SEAT Workshop Service and Repair Manuals

Removing and installing fuel tank with attached components   Caution t  If the vehicle fuel tank is emptied completely, it is necessary to actuate the contact for at least 30 seconds after fuelling without starting the engine. If an attempt is made to start the engine immediately, it will take longer than usual to start (up to one minute). This is because it is necessary to remove the air from the fuel system before the engine can start. t  The high-pressure pump must first be filled with fuel before the engine is started. The high-pressure pump must not be allowed to run while still empty. Initial fuel filling → Chapter. t  Running when dry causes irreparable damage to high-pressure pump. 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	counterhold -T10038-, see equivalent → Anchor

t	Torque wrench (5... 50 Nm) -V.A.G 1331-, see equivalent → Anchor

t	Hydraulic jack -VAG 1383A-, see equivalent → Anchor

Removing –  Observe safety precautions → Chapter. –  Observe rules for cleanliness → Chapter.   WARNING Risk of accident caused by weight of fuel tank Fuel tank must be empty when it is removed. –  Drain fuel tank → Chapter.   Caution When disconnecting battery, observe safety measures → Electrical system; Rep. gr.27.

–  Disconnect earth strap -arrow- at battery with ignition switched off. –  Briefly open filler cap for fuel tank to reduce pressure. –  Removing luggage compartment trim → trims / noise insulations; Rep. gr.70

–  Loosen the bolts -arrows- and remove the fuel delivery unit.

–  Extract the connectors -1 and 2- from the supply unit.

–  Open tank flap and detach loop -1- on tank flap.   Note Do not remove the cover. –  Clean the area around fuel filler neck. –  Lift the retaining ring -arrow- from the rubber bearing and press the rubber bearing towards the inside. –  Remove rear right wheel. –  Remove the right rear wheel well → Rep. gr.66.

–  Remove the breather line -2- from the fuel filler neck. –  Unscrew bolt -1- for fuel filler neck.   WARNING The vehicle must be secured to the lifting platform, else the it could slip. –  Secure the vehicle with support tool -T10038- on both sides of the lifting platform.

–  Remove right underbody panelling -1-, → Rep. gr.66. –  Remove rear section of exhaust system . –  Remove rear axle → Rep. gr.42.

–  Disengage the front right handbrake cable on the fuel tank at the places indicated with -arrows-. Fuel system with the return line:   WARNING The fuel system is pressurised. Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.

–  Remove fuel feed line -1- (black) and right front fuel return line -2- from fuel tank. Also press the release tabs. –  Catch any escaping fuel.   WARNING The fuel tank must be empty when it is removed from the vehicle in order to reduce weight.

–  Use engine/gearbox jack -VAG 1383A- to support fuel tank.

–  Support the fuel tank using the engine and gearbox jack -VAG 1383A-.   WARNING Risk of accident caused by weight of fuel tank Fuel tank must be empty when it is removed. –  Extract bolts -1... 7-. –  Then lower fuel tank using engine and gearbox jack -VAG 1383A-, simultaneously guiding fuel tank down by hand. Installing Reassembly is carried out in the reverse order; note the following:   Note Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue.

–  Check whether fuel lines are hooked into brackets and fuel tank -arrows-. –  Check whether the earth connection has oxidation traces on both connections. If necessary, remove them.

–  Check installation position of earth connection: l  The plug -4- must be connected firmly to the metal ring -3-. l  Contact tab -2- must be attached on fuel tank -5- and secured with spacer bush -1-, if fitted. –  Position fuel tank with retaining straps and with engine and gearbox jack -VAG 1383A-. –  When positioning the fuel tank, observe that the filler neck fits correctly in body opening.

–  Secure fuel tank by first tightening bolts at points -2-, -5-, -3- and -4-, then at points -1-, -6- and -7-. –  Secure fuel filler neck.   WARNING Safety risk due to electrostatic discharge. 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 Ω. –  Install rear axle → Rep. gr.42. –  Install rear section of exhaust system. –  Install rear right wheel housing liner → Rep. gr.66. –  Install cover for flange. –  Install luggage compartment trim → trims / noise insulations; Rep. gr.70