SEAT Workshop Service and Repair Manuals

Fuel tank: Removing and installing. 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.   Note t  To carry out this work it will be necessary to disconnect battery earth strap. For this purpose, first check whether a coded radio is fitted. Where necessary, check the anti-theft coding first. t  Carefully guide the fuel tank when lowering to avoid damage. –  Disconnect earth wire at battery with ignition switched off → Electric system; Rep. gr.27 . 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. –  Remove rear right wheel housing protection → Bodywork, exterior fitting work; Rep. gr.50 .

–  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. –  Detach electric cable -2- of speed sensor for ABS from retainer on fuel filler neck.

–  Remove exhaust system from double clamp -arrows-. –  Loosen exhaust system clamp and push clamps towards the rear.

–  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.   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 eye and hand protection when performing any type of repair work on the fuel system!

–  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-.

–  Unscrew bolts -1- and -3- first.   WARNING The fuel tank must be empty when it is removed from the vehicle in order to reduce weight. –  Use engine/gearbox jack -SAT 1040- to support fuel tank. –  Unscrew the bolts -2- and -4-. –  Lower fuel tank downwards by turning appropriately and take out. Installing Continue the installation in the reverse order of removal sequence, observing the following:   Note Secure all hose connections with serial hose clips → Electronic 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 fit fuel tank on securing points -2- and -4- first, and then -1- and -3- (26 Nm).

–  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 –  Attach electric cable of speed sensor for ABS onto retainer on fuel filler neck. –  Install rear section of exhaust system → Chapter. –  Fit rear right wheel housing protection → Bodywork, exterior fitting work; Rep. gr.66 . Tightening torques

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