Get Mixture preparation - injection Guide for Volkswagen Touareg SUV First Generation (2002-2010)

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Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

24 – Mixture preparation - injection

1

Repairing injection system

General notes on injection

♦ Fuel hoses in engine compartment must be secured only with

spring-type clips. The use of clamp or screw-type clips is not

permissible.

♦ For trouble-free operation of electrical components, a voltage

of at least 11.5 V is necessary.

Safety precautions ⇒ page 137 .

Rules for cleanliness ⇒ page 137 .

Technical data ⇒ page 137 .

Assembly overview - intake manifold ⇒ page 132 .

Assembly overview - fuel rail ⇒ page 133

Assembly overview - air filter ⇒ page 133 .

Assembly overview - vacuum hose assembly on intake manifold

⇒ page 136 .

1. Repairing injection system

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Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

1.1

Assembly overview - intake manifold

1 - Variable intake manifold

2 - To activated charcoal filter

solenoid valve 1 -N80-

3 - Sealing cap

4 - Vacuum connection

5 - Gasket

6 - To brake servo.

7 - Throttle valve module -

J338-

❑ Gold-plated connector

contacts

❑ If renewed, adapt en‐

gine control unit to throt‐

tle valve module ⇒ Ve‐

hicle diagnostic tester; ;

„Guided functions“ .

8 - 10 Nm

9 - Crankcase breather valve

10 - Connecting hose

11 - Connecting pipe

12 - 10 Nm

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13 - 10 Nm

14 - Clip

15 - Connection

❑ For crankcase ventila‐

tion.

16 - Dowel cone

❑ Fit gasket before instal‐

lation.

17 - Dowel pin, 3 Nm

18 - 10 Nm

❑ To secure intake manifold.

❑ 7 securing bolts on each side

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Rep. gr.24 - Mixture preparation - injection

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

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1.2

Assembly overview - fuel rail

1 - Threaded connection, 22

Nm

❑ Counterhold when tight‐

ening.

❑ For fuel supply.

2 - Fuel supply hose

❑ Check for secure seat‐

ing.

❑ Secure with spring-type

clip.

3 - 10 Nm

4 - Ball stud, 3 Nm

❑ For engine cover

5 - Fuel rail

❑ With retaining tabs for

knock sensor connec‐

tors.

6 - Seal

❑ Renew.

❑ Before installing, mois‐

ten lightly with clean en‐

gine oil.

7 - Valve 2 for variable intake

manifold changeover. -N261-

8 - Vacuum actuator

❑ For intake manifold

change-over.

9 - Non-return valve

❑ Black side of valve faces

intake manifold connec‐

tion

10 - Variable intake manifold changeover valve -N156-

11 - Injector (N30...N33, N83...N86)

❑ Checking ⇒ page 139 .

12 - Variable intake manifold

13 - Retaining clip

❑ Check for secure seating.

14 - Spring-type clip

1.3

Assembly overview - air filter

Separating connecting line to air suspension compressor

⇒ page 135 .

1. Repairing injection system

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Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

1 - Intake hose

2 - Spring-type clip

3 - Intake hose

4 - 6 Nm

5 - Air mass meter -G70- with

intake air temperature sender -

G42-

6 - Seal

❑ Renew if damaged.

7 - Air filter upper part

❑ On the right side with

connection to secon‐

dary air pump motor -

V101- .

8 - Filter element

9 - To secondary air pump mo‐

tor -V101-

10 - Air duct

❑ Secured to lock carrier.

11 - Rubber bush

❑ Clipped to longitudinal

member.

12 - Air filter lower part

❑ To remove lower part of

air filter on right, right

engine cover retainer

must be removed

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⇒ page 134 .

13 - 10 Nm

14 - Connection from air sus‐

pension compressor

❑ Removing ⇒ page 135

Removing bracket for right engine cover

– Press in lug -1- from below and pull bracket out in

-direction of arrow-.

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Rep. gr.24 - Mixture preparation - injection

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

1.3.1

Disconnecting connecting line to air sus‐

pension compressor

– Disconnect connecting line on right air filter -arrow- as follows:

– Carefully lever off green securing ring -1- using a screwdriver.

Then press clamping ring -2- in direction of -arrow-.

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– Now pull loosened line -B- off connection -A- on air filter.

1. Repairing injection system

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1.4

Assembly overview - vacuum hose assembly on intake manifold

1 - Combination valve

❑ For injection of secon‐

dary air

2 - To secondary air pump mo‐

tor -V101-

3 - Connecting hose

❑ Route without tension.

4 - Vacuum connection

❑ For combination valve.

5 - Secondary air inlet valve -

N112-

❑ Secured to fuel rail.

6 - Bracket

❑ Secured to fuel rail.

7 - Variable intake manifold

8 - To vacuum reservoir

❑ ⇒ Item 10 (page 156)

9 - Valve 2 for variable intake

manifold changeover. -N261-

10 - Non-return valve

❑ Black side of valve faces

intake manifold connec‐

tion

11 - Vacuum actuator

❑ For intake manifold

change-over.

12 - Variable intake manifold

changeover valve -N156-

13 - Vacuum actuator

❑ For intake manifold change-over.

14 - To cylinder block.

❑ ⇒ Item 3 (page 17)

15 - Crankcase breather valve

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Rep. gr.24 - Mixture preparation - injection

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

1.5

Safety precautions

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♦ 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.

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.

To prevent injuries to persons and/or damage to the injection and

ignition system, the following must be observed:

♦ Do not touch or disconnect ignition cables when the engine is

running or being turned at starter speed.

♦ Switch off ignition before connecting or disconnecting injection

and ignition system wiring as well as test instrument cables.

Note the following if testers and measuring instruments have to

be used during a road test:

♦ Test and measuring instruments must always be secured to

rear seat and operated by a second person from this location.

If test and measuring instruments are operated from front pas‐

senger seat and the vehicle is involved in an accident, there is a

possibility that the person sitting in this seat may receive serious

injuries when the airbag is triggered.

♦ If the engine is to be turned at starter speed without starting:

– Pull connectors off ignition coils with output stage (cylinders

1…8).

1.6

Rules for cleanliness

When working on the fuel supply and injection system, pay careful

attention to the following „5 rules“ for cleanliness:

♦ 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

Technical data

Engine codes

AXQ

BHX

Idling check

Idling speed³⁾

rpm

670...730

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Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

Engine codes

AXQ

BHX

Engine control unit

System designation

Part number

Motronic ME 7.1

⇒ Spare parts cata‐

logue

Governed speed

rpm from approx. 6500

from approx. 6500

3) Not adjustable.

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Rep. gr.24 - Mixture preparation - injection

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

2

Checking components

Checking injectors ⇒ page 139 .

Checking fuel pressure regulator and holding pressure

⇒ page 142 .

2.1

Checking injectors

Checking injectors for leaks and quantity injected ⇒ page 139

Special tools and workshop

equipment required

♦ Remote control for V.A.G

1348 -V.A.G 1348/3A- with

adapter cable - Phaeton -

V.A.G 1348/3-3- .

♦ Injection rate tester -V.A.G

1602-

♦ Adapter cable -V.A.G

1348/3-2-

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2.1.1

Checking injectors for leaks and quanti‐

ty injected

•

The fuel pressure must be in order, checking ⇒ page 142 .

2. Checking components

139

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Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

Checking for leaks

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.

– Remove complete fuel rail (fuel supply line remains connec‐

ted) ⇒ page 133 .

– Remove fuse holder cover.

– Pull fuel pump relays -1- and -2- from their sockets.

– Connect remote control -V.A.G 1348/3- with adapter line -

V.A.G 1348/3-3- -arrow- to connection of fuel pump relay for

right fuel delivery unit.

– Now connect second connection of adapter cable -

V.A.G 1348/3-3- to connector connection -arrow- for fuel pump

relay for left fuel delivery unit.

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Rep. gr.24 - Mixture preparation - injection

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Connect crocodile clip of remote control -V.A.G 1348/3- to

positive connection -1-.

– Operate remote control -V.A.G 1348/3- .

If fuel pump runs:

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– Check injectors for leaks (visual check). No more than 1 to 2

drops per minute must escape from each valve when fuel

pump is running.

If the fuel loss is greater:

– Renew defective injector.

Pay attention to the following when installing the injectors:

♦ Renew O-rings on all injectors and lightly moisten with clean

engine oil.

♦ Insert injectors vertically and in the correct position into the fuel

rail and secure with retaining clips.

♦ Fit fuel rail with secured injectors onto intake manifold and

press in evenly.

Checking quantity injected

•

Fuel pump relays and fuses 13 and 14 are fitted in their sock‐

ets.

– Connect test box -V.A.G 1598/31- to engine control unit.

– Bridge test box sockets 1 and 65 using adapter cable from

auxiliary measuring set -V.A.G 1594- .

– Insert the injector to be checked into injection rate tester meas‐

uring glass -V.A.G 1602- .

– Connect a contact of injector to be tested to engine earth using

auxiliary cables from auxiliary measuring set -V.A.G 1594- .

– Connect second injector contact to remote control -

V.A.G 1348/3- using adapter cable -V.A.G 1348/3-2- .

2. Checking components

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Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Connect crocodile clip of remote control -V.A.G 1348/3- to

battery positive (+) -1- in engine compartment.

– Switch on ignition.

– Operate remote control -V.A.G 1348/3- for 30 seconds.

– Repeat check on other injectors. Use new measuring beakers.

– Switch off ignition.

– After all injectors have been activated, place measuring beak‐

ers on a level surface and compare the quantity injected.

Specification: 95..0.115 ml per injector

If the measured values of one or more injectors are above or be‐

low the prescribed specifications:

– Renew defective injector.

Install injectors in reverse order. In the process, note the follow‐

ing:

♦ Renew O-rings on all injectors and lightly moisten with clean

engine oil.

♦ Insert injectors vertically and in the correct position into the fuel

rail and secure with retaining clips.

♦ Fit fuel rail with secured injectors onto intake manifold and

press in evenly.

2.2

Checking fuel pressure regulator and

holding pressure

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Special tools and workshop equipment required

♦ Pressure gauge -V.A.G 1318-

♦ Adapter set -V.A.G 1318/7-

♦ Adapter set -V.A.G 1318/10-

♦ Adapter set -V.A.G 1318/13-

♦ Spring-type clip pliers -VAS 6340-

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Rep. gr.24 - Mixture preparation - injection

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

Test procedure

The fuel pressure regulator maintains the fuel pressure at a con‐

stant 4.0 bar.

•

Fuel pump delivery is OK.

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.

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– Wrap a cloth around the threaded connection -arrow- and re‐

lease fuel pressure by quickly opening and closing connection.

– Loosen spring-type clip and disconnect fuel hose from con‐

nection on fuel rail ⇒ Item 14 (page 133) .

– Now connect pressure tester -V.A.G 1318- using adapters -

V.A.G 1318/7- , -V.A.G 1318/10- and -V.A.G 1318/13- as

shown in the illustration.

– The lever on pressure tester -V.A.G 1318- -1- points in direc‐

tion of flow.

– Always secure both hose ends with clips -2-.

– Start engine and run at idling speed.

– Measure fuel pressure. Specification: approx. 4.0 bar.

If the specification is not attained:

– Check delivery rate of fuel pumps ⇒ page 107 .

– Renew fuel pressure regulator -2-, if necessary.

If specification is attained:

– Switch off ignition.

– Now check for leaks and holding pressure. Do this by observ‐

ing pressure drop on gauge. After 10 minutes, there must be

a residual pressure of at least 3.0 bar.

If the holding pressure drops below 3 bar:

– Check pressure tester for leaks.

– Check non-return valves of left and right fuel pumps

⇒ page 111 and ⇒ page 113 .

– Switch off ignition.

When the pressure tester is removed after the test has been

completed:

2. Checking components

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Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Wrap a cloth around the threaded connection -arrow- and re‐

lease fuel pressure by quickly opening and closing connection.

– Remove pressure tester -V.A.G 1318- with adapters.

– Reconnect fuel hose to fuel rail and secure with spring-type

clip ⇒ Item 14 (page 133) .

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Rep. gr.24 - Mixture preparation - injection

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

3

Engine control unit

Removing and installing engine control unit ⇒ page 145 .

Reading and clearing engine control unit fault memory

⇒ page 145 .

3.1

Removing and installing engine control

unit

If you wish to replace the engine control unit, connect the vehicle

diagnosis, testing and information system -VAS 5051B- and carry

out the guided function „Renew control unit“.

Removing

– Switch off ignition.

– Remove windscreen wiper motor on right side: ⇒ Electrical

system; Rep. gr. 92 ; Removing and installing windscreen

wiper system .

– Release both connectors from control unit and pull off.

– Control unit can now be removed.

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Installing

– Place control unit into retaining frame.

– Fit connector and lock in position.

– Install windscreen wiper motor on right side: ⇒ Electrical sys‐

tem; Rep. gr. 92 ; Windscreen wiper system .

– Install plenum chamber cover.

– Adapt new engine control unit: ⇒ Vehicle diagnostic tester;

„Guided functions“ .

3.2

Reading and erasing engine control unit

fault memory

Special tools and workshop equipment required

♦ Vehicle diagnosis, testing and information system -VAS 5051-

♦ Diagnosis cable -VAS 5051/1- or -VAS 5051/3-

Procedure

– Connect vehicle diagnosis, testing and information system -

VAS 5051- as follows:

3. Engine control unit

145

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Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Connect connector of diagnosis cable -VAS 5051/1- or -

VAS 5051/3- to diagnostic connection.

– Start engine and run at idling speed.

Only when engine does not start:

– Switch on ignition.

Selecting operating mode:

– Press button on display for „Vehicle self-diagnosis“.

Selecting vehicle system:

– Press „01 - Engine electronics“ button on display.

The control unit identification with code as well as chassis number

and immobilizer identification number will be indicated on the dis‐

play.

Note

A print-out can be made if required. Tghen press the Print but‐

ton.

– Press → button.

Select diagnostic function:

– Press „02 - Read fault memory“ button on display.

– If no fault is stored in engine control unit „0 fault detected“ is

displayed.

– If faults are stored in the engine control unit, these are shown

one below the other on the display.

– Press ← button.

– Press „05 - Clear fault memory“ button on display.

– Select „06-End output“ function.

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Rep. gr.24 - Mixture preparation - injection

Mixture preparation - injection for Your Volkswagen Touareg SUV First Generation (2002-2010)

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