Service

Workshop Manual
Toledo 2013 ➤
Fuel supply system, diesel engines
Engine ID
CUS CXM
B A
Edition 07.2015

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
20 - Fuel supply system

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2015 Seat S.A D4B80532E4E

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number, engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Cleanliness specifications for working on the auxiliary heater and fuel system . . . . . . . . . . 2
3 Security standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Safety precautions when using testers and measuring instruments during a road test . . . . 5
3.3 Safety precautions for working on vehicles with start-stop system . . . . . . . . . . . . . . . . . . 5

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1 Measures after filling with the wrong fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Step 1 (Engine was started with incorrect fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Step 2 (Engine was not started with incorrect fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Step 3 (There are metal particles in fuel delivery unit and fuel tank) . . . . . . . . . . . . . . . . . . 12
1.4 Step 4 (There are no metal particles in fuel delivery unit and fuel tank) . . . . . . . . . . . . . . 12
1.5 Step 5 (There are metal particles in high-pressure pump) . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.6 Step 6 (There are no metal particles in high-pressure pump) . . . . . . . . . . . . . . . . . . . . . . 13
2 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3 Fuel tank: draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3 Fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.1 Exploded view - fuel delivery unit/fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.2 Removing and installing fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . 31
3.3 Fuel level gauge sender G : removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4 Plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.1 Separating push-fit couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5 Fuel filter: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.1 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.3 Fuel hoses in engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6 Accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
46
permitted unless6.1
authorisedExploded viewS.A- accelerator
by SEAT S.A. SEAT does not guaranteepedal module
or accept ......................................
any liability with 46
respect to the correctness of information in this document. Copyright by SEAT S.A.
7 Fuel pump: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.1 Checking fuel system pressurisation pump G6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Contents i
 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

ii Contents
 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

00 – Technical data
1 Identification
(ERL002838; Edition 07.2015)
⇒ “1.1 Engine number, engine data”, page 1

1.1 Engine number, engine data

Engine codes CUSB CXMA
Emission standards EU6 plus EU6 plus
Capacity Ltr. 1,4 1,6
Output kW 55 85
Fuel In accordance with DIN EN 590 DIN EN 590

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1. Identification 1
 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

2 General notes
⇒ “2.1 Cleanliness specifications for working on the auxiliary
heater and fuel system”, page 2

2.1 Cleanliness specifications for working

on the auxiliary heater and fuel system
When working on the fuel system and injection system, pay care‐
ful attention to the following “rules”:
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover. Use lint-
free cloths.
♦ If repairs cannot be carried out immediately, carefully cover or
seal open components.
♦ Only fit clean parts: Only remove replacement parts from
packaging immediately before assembly. Do not use parts that
have been stored loose (e.g. in toolboxes etc.).
♦ When the system is open: Do not work with compressed air.
♦ Do not move vehicle.
♦ Immediately seal open lines and connections with clean plugs,
for example from engine bung set - VAS 6122- .
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.

WARNING

ToProtected
extractbyEcopyright.
85 fuel, useforonly
Copying privatefuel extractor
or commercial - VAS
purposes, 5190
in part A- ! is not
or in whole,
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

2 Rep. gr.00 - Technical data

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

3 Security standards
⇒ “3.1 Safety precautions when working on fuel supply system”,
page 3
⇒ “3.2 Safety precautions when using testers and measuring in‐
struments during a road test”, page 5
⇒ “3.3 Safety precautions for working on vehicles with start-stop
system”, page 5

3.1 Safety precautions when working on

fuel supply system

Caution

When undertaking all assembly work, particularly in the engine

compartment due to its cramped construction, please observe
the following:
♦ Route all the various lines and electrical wiring so that they
are in their original positions.
♦ Ensure that there is adequate free access to all moving or
hot components.
♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!

WARNING

The fuel line is under pressure.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Risk of injury to eyes and skin from

respect fuel.
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
to the correctness of information in this document. Copyright by SEAT S.A.

Use protective goggles and clothing to prevent injuries and

contact with the skin. Before loosening hose connections, wrap
a cloth around the connection. Then release pressure by care‐
fully loosening the connection.

WARNING

For reasons of safety, the power supply to the fuel pump must
be interrupted before the fuel system is opened. The fuel pump
would otherwise be activated when the driver's door is opened.
Use one of the following options to interrupt the power supply:
♦ Disconnect battery.
or
♦ Remove fuse for fuel delivery unit ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting locations.
or
♦ Pull connector off fuel delivery unit flange.

Before starting work on the fuel supply system, the following steps
must be performed:
♦ Before starting work, the extraction hose of a switched-on ex‐
haust gas extraction system must be laid near to the assembly
opening of the fuel tank.

3. Security standards 3
 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

♦ The extraction hose is used to extract fuel fumes.

♦ If no exhaust extraction system is available, a radial fan (motor
not in air flow of fan) with an air flow of more than 15 m3/h must
be used.
♦ Avoid skin contact with fuel. Use fuel resistant gloves!

WARNING

Danger of scalding from very hot fuel.

♦ The temperatures of the fuel lines or the fuel itself can
reach temperatures of up to 100 °C. Before opening the
line connections allow the fuel to cool, since otherwise
there is a significant risk of burning.
♦ Wear protection gloves.
♦ Use protective goggles.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Caution

♦ Do not detach fuel hoses from the fuel filter.

♦ Please be sure to refer to the instructions ⇒ page 44 .
♦ Do not lever on unions.
♦ Otherwise this may result in leaks or that the top part of
the fuel filter may be damaged.
♦ Take care that diesel does not come into contact with other
components in the engine compartment. If this should
happen, clean immediately!

Caution

Irreversible damage to high-pressure components, especially

the high-pressure pump due to lack of lubrication though diesel
can occur when filling fuel tank with incorrect fuel. Damage due
to seizure and metal particles can be expected. These particles
can also cause further damage in the pressure control valve
and injectors.

Observe the fill level of the fuel tank:

♦ The fuel tank should only be partially full. Read the respective
job description to find out how much fuel can remain in the fuel
tank.
♦ Drain fuel tank if necessary ⇒ page 23 .
♦ Before starting work, the extraction hose of a switched-on ex‐
haust gas extraction system must be laid near to the assembly
opening of the fuel tank.
♦ The exhaust gas extraction system is used to extract fuel
fumes.
♦ If no exhaust extraction system is available, a radial fan (motor
not in air flow of fan) with an air flow of more than 15 m3/h must
be used.
♦ Avoid skin contact with fuel. Use fuel resistant gloves!

4 Rep. gr.00 - Technical data

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

Observe the following when removing and installing the fuel tank:

WARNING

There is a danger of an accident due to the weight of the fuel

tank.
♦ Fuel tank must be empty to reduce weight.
♦ The fuel tank must be empty when removing
⇒ page 23 .

To prevent injuries to persons and destruction of the injection and

glow plug system, the following must be noted:
♦ Always switch off the ignition before connecting or discon‐
necting injection and glow plug system wiring or tester cables.
♦ Wash the engine only with the ignition switched off.
♦ Because electrical connectors were unplugged and the engine
started, entries are stored in the event memory of the engine
control unit: Interrogate event memory in Controlled
Functions ⇒ Vehicle diagnostic tester.

Caution

There is a danger of damage to the electronic components

when disconnecting the battery.
♦ Heed the action to be taken when disconnecting the bat‐
tery.
♦ Always switch off the ignition before disconnecting the
battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Dis‐
connecting and connecting battery .

3.2 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury due to unsecured test and measuring equipment.
If a front passenger airbag is triggered during an accident, unse‐
cured test and measuring equipment can become dangerous
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projectiles.
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Secure test and measuring equipment with seat belts on the

rear seat.
or
– Have a second person operate test and measuring equipment
on the rear seat.

3.3 Safety precautions for working on vehicles with start-stop system

Risk of injury due to unexpected engine start-up.
In the case of vehicles with activated Start/Stop system, the en‐
gine may start up unexpectedly. The status of the Start/Stop
system is indicated by a message in the dash panel insert.
– Deactivate Start/Stop system by switching off the ignition.

3. Security standards 5
 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

6 Rep. gr.00 - Technical data

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

20 – Fuel supply system

1 Measures after filling with the wrong
fuel
⇒ “1.1 Step 1 (Engine was started with incorrect fuel)”,
page 8
⇒ “1.2 Step 2 (Engine was not started with incorrect fuel)”,
page 10
⇒ “1.3 Step 3 (There are metal particles in fuel delivery unit and
fuel tank)”, page 12
⇒ “1.4 Step 4 (There are no metal particles in fuel delivery unit
and fuel tank)”, page 12
⇒ “1.5 Step 5 (There are metal particles in high-pressure pump)”,
page 13
⇒ “1.6 Step 6 (There are no metal particles in high-pressure
pump)”, page 13

Caution

Irreversible damage to high-pressure components, especially

the high-pressure pump due to lack of lubrication though diesel
can occur when filling fuel tank with incorrect fuel. Damage due
to seizure and metal particles can be expected. These particles
can also cause further damage in the pressure control valve
and injectors. Test sample, if unsure of fuel quality. Analyse
fuel using Fuel analyser unit - VAS 6774- ⇒ Instruction man‐
ual . This analyser unit is no substitute for a laboratory test in
warranty cases.
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permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Special tools
respect to theand workshop
correctness equipment
of information required
in this document. Copyright by SEAT S.A.

♦ Fuel identification unit - VAS 6774-

Note

These instructions are intended to guide you through the individ‐

ual work steps by means of a flowchart, with various factors being
taken into account.

Was the engine started with the incorrect fuel?

Yes
⇒ “1.1 Step 1 (Engine was started with incorrect fuel)”,
page 8

1. Measures after filling with the wrong fuel 7

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

No
⇒ “1.2 Step 2 (Engine was not started with incorrect fuel)”,
page 10

1.1 Step 1 (Engine was started with incor‐

rect fuel)
Special tools and workshop equipment required
♦ Pressure gauge - VAS 6551-

♦ Adapter set - VAS 6551/5-

♦ Wedge - 3409-

♦ Vehicle diagnosis and service information system

– Empty fuel tank as far as possible via fuel filler neck using fuel
extractor - VAS 5190- ⇒ page 25 .
– Lift the rear seat bench ⇒ General
permittedbody
unless repairs, interior;
SEAT S.A.Rep.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
authorised by SEAT S.A does not guarantee or accept any liability with
gr. 72 ; Rear seats; Removing andrespect
installing rear seat
to the correctness bench .in this document. Copyright by SEAT S.A.
of information

8 Rep. gr.20 - Fuel supply system

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .

WARNING

Bear in mind that the fuel pump can be activated due to open‐
ing of a door with the battery connected. Fuel can escape if the
system has been opened.

– Pull fuel return line (blue line or blue marking) -1- off fuel de‐
livery unit. Separate connectors ⇒ page 38 .

WARNING

The fuel line is under pressure.

Risk of injury to eyes and skin from fuel.
Use protective goggles and clothing to prevent injuries and
contact with the skin. Before loosening hose connections, wrap
a cloth around the connection. Then release pressure by care‐
fully loosening the connection.

– Connect the hose - VAS 6551/1- of the pressure tester (diesel)

- VAS 6551- to the fuel return line.
– If necessary, extend the hose - VAS 6551/1- using the con‐
nection fitting - VAS 6551/5-1- and a conventional hose.
– Insert the free end of the hose - VAS 6551/1- in a suitable
container.
– Connect the Vehicle diagnostics system .
– Carry out the guided function Empty fuel tank .

Note

The fuel pump is now activated.

– Repeat procedure, if necessary, until fuel tank is completely

empty.
Remove fuel delivery unit ⇒ page 31 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Check fuelrespect
tankto for metal particles.
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
the correctness of information in this document. Copyright by SEAT S.A.

– Drain fuel pump reservoir of fuel delivery unit.

– Carry out a visual inspection for foreign bodies and metal par‐
ticles in fuel pump reservoir and on preliminary filter.
Metal particles found?
Yes
⇒ “1.3 Step 3 (There are metal particles in fuel delivery unit
and fuel tank)”, page 12
No
⇒ “1.4 Step 4 (There are no metal particles in fuel delivery unit
and fuel tank)”, page 12

1. Measures after filling with the wrong fuel 9

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

1.2 Step 2 (Engine was not started with in‐

correct fuel)
Special tools and workshop equipment required
♦ Pressure gauge - VAS 6551-

♦ Adapter set - VAS 6551/5-

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permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

♦ Wedge - 3409-

♦ Vehicle diagnosis and service information system

– Empty fuel tank as far as possible via fuel filler neck using fuel
extractor - VAS 5190- ⇒ page 25 .
– Lift the rear seat bench ⇒ General body repairs, interior; Rep.
gr. 72 ; Rear seats; Removing and installing rear seat bench .

10 Rep. gr.20 - Fuel supply system

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .

WARNING

Bear in mind that the fuel pump can be activated due to open‐
ing of a door with the battery connected. Fuel can escape if the
system has been opened.

– Disconnect fuel return line (blue, or marked blue) -1- from fuel
delivery unit and disconnect push-fit coupling ⇒ page 38 .

WARNING

The fuel line is under pressure.

Risk of injury to eyes and skin from fuel.
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Use protective goggles and clothing to permitted
prevent injuries
unless authorisedand
by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
contact with the skin. Before loosening hose connections, wrap of information in this document. Copyright by SEAT S.A.
respect to the correctness
a cloth around the connection. Then release pressure by care‐
fully loosening the connection.

– Connect the hose - VAS 6551/1- of the pressure tester (diesel)

- VAS 6551- to the fuel return line.
– If necessary, extend the hose - VAS 6551/1- using the con‐
nection fitting - VAS 6551/5-1- and a conventional hose.
– Insert the free end of the hose - VAS 6551/1- in a suitable
container.
– Connect the Vehicle diagnostics system .
– Carry out the guided function Empty fuel tank .

Note

The fuel pump is now activated.

– Repeat procedure, if necessary, until fuel tank is completely

empty.
– Fill fuel tank with 5 litres of diesel fuel.
– Completely empty fuel tank again as described above.

– Reconnect fuel return line (blue or blue marking) -1-.

– Replace fuel filter ⇒ page 43 .
– Fill up vehicle and perform road test.
End

1. Measures after filling with the wrong fuel 11

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

1.3 Step 3 (There are metal particles in fuel

delivery unit and fuel tank)
Special tools and workshop equipment required
♦ Diesel extractor - VAS 5226-

– Clean fuel delivery unit and fuel tank with diesel extractor -
VAS 5226- .
Install fuel delivery unit ⇒ page 31
– Fill fuel tank with 5 litres of diesel fuel.
– Completely empty fuel tank again as described above.
– Renew following high-pressure components:
♦ High-pressure pump ⇒ Rep. gr. 24 ; Removing and installing
high-pressure pump .
♦ High-pressure lines ⇒ Rep. gr. 23 ; Injectors/high-pressure
accumulator (fuel rail): Removing and installing high-pressure
lines .
♦ High-pressure accumulator (fuel rail) including fuel pressure
regulating valve - N276- and fuel pressure sender - G247- ⇒
Rep. gr. 23 ; Injectors/high-pressure accumulator (fuel rail):
Removing and installing high-pressure accumulator
♦ Injector ⇒ Rep. gr. 23 ; Injectors/high-pressure accumulator
(fuel rail): Removing and installing injectors .
♦ Fuel return lines (overflow oil lines) ⇒ Rep. gr. 23 ; Injector
units/high-pressure accumulator (fuel rail); Assembly over‐
view - injectors .
♦ Fuel filter ⇒ page 43 .
– Fill up vehicle.
– Bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/
bleeding fuel system .
– Test-drive vehicle.
End

1.4 Step 4 (There are no metal particles in

fuel delivery unit and fuel tank)
– Fill fuel tank with 5 litres of diesel fuel.
– Completely empty fuelProtected
tank again as Copying
by copyright. described above
for private or commercial purposes, in part or in whole, is not
⇒ page 8 . permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

12 Rep. gr.20 - Fuel supply system

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

Caution

When the fuel metering valve - N290- is removed, there is the

risk of damage to the high-pressure pump by the ingress of dirt
from the outside. Scrupulous cleanliness must therefore be
ensured.

– Carefully clean high-pressure pump in vicinity of fuel metering

valve - N290- .
– Detach connector from valve.
– Unscrew bolts -arrows- and carefully remove fuel metering
valve - N290- .
– Check fuel metering valve - N290- and high-pressure pump
for swarf.
Metal particles found?
Yes
⇒ “1.5 Step 5 (There are metal particles in high-pressure
pump)”, page 13
No
⇒ “1.6 Step 6 (There are no metal particles in high-pressure
pump)”, page 13

1.5 Step 5 (There are metal particles indoes

high-
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permitted unless authorised by SEAT S.A. SEAT S.A not guarantee or accept any liability with

pressure pump)
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Renew following high-pressure components:

♦ High-pressure pump ⇒ Rep. gr. 23 ; High-pressure pump:
Removing and installing high-pressure pump .
♦ High-pressure lines ⇒ Rep. gr. 23 ; Injectors/high-pressure
accumulator (fuel rail): Removing and installing high-pressure
lines .
♦ High-pressure accumulator (fuel rail) including fuel pressure
regulating valve - N276- and fuel pressure sender - G247- ⇒
Rep. gr. 23 ; Injectors/high-pressure accumulator (fuel rail):
Removing and installing high-pressure accumulator
♦ Injector ⇒ Rep. gr. 23 ; Injectors/high-pressure accumulator
(fuel rail): Removing and installing injectors .
♦ Fuel return lines (overflow oil lines) ⇒ Rep. gr. 23 ; Injector
units/high-pressure accumulator (fuel rail); Assembly over‐
view - injectors .
♦ Fuel filter ⇒ page 43 .
– Fill up vehicle.
– Bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/
bleeding fuel system .
– Test-drive vehicle.
End

1.6 Step 6 (There are no metal particles in

high-pressure pump)
– Replace fuel filter ⇒ page 43 .

1. Measures after filling with the wrong fuel 13

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

Caution

Ensure that the oil seals of the fuel metering valve - N290- are
undamaged. If a seal is damaged, the high-pressure pump
must be renewed.

– Moisten lower seal of fuel metering valve - N290- with fuel.

– Slide valve into high-pressure pump while turning slightly.
– Screw in both bolts -arrows- finger-tight.
– Tighten bolts initially to 3 Nm, then tighten further to 7 Nm.
– Replace fuel filter ⇒ page 43 .
– Bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/
bleeding fuel system .
– Fill up vehicle and perform road test.
End

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

14 Rep. gr.20 - Fuel supply system

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

2 Fuel tank
⇒ “2.1 Assembly overview - fuel tank”, page 15
⇒ “2.2 Removing and installing fuel tank”, page 16
⇒ “2.3 Fuel tank: draining”, page 23

2.1 Assembly overview - fuel tank

⇒ “2.1.1 Assembly overview - fuel tank”, page 15

2.1.1 Assembly overview - fuel tank

Note

♦ The connections for the flexible tubes are secured using spring type clips or screw clips.
♦ Renew clamp-type clips with spring-type clips.
♦ We recommend using spring-type clip pliers - VAS 5024/- or spring-type clip pliers - V.A.G 1921/- for in‐
stallation of spring-type clips.

1 - Bolt
❑ 20 Nm
2 - Fuel supply line
❑ To the fuel filter
❑ Do not kink.
❑ Clipped onto fuel tank
❑ Press release tab on
pipe connector to dis‐
connect
❑ Check for secure seat‐
ing
❑ Black
3 - Fuel return lineProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ From engine permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Do not kink.
❑ Clipped onto fuel tank
❑ Press release tab on
pipe connector to dis‐
connect
❑ Blue or with blue mark‐
ing.
❑ Check for secure seat‐
ing
4 - Electrical connector
❑ For fuel system pressur‐
isation pump - G6- and
fuel gauge sender - G-
5 - Overflow hose
6 - Filler cap set
❑ Removal and installa‐
tion ⇒ General body re‐
pairs, exterior; Rep. gr.
55 ; Tank flap unit; Removing and installing tank flap unit

2. Fuel tank 15
 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

7 - Cap
❑ Screw down until it clicks audibly
❑ Fastened with a safety line on the tank flap unit
8 - Earth connection
❑ For diverting electrostatic charge
❑ Installation position ⇒ page 16
❑ Make sure the connector is securely in place and screw down the cable using the bolt for fuel filler neck
-item 9-
❑ After installation, use an ohmmeter to check electrical connection between metal ring on fuel filler neck
and a bare metal part on body – Specified value approx. 0 Ω
9 - Bolt
❑ For securing fuel filler neck and earth connection -item 8-
❑ 8 Nm
10 - Bolt
❑ 20 Nm
11 - Fuel tank
❑ When removing, support using engine and gearbox jack - V.A.G 1383/A-
❑ removing and installing ⇒ page 16
12 - Bolt Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ 20 Nm respect to the correctness of information in this document. Copyright by SEAT S.A.

Earth connection for fuel filler neck

– Place the earth connection as shown in the illustration.
– Ensure that connector -2- for earth connection is properly
seated on metal ring -1- of fuel filler neck.
– First engage contact tab -3- of earth connection in mounting
hole on fuel tank -5- and then press in spacer bush -4-.

Caution

Risk of explosion due to electrostatic discharge.

After installation, check electrical connection using an Ohm‐
meter.
Check connection of metal ring on fuel filler neck by measuring
between ring and a bare metal part of the body.
• Specification: approx. 0 ohm.

2.2 Removing and installing fuel tank

⇒ “2.2.1 Removing and installing fuel tank”, page 16
⇒ “2.2.2 Removing, installing and checking breather valve”, page
22
⇒ “2.2.3 Removing, installing and checking gravity valve”,
page 23

2.2.1 Removing and installing fuel tank

Special tools and workshop equipment required

16 Rep. gr.20 - Fuel supply system

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

♦ Torque wrenches - V.A.G 1331-

♦ Wedge - 3409-

♦ Engine and gearbox jack - V.A.G 1383 A-

♦ Torque wrenches - V.A.G 1332- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Removing
– Observe safety measures ⇒ page 3 .
– Observe rules for cleanliness ⇒ page 2 .
– Drain the fuel tank ⇒ page 23 .

2. Fuel tank 17
 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

– Disconnect battery earth strap with ignition switched off ⇒

Electrical system; Rep. gr. 27 ; Disconnecting and reconnect‐
ing battery .
– Lift the rear seat bench ⇒ General body repairs, interior; Rep.
gr. 72 ; Rear seats; Removing and installing rear seat bench .
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .

– Release connector -1- and unplug.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

18 Rep. gr.20 - Fuel supply system

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

– Open tank flap unit.

– Clean area around fuel filler neck.
– Remove filler cap -arrow- for fuel filler neck.

Note

Seal off opening of fuel filler neck with a clean plug to prevent dirt
from entering.

– Remove tank flap unit -2- ⇒ General body repairs, exterior;

Rep. gr. 55 ; Tank flap unit; remove and install tank flap unit .
– Remove rear right wheel ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Wheels and tyres; Removing and installing
wheels .
– Remove rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner trim strips;
Removing and installing rear wheel housing liner trim .
Vehicles with drum brake on rear axle:
– Unhook handbrake cables on handbrake lever ⇒ Brake sys‐
tem; Rep. gr. 46 ; Handbrake; Removing and installing hand‐
brake cable, rear drum brakes .
Vehicles with disc brake on rear axle:
– Unhook handbrake cables on the brake caliper ⇒ Brake sys‐
tem; Rep. gr. 46 ; Handbrake; RemovingProtected
and installing hand‐
by copyright. Copying for private or commercial purposes, in part or in whole, is not
brake cable, rear disc brakes . permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
All vehicles (continued):
– Remove rear axle ⇒ Running gear, axles, steering; Rep. gr.
42 ; Repairing the suspension; Removing and installing rear
subframe .
– Removing front silencer together with rear silencer⇒ Rep. gr.
26 ; Exhaust pipes/silencers; Removing and installing silenc‐
ers .

– Pull off fuel supply lines -1- and -2-. Separate connectors
⇒ page 38 .

WARNING

The fuel line is under pressure.

Risk of injury to eyes and skin from fuel.
Use protective goggles and clothing to prevent injuries and
contact with the skin. Before loosening hose connections, wrap
a cloth around the connection. Then release pressure by care‐
fully loosening the connection.

2. Fuel tank 19
 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

– Unscrew bolts -arrows- on filler neck.

– Unscrew bolts -3- and -5- on fuel tank -1-.

– Remove securing strap -7-.

– Position engine and gearbox jack - V.A.G 1383 A- under ve‐

hicle to support tank, as shown in illustration.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

20 Rep. gr.20 - Fuel supply system

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

– Unscrew bolts -2-, -4- and -6-.

Note

♦ For illustration purposes the fuel tank is shown without the en‐
gine and gearbox jack - V.A.G 1383 A- .
♦ The aid of a 2nd mechanic is required to remove the fuel tank.

– Lower fuel tank with engine and gearbox jack - V.A.G 1383
A- .
– Lower fuel tank by turning it sideways.
– Guide filler neck out of body.
Installation
Installation is carried out in the reverse order. The following
should be taken into account:

Note

Opening the quick-release coupling ⇒ page 38 .

– Install breather and fuel lines free of kinks.

– Guide filler neck in between rear axle and body.
– If fitted, check that metering pump - V54- is firmly seated.
– Make sure that the filler neck of the fuel tank is correctly in‐
serted into the opening in the body.
– Position the fuel tank together with retaining strap on under‐
body, using the engine and gearbox jack - V.A.G 1383 A- .
– Make sure the bracket for the exhaust gas system is seated
correctly ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly
overview - silencers .
– Note position
authorised of retaining strap.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
– Ensure that line connections are tight.
– After installing fuel tank, check that the supply, return and
breather lines are still clipped onto the fuel tank.
– Note installation position of earth connection ⇒ page 16 .
– Check earth wire for traces of oxidation at connectors; remove
any oxidation if necessary.
– Position the fuel tank with securing strap on underbody, using
the engine and gearbox jack - V.A.G 1383 A- .
– When installing fuel tank, make sure that fuel filler neck is cor‐
rectly inserted into opening on body.

2. Fuel tank 21
 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

Caution

Risk of explosion due to electrostatic discharge.

After installation, check electrical connection using an Ohm‐
meter.
Check connection of metal ring on fuel filler neck by measuring
between ring and a bare metal part of the body.
• Specification: approx. 0 ohm.

– Note installation position of cover.

Tightening torques
♦ ⇒ “2.1 Assembly overview - fuel tank”, page 15
♦ ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seats;
Removing and installing rear search bench .
♦ ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly overview
– silencers .
♦ ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit;
Removing and installing tank flap unit .
♦ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Repairing rear
suspension; Removing and installing rear subframe .
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liner trim strips; Removing and installing wheel housing liner
trim .
♦ ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels and
tyres; Removing and installing wheels .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ ⇒ Brake system; Rep. gr. 46permitted
; Repairing rear drum
unless authorised by SEATbrakes
S.A. SEATorS.A does not guarantee or accept any liability with
⇒ Brake system; Rep. gr. 46 ; Repairing
respect to therear discofbrakes;
correctness information in this document. Copyright by SEAT S.A.

Assembly overview – rear disc brakes .

2.2.2 Removing, installing and checking

breather valve
– Pull breather valve -1- to the side out of connection -4-, for this
purpose unlock locking lug.
– Before installing breather valve, unscrew filler cap from fuel
tank.
– Check breather valve.
• Lever -3- in rest position: breather valve closed.
• Lever pushed in -direction of arrow-: breather valve open
• Make sure O-rings -2- are not damaged.

22 Rep. gr.20 - Fuel supply system

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

2.2.3 Removing, installing and checking grav‐

ity valve
– Pull gravity valve -1- upwards out of connection -3-.
– For this purpose unlock locking lug.
Checking gravity valve:
• Hold valve in a vertical position: it should be possible to blow
through valve.
• Tilt valve to 45 °; it should not be possible to blow through
valve.
• Make sure O-ring -2- is not damaged.

2.3 Fuel tank: draining

⇒ “2.3.1 Emptying fuel tank when fuel pump is intact”,
page 23
⇒ “2.3.2 Emptying fuel tank if it is more than 3/4 full”, page 25
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ “2.3.3 Emptying fuelpermitted
tank ifunless
it is authorised
less than 3/4 S.A.
by SEAT full”, page
SEAT 27not guarantee or accept any liability with
S.A does
respect to the correctness of information in this document. Copyright by SEAT S.A.
2.3.1 Emptying fuel tank when fuel pump is
intact
Special tools and workshop equipment required
♦ Fuel drainage equipment - VAS 5190-

♦ Adapter for fuel extraction - VAS 5190-

2. Fuel tank 23
 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

Note

If the fuel extraction unit - VAS 5190- is still fitted with the extrac‐
tion hose with a solid tip, the extraction hose must be replaced
with the version with a screwed tip.

– Unscrew tip -1- from extraction hose of fuel extraction unit -

VAS 5190- .
– Screw the adapter for extracting the fuel - VAS 5190 /2- from
the adapter set for fuel extraction - VAS 5190 /10- onto the
extractor hose.

WARNING

Danger of scalding from very hot fuel.

♦ The temperatures of the fuel lines or the fuel itself can
reach temperatures of up to 100 °C. Before opening the
line connections allow the fuel to cool, since otherwise
there is a significant risk of burning.
♦ Wear protection gloves.
♦ Use protective goggles.
Risk of injury - fuel system operates under high pressure.
♦ To reduce the pressure in the fuel system, wrap a clean
cloth around the connection and carefully loosen the con‐
nection.

Removing
– Observe safety measures ⇒ page 3 .
– Observe rules for cleanliness ⇒ page 2 .
– Switch off ignition.

– Pull off supply line -1- and catch escaping fuel with a cloth.
Opening the quick-release coupling ⇒ page 38 .

WARNING

The fuel line is under pressure.

Risk of injury to eyes and skin from fuel.
Use protective goggles and clothing to prevent injuries and
contact with the skin. Before loosening hose connections, wrap
a cloth around the connection. Then release pressure by care‐
fully loosening the connection.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

24 Rep. gr.20 - Fuel supply system

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

– Connect the fuel drainage equipment - VAS 5190- to the fuel

supply line using the adapter for draining the fuel - VAS 5190 /
3-.
– Connect the Vehicle diagnostics system .
– Carry out the guided function Empty fuel tank .
– Repeat the function if necessary.

Note

The fuel pump is now activated.

– Open shut-off tap on fuel extractor - VAS 5190- until fuel tank
is emptied.

2.3.2 Emptying fuel tank if it is more than 3/4

full
Special tools and workshop equipment required
♦ Fuel drainage equipment - VAS 5190-

Caution

Secure earth wire of fuel extractor - VAS 5190- to a bare metal

part of the body.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Remove cotter -2- from shaft -1- of fuel extractor - VAS 5190- .
– Observe safety measures ⇒ page 3 .
– Observe rules for cleanliness ⇒ page 2 .

2. Fuel tank 25
 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

– Make a mark on the hose -arrow- at distance -a- from end of

extraction hose.
– Use insulating tape for this.
– Dimension -a- = 1,200 mm.

– Open tank flap unit.

– Clean area around fuel filler neck.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Remove filler cap -arrow- for fuel filler neck.

– Screw shaft -1- of fuel extractor - VAS 5190- onto fuel tank
filler neck.
– Push extraction hose into fuel tank until marking on hose
-arrow- coincides with shaft end.

Note

At the lower end of the filling mouth, there is a ball valve -2- on
the fuel tank -1-. Avoid damage to this with the suction hose -3-.
Therefore, only push the hose in as far as the tape marking
-arrow-.

– Drain fuel tank via filler neck as far as possible.

– Pull extraction hose out carefully.

Note

♦ When no more fuel is extracted, the tank is emptied just

enough for the sender flange to be opened without danger.
♦ If work has to be done on fuel delivery unit or on fuel gauge
sender , proceed as follows ⇒ page 27 :

26 Rep. gr.20 - Fuel supply system

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

2.3.3 Emptying fuel tank if it is less than 3/4 full

Caution

Secure earth wire of fuel extractor to a bare metal part of the

body.
To extract E 85 fuel, use only fuel extractor - VAS 5190 A- !

Special tools and workshop

equipment required
♦ Union nut tool - 3217-
♦ Wedge - 3409-
♦ Torque wrenches - V.A.G
1332-
♦ Fuel drainage equipment -
VAS 5190-
♦ Fuel extractor - VAS 5190
A- for E 85 fuel (not shown).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Observe safety measures ⇒ page 3 .

– Observe rules for cleanliness ⇒ page 2 .
– Lift the rear seat bench ⇒ General body repairs, exterior; Rep.
gr. 55 ; Tank flap unit; Removing and installing tank flap unit .

2. Fuel tank 27
 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

– Unclip cover -1- at retaining tabs -arrows-, using removal

wedge - 3409- .

– Release connector -1- and unplug.

– Disconnect fuel lines -2- and -3- from fuel delivery unit. Open‐
ing the quick-release coupling ⇒ page 38 .

WARNING

The fuel line is under pressure.

Risk of injury to eyes and skin from fuel.
Use protective goggles and clothing to prevent injuries and
contact with the skin. Before loosening hose connections, wrap
a cloth around the connection. Then release pressure by care‐
fully loosening the connection.

– Open locking ring using union nut wrench - 3217- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

28 Rep. gr.20 - Fuel supply system

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

– Carefully lift flange of fuel delivery unit -3-.

– Remove gasket -1- and carefully lift up the flange of the fuel
delivery unit slightly more.

Caution

Secure earth wire of fuel extractor to a bare metal part of the

body.

– Insert suction hose of fuel extractor - VAS 5190- as far as

possible into fuel tank.
– Extract fuel using fuel extractor - VAS 5190- .
If fuel tank needs only to be emptied, install fuel delivery unit
again. ⇒ page 31 .
Tightening torques
♦ ⇒ “3.1 Exploded view - fuel delivery unit/fuel gauge sender”,
page 30

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

2. Fuel tank 29
 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

3 Fuel delivery unit, fuel gauge sender

⇒ “3.1 Exploded view - fuel delivery unit/fuel gauge sender”, page
30
⇒ “3.2 Removing and installing fuel delivery unit, fuel gauge send‐
er”, page 31
⇒ “3.3 Fuel level gauge sender G : removing and fitting”,
page 36

3.1 Exploded view - fuel delivery unit/fuel gauge sender

1 - Fuel delivery unit

❑ With fuel system pres‐
surisation pump - G6-
– For checking, connect a
vehicle diagnosis tester
and carry out guided
function “Checking elec‐
tronic fuel pump(s)”
⇒ page 47 .
❑ removing and installing
⇒ page 31
❑ Put at least 5 litres of
fuel into tank after instal‐
ling
❑ Note installation posi‐
tion of flange on Protected
fuel by copyright. Copying for private or commercial purposes, in part or in whole, is not
tank ⇒ page 31permitted
. unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Clean strainer if dirty
2 - Oil seal
❑ Renew
❑ Mount dry
3 - Union nut
❑ 80 Nm
❑ Remove and install us‐
ing union nut tool -
3217- .
4 - Fuel return line
❑ From engine
❑ Do not kink.
❑ To extract from sealing
flange, press release
tab on connection
❑ Note direction of arrow
(fuel supply or fuel return system) on flange when installing
❑ Clipped onto fuel tank
5 - Fuel supply line
❑ To the fuel filter
❑ Do not kink.
❑ To extract from sealing flange, press release tab on connection
❑ Note direction of arrow (fuel supply or fuel return system) on flange when installing
❑ Clipped onto fuel tank

30 Rep. gr.20 - Fuel supply system

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

6 - Electrical connector
❑ For fuel system pressurisation pump - G6- and fuel gauge sender - G-
7 - Fuel gauge senders - G-
❑ Clipped onto baffle housing
❑ Removing and installing

Fuel supply unit: assembly position

– Push sealing flange downwards against spring force and
move into installation position.
• Lug -2- on sealing flange points to »arrow marking« -1- on fuel
tank.

3.2 Removing and installing fuel delivery

unit, fuel gauge sender
Special tools and workshop equipment required
♦ Union nut tool - 3217-

♦ Wedge - 3409-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

3. Fuel delivery unit, fuel gauge sender 31

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

♦ Torque wrenches - V.A.G 1332-

Removing
– Observe safety instructions ⇒ page 3 .
– Observe rules for cleanliness ⇒ page 2 .
– Move front seats all the way forwards.
– Drain the fuel tank ⇒ page 23 .
– Disconnect battery earth strap with ignition switched off ⇒
Electrical system; Rep. gr. 27 ; Disconnecting and reconnect‐
ing battery .

WARNING

There is a danger of fuel running out.

The fuel tank must not be more than 1/3 full when removing the
fuel delivery unit, otherwise a large amount of fuel will escape.

– Fold rear seat bench forward ⇒ General body repairs, interior;

Rep. gr. 72 ; Rear seats; Removing and installing rear seat
bench .
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .

WARNING

The fuel line is under pressure.

Risk of injury to eyes and skin from fuel.
Use protective goggles and clothing to prevent injuries and
contact with the skin. Before loosening hoseProtected
connections, wrap
a cloth around the connection. Then release pressure by care‐
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
fully loosening the connection. respect to the correctness of information in this document. Copyright by SEAT S.A.

32 Rep. gr.20 - Fuel supply system

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

– Lay bare the connector -1- and disconnect.

– Pull fuel supply line -4- and fuel return line -2- off flange. Sep‐
arate connectors ⇒ page 38 .
Vehicles with auxiliary heater:
– Remove fuel line -3- leading to metering pump - V54- for aux‐
iliary heater from sealing flange.
– To do this, open clip at bottom.
– Carefully pull out fuel line -3-.

All vehicles (continued):

– Unscrew union nut using union nut tool - 3217- .

WARNING

There is a danger of fuel running out.

♦ The fuel tank must not be more than 3/4 full when remov‐
ing the fuel delivery unit, otherwise a large amount of fuel
will escape.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

3. Fuel delivery unit, fuel gauge sender 33

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

– Pull sealing flange out of the opening in fuel tank.

– Remove seal from opening in fuel tank.

WARNING

Danger due to fuel running out of the fuel extraction unit.

♦ Place a cloth underneath to absorb fuel.

– Pull fuel extraction unit -1- with fuel gauge sender out through
the installation opening of the fuel tank carefully.
– Turn and tilt it as necessary while doing so.

Note

When removing the fuel delivery unit, ensure that the float arm of
the fuel gauge sender is not bent.

Note

♦ If delivery unit is to be renewed, old delivery unit must be

drained before disposal.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ Observe environmental regulations for disposal.
respect to the correctness of information in this document. Copyright by SEAT S.A.

♦ Check fuel tank for foreign bodies and dirt.

Installation
Installation is carried out in the reverse order. The following
should be taken into account:

Note

♦ Make sure all components are mounted in the correct position.

♦ Opening the quick-release coupling ⇒ page 38 .
♦ Renew seal if damaged.

– Insert dry seal for fuel delivery unit into opening of fuel tank.
– When inserting fuel delivery unit, ensure that fuel gauge send‐
er is not bent.
– Coat inner side of seal with fuel.

34 Rep. gr.20 - Fuel supply system

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

– Carefully guide fuel delivery unit with fuel gauge sender in

through installation opening in fuel tank.

Caution

Risk of leakage
♦ The seal must not be crushed or damaged when installing
the flange.

– Push sealing flange downwards against spring force and

move into installation position.
• Lug -2- on sealing flange points to »arrow marking« -1- on fuel
tank.
– Connect fuel lines so they engage audibly.
– Plug in electrical connector and make sure it is correctly en‐
gaged.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Put at least 5 litres of fuel into tank after
permitted installing
unless fuel
authorised by SEAT delivery
S.A. SEAT S.A does not guarantee or accept any liability with
unit. respect to the correctness of information in this document. Copyright by SEAT S.A.

Vehicles with auxiliary heater

– If a new fuel delivery unit is used, check if tip of auxiliary heater
connection on flange -1- of delivery unit must be cut.

– Dimension -a- 25 mm must be observed.

– Note installation position of fuel delivery unit flange: mark on

flange must align with mark on fuel tank -arrows-.
Tightening torques
♦ ⇒ “3.1 Exploded view - fuel delivery unit/fuel gauge sender”,
page 30
♦ ⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting and
connecting battery
♦ ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seats;
Removing and installing rear seat bench

3. Fuel delivery unit, fuel gauge sender 35

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

3.3 Fuel level gauge sender - G- : removing

and fitting
Removing

Note

♦ Note that the fuel gauge sender - G- is available in different

versions.
♦ After removing the fuel delivery unit, check which version of
fuel gauge sender - G- is fitted.

– Observe safety measures ⇒ page 3 .

– Observe rules for cleanliness ⇒ page 2 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove fuelunless
permitted delivery unit
authorised ⇒ page
by SEAT 31 .S.A does not guarantee or accept any liability with
S.A. SEAT
respect to the correctness of information in this document. Copyright by SEAT S.A.
Variant 1:
– Press fuel gauge sender - G- to one side slightly while pulling
upwards.

– If the sender cannot be released in this way, the securing tabs

-arrows- must also be pushed to the side slightly.

– Note colour assignment of cables for re-installation.

– Pull off electrical connectors -1- through -3-.
– Then lift the securing hooks of the electrical connector.

36 Rep. gr.20 - Fuel supply system

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

Installing:
– Connect connectors -1- through -3-.
– Note the colour identification.
– Check connectors are secured properly by pulling.
– Insert fuel gauge sender - G- into guide on fuel delivery unit
and press down until it engages.
Installation
– Installation is carried out in the reverse order. The following
should be taken into account:
– Note colour assignment of contacts.
– Insert fuel gauge sender - G- into guides on fuel delivery unit
and press upwards until it engages.
– Check connectors are secured properly by pulling.
– Insert fuel gauge sender - G- into guide on fuel delivery unit
and press down until it engages.

Variant 2:
– Press together securing tabs
Protected by -arrows-
copyright. Copyingand remove
for private fuel gauge
or commercial purposes, in part or in whole, is not
sender - G- upwards.
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
– Note colour assignment of cables for re-installation.
– Release connector lugs on lines -1-, -2- and -3- and discon‐
nect.
Installation
– Note the colour identification.
– Check connectors are secured properly by pulling.
– Insert fuel gauge sender - G- into guides on fuel delivery unit
and press down until it engages.
– Clip lines on corresponding positions and secure on cup into
retaining slots.
All vehicles (continued):
– Fuel delivery unit: installing ⇒ page 31 .
Tightening torques
♦ ⇒ “3.1 Exploded view - fuel delivery unit/fuel gauge sender”,
page 30
♦ ⇒ “2.1 Assembly overview - fuel tank”, page 15

3. Fuel delivery unit, fuel gauge sender 37

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

4 Plug-in connectors

4.1 Separating push-fit couplings

Special tools and workshop equipment required
♦ Lever - T10468-

Assignment of plug-in connectors

Note

♦ The push-fit couplings for fuel, vacuum and breather lines are
colour coded. There is either a coloured dot on the plug-in
connector or the release button is of the respective colour
⇒ page 38 .
♦ Connections for fuel lines must engage audibly when joined.
♦ Ensure push-fit coupling is secured properly by pulling it!
♦ Observe safety instructions ⇒ page 3 .
♦ Observe rules for cleanliness ⇒ page 2 .

Colour assignment
Plug-in connector Colour code on push-fit coupling
Fuel supply line Black
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Fuel return line Blue colour
respect to the correctness of information in this document. Copyright by SEAT S.A.

Breather White, beige

Vacuum green

WARNING

The fuel line is under pressure.

Risk of injury to eyes and skin from fuel.
Use protective goggles and clothing to prevent injuries and
contact with the skin. Before loosening hose connections, wrap
a cloth around the connection. Then release pressure by care‐
fully loosening the connection.

38 Rep. gr.20 - Fuel supply system

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

WARNING

Bear in mind that the fuel pump can be activated due to open‐
ing of a door with the battery connected. Fuel can escape if the
system has been opened.

Version 1
Push-on coupling with release buttons -arrows- on right and left

Opening
Counterhold on the decoupling point -1- intended for the fuel.
– Insert -T10468- between heat shield and stop -arrow- of fuel
line -2- and counterhold.

Continuation for all separating points of fuel system:

– Push push-fit coupling -1- in -direction of arrow A-.
– Press release buttons and pull push-fit coupling -1- off fuel line
-2- in -direction of arrow B-.
Take note of colour assignment during installation ⇒ page 38
– Ensure push-fit
Protected by copyright. coupling is secured
Copying for private properly
or commercial purposes,by pulling
in part it! is not
or in whole,
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

4. Plug-in connectors 39
 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

Version 2
Push-on coupling with pull-release mechanism -arrow-

Opening
– Push push-fit coupling -1- in -direction of arrow A-.
– Pull pull-release mechanism -2- in -direction of arrow B-.
– Pull push-fit coupling -1- off fuel line -3- in
-direction of arrow B-.
Take note of colour assignment during installation ⇒ page 38
– Ensure push-fit coupling is secured properly by pulling it!

Version 3
Push-on coupling with front button -arrow-
Opening
– Press release button -arrow- and pull push-fit couplings off.
Take note of colour assignment during installation ⇒ page 38
– Ensure push-fit couplings are secured properly by pulling.

Version 4
Push-on coupling with release buttons -arrows- on right and left
Opening Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Push push-fit coupling in -direction of arrow A-.
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Press release buttons -arrows- and pull push-fit coupling off.

Take note of colour assignment during installation ⇒ page 38
– Ensure push-fit coupling is secured properly by pulling it!

40 Rep. gr.20 - Fuel supply system

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

Version 5
Push-on coupling with release buttons -arrows- on right and left
Opening
Take note of colour assignment during installation ⇒ page 38
– Press release buttons -arrows- and pull push-fit coupling off.
– Ensure push-fit coupling is secured properly by pulling it!

Version 7
Plug-in connector -1- with release buttons -2- on right and left.
Opening
– Push push-fit coupling -1- in -direction of arrow A- and main‐
tain pressure.
– Press release button -2- in -direction of arrow B- and pull off
plug-in connector -1-.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Take note of colour assignment during installation ⇒ page 38 .
Connections for fuel lines must engage audibly when joined.
– Ensure push-fit coupling is secured properly by pulling it!

4. Plug-in connectors 41
 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

5 Fuel filter:
⇒ “5.1 Assembly overview - fuel filter”, page 42
⇒ “5.2 Removing and installing fuel filter”, page 43
⇒ “5.3 Fuel hoses in engine compartment”, page 44

5.1 Assembly overview - fuel filter

1 - Fuel filter:
❑ The indented arrows on
the filter mark the fuel in‐
put and output.
❑ removing and installing
⇒ page 43
2 - Delivery line
❑ From fuel delivery unit
❑ White marking
3 - Delivery line
❑ To high-pressure fuel
pump
❑ White marking
4 - O-ring
❑ Renew
5 - O-ring
❑ Renew, included in the
scope of supply for the
fuel temperature sender
- G81-
6 - Fuel temperature sender
Protected by copyright. - for private or commercial purposes, in part or in whole, is not
Copying
G81- permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
7 - Fuel filter holder
8 - Bolt
❑ 3 off
❑ 20 Nm

Fuel transfer point

♦ A = Supply line, white or white marking.
♦ B = Return line, blue or blue marking
♦ Opening the quick-release couplings ⇒ page 38

42 Rep. gr.20 - Fuel supply system

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

5.2 Removing and installing fuel filter

Removing

Note

♦ Opening the quick-release coupling ⇒ page 38 .

♦ Fuel hoses in the engine compartment ⇒ page 44 .

– Observe safety measures ⇒ page 3 .

– Observe rules for cleanliness ⇒ page 2 .
– Release plug-in connectors -1-, and pull them off connections
-3- on fuel filter -2-. Opening the quick-release coupling
⇒ page 38 .

– Clip the fuel filter -1- out of the attachment -3-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove fuel
permitted unless filter -1-
authorised upwards.
by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Installation
Installation is carried out in the reverse order. The following
should be taken into account:
♦ Observe installation position of fuel filter. The stamped arrows
on the filter mark the fuel input and output.
♦ Note allocation ⇒ page 38 .
♦ Route fuel hoses without kinking.
♦ Ensure that quick-release couplings are firmly seated. Check
that it has engaged securely by pulling on it.

– Place the retainer ring -2- with the guide -arrow- correctly on
the ⇒ Item 2 (page 42) fuel filter -1- connection.
– Clip in the securing ring -2- on the fuel filter -1-.
– Insert the fuel filter -1- up to the end of the holder.
– Make sure that the retaining tabs -3- engage in the intended
recess -2-.
– Bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/
bleeding fuel system .

5. Fuel filter: 43
 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

5.3 Fuel hoses in engine compartment

Note

♦ On this engine, the connections for the pressurised fuel hoses

have a so-called 3-ribbed section (arrows). This reduces the
likelihood of fuel system leaks.
♦ When removing the fuel hoses, the very thin sealing layer on
the inside of the fuel hoses is usually damaged.
♦ This damage cannot be detected with the naked eye. After
some time, it leads to leaks in the fuel system.
♦ When fitting the fuel hoses on the connections again, it is im‐
possible to guarantee that the position of the hoses on the
three ribs will be the same as before. This also leads to a ten‐
dency to form leaks.
♦ This reduces the likelihood of fuel system leaks.
♦ When the fuel hoses are removed, the very thin sealing layer
on the inside of the fuel hoses is damaged.
♦ This damage cannot be detected with the naked eye.
♦ After some time, it leads to by
Protected leaks in the
copyright. fuel
Copying for system.
private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ If the fuel filter only has respect
to be toremoved to gain space, leave
the correctness of information in this document. Copyright by SEAT S.A.

the fuel hoses on the fuel filter and high-pressure pump. Lay
the fuel filter on the engine with the hoses attached in order to
avoid having to renew them unnecessarily.
♦ Disconnect at other fuel system connection points in the en‐
gine compartment.
♦ Opening the quick-release coupling ⇒ page 38 .

Caution

• After removing fuel hoses from connections with a 2 wave

profile section and engagement lip, these fuel hoses must
be replaced.

If a fuel hose cannot be removed from the connections by hand:

Caution

Never insert a screwdriver or similar tool between the hose and

the connection!
♦ Risk of damage to the connection - Component has to be
renewed.

– Turn fuel hose with suitable pliers and pull off hose.
If fuel hose still cannot be removed from the connection:
– Only cut open the textile layer of the fuel hose lengthways and
pull hose off.
• The inner rubber layer must not be cut. If the connection is
damaged, the entire component must be renewed.

44 Rep. gr.20 - Fuel supply system

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

Note

♦ Before attaching a new fuel hose, remove grease, oil and dirt
thoroughly from the hose connection. Do not use any metal
tools to do this as they could damage the hose connection.
♦ Attach fuel hose to connection without lubricant and then se‐
cure with spring-type clip.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

5. Fuel filter: 45
 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

6 Accelerator mechanism
⇒ “6.1 Exploded view - accelerator pedal module”, page 46

6.1 Exploded view - accelerator pedal module

1 - Mounting bracket
❑ Removal and installa‐
tion ⇒ Brake system;
Rep. gr. 46 ; Brake ped‐
al, vehicles with electro‐
hydraulic steering; As‐
sembly overview –
brake pedal
❑ Removal and installa‐
tion ⇒ Brake system;
Rep. gr. 46 ; Brake ped‐
al, vehicles with electro‐
mechanical power
steering; Assembly
overview – brake pedal
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2 - Electrical connector
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

❑ Black, 6 contacts
respect to the correctness of information in this document. Copyright by SEAT S.A.

3 - Accelerator pedal module

❑ With accelerator pedal
position sender - G79-
and accelerator pedal
position sender 2 -
G185-
❑ Not adjustable
❑ Checking ⇒ Vehicle di‐
agnostic tester.
4 - 9 Nm

46 Rep. gr.20 - Fuel supply system

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

7 Fuel pump:
⇒ “7.1 Checking fuel system pressurisation pump G6 ”,
page 47

7.1 Checking fuel system pressurisation

pump - G6-
⇒ “7.1.1 Checking fuel pressure”, page 47
⇒ “7.1.2 Checking delivery rate”, page 52

7.1.1 Checking fuel pressure

Special tools and workshop equipment required
♦ Pressure gauge - VAS 6551-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

♦ Adapter set - VAS 6551/5-

♦ Hose clip pliers - V.A.G 1921-

7. Fuel pump: 47
 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

♦ Wedge - 3409-

♦ Vehicle diagnosis and service information system

WARNING

Bear in mind that the fuel pump can be activated due to open‐
ing of a door with the battery connected. Fuel can escape if the
system has been opened.

Test prerequisites
• Connect battery charger, battery voltage at least 12.5 volts ⇒
Electrical system; Rep. gr. 27 ; Battery; Charging battery .
• Fuses OK. ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
• Fuel filter o.k.
• Ensure that vehicle is placed on a level surface.
• Fuel tank at least. 1 / 2 filled.
• All electrical consumers, e.g. by
Protected lights andCopying
copyright. rear for
window
private or heating,
commercial purposes, in part or in whole, is not
must be switched off.permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Note

♦ The vehicle must be filled with diesel fuel that matches the
seasonal conditions. Summer diesel fuel may coagulate
(flock) in very low winter temperatures.
♦ Diesel fuel sold in the summer is guaranteed to be capable of
filtration down to 0°C.
♦ Diesel fuel sold in the summer/winter transition is guaranteed
to be capable of filtration down to -10°C.
♦ Diesel fuel sold in the winter is guaranteed to be capable of
filtration down to -20°C.
♦ Test sample, if unsure in winter.
♦ Expose sample to low ambient temperature for approx. 1 hour.
♦ If the fuel coagulates (flocks) at temperatures down to -20°C,
it is unsuitable for low temperatures. This coagulation can
block the strainer in the fuel delivery unit as well as the fuel
filter.

Checking sequence
– Observe safety measures ⇒ page 3 .
– Observe rules for cleanliness ⇒ page 2 .

48 Rep. gr.20 - Fuel supply system

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

– Switch off ignition.

– Remove engine cover ⇒ Rep. gr. 10 ; Engine cover; Remov‐
ing and installing engine cover .
– Open clips -arrow-.

WARNING

The fuel line is under pressure.

Risk of injury to eyes and skin from fuel.
Use protective goggles and clothing to prevent injuries and
contact with the skin. Before loosening hose connections, wrap
a cloth around the connection. Then release pressure by care‐
fully loosening the connection.

– Pull fuel supply line -1- off high-pressure pump -2-.

– Insert connection fitting - VAS 6551/5-1- into fuel supply line

-1- and secure it with a clip.
– Connect the hose - VAS 6551/2- between the connecting
piece - VAS 6551/5-1- and connection -A- of the pressure
tester (Diesel) - VAS 6551- .Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Connect hose - VAS 6551/5-2- between
respect to the connection -B- of in this document. Copyright by SEAT S.A.
correctness of information
pressure tester (diesel) - VAS 6551- and high-pressure pump
-2-.
– Secure hose - VAS 6551/5-2- to high-pressure pump -2- with
a clip.
– Switch on pressure tester - VAS 6551- by pressing On/Off
button.

7. Fuel pump: 49
 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

– Ensure that drain tap -C- on pressure tester - VAS 6551- -1-
is closed.
– Shut-off valves -A- and -B- on pressure tester - VAS 6551-
-1- are open.
– Connect the
Vehicle diagnostics system .
– Select guided function 01 Actuating fuel pump .
– Select function Checking fuel pump delivery pressure/
delivery rate .

– Follow instructions on vehicle diagnosis tester .

Note

The fuel pump is now activated.

– Read off fuel pressure on pressure gauge - VAS 6551- .

• Specification: min. 4.5 bar:
If specification is not obtained:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Check fuel lines

to the in engineof compartment for possible restric‐
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect correctness information in this document. Copyright by SEAT S.A.
tions (kinks), blockages and damages.
– Check fuel lines in engine compartment for leaks.
If a fault is found:
Check fuel pressure ahead of fuel filter as follows:

Check fuel pressure ahead of fuel filter:

– Pull off fuel supply line -1-. Opening the quick-release coupling
⇒ page 38 .

WARNING

The fuel line is under pressure.

Risk of injury to eyes and skin from fuel.
Use protective goggles and clothing to prevent injuries and
contact with the skin. Before loosening hose connections, wrap
a cloth around the connection. Then release pressure by care‐
fully loosening the connection.

50 Rep. gr.20 - Fuel supply system

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

– Connect hose - VAS 6551/2- between fuel supply line from fuel
tank and connection point -B- of pressure tester - VAS 6551- .
– Connect hose - VAS 6551/1- between connection point -A- of
pressure tester (diesel) - VAS 6551- and fuel line leading to
fuel filter -1-.
– Switch on pressure tester - VAS 6551- by pressing On/Off
button.

– Ensure that drain tap -C- on pressure tester - VAS 6551- -1-
is closed.
– Shut-off valves -A- and -B- on pressure tester - VAS 6551-
-1- are open.
– Repeat function Checking fuel pump delivery pressure/
delivery rate ⇒ page 50 .

If the specified value is achieved:

Check fuel filter, renew if necessary ⇒ page 43 .
If specification is not obtained:
Proceed as follows to check fuel pressure at fuel delivery unit:
Checking fuel pressure on fuel delivery unit:
– Lift seat bench ⇒ General body repairs, interior; Rep. gr. 72 ;
Rear seats; Removing and installing rear seat bench .

– Unclip cover -1- at retaining tabs -arrows-, using removal

wedge - 3409- .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

7. Fuel pump: 51
 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

– Pull fuel lines -3- off fuel delivery unit. Opening the quick-re‐
lease coupling ⇒ page 38 .

WARNING

The fuel line is under pressure.

Risk of injury to eyes and skin from fuel.
Use protective goggles and clothing to prevent injuries and
contact with the skin. Before loosening hose connections, wrap
a cloth around the connection. Then release pressure by care‐
fully loosening the connection.

– Connect pressure tester - VAS 6551/1- and fuel supply line

-2- leading to fuel filter by means of hose - VAS 6551- .
– Connect hose - VAS 6551/2- between pressure tester - VAS
6551- and fuel delivery unit -1-.

– Ensure that drain tap -C- on pressure tester - VAS 6551- -1-
is closed.
– Shut-off valves -A- and -B- on pressure tester - VAS 6551-
-1- are open.
– Repeat function Checking fuel pump delivery pressure/
delivery rate ⇒ page 50 .

If the specified value is reached:

– Check fuel lines leading to engine for possible restrictions
(kinks), blockages and damages.
– Check fuel lines for leaks.
If specification is not obtained:
– Remove fuel delivery unit ⇒ page 31 .
– Check filter strainer for soiling.

– Check that all hose connections -arrows- are connected.

If a fault is found:
– Renew fuel delivery unit ⇒ page 31 .

7.1.2 Checking delivery

Protected by copyright.rate
Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Special tools and workshop equipment
respect required
to the correctness of information in this document. Copyright by SEAT S.A.

52 Rep. gr.20 - Fuel supply system

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

♦ Pressure gauge - VAS 6551-

♦ Adapter set - VAS 6551/5-

♦ Wedge - 3409-

♦ Hose clip pliers - V.A.G 1921-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

7. Fuel pump: 53
 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

♦ Pressure limiting valve - VAS 6551/6-

♦ Vehicle diagnosis and service information system

♦ Measuring container, capacity at least 3 litres

WARNING

Bear in mind that the fuel pump can be activated due to open‐
ing of a door with the battery connected. Fuel can escape if the
system has been opened.

Test prerequisites
• Connect battery charger, battery voltage at least 12.5 volts ⇒
Electrical system; Rep. gr. 27 ; Battery; Charging battery .
• Fuses OK. ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
• Fuel pump control unit - J538- OK ⇒ Vehicle diagnostic tester.
• Fuel filter o.k.
• Fuel tank at least. 1 / 2 filled.
• Ensure that vehicle is placed on a level surface.
• All electrical consumers, e.g. lights and rear window heating,
must be switched off.
• Fuel pressure OK ⇒ page 47 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Note respect to the correctness of information in this document. Copyright by SEAT S.A.

♦ The vehicle must be filled with diesel fuel that matches the
seasonal conditions. Summer diesel fuel may coagulate
(flock) in very low winter temperatures.
♦ Diesel fuel sold in the summer is guaranteed to be capable of
filtration down to 0°C.
♦ Diesel fuel sold in the summer/winter transition is guaranteed
to be capable of filtration down to -10°C.
♦ Diesel fuel sold in the winter is guaranteed to be capable of
filtration down to -20°C.
♦ Test a sample, if unsure in winter. Expose sample to low am‐
bient temperature for approx. 1 hour. If the fuel coagulates
(flocks) at temperatures down to -20°C, it is unsuitable for low
temperatures. This coagulation can block the strainer in the
fuel delivery unit as well as the fuel filter.

– Observe safety measures ⇒ page 3 .

54 Rep. gr.20 - Fuel supply system

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

– Observe rules for cleanliness ⇒ page 2 .

– Switch off ignition.
– Remove engine cover ⇒ Rep. gr. 10 ; Engine cover; Remov‐
ing and installing engine cover .
– Fold front right seat forwards as far as possible.
– Lift the rear seat bench ⇒ General body repairs, interior; Rep.
gr. 72 ; Rear seats; Removing and installing rear seat bench .
– Open clamp -arrow- of fuel supply line -1-.

WARNING

The fuel line is under pressure.

Risk of injury to eyes and skin from fuel.
Use protective goggles and clothing to prevent injuries and
contact with the skin. Before loosening hose connections, wrap
a cloth around the connection. Then release pressure by care‐
fully loosening the connection.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Pull fuel supply line -1- off high-pressurepermitted
pumpunless
-2-. authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Fit connection fitting - VAS 6551/5-1- in supply line and secure

it with clamp.
– Connect the hose - VAS 6551/2- between the connecting
piece - VAS 6551/5-1- and connection -A- of the pressure
tester (Diesel) - VAS 6551- .
– Connect the pressure regulating valve - VAS 6551/6- to the
connection -B- of the pressure tester - VAS 6551- .
– Hold end of hose of pressure regulating valve - VAS 6551/6-
in measuring container.
– Switch on pressure tester - VAS 6551- by pressing On/Off
button.

– Ensure that drain tap -C- on pressure tester - VAS 6551- -1-
is closed.
– Shut-off valves -A- and -B- on pressure tester - VAS 6551-
-1- are open.
– Connect the
Vehicle diagnostics system .
– Select guided function 01 Actuating fuel pump .
– Select function Checking fuel pump delivery pressure/
delivery rate .

– Follow instructions on vehicle diagnosis tester .

7. Fuel pump: 55
 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

– Adjust pressure to 4.5 bar with pressure regulating valve - VAS

6551/6- .
– Set pressure regulating valve - VAS 6551/6- to feed pressure
using adjuster wheel -arrow-.
• Specification: 4.5 bar.
– From this point on do not move position of adjuster wheel
-arrow-.
– Drain measuring container.
– Repeat function Checking fuel pump delivery pressure/
delivery rate .

Note

The fuel system pressurisation pump - G6- is now activated for

30 seconds.

– Check the amount of fuel supplied in the measuring container.

• Theoretical minimum flow rate: 1100 cm3/30 s
If the minimum flow rate is not reached:
– Check fuel lines in engine compartment for possible restric‐
tions (kinks), blockages and damages.
– Check fuel lines in engine compartment for leaks.
If no fault is found:
Check fuel delivery rate before fuel filter as follows:

Checking fuel delivery rate ahead of fuel filter:

– Pull off fuel supply line -1-. Opening the quick-release coupling
⇒ page 38 .

WARNING

The fuel line is under pressure.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Risk of injury to eyes and skin from fuel.

permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Use protective goggles and clothing to prevent injuries and

contact with the skin. Before loosening hose connections, wrap
a cloth around the connection. Then release pressure by care‐
fully loosening the connection.

56 Rep. gr.20 - Fuel supply system

 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

– Connect hose - VAS 6551/2- to fuel supply line from fuel tank.
– Connect hose - VAS 6551/2- to connection point -A- of pres‐
sure tester (diesel) - VAS 6551- .
– Connect the pressure regulating valve - VAS 6551/6- to the
connection -B- of the pressure tester - VAS 6551- .
– Hold end of hose of pressure regulating valve - VAS 6551/6-
in measuring container.
– Switch on pressure tester - VAS 6551- by pressing On/Off
button.

– Ensure that drain tap -C- on pressure tester - VAS 6551- -1-
is closed.
– Shut-off valves -A- and -B- on pressure tester - VAS 6551-
-1- are open.
– Repeat function Checking fuel pump delivery pressure/
delivery rate ⇒ page 55 .

If the minimum flow rate is now reached:

Check fuel filter, renew if necessary ⇒ page 43 .
If reading again does not match specification:
Proceed as follows to check fuel delivery rate at fuel delivery unit:
Checking fuel delivery rate on fuel delivery unit:
– Remove or raise seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing rear seat
bench .

– Unclip cover -1- at retaining tabs -arrows-, using removal

wedge - 3409- .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

7. Fuel pump: 57
 Toledo 2013 ➤
Fuel supply system, diesel engines - Edition 07.2015

– Pull fuel lines -3- off fuel delivery unit. Opening the quick-re‐
lease coupling ⇒ page 38 .

WARNING

The fuel line is under pressure.

Risk of injury to eyes and skin from fuel.
Use protective goggles and clothing to prevent injuries and
contact with the skin. Before loosening hose connections, wrap
a cloth around the connection. Then release pressure by care‐
fully loosening the connection.

– Connect hose - VAS 6551/2- to fuel supply line connection on

fuel delivery unit -1-.
– Connect hose - VAS 6551/2- to connection point -A- of pres‐
sure tester - VAS 6551- .
– Connect the pressure regulating valve - VAS 6551/6- to the
connection -B- of the pressure tester - VAS 6551- .
– Hold end of hose of pressure regulating valve - VAS 6551/6-
in measuring container.
– Switch on pressure tester - VAS 6551- by pressing On/Off
button.

– Ensure that drain tap -C- on pressure tester - VAS 6551- -1-
is closed.
– Shut-off valves -A- and -B- on pressure tester - VAS 6551-
-1- are open.
– Repeat function Checking fuel pump delivery pressure/
delivery rate ⇒ page 55 .

If the minimum flow rate is now reached:

– Check fuel lines for possible restrictions (kinks), blockages
and damages.
– Check fuel lines for leaks.
If reading again does not match specification:
– Remove fuel delivery unit ⇒ page 31 .
– Check filter strainer for soiling.

– Check that all hose connections -arrows- are connected.

Only when up to now no fault has been detected:
– Renew fuel delivery unit ⇒ page 31 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

58 Rep. gr.20 - Fuel supply system