Removing and installing natural gas tanks 3 and 4 — VW

Removing and installing natural gas tanks 3 and 4
Special tools and workshop equipment required
Engine and gearbox jack
V.A.G 1383 A
Torque wrench
V.A.G 1331
Tensioning strap
T10038
Removing
Prerequisite
Vehicle must be at room temperature (at least 14 °C).
Remove rear silencer
Rep. gr.
26
.
Remove protective covers on underbody:
Caddy
Chapter
Caddy Maxi
Chapter
To remove fuel tanks, separate connectors
1
from tank shut-off valve on all fuel tanks (natural gas).
Close mechanical shut-off valves
2
and
3
on all natural gas tanks.
Note
Due to limited space, the handwheels for mechanical shut-off valves have been discontinued.
Close the mechanical shut-off valves using a commercially available spanner.
WARNING
Release pressure in the system before working on the natural gas system.
Vehicle diagnostic tester
Connecting and carrying out Guided Function
“Releasing pressure in the natural gas high-pressure line”
.
Note
Observe safety precautions when working on natural gas system
Chapter
.
The fuel tank 3 is removed together with fuel tank 4.
Observe rules for cleanliness
Chapter
.
Fold rear seats forwards.
Release carpet under seats, and fold it to rear
General body repairs, interior
Rep. gr.
70
Load and luggage compartment trims; Removing and installing load compartment floor
.
Remove cover under rear bench seat
arrows
.
Separate connector
1
and remove electrical wiring downwards.
Remove protective covers on underbody:
Caddy
Chapter
Caddy Maxi
Chapter
Close mechanical shut-off valves on fuel tanks
1
and
2
.
Separate high-pressure lines from tank shut-off valves
arrows
.
Remove high-pressure lines from connections.
Loosen securing nuts
2
for fuel tank
1
.
Secure fuel tank to rear axle with
tensioning straps
T10038
1
.
Position
engine and gearbox jack
V.A.G 1383 A
2
below support of fuel tanks.
Remove securing bolts
arrows A, B and C
.
Lower fuel tank slightly.
Disconnect earth connection
1
from fuel tank.
Separate connector
2
on fuel delivery unit.
Take silencer out of hangers.
Unclip high-pressure line from support of fuel tanks.
Carefully lower fuel tanks with support.
Release securing straps of fuel tanks
1
.
If one tank or the tank shut-off valve is to be exchanged, empty tank
Chapter
.
Note
When the fuel tanks have to be stored temporarily, use
bracket
T10351
for this purpose.
Installing
Installation is performed in the reverse order of removal.
Note
Ensure that the handbrake cable is not trapped between fuel tank support and underbody.
Specified torque
Component
Specified torque
Securing nut for fuel tank
20 Nm
Securing bolt of securing strap
15 Nm
Fuel tank support (arrow A)
25 Nm
Fuel tank support (arrow B)
50 Nm + turn 45° further Always renew bolts after removal.
Fuel tank support (arrow C)
40 Nm
High-pressure line to union (counterhold on union with a spanner)
First tighten hand-tight then turn 90° (1/4 turn) further