Removing and installing fuel tank 1, 5-seater, natural gas — VW

🧭 Before you start

Fits: VW Touran I (1T, 2003–2015)

• Special tools named: T10523
• Renewed: as needed

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• Ensure not to damage the painted surface when working on the fuel tanks.
• When loosening high-pressure lines, counterhold on unions with a suitable tool.
• Dimension (a) and the mark eases realignment of tank to mounting when reinstalling.
• When the fuel tank has to be stored temporarily, use bracket T10351 for this purpose.

🔧 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. Remove exhaust pipe.
10. Remove protective covers from underbody .
11. Release and unplug connectors (1).
12. Close mechanical shut-off valves (2) on all natural gas tanks using hand wheel T50026.
13. Release and pull off connector (1).
14. Carefully loosen unions (2) of high-pressure lines (3) to allow remaining gas to leak out. [Note: When loosening high-pressure lines, counterhold on unions with a suitable tool.]
15. Remove high-pressure lines from connections.
16. Immediately seal open connections with suitable plugs from engine bung setVAS 6122.
17. Remove rear left and right wheel housing liners General body repairs66Wheel housing liner; Removing and installing rear wheel housing liner.
18. Unscrew bolt and nut (2).
19. Remove brackets (1) on both sides of fuel tank.
20. Place bracket T10351 on engine and gearbox jackV.A.G 1383 A.
21. Raise engine and gearbox jackV.A.G 1383 A until bracket T10351 lies on tank.
22. Secure fuel tank to engine and gearbox jackV.A.G 1383 A using tensioning straps T10038/T10523.
23. Release fuel tank support on both sides (arrows).
24. Slowly lower engine and gearbox jackV.A.G 1383 A.
25. Release and pull off connector (1).
26. Make a note of dimension (a).
27. Mark installation position of fuel tank shut-off valve in relation to support with a marker pen. [Note: Dimension (a) and the mark eases realignment of tank to mounting when reinstalling.]
28. If necessary, remove solenoid from fuel tank shut-off valve 1N361.
29. Loosen securing bolts (1) of securing straps.
30. Loosen tensioning straps(2). [Note: When the fuel tank has to be stored temporarily, use bracket T10351 for this purpose.] [Note: 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.]
31. Position self-adhesive protective pads (1) on contact points.
32. Slide securing straps (2) under mounting hooks.
33. Renew nuts (arrows) for securing straps.
34. Check natural gas supply system for leaks 24Checking natural gas supply system for leaks.
35. Perform gas system test 35.1Description of work; Performing visual inspection of natural gas tanks for corrosion and leakage test.

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