Replacing High-Pressure Fuel Pumps In A Touareg: Step-By-Step Guide

Replacing the high-pressure fuel pump on a Volkswagen Touareg is a complex process that requires a good understanding of car mechanics. The fuel pump is responsible for supplying pressurised gasoline to the fuel injectors in a car's engine. While a high-quality, OEM fuel pump can last a long time, it will eventually degrade and need to be replaced. The average cost of replacing the fuel pump on a Touareg is $673, with $190 for parts and $483 for labour. However, prices may vary depending on the model year and specific Touareg model.

Before attempting to replace the high-pressure fuel pump on a Touareg, it is important to correctly diagnose the issue and confirm that the fuel pump is indeed faulty. This can be done by scanning for fault codes and checking for symptoms such as the car not starting or stalling unexpectedly.

The process of replacing the fuel pump involves gaining access to the pump, which is located in the vehicle's fuel tank. This may require lowering the fuel tank from the vehicle. Once the pump is accessible, the fuel pump supply and return hoses, EVAP system hoses, and electrical connections must be removed. After installing the new pump, the engine is run to test for leaks.

It is recommended to replace the fuel filter when replacing the fuel pump, as well as to keep the gas tank at least a quarter full to maximise the life of the new fuel pump.

Diagnose the problem

Diagnosing a bad fuel pump in your Volkswagen Touareg can be done by looking out for some common symptoms. Here are some detailed indicators to watch out for:

Engine Behaviour and Performance Issues

• Engine Sputtering: If your engine sputters, jerks, or cuts out for brief periods at high speeds, it could indicate an inconsistent flow of fuel to the engine, which is often caused by a failing fuel pump.
• Power Loss: A faulty fuel pump may cause a sudden loss of power when accelerating. This is due to the fuel pump's inability to keep up with the engine's demands at higher speeds.
• Engine Misfire: A bad fuel pump may cause one or more cylinders to fire too late or not at all, resulting in rough idling or difficulty starting the car.
• Acceleration Issues: If your Touareg struggles to accelerate as it should, it could be due to a failing fuel pump that is unable to deliver the necessary amount of fuel.
• Poor Fuel Efficiency: A significant decrease in fuel efficiency could indicate a failing fuel pump as it may consume more power when not working properly.

Audible and Visible Indicators

• Whining Noise: A high-pitched whining noise, especially from the fuel tank area, is a telltale sign of a failing fuel pump. This noise tends to get louder as the pump works harder.
• Stalling: Stalling, often followed by the engine restarting after a few minutes, is a common symptom of low fuel pressure caused by a faulty fuel pump.
• Trouble Starting: If your Touareg struggles to start or doesn't start at all, it could be due to a bad fuel pump. Ensure you can hear the fuel pump turning on when you turn the key to the "ON" position.
• Check Engine Light: If the check engine light is on and your Touareg has code P0087, it indicates a lack of fuel pressure, which could be caused by a faulty fuel pump.

Potential Causes of Fuel Pump Failure

While the above symptoms indicate a potential problem with the fuel pump, there are other factors that could be causing these issues. Here are some possible causes:

• Fuel Pump Wear: Over time, the internal components of the fuel pump can wear out, leading to reduced efficiency in delivering fuel to the engine.
• Fuel Pump Relay Issues: A faulty fuel pump relay can cause intermittent power loss to the pump, leading to unpredictable operation and stalling.
• Clogged Fuel Filter: A clogged fuel filter can restrict fuel flow, contribute to engine misfires, and put additional strain on the fuel pump, leading to premature wear.

Purchase a new pump

When purchasing a new high-pressure fuel pump for your VW Touareg, it is important to ensure that the part is compatible with your specific vehicle model. You can use the OEM part number or your vehicle's registration number to find a fitting high-pressure fuel pump.

There are several online retailers that offer high-pressure fuel pumps for the VW Touareg, with prices ranging from as low as £19 to £696, depending on the manufacturer and specifications.

AUTODOC:

AUTODOC offers a range of high-pressure fuel pumps for the VW Touareg, with prices ranging from €19.11 to €694.86. They provide original-quality replacement parts and offer free delivery on select items.

FCP Euro:

FCP Euro carries high-pressure fuel pumps compatible with the VW Touareg, including options from brands such as Hitachi, Delphi, and Genuine VW. Prices range from $98.99 to $1,099.99.

YourMechanic:

While not a direct purchase option, the website YourMechanic provides cost estimates for a fuel pump replacement service for the VW Touareg, which includes parts and labor. The average cost is $673, with prices varying depending on the specific model and location.

When purchasing a new high-pressure fuel pump, it is advisable to read customer reviews and compare different products to ensure you are getting a reliable and compatible part for your VW Touareg.

Remove the old pump

To remove the old pump, start by testing the fuel pump to be sure it isn’t functioning. If the fuel pump is faulty, you can begin the removal process.

First, you will need to gain access to the pump. If there is an access panel above the tank in the passenger compartment, you can remove the pump through there. If not, you will need to drain the fuel from the tank and then lower the fuel tank from the vehicle.

Once you have access to the pump, you will need to remove the fuel pump supply and return hoses, as well as EVAP system hoses, and electrical connections to the pump. Be sure to mark the hoses and wires before removal to make it easier to reconnect them to the new pump.

With the hoses and wires disconnected, you can now remove the old pump. If there are any reusable brackets or pick-up screens, be sure to remove them from the old pump and attach them to the new pump.

If your fuel system uses an in-line external filter, it is often recommended to replace the filter at this time as well.

Install the new pump

Once you have purchased a new high-pressure fuel pump for your VW Touareg, you can install it by following these steps:

Step 1: Prepare the new pump

Before you install the new pump, make sure you have all the necessary parts and that any reusable components from the old pump have been transferred over. This includes brackets and pick-up screens. It is also recommended to replace the fuel filter at this time if it has not been replaced recently.

Step 2: Gain access to the pump

Accessing the fuel pump on a VW Touareg typically requires removing the rear seats and cutting a hole in the carpet above the pump cover. Use a 12-point 10mm tool to remove the bolts holding the seat brackets in place, as these can be very tight. Then, remove the pump cover by prying it off with a flat screwdriver and unscrewing the 10mm nuts.

Step 3: Disconnect the old pump

The old pump will have several hoses and wires connected to it. Label or mark these connections to ensure proper installation of the new pump. Carefully disconnect all hoses and wires, including the fuel supply and return hoses, EVAP system hoses, and electrical connections.

Step 4: Remove the old pump

With all the connections disconnected, you can now remove the old pump from the vehicle. Depending on the model of your Touareg, you may need to lower the fuel tank to gain access to the pump. If so, be sure to check the fuel tank straps and fasteners for excessive corrosion and replace them if necessary.

Step 5: Install the new pump

Position the new pump in the vehicle, ensuring that any brackets or pick-up screens are properly aligned and secured. Reattach the fuel supply and return hoses, EVAP system hoses, and electrical connections. Tighten all clamps and fittings securely.

Step 6: Test the new pump

Once the new pump is installed, add fuel to the tank and start the engine to test for leaks. Ensure that the new pump is functioning properly and that there are no fuel leaks.

Test the new pump

Once you have fitted the new high-pressure fuel pump, you will need to test it to ensure it is functioning correctly.

Testing the New High-Pressure Fuel Pump

Firstly, you will need to fill the fuel tank to at least a quarter full. This will ensure the pump is adequately cooled and lubricated.

Next, you will need to test the pump for leaks. Start the engine and inspect the pump and its connections for any signs of leaks.

You will also need to test the pressure of the new pump. This can be done either physically, by attaching a pressure gauge to the test port on the fuel rail, or electronically, by connecting a scan tool. The pressure should be at least 500 psi.

If the new pump passes all these tests, you can be confident that it is functioning correctly.

Frequently asked questions