2002-2010 Volkswagen Touareg SUV Mixture preparation - injection -> 2 Checking components User Manual
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Mixture preparation - injection -> 2 Checking components for Your Volkswagen Touareg SUV First Generation (2002-2010)

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-  
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  
lk  
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.  
140  
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:  
lk  
– 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  
141  
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  
lk  
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-  
142  
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.  
lk  
– 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  
143  
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) .  
lk  
144  
Rep. gr.24 - Mixture preparation - injection  

Related Topics

Mixture preparation - injection
1 Repairing injection system 1.1 Assembly overview - intake manifold 1.2 Assembly overview - fuel rail 1.3 Assembly overview - air filter 1.4 Assembly overview - vacuum hose assembly on intake manifold 1.5 Safety precautions 1.6 Rules for cleanliness 1.7 Technical data 2.1 Checking injectors 2.2 Checking fuel pressure regulator and holding pressure 3 Engine control unit 3.1 Removing and installing engine control unit 3.2 Reading and erasing engine control unit fault memory

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