Volkswagen Touareg (2003 year). Manual - part 26

170...180 cm into fuel filler neck and extract fuel.

Note

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

for the flanges to be opened without danger. The tank may be

removed while containing remaining fuel. If work must be per‐

formed on fuel pumps or fuel tank senders, proceed as follows:

– Cut carpet open from point -A- to point -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 .

– Hold a cloth on connections for fuel supply line and auxiliary

heater and pull off hose couplings.

Note

Release connection by pressing button on hose coupling.

– Disconnect connector for fuel pump and fuel tank sender.

– Now remove locking ring from flange using fuel tank sender

unit tool -T10202- .

– Carefully lever out flange and raise it slightly.
– Insert suction hose of fuel extractor -VAS 5190- as deeply as

possible into right and then left side of fuel tank and extract

fuel.

– For work on left side of fuel tank, proceed as described above.

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1. Parts of fuel supply system    

101

sometimes cannot be pressed in. Use assembly tool -T10118-

-arrow- to press in button.

For further work on inside of fuel tank, flanges may remain re‐

moved.
If fuel tank needed only to be emptied, install flanges again.
– First check that flange seals are properly seated.

Note

Always renew seals if the fuel has caused them to swell.

– Insert flange with locating tab facing forwards -arrow-.
– Tighten locking rings on left and right to specified torque using

wrench -T10202- .

1.8

Removing and installing fuel delivery

unit, fuel gauge sender and suction-jet

pumps

Special tools and workshop equipment required
♦ Special wrench -T10202-
Test prerequisites
• Fuel tank must be empty 

⇒ page 100

 .

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

ets.

• Connectors and wires for left and right flanges have been re‐

moved.

• Locking rings for left and right flanges have been unscrewed.
Procedure
– Note safety precautions before beginning work 

⇒ page 99

 .

Touareg 2003 ➤

102

and -4- below right flange.

– Remove flange with pressure regulator.

– Unclip black filler hose -arrow- from fuel delivery unit housing

on left and right sides of fuel tank.

– Detach fuel supply line to suction-jet pumps from fuel delivery

unit -arrow- on left and right sides of fuel tank.

– Unscrew fuel delivery unit in bottom of fuel tank by turning

about 90° to left.

Note

The fuel delivery unit housing is filled with fuel. Fuel may run out

if housing is tipped or canted.

– Now unclip fuel gauge senders on each side of fuel tank and

pull them out.

– Now unclip suction-jet pumps from bottom on each side and

remove with a slight turn.

– Pull out hose ends through left and right sender openings.

Touareg 2003 ➤

1. Parts of fuel supply system    

103

Removing and installing fuel tank with attached components

Special tools and workshop

equipment required
♦ Fuel extractor -VAS 5190-
♦ Special wrench -T10202-
♦ Torque wrench -V.A.G

1331-

♦ Torque wrench -V.A.G

1332-

♦ Engine and gearbox jack -

V.A.G 1383 A-

Prerequisites
• Fuel tank must be empty 

⇒ page 100

 .

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

ets.

Removing
– Note safety precautions before beginning work 

⇒ page 99

 .

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.

First, reduce the fuel pressure as follows:
– Wrap a cloth around the joint to catch fuel which flows out.

Touareg 2003 ➤

104