SEAT Workshop Service and Repair Manuals

Removing and installing fuel delivery unit t  Removing → Anchor t  Fitting → Anchor Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter. Special tools and workshop equipment required

t  Rotation tool -T10202- Removing –  Observe safety precautions → Chapter. –  Observe rules for cleanliness → Chapter.   WARNING Large amounts of fuel can escape. The fuel tank must not be more than 1/4 full when removing the fuel delivery unit, otherwise a large amount of fuel will escape. –  Drain fuel tank if necessary → Chapter.

–  With ignition switched off, disconnect earth wire -arrow- at battery. –  Removing luggage compartment trim → trims / noise insulations; Rep. gr.70

–  Unscrew cover for flange -arrows-.

–  Extract the connectors -1 and 2- from the supply unit.   WARNING The fuel can become extremely hot. This can cause injuries. t  In extreme cases, the temperatures of the fuel lines or the fuel itself can reach up to 100° C. Let the fuel cool down before opening the line connection, or else there is a risk of serious injuries. t  Wear protection gloves. t  Wear eye protection. Injury risk! Fuel is subjected to high pressure! To reduce the pressure in the fuel system, wrap a clean cloth around the connection and carefully loosen the connection.

–  Disconnect the fuel lines -1- and -2- from the connecting flange.

–  Remove the locking ring with key -T10202-.   WARNING Large amounts of fuel can escape. The fuel tank must not be more than 1/4 full when removing the fuel delivery unit, otherwise a large amount of fuel will escape.

–  Take flange -2- out of fuel tank and detach seal -1-. –  Carefully pull the connecting flange with fuel line -3- and electric wires through the of opening in fuel tank. –  Press the fuel pump unit still in the fuel tank a little to the side.

–  Guide hand through gap between locking flange and assembly opening in fuel tank and unlock suction-jet pump -1-   Note Fuel tank is shown in a cut-away view for illustration purposes. –  Pull out suction-jet pump -1- upward with driving jet line -2- attached. –  Remove driving-jet line from suction-jet pump, for this purpose press release button. –  Remove suction-jet pump.

–  Carefully take out the fuel supply unit -1- with sender for the fuel level indicator -2- through the assembly opening in the fuel tank by respectively turning and tilting it.   WARNING Danger due to fuel running out of the fuel extraction unit. Place a cloth underneath to absorb fuel.   Note When removing fuel delivery unit, make sure you do not bend float arm of fuel gauge sender -G-. Installing Reassembly is carried out in the reverse order; note the following:   Note t  Renew seal. t  Ensure that fuel hose connections are tight. t  When connecting the electric plug connections, make sure that these engage correctly. t  Take care not to bend float arm of fuel gauge sender when fitting fuel delivery unit.

–  Insert fuel delivery unit in fuel tank. –  Connect driving-jet line -2- to suction-jet pump connector -1-. –  Clip suction-jet pump -1- onto fuel delivery unit. To do so, reach into gap between flange and opening in fuel tank. l  The suction-jet pump should click into place. –  Check that suction-jet pump has engaged properly.   Note Fuel tank is shown in a cut-away view for illustration purposes.

–  Route the fuel hoses and electric wires as shown in the illustration. –  Position the connecting flange -4- with guide tubes -2-, -3- and the fuel return line -5- on the fuel supply unit -1-. –  Feed in the guide tubes and the fuel return line on the guides of the fuel supply unit as shown in the illustration.

–  Install a new sealing ring -1- for the connecting flange (it should be dry).   Caution Risk of leakage The seal must not be pinched or damaged when installing the flange. –  Press flange down against spring pressure and turn flange to installation position. l  The lug -2- on the connecting flange must point to the opening -arrow- of the connecting flange and must be between tabs -3, 4- on the fuel tank.

–  Tighten union nut for locking flange with rotation tool -T10202-.

–  Install fuel supply pipe -1- and fuel return pipe -2- (as marked). –  Connect the fuel lines until you hear them engaging. l  Tightening torque → Chapter „Fuel supply unit and fuel level indicator sender: Assembly overview“ Further installation is carried out in reverse order; note the following: –  Install cover for flange. –  Install luggage compartment trim → trims / noise insulations; Rep. gr.70 –  Put at least 5 litres of fuel into tank after installing fuel delivery unit.