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.
Touareg 2003 ➤
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
• 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
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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
• Fuses -13- and -14- -arrow- must be removed from their sock‐
ets.
Removing
– Note safety precautions before beginning work
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.
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