Removing and installing fuel gauge sender and suction-jet pumps — VW

🧭 Before you start

Fits: VW Touareg I (7L, 2002–2010)

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• Press in securing ring to release fuel line.

🔧 Engine codes this applies to

📋 Procedure

1. Note safety precautions before beginning work .
2. Observe rules for cleanliness .
3. Remove flange with fuel filter on left side of the fuel tank , Renewing fuel filter.
4. Now unclip fuel gauge sender and pull it out.
5. Fold rear bench seat forwards. On vehicles from 12.2006 the rear bench seat must be removed General body repairs, interior72Removing and installing bench seat (week 48, 2006►).

6. Cut open carpet on right side from point (A) to (B) in the pre-cut area (arrows), if necessary.
7. On right side remove nuts (1) from cover of fuel delivery unit. If necessary, unscrew backrest mounting (2) or support mounting General body repairs, interior72Rear seats.
8. ⚠ 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. — Pull off fuel supply line (1), fuel line for auxiliary heater (2), connector for fuel pump (3), breather line (4) and connector for fuel pump control unit J538(5). [Note: Press in securing ring to release fuel line.]
9. Now remove locking ring from sender flange using wrench T10202.
10. Lift sender flange.
11. Pull fuel pump connector (1) off flange.
12. Pull fuel gauge sender connector (2) off flange.
13. Disconnect fuel supply line (3) from sender flange. [Note: Press in securing ring to release fuel line.]
14. Unclip black supply/filler hose (1) from fuel delivery unit housing.
15. Disconnect fuel supply line (2) from suction-jet pumps. [Note: Press in securing ring to release fuel line.]
16. Now unclip suction-jet pumps on left side of fuel tank.

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