Skoda Workshop Service and Repair Manuals

Removing and installing the fuel tank Special tools and workshop equipment required t  Engine and gearbox jack, e.g. -V.A.G 1383 A- Removing l  The fuel tank must not be more than 1/4 full. l  Ignition and all electrical components switched off, ignition key withdrawn.   Note t  Empty the fuel tank if necessary → Chapter. t  Observe the safety instructions before starting fitting work → Chapter. t  Observe rules for cleanliness → Chapter. –  Removing rear seat bench → Body Work → Rep. Gr.72.

–  Unclip cover -4- with fuel pump control unit -J538--1-.   Note For vehicles with auxiliary heating, the plug connection for the dosing pump -V54- must be disconnected additionally.

–  Unplug the 5-pin connector -1- from the fuel delivery unit. –  Clean around the fuel filler neck. –  Unscrew the right rear wheel. –  Remove the rear right wheelhouse liner → Body Work → Rep. Gr.66.

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

–  Disconnect vent line -1- (white) and fuel feed line -2- (black) at the connection point.   Note t  For vehicles with auxiliary heating, the fuel line for the dosing pump -V54- must be disconnected additionally. t  Press in the securing ring in order to unlock the lines. –  Remove the middle part of the exhaust system, if necessary first the front and rear part of the exhaust system must be separated → Chapter.

–  Release fixing screws -2- and -4- and remove the tensioning strap. –  Support fuel tank using the engine and gearbox jack -V.A.G 1383 A-. –  Release fixing screws -1- and -3-. –  Slightly lower the fuel tank.   Note The filler neck must be “extracted” between structure and rear axle To this end lift down the fuel tank with a 2nd mechanic from engine and gearbox jack -V.A.G 1383 A-. Install –  Check if the earth lead shows traces of oxidation on both connections, remove if necessary.

–  Check the fitting position of the earth lead -1-. l  The plug -1- on the metal plate ring -2- must be placed on firmly. l  The contact tab -4- must be inserted into the fuel tank -3- and secured with the spacer bush -5-. –  Insert the filler neck between rear axle and structure with the assistance of a second mechanic. Then position the fuel tank on the Engine and 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 and return line (the return line is blue, the feed line is black). t  Make sure the line connections fit tightly and the 5-pin connector fit tightly. t  Check earth connection of fuel tank/body at filler neck. t  After installing the fuel tank, check whether the lines are still clipped in place on the fuel tank. t  If the fuel delivery unit was replaced on vehicles with the fuel pressure sender for low pressure -G410 - ( → Chapter, position 4), adapt the engine control unit to the fuel pump → Vehicle diagnosis, testing and information system VAS 5051. On vehicles without the fuel pressure sender for low pressure -G410-, the adaptation is performed automatically while driving.

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