SEAT Workshop Service and Repair Manuals

Removing and installing fuel tank with attached components t  Removing → Anchor t  Installing → Anchor t  Tightening torques → 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  Hydraulic jack -SAT 1040-, see equivalent → Anchor

t  Torque wrench kit -SAT 8010-, see equivalent → Anchor Removing Observe safety precautions → Chapter Observe rules for cleanliness → Chapter. l  The fuel tank must be empty when it is removed from the vehicle in order to reduce weight. If necessary, drain the tank → Chapter.

–  Remove rear right seat → bodywork - interior fitting work; Rep. gr.72. –  Release retainers -arrows- at cover for sealing flange.

–  Release carefully electrical connection -arrow- on sealing flange and take off.

–  Unclip the tabs -arrows- of the left lock clamp cover.

–  Unplug the connector -1- of the lock clamp –  Separate the connector -2- from the Haldex clutch.

–  Remove rear right mudguard → Bodywork - exterior fitting work; Rep. gr.66. –  Open tank flap. –  Clean the area around fuel filler neck. –  Remove cap -arrow- from fuel tank filler neck. –  Cover the fuel tank filler neck opening with a spongy material cloth to avoid penetration of dirt.

–  Remove bolts -1- for fuel filler neck. –  Disconnect the electrical wire -2- of speed sensor for ABS on filler neck bracket.

–  Remove the exhaust system by the surrounding sleeve -arrows-. –  Push clamp towards rear of vehicle to disconnect exhaust system.

–  Remove vehicle floor rear cross member -nuts 1 and 2-.   Note A second mechanic is required for removing the rear section of the exhaust system. –  Unhook exhaust system on mounting -arrows-. –  Take rear silencer off mountings and take off rear part of the exhaust system.

–  Remove the thermal protection plate from the cardan camshaft -arrows-. –  Dismount the cardan camshaft → Rep. gr.39.   WARNING t  The fuel system is pressurised. Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection. t  For those vehicles fitted with an injector pump, the temperature of the fuel and the fuel lines may reach up to 100 ºC in extreme cases. Before opening the duct connections, allow the fuel to cool otherwise there is a risk of severe burns. t  Wear protection gloves. t  Wear eye protection.

–  Disconnect the fuel supply tube (black) and the fuel return tube (blue) to the front right on the fuel tank; for this, press on the release tabs -arrows-.

–  First unscrew the bolts -2-, -5- and -6-.   WARNING The fuel tank must be empty when it is removed from the vehicle in order to reduce weight. –  Unhook the wiring harness -arrows- and leave it to one side. –  Use engine/gearbox jack -SAT 1040- to support fuel tank. –  Remove bolts -1-, -3-, -4- and -7-. –  Immediately lower the fuel tank with the hydraulic jack -SAT 1040-, additionally guiding the tank with your hand. –  Turn the fuel tank lowering it sideways and take it out. –  A second mechanic should manually remove the fuel filler neck using the longitudinal moving arm. Installing Installation is carried out in reverse order, noting the following:   Note Secure all hose connections with the correct hose clips (same as original equipment) → Spare parts catalogue.

–  Check whether the earth connection has oxidation traces on both connections. If necessary, eliminate these. –  Check installation position of earth connection: l  Ensure connector -3- is seated properly on metal ring -2-. l  The contact tab -4- must be hooked on the fuel tank -1- and secured using a distance bushing -5-. –  Place the fuel tank with the securing straps in the lower part of the vehicle using the hydraulic jack -SAT 1040-. –  When positioning the fuel tank, observe that the filler neck fits correctly in body opening.

–  Firmly screw the fuel tank, first from the points -1, 3, 4, 7- and then from -2, 5, 6-.

–  Secure contact tab of earth wire to fuel filler neck with collared securing bolt -arrow-.   WARNING After installation, use an ohmmeter to check the electrical connection between the metal ring on the fuel filler neck and a bare metal part on the body: Specification: approx. 0 Ohm –  Insert electrical wire of speed sensor for ABS on filler neck bracket. –  Fit the rear right mudguard → Bodywork - exterior fitting work; Rep. gr.66. –  Fit the cardan camshaft → Rep. gr.39. –  Install rear section of exhaust system → Chapter. –  Fit right rear seat → Bodywork - Interior fitting work; Rep. gr.72. Tightening torques

Component		Nm
Tensor strip to chassis		26
Fuel tank to body		26
Fuel filler neck to the wheel housing		11