2002-2010 Volkswagen Touareg SUV Fuel supply system -> 1.9 Removing and installing fuel tank with attached components User Manual
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Fuel supply system -> 1.9 Removing and installing fuel tank with attached components for Your Volkswagen Touareg SUV First Generation (2002-2010)

Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
1.9  
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.  
104  
Rep. gr.20 - Fuel supply system  
lk  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
– Disconnect fuel supply line -arrow- in engine compartment.  
Once the fuel pressure has been reduced:  
– Remove silencers and mountings .  
– Remove rear propshaft tube ⇒ Transfer box and final drive;  
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.  
1. Parts of fuel supply system  
105  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
– Remove securing bolts for filler neck -1- and activated char‐  
coal filter -2- in wheel housing.  
lk  
– 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:  
106  
Rep. gr.20 - Fuel supply system  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
♦ Connections for breather and fuel lines must engage audibly  
lk  
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  
1. Parts of fuel supply system  
107  

Related Topics

Fuel supply system
1 Parts of fuel supply system 1.1 Assembly overview - fuel tank with attachments 1.2 Assembly overview - fuel filter 1.3 Renewing fuel filter 1.4 Schematic diagram of fuel lines and components in fuel tank 1.5 Safety precautions when working on fuel supply system 1.6 Rules for cleanliness 1.7 Emptying fuel tank 1.8 Removing and installing fuel delivery unit, fuel gauge sender and suction-jet pumps 1.10 Checking fuel pumps 1.11 Checking delivery rate of pumps 1.12 Checking non-return valve of right pump 1.13 Checking non-return valve of left pump 2 Electronic power control (EPC) 3 Activated charcoal filter system 3.1 Assembly overview - activated charcoal filter system 3.2 Checking fuel system for leaks 4 Activated charcoal filter system (vehicles for USA and Canada) 4.1 Assembly overview - activated charcoal filter system 4.2 Checking fuel system for leaks

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