SEAT Workshop Service and Repair Manuals

Emptying fuel tank when fuel pump is defective Special tools and workshop equipment required

t  Fuel extractor -VAS 5190-

t  Spanner -T10202- t  Not illustrated t  Torque wrench -V.A.G 1332- (40…200 Nm) Operation process –  Note safety precautions before beginning work → Chapter. –  Observe rules for cleanliness → Chapter. –  Open fuel tank filler flap.

–  At a distance -a- = 770 mm from end of extraction hose of fuel extractor -VAS 5190-, use insulating tape to mark -arrow- the hose.   Note The extraction hose has been properly inserted when the affixed mark is level with the edge of the filler neck. –  Push hose into fuel filler neck and extract fuel.   Note t  When no more fuel is extracted, the tank is emptied just enough for the sender flange to be opened without danger. The tank may be removed while containing remaining fuel. t  If work has to be done on fuel pump or fuel gauge sender -G-, proceed as follows:

–  Lower fuel tank carefully until fuel return line -1- and fuel supply line -4- can be pulled off flange → Chapter.   Note Release connection by pressing button on hose coupling. –  Pull off fuel line -3- (if there is one) for metering pump -V54- for auxiliary heater. –  Pull connectors -2- and -5- off flange.

–  Open locking ring using wrench -T10202-. –  Raise flange of fuel delivery unit. –  Insert suction hose of fuel extractor -VAS 5190- as far as possible into fuel tank and extract fuel. If fuel tank needs only to be emptied, install fuel delivery unit again → Chapter. For further work on inside of fuel tank, sender flanges may remain removed. If fuel tank needs only to be emptied, install flange of fuel delivery unit again → Chapter. –  Renew seals of sender flange.   Note

t  Do not mix up supply and return lines on right-hand side (return line -1- blue, supply line -4- black). t  Ensure that connectors and fuel hose connections are fitted securely.