Volkswagen Touareg (2003 year). Manual - part 25

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 , Emptying fuel tank.

• Fuses -13- and -14- -arrow- must be removed from their sock‐

ets.

Procedure

WARNING

Fuel supply lines are under pressure! Wear eye protection and

gloves  to  avoid  injuries  and  skin  contact.  Before  loosening

hose connections, wrap a cloth around the connection. Then

release pressure by carefully pulling hose off connection.

Observe safety precautions 

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 .

Observe rules for cleanliness 

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 .

– Cut open carpet on left side from point -A- to -B- in the pre-cut

area -arrows-.

– Remove nuts -1- from cover. If necessary, unscrew backrest

mounting -2- or support mounting ⇒  General body repairs,

interior; Rep. gr.  72 ; Rear seats .

– Unscrew locking ring from left flange using wrench -T10202- .
– Completely remove flange on left side of tank.
– Empty fuel filter housing.

– Mark installation position of filter cover -2- using coloured felt

tip marker pen.

– Pull off earth wire -1- and unscrew filter cover -arrows- from

housing.

If filter element is changed, ensure that earth connection contacts

are not bent and have sufficient preloading.

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1.4

Schematic diagram of fuel lines and

components in fuel tank

-A- left side of fuel tank
-Arrow- points in direction of travel
-B- Right side of tank

1 - Gravity valve

❑ Left side.

2 - Flange

❑ Left side.

3 - Fuel filter
4 - Gravity valve

❑ Right side.

5 - Supply line

❑ To fuel rail.

6 - Supply line for auxiliary

heater
7 - Flange

❑ Right side.

8 - Fuel pressure regulator
9 - Return line

❑ From fuel pressure reg‐

ulator

❑ To fuel delivery unit on

left and right sides

10 - Supply line for suction-jet

pumps
11 - Fuel delivery unit

❑ Right side.

12 - Suction-jet pump

❑ Right side.

13 - Delivery line

❑ Black
❑ To fuel delivery unit on

left side.

14 - Delivery line

❑ Black

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15 - Suction-jet pump

❑ Left side.

16 - Fuel delivery unit

❑ Left side.

Installation position of fuel delivery unit flange
Insert left or right flange with marking -arrow- in direction of travel.

1.5

Safety precautions when working on

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.

♦ For safety reasons, fuse nos. -13- and -14- -arrows- must be

removed from the fuse holder before opening the fuel system.

Otherwise, the fuel pump could be activated by the driver's

door contact switch.

♦ Fuse nos. 13 and 14 are located in the E-box fuse holder in

the left plenum chamber.

When removing and installing fuel gauge sender or fuel pump

(fuel delivery unit) from a full or partly full fuel tank, observe the

following:
♦ Even before work commences, the extraction hose of an ac‐

tivated fume extraction system has to be placed in the vicinity

of the assembly opening of the fuel tank to trap any escaping

fumes. If no exhaust gas extraction system is available, a ra‐

dial fan with a displacement greater than 15 m

3

/h can be used

providing that motor is not in air flow.

♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!

1.6

Rules for cleanliness

When working on the fuel supply and injection system, pay careful

attention to the following „5 rules“ for cleanliness:

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connecting.

♦ Place removed parts on a clean surface and cover. Use only

lint-free cloths.

♦ Carefully cover opened components or seal if repairs cannot

be carried out immediately.

♦ Install clean components only. Do not remove replacement

parts from packing until immediately before installing. Do not

use parts that have not been stored in their packing (e.g. in

tool boxes etc.).

♦ When system is open: do not work with compressed air if this

can be avoided. Do not move vehicle unless absolutely nec‐

essary.

1.7

Emptying fuel tank

Special tools and workshop equipment required
♦ Fuel extractor -VAS 5190-

♦ Special wrench -T10202-

WARNING

Fuel supply lines are under pressure! Wear eye protection and

gloves  to  avoid  injuries  and  skin  contact.  Before  loosening

hose connections, wrap a cloth around the connection. Then

release pressure by carefully pulling hose off connection.

Procedure
– Note safety precautions before beginning work 

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– Open fuel tank filler flap.

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