SEAT Workshop Service and Repair Manuals

Fuel tank: removing and installing Special tools and workshop equipment required

t  Torque wrench (5 -50 Nm) -V.A.G 1331-

t  Engine/gearbox crane -V.A.G 1383 A- Removing –  Note safety precautions before starting work → Chapter –  First check whether a coded radio is fitted. Check the anti-theft code in this case. –  With the ignition switched off, disconnect battery earth strap. –  Extract the securing bolt of the fuel tank cap unit and remove the unit. –  Drain fuel tank, clean fuel filler and surrounding area. –  Fold down the rear seat forwards. –  Remove cover from fuel delivery unit.

–  Disconnect the 4-pin connector -1- from the flange. –  Remove rear right-hand side wheel. –  Remove the rear right wheel housing shell → Bodywork- exterior fitting work; Rep. Gr.66

–  Remove the pressure retention valve -1- and the vent pipe -2- (press safety ring). –  Separate the fuel inlet funnel from the bodywork. –  Remove from body all fixings from rear part of exhaust system. Then suspend the exhaust system, displaced downwards slightly, from the bodywork using a wire. –  Remove the rear axle: → Running gear, axles, steering; Rep. Gr.42   WARNING Fuel supply lines are pressurised! Wear safety gloves and glasses to avoid injury and contact with skin. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

–  Disconnect the return line -2- (blue), the fuel pipe -1- (black) and the breather pipe -3- (white) at their connections.   Note Press in safety ring to release fuel lines. –  Remove the support straps and the securing bolts. During this operation, support the fuel tank with the engine and gearbox crane -V.A.G 1383 A-. –  Lower the fuel tank. Fitting Install in reverse order. But note the following: t  The breather and fuel hoses are to be installed without any kinks. t  Ensure that wiring connections are securely seated. t  After installing fuel gauge sender, check that the supply, return and breather pipes are still clipped onto the fuel tank.

t  Check the connections on the active carbon filter -3-. The pressure retention valve -1- should be on the outside.