 1383 A with gearbox support T40173 under fuel tank (1).
24. Align gearbox support T40173 with fuel tank (1) between tensioning straps.
25. Raise engine and gearbox jackV.A.G 1383 A until gearbox support T40173 rests against fuel tank.
26. Align adjustable supports of gearbox support T40173 relative to fuel tank, and secure them.
27. In order to properly secure adjustable supports, pull lever (1) downwards, and position it such that it can be properly secured.
28. Ensure that the ratchets of the tensioning straps are offset, as shown in illustration.
29. Securely lash fuel tank (1) to gearbox support T40173 using the two tensioning straps T10523.
30. Unscrew bolts (arrows) on securing straps (2).
31. ⚠ The securing straps are slightly under tension. — Lower fuel tank slowly using engine and gearbox jackV.A.G 1383 A.
32. Slightly pull securing straps apart while doing so.
33. Draining fuel tank
34. Ensure proper seating of securing straps (1) in mounting (2).
35. Securing straps (1) must be seated in guide (arrows).
36. Check rubber pads (3) for damage and renew if necessary.
37. Renew rubber pads if damaged.
38. Position fuel tank (1) on bracket using engine and gearbox jackV.A.G 1383 A.
39. For allocation of protective film refer to the parts catalogue.
40. Close securing strap (3) with securing strap bolt (4).
41. Aligning fuel tank .
42. Mark bonding surface (arrows).
43. Open securing strap (3) again.
44. Clean bonding surface (arrows).
45. Attach protective film in marked area (arrows), as shown in illustration.
46. The upper edge of the protective film must be flush with the lower rivets (3) in securing strap (2).
47. Ensure correct installation position of dished springs.
48. 3 spring packs (arrows), each with 5 dished springs (1), must be assembled.
49. The spring packs (arrows) must be assembled with opposing sides facing each other as shown in illustration.
50. Screw in bolts (1) on securing straps (2).
51. Fuel tank must still be free to move.
52. Ensure correct installation position of protective pads .
53. Align fuel tank.
54. The outer edge of fuel tank shut-off valve 1N361(1) must be aligned flush with the outer edge of mounting (2).
55. Align fuel tank so that fuel lines can be connected free of tension.
56. ⚠ Take care not to bend or deform any fuel lines.The lines must be screwed on by hand as far as stop.The lines must be installed free of tension. — Turn fuel tank so that the union nuts (arrows) can be screwed on.
57. The lines (3) must be installed free of tension.
58. The lines (3) must be screwed on by hand as far as stop.
59. ⚠ Take care not to bend or deform the fuel lines (3).The lines (3) must be screwed on by hand as far as stop.The lines (3) must be installed free of tension.Route fuel lines in their original positions.Ensure that there is sufficient clearance to all moving or hot components. — Ensure that fuel lines are properly seated in retainers.
60. Bolt on threaded connections (arrows).

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