I am having the very same problem...I had to drive the car the very same way you did to the dealership who says the primary fuel pump is bad and is quoting $900 for it and $1700 for both pumps. I also noticed something like wax under the car after driving to the dealership. Has anybody done theirs by themselves? It would really help if anyone has a DIY pictures on how to change the Left Fuel pump.
Thanks

 

The pumps are located under the rear seats. Fold them forward and look at the carpet. There are perforated - cut the carpet. Use a brass punch to gain access to the pumps. It's best to have the fuel tank as low as possible. You will have to access both side pumps to connect and disconnect them.

 

Thanks a mil - Goelie! can you point me to a manual or something. It will be my first time working on my car.I will go to www.loweringmodules.com to see if I can find something. I beleive I can order the Fuel pump from the dealer...right...or should I get it from somewhere else? Do I need any special tools?
thanks

 

You can order the pump(s) from racepages.com.. I did and save whole lot.. dealer will charge you at least $700 for both of them. I got both for $400 with overnight delivery.. use "rpcart" for additional 10% off.
Race Pages - 2004 Volkswagen Touareg Fuel Pump Stock Replacement

New, before you do anything.. check the wire harness that connects to the pumps, make sure you are getting at least 11.5V power to them. At this point im only getting 1.5 reason why the pumps are turning on and the car does not start. I checked all the fuses and swapped all the relays but all seem fine.... anyone has another idea what to check for next?

Also... Check your filter, mine looked so filthy im even surprised the car ran this long.. only problem is that the filters are not sold separately so you will need to get aa new sending unit which will have the filter in it.. just ordered mine from reacepages for around $100 with overnight delivery vs. VW $220.
Race Pages - 2004 Volkswagen Touareg Fuel Filter Stock Replacement

 

Thanks. This sounds very helpful. Do I need any special tools to change the fuel pump?

Racepages seems to be a great site for Tregs.

Thanks

 

No special tools needed. Once you cut the carpet and remove the aluminum covers you just need to pry off metal flange to remove the sending units, I just used a flat head screw driver and a hammer... tap on it easy you will see it spin counter clockwise. The most complicated part is connecting all the gas lines. I removed both pumps first then tried to install both the next day. I would reccomend changing one at a time, this way you have all the correcting lines in front of you, you will see what I mean once you get there.

Check first if you get 11.5v out to the pumps.

 

BTW you can get just the filter replacement for about $7.00 from Wix. Check with NAPA. VW sells the entire assembly only.

Also do what axalott says. It is crazy how many lines there are .... I actually labeled them so I knew where they went.

 

Here's what they will look like: http://www.clubtouareg.com/forums/f62/no-throttle-cruising-on-highway-40448-2.html

 

Wow.. wish I new about the filter, searched all over the web but nothing on the filter itself.. at this point I ordered the entire unit but they way the old one looked im definitelly going to change it again in 40k miles... that's if I ever get the car started.

Do you guys know if maybe by pulling the fuse #13 and 14 as well as the two fuel pump relays I may have triggered the ECU to shut off? Im only getting 1.5V on the pumps wire harness. At the relay I do get 12V but it seems that the ground is shut off.. any ideas?

 

Goalie - thanks a bunch for the pictures...helps to see what to expect.

 

Well folks, I FINALLY got my baby back. After changing the left side sending unit, which contains the fuel filter, pulling all the fuses and relays out of the fuse box located under the hood and holding the gas pedal down for 30 seconds with the engine off... She started right up.

As a recommendation for those of you that experience the 30 second shut off problem, I would not assume that the pumps are the issue right away, I know that all over these forums people are talking about this issue while ended up with the dealer changing the pumps and problem solved. In my case I think the issue was the left side sending unit and the filter. I never imagined the filter would be so badly clogged especially if using nothing but 93 rated gasoline. Maybe the fuel system's pressure regulator wasn't getting enough fuel because of the filter and shut off after 30 seconds, those of you that may know more about this please shed some light.

So.. if you experience this, I would start with the easy and most inexpensive things first which in this case is the fuel filter or the entire sending unit, if you cannot find the filter itself. You will need to change the filter anyway so for $89 I would replace the entire unit. Plug everything back in and try starting the car. If you still experience the 30 seconds issue then move forward with changing the pumps. Change them one at a time and label all the fuel lines so you have a easier time figuring what goes where.

Now, the reason I'm saying to start with the sending unit/filter is that when I stopped at the dealer to pick up the rubber gaskets for the units the VW mechanic gave me a hint. He said that the reason they do not stock the pumps is that the rarely and almost never break down. I called another dealer and all they stock is the fuel filter units, not the pumps. These pumps are expensive and changing them is a nasty job so why do it if you don't have to? Since I already changed mine and im at the 100k mark I guess having new pumps and new unit and filter it's not a bad thing but if I would have to do it again I would not change the fuel pumps if I didn't have to.

Bokilo... if you didn't order the pumps yet or you did don’t change them try the filter first and see what happens. You can always return the parts.

Keep us posted, curios what is the issue with yours.

 

Axalott - thanks a mil for this very detailed and helpful guide from you. I believe experience and frankness are the best ways to help others. Since the dealership quoted $900 to replace just the left pump, I towed the car to my home. I am about to other the parts: pump and filter and will do as you say. I will keep you and the others updated as I go. My 2005 V8 treg has 69k so the filter is definitely ready to be changed.
Cheers

 

did you guys have issues with installing back the sending unit and retaining clip? i cant seem to get the clip level to lock in.

 

Unless you got the wrong part it should fit like a glove, compare it with the old one and make sure its the same. Also, the rubber gasket should go in the frame not on the unit, make sure its not being pinched.

 

i will try that, I have the gasket on the unit. So pull the rubber gasket off and put it on the unit first.

 

Thanks axalott!

you were right, the gasket goes on the frame and not the unit.

Thanks you!!

 

Hello, I have a 2004 Touareg V-6 with 99k- The engine starts with no problems, but approximately 15-20 seconds later it shut off. It feels like the engine is not getting fuel. When I open the door I do hear the fuel pump humming. I called VW and they suggested that the chip in the key may have decoded which they said actives the anti-theft. I Tried both keys to not avail. June 2010 I had a new fuel tank flange gasket installed installed. I dont recall if the fuel fuel has ever benn changed. Any suggestions? PS Have never worked on this vehicle myself.

 

I had the same problem, twice. The first time, I thought it was bad gas. This is what happened. I bought gas from a strange gas station and drove about 10miles to work. Parked the car and after 8hrs I started the car and it would start for 10-15 secs and then stops. Believing it was bad gas...I decided to burn it off....so I kept pushing it. Eventually after 30 minutes the car started driving normally. After about a month or so I filled up again at Sam's club and boom...it started again. So I got it toed to the dealership who "kaching" $140 for diagnostics and after 3 days said the Primary (driver's side)was bad...another $900. I read around and made calls to other recommended workshops and they said it was the secondary one and would cost $400 including labor. I toed the car from dealership and got thing replaced myself.

Come to think of it...the car starts...so it can only be the secondary filter. Also it is easy to replace. Took about 1hr. The part is about $243.

 

Thanks, Beside the filter, what else would i need to change (gaskets, hose clips etc)?

 

I did not change anything else. It is under the rear seat. You would just have to cut open the carpet (and there is provision for the cut...so don't feel like you are destroying the carpet). You just have to ensure that you label the tubes before unplugging them. I believe Axalott mentioned this too. It was very helpful for me. I was a little apprehensive going into it...but it was easy as soon as I could see the filter. make sure there is enough air circulation cos the fumes are strong.
I still have the part and when I have time, I will send it in for analysis...I would like to know what went wrong with it.

 

Change the rubber gaskets that go on the frame before installing the units as well, they play a big part in the epap system from what I'm told. But yeah, do it youself, its not a bad job and you fill save big$$. Let us know how all goes.

 

Is that rubber gasket a dealer item only?

 

Im not sure if you can find the gasket elsewhere, I guess depends where are you located but you can try pepboys, autozone or advance auto. In PA most of these don't carry many of the parts so I usually purchase everything I need online but these gaskets should only cost <$5 each so you can pick up from the dealer.

 

Well once again Im back with this issues... Do anyone have picture of how-to or youtube video. I need it done before it get cold in jersey lol. No Garage

 

I don't have any pictures maybe someone else does but the whole process is fairly easy, just need the patience.