Skoda Workshop Service and Repair Manuals

Removing and installing the fuel tank Special tools and workshop equipment required t  Engine/gearbox jack, e.g. -V.A.G 1383 A- l  The fuel tank must be empty for weight reasons when removing it, if necessary suction the fuel out of the fuel tank → Chapter. Removing   Note t  Observe safety measures when working on the fuel system → Chapter. t  Rules of cleanliness when working on the fuel supply system → Chapter. –  Switch off all electrical components and withdraw key from ignition key housing. –  Remove rear seat bench with brackets → Body Work → Rep. gr.72. –  Remove floor covering under the rear seat bench.

–  Unclip the cover -4- with the fuel pump control unit -J538--1-. Vehicles with auxiliary heating. –  Unplug the 2-pin plug of the dosing pump -V54-. –  Remove the rubber grommet from the cover of the fuel delivery unit and pull out the wiring. Continued for all vehicles

–  Unplug the 5-pin plug -1- from the fuel tank.

–  Remove the cover of the fuel gauge sender -2- -G169- (in the figure on the right) and unplug the plug -right arrows-. –  Open the fuel tank cap and clean around the fuel filler neck. –  Unscrew the cap from the fuel filler neck. –  Close the opening of the fuel filler neck with a clean foam piece, so that no dirt can penetrate. –  Remove the rear right wheelhouse liner → Body Work → Rep. gr.66.

–  Unscrew screws -1- for filler neck on the body. –  Unclip the electrical cable from the bracket -2- at the top and bottom of the filler neck.

–  Disconnect vent line -1- (white) and fuel feed line -2- (black) at the connection point.   Note Press in the securing ring in order to unlock the line. Vehicles with auxiliary heating. –  Separate the fuel line from the dosing pump -V54-. Continued for all vehicles

–  Remove rear tunnel bridge -arrows-. –  Unhook the rear part of the exhaust system from two retaining straps in front and behind the front silencer. –  Slacken nuts of double clamp. –  Remove screws for rear exhaust pipe hanger. –  Remove rear part of exhaust system. –  Remove propshaft → Gearbox → Rep. gr.39.

–  Disconnect plug -arrow- at four-wheel drive control unit -J492-.

–  Unhook the wiring loom -arrows- and place it to the side. –  First unscrew screws -2, 5- and -6-. –  Support the fuel tank using the engine/gearbox jack -V.A.G 1383 A-. –  Unscrew the screws for the tensioning straps -1, 3, 4- and -7-.

–  Lower slightly the fuel tank using the engine/gearbox jack -V.A.G 1383 A-. –  Then remove the fuel tank from the engine/gearbox jack -V.A.G 1383 A- and pull through the filler neck between the body and the rear axle with the help of a second mechanic. Install –  Check both earth connections for corrosion, if necessary remove corrosion.

–  Check fitting position of the earth lead -1-. l  The plug -1- must tightly fit on the plate ring -2-. l  The contact tab -4- must be hung in the fuel tank -3- and secured with the spacer bush -5-. –  Guide the filler neck between rear axle and structure with the assistance of a 2nd mechanic. Then position the fuel tank onto the engine/gearbox jack -V.A.G 1383 A-. Further installation occurs in reverse order. Pay attention to the following: t  Lay the vent and fuel lines without any kinks. t  Do not mix-up the feed line and the return-flow line (the return-flow line is blue, the feed line is black). t  Make sure the line connections fit tightly. t  Check the earth connection of the fuel tank at the body on the filler neck. t  After installing the fuel tank, check whether the lines are also clipped in place on the fuel tank.

–  Clip on cover -4- with fuel pump control unit -J538--1-.    The arrow -2- on the cover points in direction of travel.