Volkswagen Touareg (2003 year). Manual - part 33

❑ 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

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

Touareg 2003 ➤

4. Activated charcoal filter system (vehicles for USA and Canada)    

129

♦ T piece -251 201 346-
♦ Hose ∅ 6 mm

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.

Touareg 2003 ➤

130

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

 .

Touareg 2003 ➤

1. Repairing injection system    

131

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
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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