Volkswagen Touareg (2003 year). Manual - part 24

1

Parts of fuel supply system

Caution

When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐

tions:

♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐

vated charcoal filter system, coolant, refrigerant, brake

fluid and vacuum) and electrical wiring in their original po‐

sitions.

♦ To avoid damage to lines, ensure sufficient clearance to

all moving or hot components.

Note

♦

Hose connections are secured with couplings or spring-type

or clamp-type clips.

♦

Always renew clamp-type clips with spring-type clips.

♦

Fuel hoses on engine must be secured with spring-type clips

only. The use of clamp or screw-type clips is not permissible.

♦

Spring-type clip pliers -VAS 6340- or spring-type clip pliers -

VAS 5024 A- are recommended for installation of spring-type

clips.

Observe safety precautions 

⇒ page 99

 .

Observe rules for cleanliness 

⇒ page 99

 .

Assembly overview - fuel tank with attachments 

⇒ page 94

 .

Assembly overview - fuel filter 

⇒ page 96

 .

Renewing fuel filter 

⇒ page 96

Schematic diagram of fuel lines and components in fuel tank

⇒ page 98

 .

Draining fuel tank 

⇒ page 100

Removing and installing fuel delivery unit, fuel gauge sender and

suction-jet pumps 

⇒ page 102

Removing and installing fuel tank with attachments

⇒ page 104

 .

Checking fuel pumps 

⇒ page 107

Touareg 2003 ➤

1. Parts of fuel supply system    

93

Assembly overview - fuel tank with attachments

1 - Fuel filler neck
2 - To activated charcoal filter.
3 - Fuel tank

❑ When removing, sup‐

port using engine and

gearbox jack -V.A.G

1383 A- .

4 - Flange

❑ Left side.
❑ With fuel filter
❑ The fuel tank must not

be more than 

1

/2 full

when removing.

5 - Locking ring, 110 Nm

❑ Remove and install us‐

ing wrench -T10202- .

❑ Check for secure seat‐

ing.

6 - Fuel delivery unit

❑ Left side.
❑ Checking fuel pump

⇒ page 107

 .

7 - Fuel gauge sender 3 -

G237-

❑ Left side.
❑ Flat, square float
❑ Clipped into bottom of

tank.

❑ Checking: ⇒ Current

flow diagrams, Electri‐

cal fault finding and Fit‐

ting locations.

8 - Suction-jet pump

❑ Left side.
❑ Clipped into bottom of tank.

9 - Protective cover

❑ For bottom of fuel tank.

10 - Securing strap

❑ Note installation position.
❑ Check for secure seating.

11 - 20 Nm + 

1

/4 turn (90°) further

12 - Protective cover

❑ For top of fuel tank

13 - Suction-jet pump

❑ Right side.
❑ Checking fuel pump 

⇒ page 107

 .

14 - Fuel delivery unit

❑ Right side.

Touareg 2003 ➤

94

⇒ page 107

 .

15 - Fuel gauge sender -G-

❑ Right side.
❑ Round, ball float
❑ Checking: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.

16 - Flange

❑ Right side.
❑ The fuel tank must not be more than 

1

/2 full when removing.

❑ With fuel pressure regulator
❑ With gravity valve
❑ Individual parts 

⇒ page 98

❑ Note installation position on fuel tank 

⇒ page 99

 .

17 - Breather line

❑ Check for secure seating.

18 - Expansion tank
19 - Gravity valve
20 - To pressure retention valve

Touareg 2003 ➤

1. Parts of fuel supply system    

95

Assembly overview - fuel filter

1 - Connection

❑ For breather line.

2 - Flange

❑ Left side.
❑ With fuel filter housing
❑ Note installation posi‐

tion on fuel tank

⇒ page 99

 .

3 - Filter element
4 - Seal

❑ Renew.

5 - Earth wire
6 - 10 Nm
7 - Supply line

❑ To fuel pressure regula‐

tor.

8 - Connection

❑ Filter feed from left fuel

delivery unit

9 - Connection

❑ Filter feed from right fuel

delivery unit

10 - Earth connection
11 - Cap

❑ For filter housing

12 - Locating pin

1.3

Renewing fuel filter

Note

The fuel filter is located in the left opening of fuel tank, as seen

from direction of travel.

Touareg 2003 ➤

96