Volkswagen Touareg (2003 year). Manual - part 27

Rep. gr.  39 ; Removing and installing propshaft .

– Remove rear axle ⇒  Running gear, axles, steering; Rep. gr. 

42 ; Repairing rear axle; Removing and installing rear axle .

– Open fuel flap and remove fuel tank cap.
– Pull rubber gasket off filler neck.

– Remove securing bolts -1- on filler neck and pull off earth wire

-2-.

– Remove rear right wheel housing liner: ⇒  General body re‐

pairs, exterior; Rep. gr.  66 ; Removing and installing wheel

housing liner .

– Unbolt cover plate -arrows-.

– Fuel tank breather lines are attached to longitudinal member.

Unclip them at securing clip.

Touareg 2003 ➤

1. Parts of fuel supply system    

105

coal filter -2- in wheel housing.

– Now bend filler neck slightly downwards and pull off breather

line connections to activated charcoal filter.

Note

Release connection by pressing button on hose coupling.

– Pull off earth wire clipped to activated charcoal filter and re‐

move activated charcoal filter.

– Disconnect connector to fuel pumps on left next to fuel tank.
– Now remove securing straps to left and right with cover below

fuel tank.

– Support fuel tank using engine and gearbox jack -V.A.G 1383

A- and remove securing strap at middle of fuel tank.

– Carefully lower fuel tank about 30 cm.

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.

– Reach through between fuel tank and vehicle floor and hold a

cloth above fuel supply hose. Now disconnect fuel supply line

and breather line from flange.

Note

This step saves cutting carpet in vehicle interior in vicinity of

flange cover.

– Lower fuel tank.
Installing
Installation is carried out in the reverse order. When installing,

note the following:

Touareg 2003 ➤

106

when joined.

♦ Install breather and fuel hoses free of kinks.
♦ Secure fuel hoses with spring-type clips.
♦ Ensure that fuel hose connections are tight.
♦ Ensure earth cable -2- is secured tight to body.

Note

Before bolting on fuel tank, check that supply and breather lines

are still clipped onto fuel tank.

1.10

Checking fuel pumps

Checking delivery rate of pumps 

⇒ page 108

Checking current draw of pumps 

⇒ page 109

 .

Checking non-return valve of right pump 

⇒ page 111

Checking non-return valve of left pump 

⇒ page 113

Special tools and workshop

equipment required
♦ Diesel extractor -VAS

5226-

♦ Pressure gauge -V.A.G

1318-

♦ Adapter -V.A.G 1318/9-
♦ Adapter -V.A.G 1318/10-
♦ Adapter -V.A.G 1318/24-
♦ Remote control for V.A.G

1348 -V.A.G 1348/3 A-

♦ Multimeter -V.A.G 1715- or

hand-held multimeter -

V.A.G 1526D- with pickup

clamp -V.A.G 1526B/2-

♦ Spring-type clip pliers -VAS

5024 A-

♦ Current flow diagram
♦ Measuring container

Touareg 2003 ➤

1. Parts of fuel supply system    

107

Checking delivery rate of pumps

Checking delivery rate of right pump 

⇒ page 109

Checking delivery rate of left pump 

⇒ page 109

Test prerequisites

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

ets.

• Battery voltage at least 11.5 V
• Fuel pump relays -1- for right fuel delivery unit and -2- for left

fuel delivery unit must be removed from their sockets.

Test procedure
– Note safety precautions before beginning work 

⇒ page 99

 .

– Remove filler cap from fuel tank filler neck.
– First, reduce the fuel pressure as follows:

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.

– Wrap a cloth around the joint to catch fuel which flows out and

disconnect fuel supply line -arrow-.

Once the fuel pressure has been reduced:
– Retighten threaded connection.

Touareg 2003 ➤

108