Advertisement

Advertisement

Fuel supply system -> 1 Parts of 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  
93  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
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.  
94  
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 ➤  
8-cylinder injection engine - Edition 11.2011  
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  
98  
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  
101  
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  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
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 ➤  
8-cylinder injection engine - Edition 11.2011  
– 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 ➤  
8-cylinder injection engine - Edition 11.2011  
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  
Touareg 2003 ➤  
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  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
– 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  
lk  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
– 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  
113  
lk  
Touareg 2003 ➤  
8-cylinder injection engine - Edition 11.2011  
– 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.  
114  
Rep. gr.20 - Fuel supply system