Fuel Supply System - Petrol Engines-Touran

Service
Workshop Manual
Touran 2003 ➤
Fuel supply system - Petrol engines
Engine ID
CAV CAV CBZ CTH CTH
B C B B C
Edition 12.2013
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
20 - Fuel supply system
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg D3E803B0CE1

Touran 2003 ➤
Fuel supply system - Petrol engines - Edition 12.2013
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Safety precautions for when using test and measuring equipment during a road test . . . . 3
3 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Fuel delivery unit and fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Removing and installing fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3 Plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.1 Separating plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.1 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6 Accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.1 Assembly overview - accelerator module ge. n.A.G.. .Vo. l.ks.w.a.ge. n. A.G. d. . . . . . . . . . . . . . . . . . . . . . . . 28
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6.2 Removing and installing accelerator lksw
Vomodule . . . . . . . . . . . . . . s.n.ot. g.u. . . . . . . . . . . . . . . . . . 28
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7 Fuel pump . . . . . . . . . . . . . o.ri.se. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .an.te.e. . . . . . . . . . . . . . 31
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7.1 Checking fuel pump . . . s.au. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.ac. . . . . . . . . . . . 31
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Contents i
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ii Contents
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00 – Technical data
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1 Engine data
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(VRL006392; Edition 12.2013)
spec
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Engine code CBZB CAVB CAVC CTHB CTHC
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Emission standards EU 5 EU 5 EU 5 EU 5 EU 5
Capacity l 1.2 1.4 1.4 1.4 1.4
rrectness of i
Output kW 77 125 103 125 103
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RON 95 unleaded 95 unleaded 95 unleaded 95 unleaded 95 unleaded
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1. Engine data 1
Touran 2003 ➤
2 Safety precautions
⇒ “2.1 Safety precautions when working on fuel supply system”,
page 2
⇒ “2.2 Safety precautions for when using test and measuring
equipment during a road test”, page 3
2.1 Safety precautions when working on

fuel supply system
WARNING
The fuel pressure in the high-pressure pipe can reach 120 bar!
Observe the safety precautions when releasing pressure in the
high-pressure section.
♦ Pressure reduction in high-pressure area ⇒ Rep. gr. 24 ;
Pressure reduction in high-pressure area .
♦ Fuel supply line is pressurised. Wear eye protection and
protective clothing to avoid possible injury and skin con‐
tact. Before loosening hose connections, wrap a cloth
around the connection. Then release pressure by carefully
pulling hose off connection.
For reasons of safety, the power supply to the fuel pump must
be interrupted before the fuel system is opened. The fuel pump
would otherwise be activated when the driver's door is opened.
Use the following options to interrupt the power supply: AG. Volkswagen AG d
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♦ Disconnect battery. d by ara
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♦ Remove fuse for fuel pump control unit - J538- or for fuel
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delivery unit.
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♦ Pull off connector from fuel delivery unit flange or fuel
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pump control unit - J538- .
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spec
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Caution
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When doing any repair work, especially in the engine compart‐
ment, pay attention to the following due to the cramped condi‐
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tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
nform
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vated charcoal filter system, coolant and refrigerant, brake

m
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fluid and vacuum) and electrical wiring in their original po‐

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♦ To avoid damage to lines, ensure sufficient clearance to

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all moving or hot components.

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When removing and installing fuel gauge sender - G- or fuel pump t. C rig
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(fuel delivery unit) from a full or partly full fuel tank, observe the pyri by
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Remove fuse for fuel pump. Fuse assignment ⇒ Current flow di‐
agrams, Electrical fault finding and Fitting locations
2 Rep. gr.00 - Technical data

Touran 2003 ➤
WARNING
Fuel system is under pressure! Wear eye protection and gloves

to avoid injuries and skin contact. Before loosening hose con‐
nections, wrap a cloth around the connection. Then release
pressure by carefully pulling hose off connection.
♦ 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 extract any escap‐
ing fumes. If no exhaust gas extraction system is available, a
radial fan with a displacement greater than 15 m3/h can be
used providing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
To prevent injuries to persons and/or damage to the injection and
ignition system, the following must be observed:
♦ Do not touch or pull off ignition coils with output stage when
engine is running or turning at starter speed.
♦ Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as test instrument cables.
When removing and installing fuel gauge sender or fuel pump
(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
♦ Before starting work, the extraction hose of a switched-on ex‐
haust gas extraction system must be laid near to the assembly
opening of the fuel tank. This draws away the fuel fumes that
escape. If no exhaust gas extraction system is available, a ra‐
dial fan with a displacement greater than 15 m3/h can be used
providing that motor is not in air flow. AG. Volkswagen AG d
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♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
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2.2 Safety precautions for when using test
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and measuring equipment during a road
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Note the following if testers and measuring instruments have to
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be used during a road test:
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♦ Test and measuring instruments must always be secured to spec

the rear seat and operated by a second person from this lo‐
es, in part or in w
t to the co
cation.
♦ If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there
rrectness of i
is a possibility that the person sitting in this seat may receive

serious injuries when the airbag is triggered.
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2. Safety precautions 3
Touran 2003 ➤
3 General repair notes
3.1 Rules for cleanliness

When working on the fuel supply and injection system, observe
the following “5 rules” for cleanliness:
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♦ Thoroughly clean all unions and surrounding
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♦ Place removed parts on aauthclean surface and cover. Use only eo
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lint-free cloths. ss c
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♦ Carefully cover opened components or seal if repairs cannot
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be carried out immediately.
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♦ Install clean components only. Do not remove replacement
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parts from packing until immediately before installing. Do not
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use parts that have not been stored in their packing (e.g. in
ole,
tool boxes etc.).
spec
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♦ When system is open: do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely nec‐
essary.
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4 Rep. gr.00 - Technical data

Touran 2003 ➤
20 – Fuel supply system lkswage

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1 Fuel tank utho
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⇒ “1.1 Assembly overview - fuel tank”, page 5
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⇒ “1.2 Removing and installing fuel tank”, page 6
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⇒ “1.3 Emptying fuel tank”, page 10
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1.1 Assembly overview - fuel tank
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1 - Cap
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2 - Securing bolt
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3 - Tank flap unit
❑ With rubber cup
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❑ Removing and installing

⇒ General body repairs,
nform
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exterior; Rep. gr. 55 ;

Tank flap unit; Remov‐
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tank flap unit
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4 - Earth connection
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❑ Ensure secure seating
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❑ When removing, sup‐
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port using engine and
gearbox jack - V.A.G
1383 A- .
⇒ page 6
7 - 20 Nm + 1/4 turn (90°) fur‐
ther
❑ Renew
Note
To secure the securing straps for

the fuel tank, only bolts with loose
washers must be used. If different
bolts are used, the securing straps
might twist during tightening.
8 - Heat shield
9 - Securing strap
Note
To secure the securing straps for

the fuel tank, only bolts with loose
washers must be used. If different
bolts are used, the securing straps
might twist during tightening.
10 - Supply line
❑ Black
1. Fuel tank 5
Touran 2003 ➤
11 - Fuel filter
❑ Installation position: arrow indicates direction of flow.
12 - Breather line
13 - Activated charcoal filter
❑ Location: on fuel tank.
14 - Breather line
15 - Fuel delivery unit
❑ Removing and installing ⇒ page 17
❑ With fuel gauge sender - G- ⇒ page 20 .
❑ Checking fuel pump ⇒ page 31
❑ Note installation position on fuel tank ⇒ page 6
❑ Removing and installing fuel gauge sender - G- ⇒ page 20 .
❑ Clean strainer if soiled
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❑ When installing, fit dry in fuel tank opening
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❑ Moisten with fuel only when installingau flange ra
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17 - Union nut, 80 Nm
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❑ Remove and install using union nut tool - 3217- .
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❑ Position union nut tool - 3217- on three rounded pins
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18 - Supply line
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❑ Black
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❑ Clipped onto side of fuel tank.
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19 - Return line
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❑ Blue
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❑ Clipped onto side of fuel tank.

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Installation position of fuel delivery unit

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Marking on sender must align with the marking on fuel tank

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-arrows-.
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Return line (blue or with blue mark) -2-

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Black supply line -3-
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After installing fuel delivery unit flange, check that supply, return
and breather lines are still clipped onto fuel tank.
1.2 Removing and installing fuel tank

• Fuel tank must not be more than 1/2 full.
6 Rep. gr.20 - Fuel supply system

Touran 2003 ➤
Note
If necessary, empty fuel tank using fuel extractor - VAS 5190-

⇒ page 10 .
Special tools and workshop equipment required

♦ Torque wrench (5... 50 Nm) - V.A.G 1331-
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♦ Engine and gearbox jack - V.A.G 1383 A-
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– Note safety precautions before beginning work ⇒ page 2 .
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– First check whether a coded radio is fitted. If so, obtain anti-
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– With the ignition switched off, disconnect battery earth strap. C py
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– Unscrew securing bolts and remove tank flap unit.
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– Drain fuel tank and clean fuel filler neck and surrounding area.
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– Fold rear seat bench forwards.

Vehicles with bolt-on cover
– Remove bolts -arrows- and remove fuel delivery unit cover.
1. Fuel tank 7
Touran 2003 ➤
Vehicles with push-on cover

– Pull cover off fuel delivery unit in -direction of arrow-.
Continuation for all vehicles

– Remove cover -1- with fuel pump control unit -J538- -2- from
fuel delivery unit.
– Pull 5-pin connector -1- off flange.

– Remove rear right wheel.
– Remove rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Removing and installing wheel
housing liner; Rear wheel housing liner .
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– Unbolt filler neck from body -arrows-.

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Touran 2003 ➤
– Remove securing nuts -arrows- if there are any and remove

fuel tank cover.
– Disconnect all rear exhaust system retainers from body. Then
support lowered exhaust system on body with wire.
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Fuel supply lines are under pressure! Wear eye protection and
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gloves to avoid injuries and skin contact. Before loosening
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hose connections, wrap a cloth around the connection. Then
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release pressure by carefully pulling hose off connection.
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– Disconnect breather line -1- (white) and fuel line -2- (black) at
hole
spec
connecting point. Separate plug-in connectors ⇒ page 21 .
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t to the co
– Unscrew securing strap and securing bolts. When doing this,
support fuel tank with engine and gearbox jack -
V.A.G 1383 A- .
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– Lower fuel tank.
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Installing
Install in reverse order of removal. In the process, note the fol‐
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lowing:
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To secure the securing straps for the fuel tank, only bolts with
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loose washers must be used. If different bolts are used, the se‐
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curing straps might twist during tightening. t. Cop py
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♦ Install breather and fuel lines free of kinks.
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♦ Ensure that line connections are tight.
♦ After installing fuel tank, check that the supply, return and
breather lines are still clipped onto the fuel tank.
– Fill fuel tank with at least 5 litres of fuel.
WARNING
Risk of explosion of fuel tank. If a new or completely empty fuel

tank has been installed, it must be filled immediately with at
least 5 litres of fuel. The fuel pump must not be allowed to run
when the fuel tank is empty.
Specified torque
♦ ⇒ “1.1 Assembly overview - fuel tank”, page 5
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Removing and
installing wheel housing liner; Rear wheel housing liner .
1. Fuel tank 9
Touran 2003 ➤
1.3 Emptying fuel tank

⇒ “1.3.1 Emptying fuel tank when fuel pump is intact”,
page 10
⇒ “1.3.2 Emptying fuel tank if it is more than 3/4 full”, page 13
⇒ “1.3.3 Emptying fuel tank if it is less than 3/4 full”, page 14
1.3.1 Emptying fuel tank when fuel pump is intact
Caution
Secure earth wire of fuel extractor to a bare metal part of the

body.
To extract E 85 fuel, use only fuel extractor - VAS 5190 A- !
Special tools and workshop

equipment required
♦ Removal wedge - 3409-
♦ Remote control - V.A.G
1348/3A-
♦ Test instrument adapter/
DSO (5-pin) - VAS 5565-
♦ Fuel extractor - VAS 5190-
♦ Fuel extractor - VAS 5190
A- for E 85 fuel (not shown).
♦ Adapter for fuel extraction -
VAS 5190-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
10
Prote AG.
Rep. gr.20 - Fuel supply system
Touran 2003 ➤
Note
If the fuel extraction unit - VAS 5190- gisenstill

AG. fitted
Volkswwith the
agen AG doextrac‐
tion hose with a solid tip, the extraction
o lkswa hose must be replaced es n
ot g
with the version with a screweded
by V
tip. ua
ra
ris nte
utho eo
ra
a c
ss
Caution
ce
e
nl
pt
du
an
itte
y li
Fuel supply line is pressurised. Wear eye protection and pro‐
erm
ab
tective clothing to avoid eye injuries and skin contact. Before
ility
ot p
loosening hose connections, wrap a cloth around the connec‐
wit
, is n
tion. Then release pressure by carefully pulling hose off con‐
h re
nection.
hole
spec
es, in part or in w
Connect fuel extractor earth wire to earth.
t to the co
rrectness of i
l purpos
Note
nform
ercia
♦ Plug-in connectors for fuel lines must engage »audibly« when

m
joined.
at
om
ion
c
♦ Note colour assignment when installing the plug-in connectors
in t
or
his
⇒ page 21
ate
do
priv
c
♦ Ensure plug-in connector is secured properly by pulling. um
for
en
ng
t.
♦ Separate plug-in connectors ⇒ page 21 .
yi Co
Cop py
t. rig
gh ht
yri by
– Observe safety precautions ⇒ page 2 . cop Vo
by lksw
cted agen
Prote
– Observe rules for cleanliness ⇒ page 4 .
AG.
– Pull off supply line (metal coupling) -1- and catch escaping fuel
with a cloth. Separate plug-in connectors ⇒ page 21 .
– Connect fuel extractor - VAS 5190- with adapter for fuel ex‐
tractor - VAS 5190 /3- to fuel supply line.
– Fold rear seats forwards.
– Detach carpet under seats and fold it back ⇒ General body
repairs, interior; Rep. gr. 70 ; Load and luggage compartment
trims; Removing and installing load compartment floor .
1. Fuel tank 11
Touran 2003 ➤

Vehicles with push-on cover n AG. Volkswagen AG do

lkswage es n
– Pull cover off fuel delivery unit ind b-direction
yV
o
of arrow-. ot g
ua
ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove cover -1-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
– Pull off connector -arrow-. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
– Connect test instrument adapter/DSO (5-pin) - VAS 5565- to

connector and fuel delivery unit.
– Connect remote control - V.A.G 1348/3A- to test instrument
adapter/DSO (5-pin) - VAS 5565- and to battery positive (+).
Note
olkswagen AG
This step serves only to have the fuel pump running when the swagen AG. V does
engine is stopped. by
Vol
k not
gu
ara
ed nte
oris eo
h
– Remove filler cap from fuel tank filler neck. au
t ra
c
ss
– Operate remote control - V.A.G 1348/3A- and shut-off tap on
ce
le
un
pt
fuel extractor - VAS 5190- until fuel tank is empty.
an
d
itte
y li
rm
ab
pe
ility
Caution
ot
wit
, is n
h re
Fuel pump must not run »dry«.
hole
spec
es, in part or in w
t to the co
1.3.2 Emptying fuel tank if it is more than 3/4
rrectness of i
full
l purpos
Caution
nform
ercia

m
a
com
t
body.
ion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
g

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Fuel extractor - VAS 5190 A- for E 85 fuel (not shown).

– Observe safety precautions ⇒ page 2 .
1. Fuel tank 13
Touran 2003 ➤
– Remove cotter -2- from shaft -1- of fuel extractor - VAS 5190- .
– At distance -a- = 1,200 mm from end, mark extraction hose
with insulating tape -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
– Remove filler cap from fuel tank filler neck.
erm
ab
ility
ot p
– Screw shaft end -1- of fuel extractor unit - VAS 5190- onto fuel
wit
, is n
filler neck.
h re
hole
spec
– Push extraction hose into fuel tank until marking on hose
es, in part or in w
-arrow- coincides with shaft end.
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
Note
o
n in
or c
thi
te
sd
a
A ball valve -2- is located at the bottom of the filler neck in the fuel
iv
o
r
rp
cu
tank -1-; it must not be damaged by the extraction hose -3-.

o
m
f
Therefore push hose into filler neck only as far as marking

en
ng
t.
yi
-arrow-.
Co
Cop py
t. rig
gh ht
pyri by
– Drain fuel tank as much as possible through fuel filler neck.
o Vo
by c lksw
cted agen
Prote AG.
– Carefully pull out extraction hose.
Note
♦ When no more fuel is extracted, the tank is emptied just

enough for the sender flange to be opened without danger.
The tank may be removed while containing remaining fuel.
♦ If work must be performed on fuel pump or fuel tank sender,
proceed as follows:
1.3.3 Emptying fuel tank if it is less than 3/4 full
Caution

body.

Touran 2003 ➤

equipment required
. Volkswagen AG
a gen AG does
Vol
ksw not
gu
y
db ara
♦ Wrench - T10202-
or
ise nte
eo
h
ut ra
♦ Torque wrench
ss
a
- V.A.G c
1332-
ce
le
un
pt
an
d

itte
y li
rm
ab
pe
♦ Fuel extractor - VAS 5190
ility
ot
A- for E 85 fuel (not shown).
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note

joined.
⇒ page 21
♦ Ensure plug-in connector is secured properly by pulling.

– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
72 ; Rear seats; Removing and installing bench seat .
– Remove cover from fuel delivery unit.
1. Fuel tank 15
Touran 2003 ➤
WARNING

tective clothing to avoid possible injury and skin contact. Before
nection.
– Pull connector and fuel lines off flange.
Note
Press buttons on hose couplings to do this.
– Open locking ring using union nut tool - 3217- .

– Raise fuel delivery unit.
– Insert extraction hose of fuel extractor - VAS 5190- as deeply
as possible into fuel tank and extract fuel.
If fuel tank needed only to be emptied, install fuel delivery unit
again ⇒ page 17 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
2 Fuel delivery unit and fuel gauge

sender
⇒ “2.1 Removing and installing fuel delivery unit, fuel gauge send‐
er”, page 17
⇒ “2.2 Removing and installing fuel gauge sender”, page 20
2.1 Removing and installing fuel delivery

unit, fuel gauge sender
Note
After removing fuel delivery unit, check fuel tank for heavy soiling
and clean if necessary.

♦ Union nut tool - 3217-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Torque wrench (40... 200 Nm) - V.A.G 1332-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Fuel delivery unit and fuel gauge sender 17

Touran 2003 ➤
Removing
Caution
Prerequisites:
• Fuel tank must not be more than 3/4 full. This ensures that
the fill level is below the flange of the fuel delivery unit.
Note
♦ If necessary, drain fuel tank using fuel extractor - VAS 5190- .

♦ Note safety precautions before beginning work ⇒ page 2 .
♦ Observe rules for cleanliness ⇒ page 4 .
– First check whether a coded radio is fitted. If so, obtain anti-

theft coding.
– With the ignition switched off, disconnect battery earth strap.
– Detach carpet under rear seats and fold it back ⇒ General
body repairs, interior; Rep. gr. 70 ; Load and luggage com‐
partment trims; Removing and installing load compartment
floor .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p

wit
, is n
h re

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touran 2003 ➤

– Remove cover -1- with fuel pump control unit -J538- -2- from
fuel delivery unit.
WARNING
Fuel supply lines are under pressure! Wear eye protection

en AG. V
olkswagand
en AG
gloves to avoid injuries and skin contact.olksw Before
ag loosening does no
hose connections, wrap a cloth arounddb
y V the connection. Then t gu
ara
release pressure by carefully pulling
ho
rise
hose off connection. nte
e t or
au ac
ss
ce
le
un
pt
an
d
– Pull connector -1- and fuel lines -2- and -3- off flange. Separate
itte
y li
plug-in connectors ⇒ page 21 .
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
– Fit union nut tool - 3217- on three rounded ribs of union nut
mer
and unscrew union nut from flange. When doing this, press
atio
m
union nut tool - 3217- firmly onto union nut.

o
n
c
i
or
n thi
– Pull fuel delivery unit and seal out of the opening in fuel tank.
te
sd
iva
o
pr
cum
r
fo
en
ng
Note
t.
yi Co
Cop py
t. rig
gh
If delivery unit is to be renewed, drain old delivery unit before dis‐
ht
pyri by
Vo
o
posal.
c by lksw
cted agen
Prote AG.
Installing
– Installing the fuel delivery unit is carried out in reverse order
of removal.
Note
♦ When inserting fuel delivery unit, ensure that fuel gauge send‐
er is not bent.
♦ Insert seal for fuel delivery unit dry into opening of fuel tank.
♦ Moisten seal with fuel only when installing fuel delivery unit.
♦ Note installation position of fuel delivery unit flange: mark on
flange must align with mark on fuel tank -arrows-.
♦ Do not interchange supply and return lines.
♦ Ensure that line connections are tight.
♦ After installing fuel delivery unit, check that the supply, return
and breather lines are still clipped onto the fuel tank.
2. Fuel delivery unit and fuel gauge sender 19

Touran 2003 ➤
2.2 Removing and installing fuel gauge

sender
Removing
– Remove fuel delivery unit ⇒ page 17 .
– Pull fuel gauge sender - G- slightly to side and upwards at the
same time.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
ho eo
– If the sender cannot be released in this
aut way, the retaining tabs ra
c
-arrows- must also be pushed to thes side slightly.
s
ce
le
un
pt
– Note colour co-ordination of cables for reinstallation.
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Release electrical connectors -1…3- and pull them off. Then

bend back locking devices of connector.
nform
ercia
Installing:
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Connect connectors -1…3-. Observe colour co-ordination.
– Check connectors are secured properly by pulling.
– Insert fuel gauge sender - G- into guide on fuel delivery unit
and press down until it engages.
– Install fuel delivery unit ⇒ page 17 .

Touran 2003 ➤
3 Plug-in connectors
⇒ “3.1 Separating plug-in connectors”, page 21
3.1 Separating plug-in connectors

. Volkswagen AG
a gen AG d
Vol
ksw equipment required
oes
not
g y ua
db ran
♦ -T10468- orise tee
th or
s au ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Assignment of plug-in connectors
l purpos
nf
ercia
Note
orm
m
atio
m
The plug-in connectors for fuel, vacuum and breather lines are
o
n in
c
colour coded. There is either a coloured dot on the plug-in con‐

or
thi
nector or the release button is coloured.

te
sd
iva
o
r
rp
cu
o
m
f
Plug-in connector Colour code on plug-in connec‐

en
ng
t.
yi
tor
Co
Cop py
t. rig
gh
Fuel supply Black
ht
pyri by
Vo
co lksw
by
Fuel return line Prote
cted Blue AG.
agen
Breather White
Vacuum Green
WARNING

tective clothing to avoid eye injuries and skin contact. Before
nection.
Variant 1
Plug-in connector with release buttons -arrows- on right and left
3. Plug-in connectors 21
Touran 2003 ➤
Opening
It is necessary to counterhold the separating point for fuel -1- in
the engine compartment.
– Insert -T10468- between heat shield and stop -arrow- of fuel
line -2- and counterhold.
Continuation for all separating points of the fuel system

– Push plug-in connector -1- in -direction of arrow A-.
– Press release buttons -arrows- and pull plug-in connector -1-
off fuel line -2- in -direction of arrow B-.
Note colour assignment during installation ⇒ page 21 .
– Ensure plug-in connector is secured properly by pulling.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
Variant 2
rm
ab
pe
ility
Plug-in connector with pull-release mechanism -arrow-

ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
22
AG.
Rep. gr.20 - Fuel supply system
Touran 2003 ➤
Opening
AG . Volkswage
– Push plug-in connector
ksw
agen -1- in -direction
n AG d
oesof arrow A-.
n
ol ot g
yV ua
– Pull pull-release
edb mechanism -2- in -direction ofranarrow B-.
oris tee
h
– Pull
s au plug-in connector -1- off fuel line -3- in
t or
ac
-direction of arrow B-.
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Variant 3
m
a
Plug-in connector with front button -arrow-
com
tion in
r
Opening
te o
thi
s
iva
do
– Press release button -arrow- and pull off plug-in connectors.

r
rp
cum
fo

en
ng
t.
yi Co
op py
– Ensure plug-in connectors are secured properly by pulling.
t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Variant 4
Plug-in connector with release button -arrows- on right and left
Opening
– Push plug-in connector in -direction of arrow A-.
– Press release buttons -arrows- and pull off plug-in connector.
Variant 5
Opening
– Press release buttons -arrows- and pull off plug-in connector.
3. Plug-in connectors 23
Touran 2003 ➤
Variant 6
Opening
– Push plug-in connector in -direction of arrow-.
– Press and hold release buttons -arrows-.
– Pull off plug-in connector.
Variant 7
Plug-in connector -1- with release buttons -2- on right and left:
Opening
– Press plug-in connector -1- in -direction of arrow A- and main‐
tain pressure. G. Volkswagen nA AG do
wage es n
– Press release button -2- in -direction of arrow
Vol B- and pull off
ks ot g
by ua
plug-in connector -1-. ris
ed ran
tee
tho or
Note colour assignment during installation
sa
u ⇒ page 21 . ac
s
ce
e
Plug-in connectors for fuel lines must engage »audibly« when

nl
pt
du
joined.
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
ksw
agen oes
not
Touran 2003 ➤
ol
Fuel d bsupply
yV system - Petrol engines - Edition
gu
ara 12.2013
rise nte
tho e or
au ac
4 Fuel filter ss
ce
le
un
pt
an
d
⇒ “4.1 Assembly overview - fuel filter”, page 25
itte
y li
erm
ab
⇒ “4.2 Removing and installing fuel filter”, page 25
ility
ot p
wit
is n
4.1 Assembly overview - fuel filter
h re
ole,
spec
If the fuel system does not have a return line, there is a pressure
limiting valve in the fuel filter. With this kind of system, only the
t to the co
supply line is routed forwards into the engine compartment.
rrectne
1 - Fuel filter
❑ With pressure limiting
ss
valve
o
cial p
f in
❑ Direction of flow is
form
mer
marked with arrows.
atio
m
❑ Do not interchange con‐

o
n
c
nections.
i
or
n thi
te
❑ Installation position: pin
sd
iva
o
r
on filter housing must

p
cum
r
fo
engage in notch of guide
en
ng
t.
yi
in filter bracket
Co
op py
⇒ page 26 .
. C rig
ht ht
rig by
❑ Removing and installing copy Vo
by lksw
⇒ page 25 cted agen
Prote AG.
2 - Fuel supply line

❑ Black
❑ From fuel tank
❑ To pull off, press release
button on connection.
3 - Fuel return line
❑ Blue
❑ To fuel tank
4 - Fuel line
❑ Black
❑ To engine.
5 - 3 Nm
6 - Fuel filter holder
❑ Secured to fuel tank
4.2 Removing and installing fuel filter

♦ Drip tray
Removing
Observe safety precautions when working on the fuel supply sys‐
tem ⇒ page 2
Observe rules for cleanliness ⇒ page 4 .
4. Fuel filter 25
Touran 2003 ➤
– Place tray under fuel filter.
WARNING

nection.
– Pull off fuel lines -1-, -2- and -3-. Detach plug-in connectors
⇒ page 21 .
– Remove bolt -4-.
– Remove fuel filter. agen
AG. Volkswagen AG d
oes
olksw not
byV gu
ara
Installing rised
nte
ho eo
ut
Installation is carried out in the reversessorder. When installing,
a ra
c
note the following:
ce
le
un
pt
an
d
Installation position:
itte
y li
rm
ab
• Specified torque ⇒ page 25 .
pe
ility
ot
wit
, is n
• Direction of flow is indicated with an arrow on filter housing.
h re
hole
• Pin -2- on filter housing must engage in notch of guide -1- in
spec
filter bracket.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touran 2003 ➤
5 Activated charcoal filter system

⇒ “5.1 Checking fuel tank breather”, page 27
5.1 Checking fuel tank breather

♦ Hand vacuum pump - VAS 6213-
lkswage es n
o ot g
yV ua
Test prerequisite rised b ran
tee
tho
or
• Ignition mustau be switched off. ac
ss ce
e
Test procedure
nl
pt
du
an
itte
– First disconnect white breather hose at hose connection -2-.

y li
erm
ab
Separate plug-in connectors ⇒ page 21 .

ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Then connect hand vacuum pump - VAS 6213- to hose -1- as

m
at
shown.
om
ion
c
in t
r
– Operate hand vacuum pump - VAS 6213- several times. Vac‐

o
his
te
uum must not build up.

a
do
priv
cum
or
If vacuum builds up:

f
en
ng
t.
yi Co
– Check breather hose -3- on activated charcoal filter -2- for Cop py
soiling and clean if necessary.
t. rig
gh ht
pyri by
Vo
co
If vacuum does not build up:
by lksw
cted agen
Prote AG.
– Hold breather hose -3- shut and operate vacuum pump again
several times. Vacuum must build up.
If vacuum does not build up:
– Renew activated charcoal filter -2-.
Note
The fuel tank will have to be removed in order to remove and

install the activated charcoal filter ⇒ page 6 .
5. Activated charcoal filter system 27

Touran 2003 ➤
6 Accelerator mechanism
⇒ “6.1 Assembly overview - accelerator module”, page 28
⇒ “6.2 Removing and installing accelerator module”, page 28
6.1 Assembly overview - accelerator module

. Volkswagen AG
gen AG does
swa
1 - Connector yV
olk not
gu
d b ara
❑ Black, 6-pin. orise nte
eo
h
ut ra
2 - Accelerator position
ss a
sender c
- G79- and accelerator position
ce
le
un
pt
sender 2 - G185-
an
d
itte
y li
❑ Openings -A- for re‐
rm
ab
pe
lease tool.
ility
ot
wit
❑ To remove, remove
, is n
h re
dash panel cover and
hole
spec
pedal cluster cover.
es, in part or in w
t to the co
accelerator module
⇒ page 28
rrectness of i
3 - 10 Nm
l purpos
4 - Protective cap
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
6.2 Removing and installing accelerator

module

Touran 2003 ➤
♦ Release tool - T10269-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
♦ Release tool - T10297- (for right-hand drive)
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
c
Removing
or
thi
te
sd
a
– Remove steering column cover -arrows-.

iv
o
r
rp
cu
o
– Pull connector off accelerator module. m

f
en
ng
t.
yi Co
op
– Pull off cover cap in upper area of accelerator module. C py
t. rig
gh ht
yri by
– Remove securing bolt. cop Vo
by lksw
cted agen
Prote AG.
– To remove accelerator module, push release tool - T10269-

(for right-hand drive models -T10297- ) into openings provided
to stop.
– Pull out accelerator pedal module vertically.
6. Accelerator mechanism 29
Touran 2003 ➤
Installing
– Push wiring guide -1- and electrical connector -2- onto accel‐
erator module.
– Press accelerator module onto securing pins -6-.
– Insert centring pin -7- into hole in underbody.
– Secure accelerator module with bolt -3-, specified torque
10 Nm and fit cap -4-.
– Install steering column trim.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
30
c by lksw
cted agen
Rep. gr.20 - Fuel supply system Prote AG.
Touran 2003 ➤
7 Fuel pump
⇒ “7.1 Checking fuel pump”, page 31
7.1 Checking fuel pump

⇒ “7.1.1 Checking function and voltage supply”, page 31
⇒ “7.1.2 Checking fuel pressure”, page 34
⇒ “7.1.3 Checking holding pressure”, page 39
⇒ “7.1.4 Checking fuel delivery rate”, page 44
⇒ “7.1.5 Checking current draw”, page 52
7.1.1 Checking function and voltage supply

AG. Volkswagen AG d
agen oes
olksw not
yV gu
♦ Multimeterise.g.
ed hand-held multimeter - V.A.G 1526E-
b ara
nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
♦ Auxiliary measuring set - V.A.G 1594C-

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
♦ Vehicle diagnostic tester
AG.
7. Fuel pump 31
Touran 2003 ➤
Test prerequisites
• Battery voltage must be at least 11.5 V. If necessary, charge
battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Charging
battery .
• Fuse for fuel pump control unit - J538- OK ⇒ Current flow di‐
agrams, Electrical fault finding and Fitting locations.
• Fuel pump control unit - J538- OK ⇒ Vehicle diagnostic tester.
Test sequence:
– Connect vehicle diagnostic tester -1- as follows:
– Connect diagnosis cable connector -2- to diagnostic connec‐
tion in driver footwell.
– Switch ignition on.
– Select final control diagnosis for fuel
en AG. V
olkswpump
agen AGin vehicle self-di‐
agnosis program. olkswag does
no
V t gu
by a
The fuel pump must
ris now run slowly up to maximum speed.
ed ran
te
tho eo
s au ra
c
s
ce
Note
e
nl
pt
du
an
itte
y li
♦ Function of fuel pump is checked using final control diagnosis.

erm
ab
ility
ot p
♦ The fuel pump is now activated.

wit
, is n
h re
♦ The fuel pump runs very quietly.

hole
spec
♦ If the final control diagnosis is to be carried out several times

es, in part or in w
t to the co
in succession, it may be necessary to start the engine briefly

before repeating the final control diagnosis.
rrectness of i
– Switch off ignition.

l purpos
If fuel pump does not run:

nf
ercia
orm
– Detach carpet under rear seats and fold it back ⇒ General

m
atio
m
body repairs, interior; Rep. gr. 70 ; Load and luggage com‐

o
n in
c
partment trims; Removing and installing load compartment

or
thi
floor .
te
sd
iva
o
r
rp
cu
o

f
en
ng
t.
yi Co
op
– Remove bolts -arrows- and remove fuel delivery unit cover. C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ut
ho Touran
eo
ra
2003 ➤
a
ss Fuel supply system - Petrol engines - Edition c 12.2013
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia

m
a
– First check that the connector -arrow- is fitted securely by pull‐
com
tion in
ing the connector without pressing the catch. If connector was
r
te o
thi
not inserted correctly, repeat functional check of fuel pump.
s
iva
do
r
– Pull connector off fuel pump control unit - J538- .

rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Check voltage supply between contacts -1- and -6- using mul‐
timeter - V.A.G 1715- .
• Specification: approx. battery voltage
Voltage supply not OK:
– Locate and eliminate open circuit referring to current flow di‐
agram ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
Voltage supply OK:
– Remove cover -1- with fuel pump control unit - J538- -2- from
fuel delivery unit.
7. Fuel pump 33
lkswage es n
o ot g
byV ua
ed ran
Touran 2003 ➤ hor is tee
t or
Fuel supply system
au - Petrol engines - Edition 12.2013 ac
ss
ce
le
un
– First check that the connector -arrow- is fitted securely by pull‐
pt
an
d
itte
ing the connector without pressing the catch. If connector was
y li
rm
ab
not inserted correctly, repeat functional check of fuel pump.
pe
ility
ot
– Now pull off connector.
wit
, is n
h re
hole
– Check the contacts on the connector and on the fuel delivery
spec
unit for damage.
es, in part or in w
t to the co
WARNING
rrectness of i
l purpos

nform
ercia
nection.
m
a
com
tion in
r
te o
thi
– Pull fuel lines -1- and -2- off flange. Separate plug-in connec‐
s
iva
tors ⇒ page 21 .
do
r
rp
cum
fo
en
ng
t.
yi Co
op
Note C py
t. rig
gh ht
pyri by
Vo
On vehicles with auxiliary heater the connector and the fuel line
co lksw
by
cted agen
of the metering pump - V54- must also be separated. Prote AG.
– Fit union nut tool - 3217- on three rounded ribs of union nut
and unscrew union nut from flange. When doing this, press
union nut tool - 3217- firmly onto union nut.
– Pull fuel delivery unit and seal out of the opening in fuel tank.
– Check that electrical wires between flange and fuel pump are
connected.
If no open circuit can be found:
– Fuel pump is defective; renew fuel delivery unit ⇒ page 17 .
7.1.2 Checking fuel pressure

♦ Pressure tester - VAS 6550-

Touran 2003 ➤

Test prerequisites
• Voltage supply OK.
– Pull off supply line (metal coupling) -arrow- and catch escaping
fuel with a cloth. Separate plug-in connectors ⇒ page 21 .
WARNING

nection.
– Connect pressure tester - VAS 6550- to fuel supply line with

adapter - VAS 6550/1- and -VAS 6550/2- . AG. Volkswagen AG d
agen oes
lksw not
– Make sure that drain tap is closed and cut-off taps are open. by Vo gu
ara
d
ise nte
– Actuate fuel pump with final control diagnosis to build
uthor
up fuel eo
ra
pressure. ss a c
ce
e
– Read fuel pressure on pressure gauge.

nl
pt
du
an
itte
• Specification: 4.0…7.0 bar. y li

erm
ab
ility
ot p
If fuel pressure is OK, check holding pressure ⇒ page 39 . wit

, is n
h re
If the specification is exceeded:
hole
spec
– Check return line between fuel filter and fuel pump for kinks
es, in part or in w
t to the co
and blockages.
If no fault is found:
rrectness of i
– Pressure limit valve in fuel filter is defective. Renew fuel filter.

l purpos
If the specification is not attained:

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
7. Fuel pump 35
Touran 2003 ➤
– Check fuel pressure upstream of fuel filter; proceed as follows:

– Pull fuel supply line -arrow- off fuel filter. Separate plug-in con‐en AG. Volkswagen AG
nectors ⇒ page 21 . olks
wag does
no
yV t gu
db ara
rise nte
tho eo
s au ra
c
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
– Connect pressure tester - VAS 6550- between fuel filter and
t to the co
fuel supply line with adapter - VAS 6550/1- and -VAS 6550/2- .
– Make sure that drain tap is closed and cut-off taps are open.
rrectness of i
– Actuate fuel pump with final control diagnosis to build up fuel
pressure.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Slowly close cut-off tap -A-. Pressure must rise to min. 7.0 bar.
When 7.0 bar is reached, open shut-off tap again immediately.
If specification is attained:
– Check fuel line between fuel filter and engine compartment for
restrictions (kinks) or blockages.
– Check fuel line between fuel filter and engine compartment for
leaks and damage.
If no fault is detected:
– Fuel filter is blocked. Renew fuel filter ⇒ page 25 .
– Pressure limiting valve in fuel filter is defective. Renew fuel
filter ⇒ page 25 .
Proceed as follows to check fuel pressure at fuel delivery unit:
Checking fuel pressure on fuel delivery unit:

Touran 2003 ➤


AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
– Remove cover -1- with fuel pumporis control unit - J538- -2- from
ed
nte
fuel delivery unit. aut
h eo
ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Unclip right cover -1- at retaining tabs -arrows-, using removal

wedge - 3409- .
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
7. Fuel pump 37
Touran 2003 ➤
– Pull fuel line -1- off flange. Separate plug-in connectors

⇒ page 21 .
WARNING
The fuel line is under pressure.

Risk of injury to eyes and skin from fuel.
Wear eye protection and protective clothing to avoid eye inju‐
ries and skin contact. Before loosening hose connections,
wrap a cloth around the connection. Then release pressure by
carefully opening the connection point.
AG. Volkswagen AG d
agen oes
olksw not
– Connect pressure tester - VAS 6550- between fuel filter d byand
V gu
ara
fuel supply line using hose - VAS 6550/1- and hose horis- VAS
e nte
eo
6550/2- . aut ra
c
ss
– Connect hose - VAS 6550/2- between connection -A- of pres‐
ce
le
un
pt
sure tester - VAS 6550- and the fuel delivery unit -1-.
an
d
itte
y li
rm
ab
– Connect hose - VAS 6550/1- between connection -B- of pres‐
pe
ility
sure tester - VAS 6550- and the fuel supply line -2-.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
– Ensure that drain tap -C- on pressure tester -1- is closed.
r
te o
thi
s
iva
– Shut-off valves -A- and -B- on pressure tester -1- are open.
do
r
rp
cum
fo
– Repeat final control diagnosis of fuel pump to build up fuel

en
ng
t.
pressure.
yi Co
Cop py
ht. rig
If specification is attained: rig ht
py by
co Vo
by lksw
– Check fuel lines for possible restrictions (kinks) or blockages. Prote
cted AG.
agen
– Check fuel line for leaks and damage.

– Remove fuel delivery unit and check for contamination
⇒ page 17 .
– Check that all hoses are connected -arrows-.
– Check fuel lines for possible restrictions (kinks) or blockages.
– Check fuel lines for leaks and damage.
– Fuel pump is defective, renew fuel delivery unit ⇒ page 17 .

Touran 2003 ➤
7.1.3 Checking holding pressure

♦ Pressure tester - VAS 6550-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Test prerequisites
rrectne
• Voltage supply OK ⇒ page 31 .
ss
• Fuel pressure OK ⇒ page 34 .
o
cial p
f in
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
7. Fuel pump 39
Touran 2003 ➤
– Connect hose - VAS 6550/2- between fuel line from fuel tank
to shut-off tap -A- of pressure tester - VAS 6550- .
– Connect hose - VAS 6550/1- between fuel line leading to en‐
gine and shut-off tap -B- of pressure tester - VAS 6550- .
Test sequence:
– Actuate fuel pump with final control diagnosis to build up fuel
pressure.
Note
♦ The fuel pump is now actuated to build up fuel pressure.

♦ If the final control diagnosis is to be carried out several times
in succession, it may be necessary to start the engine briefly
before repeating the final control diagnosis.
– Read fuel pressure on pressure gauge and observe.

Specification:
Engine code Specified fuel
agenpressure in bar
AG. Volkswagen AG d
o
ksw es n
CAVB, CAVC, Vol ≥ 4.0
ot g
d by ua
ran
CBZB, CTHB, CTHC rise tee
tho or
au ac
– End self-diagnosis and
s switch off ignition.
s
ce
e
nl
• Observe pressure drop on pressure gauge. After 10 minutes, pt

du
an
itte
the pressure must not drop by more than 1 bar. y li

erm
ab
ility
If pressure drops:
ot p
wit
, is n
– Check all fuel lines for leaks and damage.

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
– Ensure that drain tap g-C- on
en AG. Vpressure
olkswagen Atester
Gd -1- is closed.
wa oes
olks no
– Shut-off valves
d b -A- and -B- on pressure tester -1-
yV t gu are open.
ar
e an
ris te
– Actuateuthfuel
o pump with final control diagnosis to builde oup
r a fuel
pressure.
ss a c
ce
e
nl
– After pressure has built up, close shut-off tap -B- of pressure
pt
du
an
tester immediately. Lever is then at right angle to direction of
itte
y li
erm
flow.
ab
ility
ot p
If the pressure now drops (leak on fuel tank side):
wit
, is n
h re
Check holding pressure on fuel filter ⇒ page 41 .
hole
spec
es, in part or in w
If the pressure does not drop anymore now (leak on engine side):
t to the co
Note
rrectness of i
l purpos
Search for leak on engine side. Repeat holding pressure check.

This time, close shut-off tap -A- to check whether leak actually is
on engine side.
nform
mercia
– If there is a leak on engine side, carry out external check of
at
om
io
fuel pipes and high-pressure pump for leaks.
n
c
in t
or
his
e
If no fault can be determined, check the injectors for leaks:

at
do
priv
– Remove spark plugs. Open shut-off valves -A- and -B-. Ac‐
um
for
en
g
tuate fuel pump with final control diagnosis.

n
t.
yi Co
op py
– Check through spark plug holes whether fuel has collected on
. C rig
ht ht
rig
piston crown due to a leaking injector. py by
co Vo
by lksw
cted agen
Prote AG.
Checking holding pressure on fuel filter:
– Pull fuel supply line -arrow- off fuel filter. Separate plug-in con‐
nectors ⇒ page 21 .
WARNING

7. Fuel pump 41
Touran 2003 ➤

fuel supply line using hose - VAS 6550/1- and hose - VAS
6550/2- .
– Connect hose - VAS 6550/2- to connection -A- of pressure
tester - VAS 6550- .
– Connect hose - VAS 6550/1- to connection -B- of pressure

G. Volkswage nA n AG d
wage oes
– Shut-off valves -A- and -B- on pressure
y V tester -1- are open.
olks not
gu
b ara
ed
– Repeat holding pressure checkho⇒
ris page 40 . nte
eo
t
au ra
– After pressure has built up,ssclose shut-off tap -A-. c
ce
le
un
pt
– Observe pressure drop on pressure gauge. After 10 minutes,
an
d
itte
the pressure must not drop by more than 1 bar.
y li
rm
ab
pe
ility
If pressure no longer drops:
ot
wit
, is n
– Check fuel line leading to engine for leaks.

h re
hole
– Check fuel filter for leaks. spec

es, in part or in w
t to the co
– Pressure limiting valve in fuel filter is defective. Renew fuel
rrectness of i
filter ⇒ page 25 .
l purpos
If pressure drops:
Proceed as follows to check holding pressure at fuel delivery unit:
nform
ercia
Checking holding pressure on fuel delivery unit:

m
a
com

ion in
r
te o

thi
s
iva

do
r
rp

um
fo
en
ng
t.
yi Co
op
Vehicles with bolt-on cover C py
t. rig
gh ht
yri by
– Remove bolts -arrows- and remove fuel delivery unit cover. op Vo
by c lksw
cted agen
Prote AG.

Touran 2003 ➤

– Remove fuel pump control unit - J538- -2- from cover -1-.
. Volkswagen AG
gen AG does
swa
– Unclip rightbcover
yV
olk -1- at retaining tabs -arrows-,
not using removal
gu
wedge -ris3409-
ed . ara
nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co

rrectness of i
⇒ page 21 .
l purpos
WARNING
nform
ercia

m
at
om
io

n
c
in t
or
his
e

at
do
riv

p
cum
or

f
en
g

n
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
7. Fuel pump 43
Touran 2003 ➤

fuel supply line using hose - VAS 6550/1- and hose - VAS
6550/2- .
– Connect hose - VAS 6550/2- between connection -A- of pres‐
sure tester - VAS 6550- and the fuel delivery unit -1-.
– Connect hose - VAS 6550/1- between connection -B- of pres‐
sure tester - VAS 6550- and the fuel supply line -2-.

– Repeat holding pressure check ⇒ page 40 .
– After pressure has built up, close cut-off tap -B-.
– Observe pressure drop on pressure gauge. After 10 minutes,
the pressure must not drop by more than 1 bar.
If the pressure does not drop:
– Check fuel line leading to fuel filter for leaks. n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
ho
If pressure drops: aut or
ac
ss
ce
le
un
pt
an
d
itte
– Check that all hoses are connected -arrows-.

y li
erm
ab
ility

ot p
wit
is n
h re
ole,
spec
– If pressure retention valve in fuel pump is defective; renew fuel

delivery unit ⇒ page 17 .

t to the co
rrectne
7.1.4 Checking fuel delivery rate

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤

equipment required
♦ Remote control for
V.A.G 1348 - V.A.G
1348/3A-
♦ Multimeter e.g. hand-held
multimeter - V.A.G 1526E-
♦ Test instrument adapter/
DSO (5-pin) - VAS 5565-
♦ Pressure tester - VAS
6550-
♦ Pressure regulator valve -
VAS 6550/4-
♦ Measuring container, ca‐
pacity 3 litres
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
When driving characteristic problems occur when the fuel tank is

a approx. 1/4 filled, then check fuel delivery rates with approx. 1/
4 filled tank or less.
Test prerequisites
• Voltage supply OK ⇒ page 31 .
7. Fuel pump 45
Touran 2003 ➤
• Fuel pressure OK ⇒ page 34 .

• Battery voltage must be at least 11.5 V. If necessary, charge
battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Charging
battery .
• Fuse for fuel pump control unit - J538- OK ⇒ Current flow di‐
agrams, Electrical fault finding and Fitting locations.
• Fuel pump control unit - J538- OK ⇒ Vehicle diagnostic tester.
• Fuel pump relay - J17- OK ⇒ Vehicle diagnostic tester
• Fuel pump fuse OK ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations
• Check that connector is fitted securely by pulling connector
without pressing catch. If connector was not inserted correctly,
repeat functional check of fuel pump.
• Filling level in fuel tank above reserve.
Test sequence:
Checking fuel delivery rate in engine compartment:
– Fold rear seats forwards and detach carpet ⇒ General body
repairs, interior; Rep. gr. 72 ; Rear seats; Removing and in‐
stalling bench seat .
AG. Volkswagen AG d
– Remove bolts -arrows- and remove fuel delivery unit cover. agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touran 2003 ➤

– Remove fuel pump control unit - J538- -2- from cover -1-.
– Unclip cover -1- at retaining tabs -arrows-, using removal

wedge - 3409- .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Check that connector -arrow- is fitted securely by pulling con‐
nector without pressing catch. The connector can cause a fault
t to the co
if it has not been fitted correctly.
– Release and unplug connector -arrow-.
rrectne
– Check contacts on plug and on fuel delivery unit for damage.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr

cum
r
fo

en
ng
t.
yi Co
op
– Connect remote control - V.A.G 1348/3A- to adapter - VAS
C py
ht. rig
5565- and to battery positive terminal in engine compartment.
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
This step serves only to have the fuel pump running when the
engine is stopped.
7. Fuel pump 47
Touran 2003 ➤
– The delivery rate of the fuel pump depends on the battery volt‐
age. Therefore also connect multimeter - V.A.G 1526E- to
contacts -1- and -5- of adapter - VAS 5565- .
AG. Volkswagen AG d
agen oes
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ho eo
aut ra
ss c
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un
pt
an
d
itte
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rm
ab
pe
– Pull off supply line -1-. Separate plug-in connectors
ility
ot
⇒ page 21 .
wit
, is n
h re
hole
spec
WARNING
es, in part or in w
t to the co
rrectness of i
l purpos

nform
ercia

m
a
com
tion in
– Collect escaping fuel with a cleaning cloth.

r
te o
thi
s
iva
do

r
rp
cum
fo

en
ng
t.
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op
– Connect hose - VAS 6550/2- between fuel line leading from C py
ht. rig
fuel tank and pressure tester - VAS 6550- . rig ht
py by
co Vo
by lksw
– Connect pressure regulating valve - VAS 6550/4- to connec‐ Prote
cted AG.
agen
tion -B- of pressure tester - VAS 6550-
– Hold end of hose of pressure regulating valve - VAS 6550/4-
in measuring container.

Touran 2003 ➤
Fuel supply system
gen AG-. Petrol
Volkswaengines
gen AG d
- Edition 12.2013
wa oes
olks not
yV gu
– Ensure that drain tap -C- on pressure tester -1-isised closed.
b ara
nte
r
ho eo
– Shut-off valves -A- and -B- on pressure tester
au -1- are open.
t ra
c
ss
– Press remote control - V.A.G 1348/3A- .
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
h re
The fuel system pressurisation pump - G6- will be actuated.
hole
spec
es, in part or in w
t to the co
rrectness of i
– Set pressure of 4.0 bar on pressure regulating valve -arrow-
using adjuster wheel.
l purpos
– Keep the adjuster in this position from this point on.
nform
ercia
– Drain measuring container.

m
at
– Press remote control for 60 seconds whilst measuring voltage
om
ion
at fuel pump.
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
– Compare delivered quantity of fuel with specification indicated
by lksw
cted agen
Prote
in chart.
AG.
Name of axis Unit

Minimum delivery rate cm3
Voltage at fuel pump with en‐ Volt
gine not running and pump run‐
ning.
Example:
During the test a voltage of 10.5 volts is measured. This equates
to a minimum delivery rate of approx. 1,200 cm3 in 60 seconds.

– Open tank flap unit.
– Clean area around fuel filler neck.
– Unscrew cap from fuel filler neck -arrow-.
– Repeat fuel delivery rate check ⇒ page 46 .
– Check fuel tank breather ⇒ page 27 .
Check fuel delivery rate at fuel filter as follows:
7. Fuel pump 49
Touran 2003 ➤
Checking fuel delivery rate at fuel filter:

– Pull fuel supply line -arrow- off fuel filter. Separate plug-in con‐
nectors ⇒ page 21 .
WARNING
AG. Volkswagen AG d
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lksw not
The fuel line is under pressure. d by
Vo gu
ara
ise nte
r
Risk of injury to eyes andut skin from fuel.
ho eo
ra
s a c
s
ce
le

un
pt
an
d

itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
– Connect pressure tester - VAS 6550- to fuel supply line -2- by
spec
means of hose - VAS 6550/1- .
es, in part or in w
t to the co
rrectness of i
– Connect pressure regulating valve - VAS 6550/4- to connec‐
l purpos

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Note

Touran 2003 ➤

– Keep the adjuster in this position from this point
wage
on.
e
olks s no
yV t gu
– Drain measuring container. edb ara
ris nte
– Press remote control for 60 seconds ho
ut whilst measuring voltage
eo
a ra
at fuel pump. ss c
ce
le
un
pt
an
d
itte
y li
– Check fuel line leading to engine for possible restrictions rm
ab
pe
ility
(kinks) or blockages.
ot
wit
, is n
– Check fuel line leading to engine for leaks and damage.
h re
hole
spec
es, in part or in w
t to the co
– Renew fuel filter ⇒ page 25 .
rrectness of i
Proceed as follows to check fuel delivery rate at fuel delivery unit:
l purpos
Checking fuel delivery rate at fuel delivery unit:
nform
ercia

⇒ page 21 .
m
a
com
tion in
r
te o
WARNING
thi
s
iva
do
r
rp
c
um
fo
en
ng
t.
yi
Co
Cop py
ht. rig
rig ht
py by
o Vo
ries and skin contact. Before loosening hose connections, by c lksw
cted agen
Prote AG.
– Connect pressure tester - VAS 6550- to fuel delivery unit -1-

using hose - VAS 6550/2- .
– Connect pressure regulating valve - VAS 6550/4- to connec‐
7. Fuel pump 51
Touran 2003 ➤

Note

– Keep the adjuster in this position from this point on.
– Drain measuring container.
– Press remote control for 60 seconds whilst measuring voltage
at fuel pump.

– Remove fuel delivery unit and check filter strainer for dirt.
– Check fuel lines for leaks and damage. lkswage es n
o ot g
byV ua
d ran
– Check that all fuel delivery unit -1- hose connections o
ir se tee
-arrows- are connected. auth or
ac
ss
ce
le
un
pt
an
d
– Check current draw of fuel pump ⇒ page 52 .

itte
y li
rm
ab
If no fault was detected in the current draw:
pe
ility
ot
wit
, is n
– Renew fuel delivery unit ⇒ page 17 . h re

hole
spec
If fuel delivery rate has been attained, but nevertheless you sus‐
es, in part or in w
pect a fuel supply system fault (e.g. intermittent failure of fuel

t to the co
supply system):
– Check current draw of fuel pump ⇒ page 52 .
rrectness of i
7.1.5 Checking current draw

l purpos

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
horis Touran e o 2003 ➤
ut
ss a Fuel supply system - Petrol engines - Edition 12.2013
ra
c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
♦ Multimeter e.g. hand-held multimeter - V.A.G 1526E-

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Pickup clamp e.g. pickup clamp - V.A.G 1526B/2-

♦ Test instrument adapter/DSO (5-pin) - VAS 5565-
Note

joined.
⇒ page 21
♦ Ensure plug-in connector is secured properly by pulling.

– Fold rear seats forwards and detach carpet ⇒ General body
repairs, interior; Rep. gr. 72 ; Rear seats; Removing and in‐
stalling bench seat .
7. Fuel pump 53
Touran 2003 ➤



– Remove cover -1- with fuel pump control unit - J538- -2- from
fuel delivery unit.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
– To do this, unclip cover -1- for flange at retaining tabs

h re
ole,
-arrows-, using removal wedge - 3409- .

spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
– Check that connector -arrow- is fitted securely by pulling con‐

nector without pressing catch. The connector can cause a fault
if it has not been fitted correctly.
– Release and unplug connector.
– Check contacts on plug and on fuel delivery unit for damage.

– Connect pick-up clamp -A- to red terminal with lettering “pick-
up clamp” for test instrument adapter/DSO (5-pin) - VAS
5565- .
– Start engine and run itnat
AGidling speed.
. Volkswagen AG
age does
ksw not
– Measure current
by
Vol draw of fuel pump. gu
ara
d
ise nte
• Specification:
tho
r
max. 9 amps. eo
au ra
c
ss
ce
e
nl
pt
Note
du
an
itte
y li
erm
ab
♦ The starting current for the fuel pump can lie briefly above
ility
ot p
specifications when starting the engine.

wit
, is n
h re
♦ If the fault in the fuel system is not always evident, the check
hole
spec
can also be carried out during a road test. A 2nd person is

es, in part or in w
required to do this, however.

t to the co
If the current draw is exceeded:

rrectness of i

l purpos
– Remove fuel delivery unit ⇒ page 17 and check for contami‐

nation.
nform
ercia
– Check fuel pressure ⇒ page 34 .

m
at
om
ion
c
in t
or
– Renew fuel delivery unit ⇒ page 17 .

his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
7. Fuel pump 55

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Fuel Supply System - Petrol Engines-Touran

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Service

Service Department. Technical Information

All rights reserved.

Copyright © 2015 Volkswagen AG, Wolfsburg D3E803B0CE1

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

RON 95 unleaded 95 unleaded 95 unleaded 95 unleaded 95 unleaded

2.1 Safety precautions when working on

♦ Pull off connector from fuel delivery unit flange or fuel

vated charcoal filter system, coolant and refrigerant, brake

fluid and vacuum) and electrical wiring in their original po‐

♦ To avoid damage to lines, ensure sufficient clearance to

all moving or hot components.

2 Rep. gr.00 - Technical data

Fuel system is under pressure! Wear eye protection and gloves

♦ Even before work commences, the extraction hose of an ac‐

♦ Test and measuring instruments must always be secured to spec

is a possibility that the person sitting in this seat may receive

3 General repair notes

3.1 Rules for cleanliness

be carried out immediately.

tool boxes etc.).

4 Rep. gr.00 - Technical data

20 – Fuel supply system lkswage

❑ Removing and installing

exterior; Rep. gr. 55 ;

To secure the securing straps for

To secure the securing straps for

❑ Clipped onto side of fuel tank.

Installation position of fuel delivery unit

Marking on sender must align with the marking on fuel tank

Return line (blue or with blue mark) -2-

1.2 Removing and installing fuel tank

6 Rep. gr.20 - Fuel supply system

If necessary, empty fuel tank using fuel extractor - VAS 5190-

Special tools and workshop equipment required

♦ Engine and gearbox jack - V.A.G 1383 A-

– Note safety precautions before beginning work ⇒ page 2 .

– Fold rear seat bench forwards.

Vehicles with push-on cover

Continuation for all vehicles

– Pull 5-pin connector -1- off flange.

– Unbolt filler neck from body -arrows-.

8 Rep. gr.20 - Fuel supply system

– Remove securing nuts -arrows- if there are any and remove

hose connections, wrap a cloth around the connection. Then

release pressure by carefully pulling hose off connection.

Risk of explosion of fuel tank. If a new or completely empty fuel

1.3 Emptying fuel tank

1.3.1 Emptying fuel tank when fuel pump is intact

Secure earth wire of fuel extractor to a bare metal part of the

Special tools and workshop

If the fuel extraction unit - VAS 5190- gisenstill

loosening hose connections, wrap a cloth around the connec‐

tion. Then release pressure by carefully pulling hose off con‐

Connect fuel extractor earth wire to earth.

♦ Plug-in connectors for fuel lines must engage »audibly« when

♦ Note colour assignment when installing the plug-in connectors

Vehicles with bolt-on cover

Vehicles with push-on cover n AG. Volkswagen AG do

12 Rep. gr.20 - Fuel supply system

– Connect test instrument adapter/DSO (5-pin) - VAS 5565- to

Secure earth wire of fuel extractor to a bare metal part of the

To extract E 85 fuel, use only fuel extractor - VAS 5190 A- !

Special tools and workshop equipment required