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.
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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:
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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
Checking current draw of pumps
Checking non-return valve of right pump
Checking non-return valve of left pump
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
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107
Checking delivery rate of pumps
Checking delivery rate of right pump
Checking delivery rate of left pump
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
– 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.
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