Removing and installing fuel tanks together with mounting, natural gas tanks made of steel — VW

🔧 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. — Prepare engine and gearbox jackV.A.G 1383 A or engine and gearbox jackVAS 6931 with gearbox support T40173, adapter T40173/2 and supports T40173/3 as shown in illustration.
5. Take care not to damage surfaces when working on fuel tanks.

6. If necessary, protect surface with suitable workshop equipment.
7. Remove underbody cover General body repairs, exterior66Underbody cover; Assembly overview – underbody cover.
8. Release pressure in high-pressure line .
9. Close mechanical shut-off valves on fuel tank shut-off valves N361/N362 of all natural gas tanks .
10. Disconnect battery Electrical system27Battery; Disconnecting and reconnecting battery.
11. Remove filler connection .
12. Unclip electrical wiring (1) from mounting (arrows).
13. Release connector (4), and pull it off fuel tank shut-off valve 2N362(1).
14. Carefully loosen union nut (3) to allow remaining gas to escape.
15. When doing so, counterhold on union with a suitable tool.
16. Unscrew union nut (3).
17. Remove high-pressure line (2) from connection.
18. ⚠ Take care not to bend or deform any lines. — Immediately seal open connections using suitable plugs from engine bung setVAS 6122.
19. Carefully loosen union nut (2) on tank shut-off valve 1N361 on fuel tank 1 to allow residual gas to escape.
20. When loosening, counterhold on union with a suitable tool.
21. Unscrew union nut (2).
22. Remove high-pressure line (3) from connection.
23. Immediately seal open connections using suitable plugs from engine bung setVAS 6122.
24. ⚠ Take care not to bend or deform any lines. — Remove clip (arrow) between breather line (4) and fuel line (1).
25. Unscrew fuel lines (2) from connecting piece (1).
26. When loosening, counterhold on union with a suitable tool.
27. Unclip fuel lines from retainers (arrows).
28. Seal open connections using suitable plugs from engine bung setVAS 6122.
29. Remove fuel lines.
30. Unscrew fuel lines (3) and (4) from connecting piece (5).
31. When doing so, counterhold on union with a suitable tool.
32. Seal open connections using suitable plugs from engine bung setVAS 6122.
33. Unclip fuel lines (1) and (2) from retainers (arrow A) and (arrow B).
34. Open retainers (arrow A) and (arrow B).
35. Unclip fuel lines (1) and (2) from retainers.
36. Remove fuel lines.
37. Unclip breather lines (1) from mounting (arrows).
38. Pull breather lines (1) and (2) off activated charcoal filter. Separate plug-in connectors .
39. Unclip breather lines from retainer (arrows), and lay them to one side.
40. Position engine and gearbox jack(3) together with gearbox support T40173 under fuel tanks.
41. Raise engine and gearbox jackV.A.G 1383 A until gearbox support T40173 rests against fuel tank.
42. Make sure that supports T40173/3 are located on fuel tank (1) between securing straps as shown in illustration.
43. Make sure that supports T40173/3 are located on fuel tank (2) between securing straps as shown in illustration.
44. Again, align gearbox support T40173 under fuel tanks .
45. Raise engine and gearbox jack until gearbox support T40173 makes contact with supports T40173/3.
46. Align adjustable supports of gearbox support T40173 relative to fuel tank, and secure them.
47. In order to properly secure adjustable supports, pull lever (1) downwards, and position it such that it can be properly secured.
48. Support fuel tanks with engine and gearbox jack.
49. Unscrew bolts (arrows). [Note: For reasons of clarity, the fuel tank is shown without the engine and gearbox jack.]
50. Using engine and gearbox jack, carefully lower fuel tanks together with mounting by 2 cm.
51. Guide in tensioning straps T10523 above mounting.
52. Ensure that fuel line is not located under tensioning straps.
53. Ensure that the ratchets of the tensioning straps are offset, as shown in illustration.
54. Securely lash fuel tanks (1) to gearbox support T40173 using the two tensioning straps T10523.
55. Unclip brake lines (arrow) on left and right.
56. Using engine and gearbox jack, lower fuel tanks together with mounting.
57. When installing, pay particular attention not to damage surface of fuel tank.
58. Take care not to bend or deform any fuel lines.
59. The lines must be installed free of stress.
60. The lines must be screwed on by hand as far as stop.

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