Volkswagen Touareg (2003 year). Manual — part 24
1
Parts of 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.
Note
♦
Hose connections are secured with couplings or spring-type
or clamp-type clips.
♦
Always renew clamp-type clips with spring-type clips.
♦
Fuel hoses on engine must be secured with spring-type clips
only. The use of clamp or screw-type clips is not permissible.
♦
Spring-type clip pliers -VAS 6340- or spring-type clip pliers -
VAS 5024 A- are recommended for installation of spring-type
clips.
.
Observe rules for cleanliness
Assembly overview - fuel tank with attachments
Assembly overview - fuel filter
Schematic diagram of fuel lines and components in fuel tank
.
Removing and installing fuel delivery unit, fuel gauge sender and
Removing and installing fuel tank with attachments
Checking fuel pumps
Touareg 2003 ➤
1. Parts of fuel supply system
93
Assembly overview - fuel tank with attachments
1 - Fuel filler neck
2 - To activated charcoal filter.
3 - Fuel tank
❑ When removing, sup‐
port using engine and
gearbox jack -V.A.G
1383 A- .
4 - Flange
❑ Left side.
❑ With fuel filter
❑ The fuel tank must not
be more than
1
/2 full
when removing.
5 - Locking ring, 110 Nm
❑ Remove and install us‐
ing wrench -T10202- .
❑ Check for secure seat‐
ing.
6 - Fuel delivery unit
❑ Left side.
❑ Checking fuel pump
7 - Fuel gauge sender 3 -
G237-
❑ Left side.
❑ Flat, square float
❑ Clipped into bottom of
tank.
❑ Checking: ⇒ Current
flow diagrams, Electri‐
cal fault finding and Fit‐
ting locations.
8 - Suction-jet pump
❑ Left side.
❑ Clipped into bottom of tank.
9 - Protective cover
❑ For bottom of fuel tank.
10 - Securing strap
❑ Note installation position.
❑ Check for secure seating.
11 - 20 Nm +
1
/4 turn (90°) further
12 - Protective cover
❑ For top of fuel tank
13 - Suction-jet pump
❑ Right side.
❑ Checking fuel pump
.
14 - Fuel delivery unit
❑ Right side.
Touareg 2003 ➤
94
15 - Fuel gauge sender -G-
❑ Right side.
❑ Round, ball float
❑ Checking: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.
16 - Flange
❑ Right side.
❑ The fuel tank must not be more than
1
/2 full when removing.
❑ With fuel pressure regulator
❑ With gravity valve
❑ Individual parts
❑ Note installation position on fuel tank
.
17 - Breather line
❑ Check for secure seating.
18 - Expansion tank
19 - Gravity valve
20 - To pressure retention valve
Touareg 2003 ➤
1. Parts of fuel supply system
95
Assembly overview - fuel filter
1 - Connection
❑ For breather line.
2 - Flange
❑ Left side.
❑ With fuel filter housing
❑ Note installation posi‐
tion on fuel tank
.
3 - Filter element
4 - Seal
❑ Renew.
5 - Earth wire
6 - 10 Nm
7 - Supply line
❑ To fuel pressure regula‐
tor.
8 - Connection
❑ Filter feed from left fuel
delivery unit
9 - Connection
❑ Filter feed from right fuel
delivery unit
10 - Earth connection
11 - Cap
❑ For filter housing
12 - Locating pin
1.3
Renewing fuel filter
Note
The fuel filter is located in the left opening of fuel tank, as seen
from direction of travel.
Touareg 2003 ➤
96
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