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2002-2010 Volkswagen Touareg SUV Fuel supply system User Manual

MY CAR USER MANUAL

Fuel supply system for Your Volkswagen Touareg SUV First Generation (2002-2010)

Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
20 – Fuel supply system  
1
Parts of fuel supply system  
Caution  
When doing any repair work, especially in the engine compart‐  
ment, pay attention to the following due to the cramped condi‐  
tions:  
lk  
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐  
vated charcoal filter system, coolant, refrigerant, brake  
fluid and vacuum) and electrical wiring in their original po‐  
sitions.  
♦ To avoid damage to lines, ensure sufficient clearance to  
all moving or hot components.  
Note  
♦ Hose connections are secured with couplings or spring-type  
or clamp-type clips.  
♦ Always renew clamp-type clips with spring-type clips.  
♦ Fuel hoses on engine must be secured with spring-type clips  
only. The use of clamp or screw-type clips is not permissible.  
♦ Spring-type clip pliers -VAS 6340- or spring-type clip pliers -  
VAS 5024 A- are recommended for installation of spring-type  
clips.  
Observe safety precautions ⇒ page 99 .  
Observe rules for cleanliness ⇒ page 99 .  
Assembly overview - fuel tank with attachments ⇒ page 94 .  
Assembly overview - fuel filter ⇒ page 96 .  
Renewing fuel filter ⇒ page 96  
Schematic diagram of fuel lines and components in fuel tank  
⇒ page 98 .  
Draining fuel tank ⇒ page 100  
Removing and installing fuel delivery unit, fuel gauge sender and  
suction-jet pumps ⇒ page 102  
Removing and installing fuel tank with attachments  
⇒ page 104 .  
Checking fuel pumps ⇒ page 107  
1. Parts of fuel supply system  
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Touareg 2003 ➤  
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1.1  
Assembly overview - fuel tank with attachments  
1 - Fuel filler neck  
2 - To activated charcoal filter.  
3 - Fuel tank  
❑ When removing, sup‐  
port using engine and  
gearbox jack -V.A.G  
1383 A- .  
4 - Flange  
❑ Left side.  
❑ With fuel filter  
❑ The fuel tank must not  
1
be more than / full  
2
when removing.  
5 - Locking ring, 110 Nm  
❑ Remove and install us‐  
ing wrench -T10202- .  
❑ Check for secure seat‐  
ing.  
6 - Fuel delivery unit  
❑ Left side.  
❑ Checking fuel pump  
⇒ page 107 .  
7 - Fuel gauge sender 3 -  
G237-  
❑ Left side.  
❑ Flat, square float  
❑ Clipped into bottom of  
tank.  
❑ Checking: ⇒ Current  
flow diagrams, Electri‐  
cal fault finding and Fit‐  
ting locations.  
8 - Suction-jet pump  
❑ Left side.  
❑ Clipped into bottom of tank.  
9 - Protective cover  
❑ For bottom of fuel tank.  
10 - Securing strap  
❑ Note installation position.  
❑ Check for secure seating.  
1
11 - 20 Nm + / turn (90°) further  
4
12 - Protective cover  
❑ For top of fuel tank  
13 - Suction-jet pump  
❑ Right side.  
❑ Checking fuel pump ⇒ page 107 .  
14 - Fuel delivery unit  
❑ Right side.  
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Rep. gr.20 - Fuel supply system  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
❑ Checking fuel pump ⇒ page 107 .  
15 - Fuel gauge sender -G-  
❑ Right side.  
❑ Round, ball float  
❑ Checking: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.  
16 - Flange  
❑ Right side.  
1
❑
The fuel tank must not be more than / full when removing.  
2
❑ With fuel pressure regulator  
❑ With gravity valve  
❑ Individual parts ⇒ page 98  
❑ Note installation position on fuel tank ⇒ page 99 .  
lk  
17 - Breather line  
❑ Check for secure seating.  
18 - Expansion tank  
19 - Gravity valve  
20 - To pressure retention valve  
1. Parts of fuel supply system  
95  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
1.2  
Assembly overview - fuel filter  
1 - Connection  
❑ For breather line.  
2 - Flange  
❑ Left side.  
❑ With fuel filter housing  
❑ Note installation posi‐  
tion on fuel tank  
⇒ page 99 .  
3 - Filter element  
4 - Seal  
❑ Renew.  
5 - Earth wire  
6 - 10 Nm  
7 - Supply line  
❑ To fuel pressure regula‐  
tor.  
8 - Connection  
❑ Filter feed from left fuel  
delivery unit  
9 - Connection  
❑ Filter feed from right fuel  
delivery unit  
10 - Earth connection  
11 - Cap  
❑ For filter housing  
12 - Locating pin  
1.3  
Renewing fuel filter  
Note  
The fuel filter is located in the left opening of fuel tank, as seen  
from direction of travel.  
96  
Rep. gr.20 - Fuel supply system  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
Prerequisites  
•
•
Fuel tank must be emptied ⇒ page 100 , Emptying fuel tank.  
Fuses -13- and -14- -arrow- must be removed from their sock‐  
ets.  
Procedure  
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.  
Observe safety precautions ⇒ page 99 .  
Observe rules for cleanliness ⇒ page 99 .  
lk  
– Cut open carpet on left side from point -A- to -B- in the pre-cut  
area -arrows-.  
– Remove nuts -1- from cover. If necessary, unscrew backrest  
mounting -2- or support mounting ⇒ General body repairs,  
interior; Rep. gr. 72 ; Rear seats .  
– Unscrew locking ring from left flange using wrench -T10202- .  
– Completely remove flange on left side of tank.  
– Empty fuel filter housing.  
– Mark installation position of filter cover -2- using coloured felt  
tip marker pen.  
– Pull off earth wire -1- and unscrew filter cover -arrows- from  
housing.  
If filter element is changed, ensure that earth connection contacts  
are not bent and have sufficient preloading.  
1. Parts of fuel supply system  
97  
Touareg 2003 ➤  
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Individual parts of flange, right side  
1 - Connectors for fuel pump and fuel gauge sender  
2 - Fuel pressure regulator (4 bar)  
3 - Earth wire  
4 - Pressure regulator inlet (from fuel filter)  
5 - Connection to left and right fuel delivery units (no pressure)  
6 - Gravity valve  
1.4  
Schematic diagram of fuel lines and  
components in fuel tank  
-A- left side of fuel tank  
-Arrow- points in direction of travel  
-B- Right side of tank  
1 - Gravity valve  
❑ Left side.  
2 - Flange  
❑ Left side.  
3 - Fuel filter  
4 - Gravity valve  
❑ Right side.  
5 - Supply line  
❑ To fuel rail.  
6 - Supply line for auxiliary  
heater  
7 - Flange  
❑ Right side.  
8 - Fuel pressure regulator  
9 - Return line  
❑ From fuel pressure reg‐  
ulator  
❑ To fuel delivery unit on  
left and right sides  
10 - Supply line for suction-jet  
pumps  
11 - Fuel delivery unit  
❑ Right side.  
12 - Suction-jet pump  
❑ Right side.  
13 - Delivery line  
❑ Black  
❑ To fuel delivery unit on  
left side.  
14 - Delivery line  
❑ Black  
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Rep. gr.20 - Fuel supply system  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
❑ To fuel delivery unit on right side  
15 - Suction-jet pump  
lk  
❑ Left side.  
16 - Fuel delivery unit  
❑ Left side.  
Installation position of fuel delivery unit flange  
Insert left or right flange with marking -arrow- in direction of travel.  
1.5  
Safety precautions when working on  
fuel supply system  
Caution  
When doing any repair work, especially in the engine compart‐  
ment, pay attention to the following due to the cramped condi‐  
tions:  
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐  
vated charcoal filter system, coolant, refrigerant, brake  
fluid and vacuum) and electrical wiring in their original po‐  
sitions.  
♦ To avoid damage to lines, ensure sufficient clearance to  
all moving or hot components.  
♦ For safety reasons, fuse nos. -13- and -14- -arrows- must be  
removed from the fuse holder before opening the fuel system.  
Otherwise, the fuel pump could be activated by the driver's  
door contact switch.  
♦ Fuse nos. 13 and 14 are located in the E-box fuse holder in  
the left plenum chamber.  
When removing and installing fuel gauge sender or fuel pump  
(fuel delivery unit) from a full or partly full fuel tank, observe the  
following:  
♦ Even before work commences, the extraction hose of an ac‐  
tivated fume extraction system has to be placed in the vicinity  
of the assembly opening of the fuel tank to trap any escaping  
fumes. If no exhaust gas extraction system is available, a ra‐  
3
dial fan with a displacement greater than 15 m /h can be used  
providing that motor is not in air flow.  
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!  
1.6  
Rules for cleanliness  
When working on the fuel supply and injection system, pay careful  
attention to the following „5 rules“ for cleanliness:  
1. Parts of fuel supply system  
99  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
♦ Thoroughly clean all unions and surrounding areas before dis‐  
connecting.  
♦ Place removed parts on a clean surface and cover. Use only  
lint-free cloths.  
♦ Carefully cover opened components or seal if repairs cannot  
be carried out immediately.  
♦ Install clean components only. Do not remove replacement  
parts from packing until immediately before installing. Do not  
use parts that have not been stored in their packing (e.g. in  
tool boxes etc.).  
♦ When system is open: do not work with compressed air if this  
can be avoided. Do not move vehicle unless absolutely nec‐  
essary.  
1.7  
Emptying fuel tank  
Special tools and workshop equipment required  
lk  
♦ Fuel extractor -VAS 5190-  
♦ Special wrench -T10202-  
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.  
Procedure  
– Note safety precautions before beginning work ⇒ page 99 .  
– Open fuel tank filler flap.  
100  
Rep. gr.20 - Fuel supply system  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
– Push suction hose -arrow- of fuel extractor -VAS 5190- about  
170...180 cm into fuel filler neck and extract fuel.  
Note  
When no more fuel is extracted, the tank is emptied just enough  
for the flanges to be opened without danger. The tank may be  
removed while containing remaining fuel. If work must be per‐  
formed on fuel pumps or fuel tank senders, proceed as follows:  
– Cut carpet open from point -A- to point -B- in the pre-cut area  
-arrows-.  
– Remove nuts -1- from cover. If necessary, unscrew backrest  
mounting -2- or support mounting ⇒ General body repairs,  
interior; Rep. gr. 72 ; Rear seats .  
– Hold a cloth on connections for fuel supply line and auxiliary  
heater and pull off hose couplings.  
Note  
Release connection by pressing button on hose coupling.  
– Disconnect connector for fuel pump and fuel tank sender.  
– Now remove locking ring from flange using fuel tank sender  
unit tool -T10202- .  
– Carefully lever out flange and raise it slightly.  
– Insert suction hose of fuel extractor -VAS 5190- as deeply as  
possible into right and then left side of fuel tank and extract  
fuel.  
– For work on left side of fuel tank, proceed as described above.  
1. Parts of fuel supply system  
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Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
– When breather lines are pulled off, buttons of hose couplings  
sometimes cannot be pressed in. Use assembly tool -T10118-  
-arrow- to press in button.  
For further work on inside of fuel tank, flanges may remain re‐  
moved.  
If fuel tank needed only to be emptied, install flanges again.  
– First check that flange seals are properly seated.  
Note  
Always renew seals if the fuel has caused them to swell.  
– Insert flange with locating tab facing forwards -arrow-.  
– Tighten locking rings on left and right to specified torque using  
wrench -T10202- .  
lk  
1.8  
Removing and installing fuel delivery  
unit, fuel gauge sender and suction-jet  
pumps  
Special tools and workshop equipment required  
♦ Special wrench -T10202-  
Test prerequisites  
•
•
Fuel tank must be empty ⇒ page 100 .  
Fuses -13- and -14- -arrow- must be removed from their sock‐  
ets.  
•
Connectors and wires for left and right flanges have been re‐  
moved.  
•
Locking rings for left and right flanges have been unscrewed.  
Procedure  
– Note safety precautions before beginning work ⇒ page 99 .  
102  
Rep. gr.20 - Fuel supply system  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
– Pull off connectors -1- and -2- as well as hose couplings -3-  
and -4- below right flange.  
– Remove flange with pressure regulator.  
– Unclip black filler hose -arrow- from fuel delivery unit housing  
on left and right sides of fuel tank.  
lk  
– Detach fuel supply line to suction-jet pumps from fuel delivery  
unit -arrow- on left and right sides of fuel tank.  
– Unscrew fuel delivery unit in bottom of fuel tank by turning  
about 90° to left.  
Note  
The fuel delivery unit housing is filled with fuel. Fuel may run out  
if housing is tipped or canted.  
– Now unclip fuel gauge senders on each side of fuel tank and  
pull them out.  
– Now unclip suction-jet pumps from bottom on each side and  
remove with a slight turn.  
– Pull out hose ends through left and right sender openings.  
1. Parts of fuel supply system  
103  
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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 ➤  
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– 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  
Touareg 2003 ➤  
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1.11  
Checking delivery rate of pumps  
Checking delivery rate of right pump ⇒ page 109  
Checking delivery rate of left pump ⇒ page 109  
Test prerequisites  
•
Fuses -13- and -14- -arrow- must be removed from theirlksock‐  
ets.  
•
•
Battery voltage at least 11.5 V  
Fuel pump relays -1- for right fuel delivery unit and -2- for left  
fuel delivery unit must be removed from their sockets.  
Test procedure  
– Note safety precautions before beginning work ⇒ page 99 .  
– Remove filler cap from fuel tank filler neck.  
– First, reduce the fuel pressure as follows:  
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.  
– Wrap a cloth around the joint to catch fuel which flows out and  
disconnect fuel supply line -arrow-.  
Once the fuel pressure has been reduced:  
– Retighten threaded connection.  
108  
Rep. gr.20 - Fuel supply system  
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8-cylinder injection engine - Edition 11.2011  
1.11.1  
Checking delivery quantity of right pump  
– Connect remote control -V.A.G 1348/3 A- with adapter cable  
- Phaeton -V.A.G 1348/3-3- to connection -arrow- of fuel pump  
relay for right fuel delivery unit.  
– Connect positive terminal of remote control to positive pole in  
engine compartment.  
lk  
– Disconnect fuel supply hose -1- from fuel rail.  
– Hold hose in measuring container -2- with minimum capacity  
3
of 1000 cm .  
– Empty measuring container before making measurement.  
3
–
Operate remote control for 15 seconds. At least 800 cm fuel  
per 15 seconds must be delivered.  
1.11.2  
Checking delivery quantity of left pump  
– Connect remote control -V.A.G 1348/3 A- with adapter cable  
- Phaeton -V.A.G 1348/3-3- to connection -arrow- of fuel pump  
relay for left fuel delivery unit.  
– Empty measuring container before making measurement.  
3
–
Operate remote control 15 seconds again. At least 800 cm  
fuel per 15 seconds must be delivered.  
– In addition, check both fuel delivery units.  
– To do so, connect adapter cable - Phaeton -V.A.G 1348/3-3-  
to connections of relays for left and right fuel delivery units.  
– Empty measuring container before making measurement.  
3
–
Operate remote control 10 seconds. At least 800 cm fuel per  
10 seconds must be delivered.  
If the minimum delivery rate is not attained during one of the tests:  
– Check fuel lines for possible restrictions (kinks) or blockages.  
If fuel lines are ok:  
– Renew fuel filter.  
If delivery rate has been attained, but nevertheless you suspect  
a fuel supply system fault (e.g. intermittent failure of fuel supply  
system):  
– Check current draw of fuel pumps ⇒ page 109 .  
1.11.3  
Checking current draw of pumps  
– Check current draw of each fuel pump separately as follows:  
– Reconnect all disconnected fuel lines.  
1. Parts of fuel supply system  
109  
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– Cut carpet open from point -A- to point -B- in the pre-cut area  
-arrows-.  
– Remove nuts -1- from cover. If necessary, unscrew backrest  
mounting -2- or support mounting ⇒ General body repairs,  
interior; Rep. gr. 72 ; Rear seats .  
lk  
110  
Rep. gr.20 - Fuel supply system  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
– Connect multimeter -V.A.G 1715- pick-up clamp to wiring of 4-  
pin connector contact -1- -arrow- of wiring harness to right fuel  
delivery unit.  
Note  
The hand-held multimeter -V.A.G 1526D- with pickup clamp -  
V.A.G 1526B/2- can also be used.  
– Start engine and run at idling speed.  
– Measure current draw of fuel pump. Specification: max. 11  
amps.  
If current draw is exceeded:  
– Right fuel pump is defective. Renew fuel delivery unit  
⇒ page 102 .  
– Repeat test on left fuel delivery unit.  
If current draw is exceeded:  
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.  
– Left fuel pump is defective. Renew fuel delivery unit.  
Note  
If the fuel system malfunction is intermittent, you can perform the  
check during a road test, but a 2nd person is necessary.  
lk  
1.12  
Checking non-return valve of right pump  
Test prerequisites  
•
Fuel pump relays -1- for right fuel delivery unit and -2- for left  
fuel delivery unit must be removed from their sockets.  
1. Parts of fuel supply system  
111  
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– Now unscrew locking ring from flange (fuel filter) using wrench  
-T10202- .  
– Carefully lever flange and raise it slightly.  
– Disconnect connectors next to fuel filter.  
– Then detach fuel supply hose -2- leading from right fuel deliv‐  
ery unit from fuel filter -1-.  
– Allow fuel from connection -1- to flow back into fuel tank.  
– Close pressure gauge shut-off tap (lever at right angles to di‐  
rection of flow).  
– Connect pressure tester -V.A.G 1318- with adapter -  
V.A.G 1318/7- , adapter -V.A.G 1318/13- and adapter -  
V.A.G 1318/17- as shown.  
Note  
Ensure that fuel supply line connection engages audibly when  
joined.  
112  
Rep. gr.20 - Fuel supply system  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
– Now connect remote control -V.A.G 1348/3A- with adapter -  
V.A.G 1348/3-3- to connection -arrow- of fuel pump relay for  
right fuel delivery unit.  
– Operate remote control at short intervals until a pressure of  
approx. 4 bar has built up.  
– Watch pressure drop on pressure gauge. After 10 minutes,  
pressure must not drop below 3.0 bar.  
If pressure drops:  
– Right fuel pump is defective. Renew right fuel delivery unit  
⇒ page 102 .  
To convert the pressure tester for the left fuel pump:  
– Open lever of pressure tester and let fuel flow back to fuel tank  
through hose -V.A.G 1318/13- .  
lk  
1.13  
Checking non-return valve of left pump  
Test prerequisites  
•
Remote control -V.A.G 1348/3 A- is still connected.  
Note  
At the same time, this test checks for leaks in the fuel supply line  
connections from the fuel delivery units to the point at which the  
pressure tester -V.A.G 1318- is connected.  
– Then detach fuel supply hose -2- leading from left fuel delivery  
unit from fuel filter -1-.  
1. Parts of fuel supply system  
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– Close pressure gauge shut-off tap -arrow- (lever at right an‐  
gles to direction of flow).  
– Connect pressure tester -V.A.G 1318- with adapter -  
V.A.G 1318/7- , adapter -V.A.G 1318/13- and adapter -  
V.A.G 1318/24- as shown.  
Note  
Ensure that fuel supply line connection engages audibly when  
joined.  
– Connect remote control -V.A.G 1348/3 A- with adapter -  
V.A.G 1348/3-3- to connection -arrow- of fuel pump relay for  
left fuel delivery unit.  
– Operate remote control at short intervals until a pressure of  
approx. 4 bar has built up.  
– Watch pressure drop on pressure gauge. After 10 minutes,  
pressure must not drop below 3.0 bar.  
If pressure drops:  
– Left fuel pump is defective. Renew left fuel delivery unit  
⇒ page 102 .  
– Open lever of pressure tester and let fuel flow back to fuel tank  
through hose -V.A.G 1318/13- .  
– Remove pressure tester -V.A.G 1318- with adapters.  
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2
Electronic power control (EPC)  
1 - Bearing bracket  
❑ Removing and instal‐  
ling: ⇒ Brake systems;  
Rep. gr. 46 ; Assembly  
overview - brake pedal  
(LHD) .  
2 - Connector  
❑ Black, 6-pin.  
3 - 10 Nm  
4 - Accelerator position sender  
-G79- and accelerator position  
sender 2 -G185-  
❑ Not adjustable.  
❑ Remove footwell cover  
to remove sender.  
Function of EPC system  
The position of the accelerator is transmitted to the engine control  
unit by two accelerator position senders (variable resistors to‐  
gether in one housing) connected to the accelerator.  
The position of the accelerator (driver's requirement) is a main  
input value for the engine control unit.  
The throttle valve is operated over the complete engine speed  
and load range by an electric motor (throttle valve positioner) in  
the throttle valve module.  
The throttle valve is operated by the throttle valve positioner which  
is controlled by the engine control unit.  
When the engine is not running and the ignition is switched on,  
the engine control unit moves the throttle valve exactly as pre‐  
scribed by the accelerator position sender. That is, when the  
accelerator is depressed halfway, the throttle valve positioner  
opens the throttle valve by the same amount. The throttle is then  
approximately half open.  
2. Electronic power control (EPC)  
115  
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When the engine is running (under load), the engine control unit  
can open or close the throttle valve independently of the accel‐  
erator position sender.  
This means that the throttle valve can already be completely open  
even though the accelerator is only depressed half way. This has  
the advantage of preventing throttling losses at the throttle valve.  
This also results in significantly improved consumption and ex‐  
haust emission values under certain load conditions.  
The torque required by the engine can be produced by the engine  
control unit by optimising the combination of throttle valve cross-  
section and charge pressure.  
After evaluating the torque requirements of various components  
(e.g. air conditioning system, automatic gearbox, ABS/ESP and  
so on), the engine control unit calculates the optimal throttle valve  
opening angle for the respective situation.  
Observe safety precautions.  
Observe rules for cleanliness.  
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3
Activated charcoal filter system  
Function  
Depending on the air pressure and ambient temperature, fuel va‐  
pour will form above the level of fuel in the tank.  
The activated charcoal filter system prevents these HC emissions  
escaping to the atmosphere.  
Fuel vapours pass from the highest point in the tank (on filler neck)  
through the expansion tank and into the activated charcoal filter.  
The activated charcoal stores these vapours like a sponge.  
When the car is being driven and the Lambda control is active  
(engine warm), the activated charcoal filter solenoid valve 1 -N80-  
is activated (pulsed) by the engine control unit depending upon  
load and engine speed. The opening period depends on the input  
signals.  
During the purging procedure (regeneration of activated char‐  
coal), the intake manifold vacuum draws fresh air through the vent  
of the activated charcoal filter. The fuel vapours stored in the ac‐  
tivated charcoal and fresh air are fed to combustion in metered  
quantities.  
The activated charcoal filter solenoid valve 1 -N80- is closed when  
it is not supplied with current (e.g. open circuit). The activated  
charcoal filter will not be purged.  
lk  
Note  
♦ Hose connections are secured with either spring-type or  
clamp-type clips.  
♦ Spring-type clip pliers -VAS 6340- or spring-type clip pliers -  
VAS 5024 A- are recommended for installation of spring-type  
clips.  
Observe safety precautions ⇒ page 99 .  
Observe rules for cleanliness ⇒ page 99 .  
Assembly overview - activated charcoal filter system  
⇒ page 118 .  
Function of pressure retention valve ⇒ page 118  
Checking fuel system for leaks ⇒ page 118 .  
3. Activated charcoal filter system  
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3.1  
Assembly overview - activated charcoal filter system  
1 - Expansion tank  
2 - Gravity valve  
3 - To gravity valve  
4 - Pressure retention valve  
❑ Function ⇒ page 118 .  
5 - 9 Nm  
6 - Connecting hose  
7 - Air filter  
❑ Clean if soiled.  
8 - Connector  
❑ For breather line.  
9 - Activated charcoal filter  
10 - 9 Nm  
11 - Connector  
12 - Activated charcoal filter  
solenoid valve 1 -N80-  
13 - Rubber bracket  
14 - To connection  
❑ On intake manifold  
15 - Breather line  
Function of pressure retention valve  
From gravity valve (on expansion tank) the pressure retention  
valve is open in both directions of flow. -Arrow 1- is the side to  
expansion tank.  
On the other side it is only open for flow in one direction.  
-Arrow 2- is the side to activated charcoal filter.  
3.2  
Checking fuel system for leaks  
Special tools and workshop equipment required  
118  
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♦ Hose clips up to 25 mm Ø -3094-  
♦ Tester -V.A.G 1371-  
Procedure:  
– Remove rear right wheel and wheel housing liner.  
– Clamp off hose -arrow- between activated charcoal filter and  
air filter using a hose clamp -3094- .  
– Disconnect breather line -arrow- to solenoid valve in engine  
compartment.  
3. Activated charcoal filter system  
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– Connect tester -V.A.G 1371- to breather line -arrow- as shown  
in illustration.  
– Connect valve adapter of tester -V.A.G 1371- to tyre valve.  
– Regulate the pressure to 35 mbar with valve -A-. When the  
pressure has stabilised, it must not drop below 30 mbar after  
5 minutes.  
If no pressure builds up or the pressure is not held for at least 5  
minutes, localise leak as follows:  
– Perform visual check on all components and hoses of the fuel  
system.  
Note  
Also check fuel tank cap for leaks.  
Only if still no fault has been detected:  
– Check breather line and activated charcoal filter for leaks. To  
do this, disconnect breather line -A- from activated charcoal  
filter and seal connection with a plug -B-.  
– Repeat pressure test.  
lk  
If pressure still drops, the leakage can be found on the activated  
charcoal filter or breather line:  
– When valve is open -A-, check the following lines and compo‐  
nents for leaks by hearing, touching, with commercially avail‐  
able leak detector spray or using ultrasonic tester -V.A.G  
1842- .  
♦ Line from engine compartment to activated charcoal filter.  
♦ Activated charcoal filter  
If the pressure does not drop again, the leakage can be found on  
fuel tank:  
– To do this, reconnect breather line -A- to activated charcoal  
filter.  
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– With valve -A- is open, check fuel tank for leaks by hearing,  
touching, with commercially available leak detector spray or  
ultrasonic tester -V.A.G 1842- .  
Caution  
After completing work check tyre pressure!  
3. Activated charcoal filter system  
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4
Activated charcoal filter system (ve‐  
hicles for USA and Canada)  
Assembly overview - activated charcoal filter system  
⇒ page 123 .  
Checking fuel system for leaks ⇒ page 124 .  
Function  
Fuel vapour forms above the surface of the fuel in the fuel tank;  
the quantity depends upon the air pressure and ambient temper‐  
ature.  
The activated charcoal filter system prevents these HC emissions  
escaping to the atmosphere.  
Fuel vapours pass from the highest point in the tank (on filler neck)  
through the expansion tank and into the activated charcoal filter.  
The activated charcoal stores these vapours like a sponge.  
When the vehicle is being operated and the Lambda control is  
active (engine warm), the activated charcoal filter system sole‐  
noid valve 1 -N80- is activated (pulsed) by the engine control unit  
-J623- depending on load and engine speed. The opening period  
depends on the input signals.  
During the purging procedure (regeneration of activated char‐  
coal), the intake manifold vacuum draws fresh air through the vent  
of the activated charcoal filter. The fuel vapours stored in the ac‐  
tivated charcoal and fresh air are fed to combustion in metered  
quantities.  
The activated charcoal filter solenoid valve 1 -lNk 80- is closed when  
it is not supplied with current (e.g. open circuit). The activated  
charcoal filter will not be purged.  
Description of leakage diagnosis  
The activated charcoal filter system, including fuel tank, is equip‐  
ped with leakage diagnosis which can detect if there is a leak in  
the system.  
The diagnosis is based on a pressure method and indicates leaks  
with a diameter greater than 0.5 mm.  
During the diagnosis, the fuel system diagnostic pump -V144-  
builds up pressure in the activated charcoal system. For this, the  
activated charcoal filter solenoid valve 2 -N115- is closed. Once  
the pressure is attained, the pump switches off. If the pressure  
drops below a certain value, the pump switches on again. Self-  
diagnosis monitors the intervals at which the pump is switched on  
or off and if the intervals are too short, writes a fault to the fault  
memory.  
122  
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lk  
Note  
♦ Hose connections are secured with either spring-type or  
clamp-type clips.  
♦ Use spring-type clip pliers -VAS 6340- for installation of spring-  
type clips  
♦ or space-saving hose clip pliers -VAS 6362- .  
Observe safety precautions ⇒ page 99 .  
Observe rules for cleanliness ⇒ page 99 .  
4.1  
Assembly overview - activated charcoal filter system  
1 - Expansion tank  
❑ Right side.  
2 - Gravity valve  
3 - Fuel filler neck  
4 - 5 Nm  
5 - Bracket  
6 - Vacuum line  
❑ For vacuum supply of  
fuel system diagnostic  
pump -V144-  
❑ To vacuum connection  
on intake manifold  
❑ Check for secure seat‐  
ing.  
7 - Fuel system diagnostic  
pump -V144-  
❑ Checking fuel system  
for leaks ⇒ page 124 .  
❑ Black connector, 3-pin  
8 - Connecting hose  
❑ Between air filter, fuel  
system diagnostic pump  
-V144- and activated  
charcoal filter solenoid  
valve 2 -N115-  
❑ Check for secure seat‐  
ing.  
9 - 5 Nm  
10 - Air filter  
❑ Clean if soiled.  
11 - Rubber bush  
❑ Note installation position.  
❑ Renew if damaged.  
12 - Activated charcoal filter solenoid valve 2 -N115-  
❑ Black connector, 2-pin  
13 - Activated charcoal filter  
❑ Location: in rear right wheel housing.  
4. Activated charcoal filter system (vehicles for USA and Canada)  
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14 - Securing bolts  
❑ Qty. 3  
❑ 9 Nm  
15 - Breather line  
❑ To vacuum connection on intake manifold  
❑ Check for secure seating.  
16 - Connector  
❑ Black, 2-pin.  
17 - Activated charcoal filter solenoid valve 1 -N80-  
❑ Note installation position.  
18 - Rubber bracket  
❑ Note installation position.  
19 - Breather line  
❑ Check for secure seating.  
20 - Pressure retention valve  
❑ Function ⇒ page 124 .  
Function of pressure retention valve  
From gravity valve (on expansion tank) the pressure retention  
valve is open in both directions of flow. -Arrow 1- is the side to  
expansion tank.  
lk  
On the other side it is only open for flow in one direction.  
-Arrow 2- is the side to activated charcoal filter.  
4.2  
Checking fuel system for leaks  
Special tools and workshop equipment required  
♦ Fuel system tester (so-called smoke tester) -KLI 9210-  
♦ Adapter hose -KLI 9210/55-2-  
♦ Vehicle diagnosis tester -VAS 5051B- , -VAS 5052- or -VAS  
5053-  
♦ Hose clamps up to 25 mm -3094-  
Test prerequisite:  
•
A leak has been detected by the fuel system diagnostic pump  
-V144- .  
•
Guided fault finding has been performed with the vehicle di‐  
agnosis tester .  
Preparation of fuel system tester -KLI 9210- :  
Note  
The fuel system tester -KLI 9210- may differ in appearance de‐  
pending on the version.  
124  
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– Check on fuel system tester -KLI 9210- if there is enough fluid  
in smoke generator.  
– Set valve -D- to „Hold“.  
– Open nitrogen bottle -H-.  
– Connect test hose -G- to self-test connection -B-.  
lk  
– Set valve -D- to „Test“.  
– Regulate pressure to 25 mbar (10 in. H2O) with pressure re‐  
ducer -J-.  
– Set valve -D- to „Hold“.  
– Now pressure must be maintained for at least 2 minutes.  
Check tester if pressure is not maintained.  
Checking fuel system for leaks:  
– Pull off rear engine cover -arrows-.  
– In engine compartment, disconnect breather line -arrow- to  
activated charcoal filter solenoid valve 1 -N80- .  
– Connect adapter hose -KLI 9210/55-2- between activated  
charcoal filter solenoid valve 1 -N80- and breather line -A- as  
shown in illustration.  
– Connect measuring hose -G- from fuel system tester -KLI  
9210- to adapter hose -KLI 9210/55-2- .  
– Connect fuel system tester -KLI 9210- to vehicle battery.  
4. Activated charcoal filter system (vehicles for USA and Canada)  
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– Connect vehicle system tester to vehicle.  
– Start engine and run at idling speed.  
– On vehicle system tester, select operating mode OBD .  
– Now select diagnostic mode 8 „Tank leak test“.  
– Select entry „Tank leak test“ and press right arrow button ► to  
initiate test.  
Note  
♦ Once the diagnostic mode 8 „Tank leak test“ has been acti‐  
vated, the leak diagnostic pump and the activated charcoal  
filter solenoid valve 2 -N115- are closed for max. 1,000 sec‐  
onds. The activated charcoal filter solenoid valve 1 -N80- is  
not activated. Now the entire system is closed.  
lk  
♦ If the engine control unit cancels the test, it is possible to ini‐  
tiate it again by switching off and restarting the engine.  
– Set valve -D- to „Test“. The fuel system will now be filled with  
nitrogen.  
– Observe pressure gauge -C- and flow meter -E-. When the  
throughput quantity decreases and the pressure increases to  
25 mbar (10 in. H2O), the fuel system is filled.  
Note  
Depending on the filling level of the fuel tank, this process can  
take up to 3 minutes.  
– Once pressure has stabilised, set valve -D- to „Hold“.  
•
After 5 minutes the pressure must not drop below 20 mbar  
(8 in. H2O).  
If pressure does not drop, exit from diagnostic mode 8 and check  
if fuel system diagnostic pump -V144- can build up pressure  
⇒ page 129 .  
If no pressure builds up or the pressure is not held for at least 5  
minutes, localise leak as follows:  
Leave engine running at idling speed for at least 8 minutes with  
activated diagnostic mode 8.  
– First check activated charcoal filter solenoid valve 1 -N80- for  
leaks. To do this, clamp off hose to activated charcoal filter  
solenoid valve 1 -N80- using a hose clip -arrow-. Also refer to  
⇒ Item A (page 128) .  
126  
Rep. gr.20 - Fuel supply system  
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– Repeat pressure test by setting valve -D- again to „Test“.  
– Observe pressure gauge and flow meter. When the through‐  
put quantity decreases and the pressure increases to 25 mbar  
(10 in. H2O), the fuel system is filled.  
– Once pressure has stabilised, set valve -D- to „Hold“.  
– If the pressure does not drop again, renew activated charcoal  
filter solenoid valve 1 -N80- .  
If pressure still drops:  
– Set valve -D- again to „Test“.  
– While fuel system is being filled, press button -I- for smoke  
generator for approx. one minute.  
The fuel system is now pressurised and filled with smoke.  
– Check whether smoke escapes from any visible fuel system  
line or hose. Also check fuel tank cap.  
Note  
♦ Light up the components and hoses with a strong floodlight. In  
the floodlight, smoke is more visible.  
♦ For leak detection in accessible areas, also use ultrasonic de‐  
tector or commercially available leak detecting spray.  
♦ Depending on how long the fault finding takes, it may be nec‐  
essary to press the smoke generator button from time to time.  
This ensures that sufficient smoke is present in the fuel sys‐  
tem.  
If no fault is found:  
– Remove rear right wheel housing liner.  
If smoke escapes from air filter ⇒ Item l7k (page 128) :  
– Clamp off hose between activated charcoal filter solenoid  
valve 2 -N115- and air filter -arrow-. Also refer to  
⇒ Item B (page 128) .  
– Observe air filter. If smoke no longer escapes, activated char‐  
coal filter solenoid valve 2 -N115- is leaking. Renew activated  
charcoal filter system solenoid valve 2 -N115- .  
4. Activated charcoal filter system (vehicles for USA and Canada)  
127  
Touareg 2003 ➤  
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If smoke still escapes from air filter:  
– Clamp off hose between fuel system diagnostic pump -V144-  
and air filter -arrow-. Also refer to ⇒ Item C (page 128) .  
– Observe air filter. If smoke no longer escapes, shut-off valve  
in fuel system diagnostic pump -V144- is leaking. Renew fuel  
system diagnostic pump -V144- .  
If no smoke escapes from air filter ⇒ Item 7 (page 128) :  
– Check whether smoke escapes from any fuel system compo‐  
nent or hose.  
To inspect flanges for fuel pump and fuel filter, open assembly  
openings in vehicle interior.  
– Renew leaking hoses or components.  
After completing work, perform guided function „checking fuel  
tank breather system for leaks“ using ⇒ Vehicle diagnostic tester.  
4.2.1  
Overview of activated charcoal filter system  
1 - Activated charcoal filter  
2 - Location of adapter hose -  
KLI 9210/55-2-  
❑ For leak detection in fuel  
system  
3 - Activated charcoal filter sol‐  
enoid valve 1 -N80-  
4 - Breather line  
❑ To intake manifold.  
5 - Solenoid valve  
❑ For fuel system diag‐  
nostic pump -V144-  
6 - Vacuum line  
❑ To intake manifold.  
7 - Air filter  
❑ For fuel system diag‐  
nostic pump -V144-  
8 - Fuel system diagnostic  
pump -V144-  
9 - Fuel tank  
10 - Cap  
11 - Activated charcoal filter  
solenoid valve 2 -N115-  
12 - Pressure retention valve  
A - Clamp off in this area  
❑ For leak detection in fuel  
system  
❑ For checking activated  
charcoal filter solenoid  
valve 1 -N80- .  
B - Clamp off in this area  
❑ For leak detection in fuel system  
❑ For checking activated charcoal filter solenoid valve 2 -N115- .  
128  
Rep. gr.20 - Fuel supply system  
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C - Clamp off in this area  
❑ For leak detection in fuel system  
❑ For checking fuel system diagnosis pump -V144- .  
4.2.2  
Checking build-up of pressure of fuel  
system diagnostic pump -V144-  
Test prerequisite:  
•
Fuel system tester -KLI 9210- is connected to vehicle via  
adapter hose -KLI 9210/55-2- .  
•
•
Valve -D- is set to „Hold“.  
Diagnostic mode 8 is completed and engine is running at idling  
speed.  
Fuel system must not be under pressure for test. Proceed as fol‐  
lows to reduce residual pressure:  
– Briefly open quick-release coupling -arrow- for adapter hose -  
KLI 9210/55-2- to release pressure in fuel system. Pressure  
gauge -D- must drop to 0 in. H2O.  
– On vehicle system tester, select operating mode Guided  
lk  
functions .  
– Select guided function „Checking tank ventilation system for  
leaks“.  
– Initiate test.  
– Observe pressure gauge while test is running.  
– Fuel system diagnostic pump -V144- must pump up pressure  
in fuel system at least to 18 mbar (7 in. H2O).  
– If pressure is not reached, check vacuum supply of fuel system  
diagnostic pump -V144- ⇒ page 129 .  
– If fuel system is free of leaks and vacuum supply of fuel system  
diagnostic pump -V144- is OK, renew fuel system diagnostic  
pump -V144- .  
4.2.3  
Checking vacuum supply of fuel system  
diagnostic pump -V144-  
Special tools and workshop equipment required  
4. Activated charcoal filter system (vehicles for USA and Canada)  
129  
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♦ Turbocharger tester -V.A.G 1397A-  
♦ T piece -251 201 346-  
♦ Hose ∅ 6 mm  
lk  
Note  
Fitting location of fuel system diagnosis pump -V144- : in rear right  
wheel housing under wheel housing liner.  
– Remove rear right wheel and wheel housing liner.  
– Remove securing bolts ⇒ Item 14 (page 123) of activated  
charcoal filter and lower filter to have better access to vacuum  
line.  
Caution  
Support activated charcoal filter to prevent its hanging down  
from hoses and lines. This prevents damages.  
– Disconnect vacuum line -1- from fuel system diagnostic pump  
-V144- .  
– Connect turbocharger tester -V.A.G 1397A- with T-piece and  
hose ∅ 6mm, between vacuum line -1- and fuel system diag‐  
nostic pump -V144- -2-.  
– Switch on measuring range I (absolute pressure measure‐  
ment).  
– Connect vehicle diagnosis tester and start engine.  
– On vehicle diagnosis tester, select operating mode Guided  
functions .  
– Select guided function „Checking tank ventilation system for  
leaks“.  
– Observe display on turbocharger tester -V.A.G 1397A- while  
test is running.  
•
Pressure must pulsate and must not exceed 0.700 bar during  
test.  
– If pressure exceeds 0.7 bar during test, vacuum supply is too  
low. Check vacuum line to intake manifold for possible kinks  
or blockages.  
130  
Rep. gr.20 - Fuel supply system  

Related Topics

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
1.9 Removing and installing fuel tank with attached components
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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