Fuel Tank, Draining With Faulty Fuel Pump: Procedure

WARNING: This page is about a different car, the 2014 Volkswagen Touareg, 2013 Volkswagen Touareg, 2012 Volkswagen Touareg, and 2011 Volkswagen Touareg. However, it is still accessible from the selected car via links, so may be relevant.

-- Open the fuel filler door.

-- Remove the misfueling guard. Refer to MISFUELING GUARD, REMOVING AND INSTALLING .

NOTE:

The intake hose from the fuel siphoning device could damage the fuel filler neck door. The fuel tank may only be drained via the flange.

When work is performed on the Fuel Level Sensor 2 -G169- or on the suction jet pump. Refer to FUEL TANK, DRAINING WITH FAULTY FUEL PUMP .

When work is performed on the fuel pump or on the Fuel Level Sensor -G-.

-- Remove the right rear seat or rear bench seat. Refer to REAR SEATS, REMOVING AND INSTALLING .

-- Fold the right carpet to the side.

Fig 1: Identifying Locking Flange Cover - Tightening Sequence

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-- Loosen the nuts -1 through 4- on the flange cover.

-- Remove the flange cover.

-- Disconnect the connector -3- from the fuel gauge sensor and the connector -5- from the fuel pump.

Fig 2: Fuel Lines

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-- Remove the fuel return line -1-.

-- Remove the fuel supply line -2- and the fuel line for the parking heater -4-. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

-- Remove the locking ring from the sensor flange using the :T10202 .

Fig 3: Identifying Wrench T10202 In Locking Ring

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-- Carefully lift up the sensor flange.

-- Insert the : VAS5190 suction hose as far as possible into the fuel tank and extract the fuel.

-- To extract the fuel and work on the left side of the fuel tank proceed as follows:

-- Remove the left rear seat or rear bench seat. Refer to REAR SEATS, REMOVING AND INSTALLING .

-- Fold the carpet to the side.

Fig 4: Identifying Locking Flange Cover - Tightening Sequence

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-- Loosen the nuts -1 through 4- on the flange cover.

-- Remove the flange cover.

-- Disconnect the connector -arrow- from the sensor flange.

Fig 5: Connector -Arrow- From The Flange

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-- Remove the locking ring from the sensor flange using the :T10202 .

Fig 6: Identifying Wrench T10202 In Locking Ring

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-- Carefully lift up the sensor flange.

-- If necessary, remove the connector -arrow- for the Fuel Level Sensor 2 -G169- from the flange.

Fig 7: Fuel Level Sensor

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-- Then insert the : VAS5190 suction hose as far as possible into the fuel tank and extract the fuel.

For additional work on components inside of fuel tank, sensor flanges may remain removed.

If fuel tank only needed to be emptied, install sensor flanges again.

-- Replace the seals on the sensor flange if damaged.

-- Insert the flanges in direction of travel -arrow-.

Fig 8: Installed Position of Flange on Fuel Tank

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The tab on the flange -2- must be between the guides -1- and -3- on the fuel tank.

-- Tighten the locking ring to 145 Nm using the :T10202 .

Fig 9: Identifying Wrench T10202 In Locking Ring

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NOTE:

Do not interchange the supply and return lines on the right side. The return line is blue -1- and the supply line is black -2-.

Fig 10: Fuel Lines

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Make sure the connectors and the fuel hoses are secure.