Get Mixture preparation - injection -> 1 Repairing injection system 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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Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

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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

1. Repairing injection system

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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

Mixture preparation - injection -> 1 Repairing injection system for Your Volkswagen Touareg SUV First Generation (2002-2010)

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