Volkswagen Touareg 2004-06

Removal & Installation

Print

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the fuel tank.
  4.  
  5. Relieve the pressure in the fuel system.
  6.  
  7. Remove the nuts on the right side of the fuel delivery unit cover. If necessary, remove backrest support or mounting bracket (refer to the Fuel Filter procedure).
  8.  
  9. Disconnect the fuel lines, fuel pump electrical plugs and vent line. Press in the securing ring to disengage the fuel lines.
  10.  
  11. Remove the bolts securing the mufflers to the pipes and their mounts. With the aid of an assistant, lower and remove the muffler and mount assemblies from the vehicle.
  12.  
  13. Remove the rear axle housing assembly.
  14.  
  15. Open the fuel filler flap and remove the fuel tank cap. Pull the rubber gasket off the filler neck.
  16.  
  17. Remove the bolts securing the filler neck and pull off ground wire.
  18.  
  19. Remove the right rear wheelhousing liner.
  20.  
  21. Remove the cover plate. Unclip the fuel tank breather lines at the securing clip attached to the longitudinal crossmember.
  22.  
  23. Remove the securing bolts for the filler pipe and EVAP canister.
  24.  
  25. Bend the filler neck slightly downward then label and pull off the breather line connections on the EVAP canister. Release the connection by pressing the button on the hose coupling.
  26.  
  27. Disconnect the ground wire clipped to the EVAP canister and remove the canister.
  28.  
  29. Unplug the connector to the fuel pump on the left near the fuel tank.
  30.  
  31. Remove the left and right securing straps on the fuel tank.
  32.  
  33. Support the fuel tank using a transmission jack. Remove the center securing strap.
  34.  
  35. Carefully lower fuel tank just enough to reach between the fuel tank and vehicle floor and disconnect the vent line from left sensor flange.
  36.  
  37. Lower and remove the fuel tank.
  38.  
  39. Installation is the reverse of removal. Observe the following:

    Connections for the breather and fuel lines must engage audibly when joined.
     
    Make sure the ventilation and fuel lines are not kinked when installed.
     
    Secure the fuel hoses with spring type clamps. Ensure the fuel hoses are seated securely.
     
    The ground strap at the fuel filler tube must be securely connected to the body.
     
    Before securing the fuel tank make sure that the supply and ventilation lines are still clipped onto the fuel tank.
     
    Tighten the securing strap bolts to ft. lbs. (20 Nm), plus an additional 90° turn.
     

  40.  

 
label.common.footer.alt.autozoneLogo