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Service
Workshop Manual
Touareg 2003 ➤
8-cylinder injection engine
Engine ID
Edition 11.2011
Service Department. Technical Information
AXQ BHX

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   Summary of Contents for Volkswagen Touareg 2003

  • Page 1

    Service Workshop Manual Touareg 2003 ➤ 8-cylinder injection engine AXQ BHX Engine ID Edition 11.2011 Service Department. Technical Information...

  • Page 2

    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 © 2011 Volkswagen AG, Wolfsburg K0058961520...

  • Page 3: Table Of Contents

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Contents 00 - Technical data ........... .

  • Page 4

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Assembly overview - parts of cooling system, engine side, rear ....Assembly overview - parts of cooling system, body side ......

  • Page 5

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Assembly overview - removing and installing parts of secondary air system ... . 155 28 - Ignition system ........... . 157 Repairing ignition system .

  • Page 6

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Contents...

  • Page 7: Technical Data

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 00 – Technical data Technical data Engine data ⇒ page 1 Engine number The engine number („engine code“ and „serial number“) is stam‐ ped on the right side of the cylinder block.

  • Page 8: Removing And Installing Engine

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 10 – Removing and installing engine Removing and installing engine Removing engine ⇒ page 3 Securing engine on engine and gearbox support -VAS 6095- ⇒ page 9 Notes on installing ⇒ page 10...

  • Page 9: Removing Engine

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 ♦ Stepladder -VAS 5085- ♦ Torque wrench (5…50 Nm) -V.A.G 1331- Removing engine The engine is removed from below with the gearbox – Read fault memories of all control units before removal: ⇒...

  • Page 10

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Disconnect fuel supply line -arrow-. – Disconnect breather line -arrow- to solenoid valve in engine compartment. – Disconnect small connector -A- from engine control unit -1- and disconnect earth connection -arrow- of wiring harness.

  • Page 11

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Disconnect starter wire -1- and and lay it on engine. – Disconnect connector from air mass meter on left and remove intake hose and air filter housing on left. – Separate connectors -1- to -4- for Lambda probes and lay connectors on engine.

  • Page 12

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Remove heat shield -A- from steering box and separate uni‐ versal joint -B-. ⇒ Running gear, axles, steering; Rep. gr. 48 ; Repairing steering, power-assisted steering – Separate connectors -A- on gearbox as well as transfer box -B- and separate selector lever cable ⇒...

  • Page 13

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Disconnect lines on lower right of radiator -arrow- for gearbox oil. Collect escaping oil. – Now disconnect line from power steering oil cooler on bottom left. Collect escaping oil. – Unscrew earth cable -1- from longitudinal member on front right.

  • Page 14

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Install front supports -VAS 6131/6-1- left -1-, as well as - VAS 6131/6-2- right -2- on the assembly platform. Arrows on the supports point forwards. Secure the bolts in the following positions: left support -1-: A5, B4 and B5.

  • Page 15

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Loosen subframe bolts -1- and -2- as well as gearbox trans‐ verse support -4-. – Unscrew the third bolt of each suspension strut using steplad‐ der -VAS 5085- . – Now slowly lower engine/gearbox assembly, constantly ob‐...

  • Page 16

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Attach lifting tackle -3033- as shown in illustration and lift en‐ gine from scissor-type assembly platform using workshop crane -VAS 6100- . – Lift engine using workshop crane -VAS 6100- until the centre of the flywheel is at the same height as the assembly plate of the engine and gearbox support -VAS 6095- .

  • Page 17

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Reposition subframe with engine carrier onto prepared as‐ sembly platform. – Set engine on subframe. If gearbox is not yet bolted on: – Support engine from below using support -VAS 6131/8- .

  • Page 18

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Generate the readiness code in combination with a road test. Observe applicable safety precautions during road test. – Carry out road test. – Then carry out vehicle system test again and rectify any faults which may have occurred.

  • Page 19: Crankshaft Group

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 13 – Crankshaft group Dismantling and assembling engine Assembly overview Part I: toothed belt drive ⇒ page 15 Part II: cylinder block ⇒ page 17 1. Dismantling and assembling engine...

  • Page 20

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Caution Warning, aluminium cylinder block! The crankshaft and pistons must not be removed. Just loosening the main bearing caps will cause deformation of the cylinder block bearing pedestals. This deformation will cause a reduction of the bearing clear‐...

  • Page 21: Assembly Overview - Part I, Toothed Belt Drive

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Assembly overview - part I, toothed belt drive 1 - 10 Nm 2 - Bearing sleeve 3 - 20 Nm + / 4 turn (90°) fur‐ ther ❑ Renew. 4 - Washer ❑...

  • Page 22

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 ❑ Removing and installing ⇒ page 34 Removing, installing and tensioning toothed belt. 23 - Securing plate ❑ Renew. ❑ Observe installation position: side with lettering faces to rear. 24 - 55 Nm ❑...

  • Page 23: Assembly Overview - Part Ii, Cylinder Block

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Assembly overview - part II, cylinder block 1 - 10 Nm 2 - Cover ❑ With connection for crankcase breather 3 - Connecting hose ❑ For crankcase ventila‐ tion. 4 - Clip 5 - Baffle plate ❑...

  • Page 24: Removing And Installing Poly V-belt

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Specified torque for engine bracket Specified torque for securing bolt -1-: 60 Nm. Specified torque for securing nut -2-: 75 Nm. Removing and installing poly V-belt Special tools and workshop equipment required ♦...

  • Page 25: Checking Alignment Of Poly V-belt

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Fit poly V-belt as illustrated. After completing repairs always: – Start engine and check that belt runs properly. Checking alignment of poly V-belt Note Alignment of poly V-belt must always be checked to prevent dam‐...

  • Page 26

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Remove idler roller -1-. – Position aligning gauge -3201- on air conditioning system compressor belt pulley. Note The air conditioning system compressor pulley must align with the power-assisted steering vane pump pulley.

  • Page 27: Removing And Installing Sealing Flange And Drive Plate

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Removing and installing sealing flange and drive plate Note Secure engine to engine and gearbox support -VAS 6095- to car‐ ry out repairs. Assembly overview ⇒ page 21 Removing and installing drive plate ⇒...

  • Page 28: Removing And Installing Drive Plate

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 6 - 30 Nm + / 4 turn (90°) further ❑ Renew. 7 - 10 Nm 8 - 15 Nm 9 - Cylinder block 10 - Oil sump ❑ Removing and installing ⇒...

  • Page 29

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 ♦ Locking pin -3242- ♦ Torque wrench (5…50 Nm) -V.A.G 1331- Removing – Remove engine ⇒ page 3 – Separate engine from gearbox. – Set engine to TDC. For this, notches -A- and -B- must align.

  • Page 30: Removing And Installing Sealing Flange At Drive Plate End

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Screw locking pin -3242- into crankshaft. – Loosen drive plate securing bolts diagonally and remove. – Remove drive plate together with washer and shim. Installing Installation is carried out in the reverse order. When installing, note the following: –...

  • Page 31

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 2.3.1 Removing – Remove engine ⇒ page 3 – Separate engine from gearbox. – Remove drive plate ⇒ page 22 – Remove sump ⇒ page 70 – Remove sealing flange -arrow- from cylinder block.

  • Page 32: Renewing Crankshaft Oil Seal, Vibration Damper End

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Pull oil seal with sealing flange -A- by the outside over sleeve -T10122/1- onto pulling sleeve -T10122/2- . – Separate the two fitting sleeves. – Then set pulling sleeve -T10122/2- with dry seal and sealing flange onto crankshaft journal.

  • Page 33

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Remove thrust washer from crankshaft journal and mark thrust washer front face -arrow- using a waterproof felt-tip marker. Installing – Remove oil residue from crankshaft journal and thrust washer using a clean cloth.

  • Page 34: Cylinder Head, Valve Gear

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 15 – Cylinder head, valve gear Cylinder head Assembly overview ⇒ page 29 Removing and installing right cylinder head cover ⇒ page 30 Removing and installing left cylinder head cover ⇒ page 32 Removing, installing and tensioning toothed belt ⇒...

  • Page 35: Assembly Overview

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Assembly overview 1 - Cap ❑ Renew seal if damaged. 2 - Boot ❑ Renew if damaged. 3 - Oil filler neck ❑ Renew seal if damaged. 4 - Connecting hose ❑...

  • Page 36: Removing And Installing Right Cylinder Head Cover

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 ❑ Removing and installing right cylinder head ⇒ page 44 ❑ Removing and installing left cylinder head ⇒ page 40 15 - Cylinder head ❑ Check for distortion ⇒ page 30 ❑...

  • Page 37

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 ♦ Torque wrench (5…50 Nm) -V.A.G 1331- ♦ Not illustrated: ♦ Cable ties ♦ Sealant -D 454 300 A2- Removing Caution When doing any repair work, especially in the engine compart‐...

  • Page 38: Removing And Installing Left Cylinder Head Cover

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Loosen securing bolts in the sequence -12- to -1- and remove cylinder head cover. Installing Installation is carried out in the reverse order. When installing, note the following: Note Renew gasket if damaged or leaking.

  • Page 39

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 ♦ Torque wrench (5…50 Nm) -V.A.G 1331- ♦ Not illustrated: ♦ Cable ties ♦ Sealant -D 454 300 A2- Removing Caution When doing any repair work, especially in the engine compart‐...

  • Page 40: Removing, Installing And Tensioning Toothed Belt

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Loosen securing bolts in the sequence -12- to -1- and remove cylinder head cover. Installing Installation is carried out in the reverse order. When installing, note the following: Note Renew gasket if damaged or leaking.

  • Page 41

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Special tools and workshop equipment required ♦ Locking pin -3242- ♦ Two-arm puller -T40001- ♦ Camshaft clamp -T40005- ♦ Tensioner wrench - T40009- ♦ Locking pin -T40011- ♦ Reversible ratchet -VAS 5122- ♦...

  • Page 42

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Mark and remove poly V-belt. ⇒ page 18 – Remove toothed belt guards on left and right. – Mark direction of rotation of toothed belt using a coloured felt- tip marker.

  • Page 43

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Remove securing bolts -arrows- for alternator. Move alternator aside slightly. – First unscrew bolt -1- from oil filter housing. Then unscrew bolts -2- from cover for toothed belt tensioning element.

  • Page 44

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Now pull camshaft sprockets off camshaft tapers using two- arm puller -T40001- and hook -T40001/2- . – Loosen tensioning roller -arrow- and remove toothed belt. 1.4.2 Installing and tensioning – Note marking for direction of rotation when reinstalling the ex‐...

  • Page 45

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Insert a 5 mm drill bit between the tensioning lever and the tensioning element piston -arrow-. – Now pre-tension tensioning roller (still in loosened condition) using torque wrench -V.A.G 1410- with attached reversible ratchet -VAS 5122- and tensioner wrench -T40009- in anti- clockwise direction -arrow- to 4 Nm.

  • Page 46: Removing And Installing Left Cylinder Head

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Remove clamping bolt -3242- from hole, install sealing plug -arrow- and tighten to 30 Nm. – Turn crankshaft two full turns in direction of engine rotation and check setting dimension -a-: specification 5 mm.

  • Page 47

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Special tools and workshop equipment required ♦ Drip tray -V.A.G 1306- ♦ Torque wrench (5…50 Nm) -V.A.G 1331- ♦ Torque wrench (40…200 Nm) -V.A.G 1332- ♦ Spring-type clip pliers -VAS 5024A- Not illustrated: ♦...

  • Page 48

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – All cable ties which are opened or cut open when engine is removed must be replaced in the same position when engine is installed. – Remove front exhaust pipe from exhaust manifold ⇒...

  • Page 49

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Remove bolts securing coolant pipe -arrow-. – Disconnect connectors from knock sensors. – Pull connectors off all injectors. – Disconnect connector -1-. – Disconnect hose -2-. – Remove bolts -8-.

  • Page 50: Removing And Installing Right Cylinder Head

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Ensure dowel sleeves -arrows- are inserted into cylinder block holes and the cylinder head gasket is located. – Fit cylinder head, screw in new cylinder head bolts and tighten hand tight.

  • Page 51

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Special tools and workshop equipment required ♦ Drip tray -V.A.G 1306- ♦ Torque wrench (5…50 Nm) -V.A.G 1331- ♦ Torque wrench (40…200 Nm) -V.A.G 1332- ♦ Spring-type clip pliers -VAS 5024A- Not illustrated: ♦...

  • Page 52

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – All cable ties which are opened or cut open when engine is removed must be replaced in the same position when engine is installed. – Remove front exhaust pipe from exhaust manifold ⇒...

  • Page 53

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Loosen cylinder head bolts in the sequence given starting at the outside and working inwards and then remove completely. – Carefully remove cylinder head. – Place clean cloths in cylinders so that no dirt or emery cloth particles can get in between cylinder wall and piston.

  • Page 54: Checking Compression

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Tighten cylinder head bolts in tightening sequence shown working from inside to outside. – Pre-tighten all bolts to 35 Nm. – Then tighten all bolts to 60 Nm. – Then tighten all bolts / 4 turn (90°) further using a rigid wrench.

  • Page 55

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Test prerequisites • Engine oil temperature must be at least 30°C. • The battery voltage must be at least 11.5 V. • All electrical consumers, e.g. lights and rear window heating, must be switched off.

  • Page 56: Repairing Valve Gear

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Repairing valve gear Assembly overview Camshafts, checking axial clearance ⇒ page 53 Renewing camshaft oil seal ⇒ page 54 Renewing Hall sender seals ⇒ page 55 Removing and installing camshafts and variable camshaft timing adjusters ⇒...

  • Page 57

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 9 - Cap ❑ Renew. ❑ Punch through using a screwdriver and lever out for removal. ❑ Install using tool 3202. 10 - Bearing cap When installing, seal parting surfaces of outer bearing caps with sealant -AMV 188 001 02- ⇒...

  • Page 58

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 ❑ Removing and installing right cylinder head ⇒ page 44 ❑ Removing and installing left cylinder head ⇒ page 40 ❑ After renewing, renew entire coolant. 24 - Exhaust valve ❑ Do not rework, only lapping-in is permitted.

  • Page 59: Camshafts, Checking Axial Clearance

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Valve dimensions Note Valves must not be reworked. Only lapping-in is permitted. Valve dimensions Dimension Inlet valve Exhaust valve -∅ a- 26.8...27.0 29.8...30.0 -∅ b- 5.96...5.97 5.94...5.95 104.84...105.34 103.64...104.14 -α- ∠°...

  • Page 60: Renewing Camshaft Oil Seals

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Insert camshaft and secure with bearing caps -3-, -5- and -7-. Inlet camshaft – Attach dial gauge with universal dial gauge bracket to cylinder head, as shown. Wear limit for axial clearance: max. 0.20 mm.

  • Page 61: Renewing Hall Sender Seals

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Unscrew inner part of oil seal extractor -3240- several turns out of the outer part and lock with knurled screw. – Lubricate threaded head of oil seal extractor, place it in posi‐...

  • Page 62: Removing And Installing Camshafts And Variable Camshaft Timing Adjusters

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Unscrew bolts -1- from Hall sender. – Unscrew bolt -2- from rear of toothed belt guard. – Slightly pull rear of toothed belt guard towards front and re‐ move Hall sender housing with Hall sender screen and taper.

  • Page 63

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 ♦ Chain tensioner retainer -3366- ♦ Torque wrench (5…50 Nm) -V.A.G 1331- ♦ Sealant -AMV 188 001 02- 2.4.1 Removing – Set engine to TDC ⇒ page 34 – Remove toothed belt and camshaft sprocket ⇒...

  • Page 64

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Remove idler roller -1-. – Loosen securing bolts -arrows- and remove rear toothed belt guard. Continuation for both cylinder heads – Disconnect connector from Hall sender and remove Hall send‐...

  • Page 65

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Hold camshaft adjuster in position using retainer for chain ten‐ sioner -3366- . Note Camshaft adjuster can be damaged if chain tensioner is tightened too far. – Mark installation position of all bearing caps (e.g. using a wa‐...

  • Page 66

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Align coloured markings -arrows-. When using new camshaft timing chain The distance between tooth -A- and tooth -B- of the camshaft ad‐ juster must be exactly 16 rollers of the camshaft roller chain. The illustration shows the exact positions of the -1st- and -16th- rollers on the chain sprockets.

  • Page 67

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Check TDC position of camshafts. The markings on the cam‐ shafts must be in line with the arrow on both bearing caps -arrows-. Note If necessary, slightly turn camshaft back and forth in order to en‐...

  • Page 68: Removing And Installing Roller Rocker Finger

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Removing and installing roller rocker fin‐ Special tools and workshop equipment required ♦ Torque wrench (5…50 Nm) -V.A.G 1331- Procedure – Remove engine ⇒ page 2 – Remove camshafts with camshaft adjuster ⇒...

  • Page 69

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Special tools and workshop equipment required ♦ Spark plug socket and ex‐ tension -3122 B- ♦ Valve stem seal puller -3364- ♦ Valve stem seal fitting tool -3365- ♦ Adapter -T40012- ♦...

  • Page 70

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Fit guide plate -VAS 5161/7- onto cylinder head as shown in illustration. – Secure guide plate using the knurled screws -VAS 5161/12- . – Insert drift -VAS 5161/3- into guide plate and knock valve cot‐...

  • Page 71: Checking Valve Guides

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 2.6.2 Installing – To prevent damage to new valve stem seals, place plastic sleeve -A- on valve stem. – Lubricate sealing lip of valve stem seal -B-, place it in the valve stem oil seal fitting tool -3365- and push carefully onto valve guide.

  • Page 72: Reworking Valve Seats

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 ♦ Universal dial gauge bracket -VW 387- ♦ Dial gauge Test procedure – Insert new valve into guide. The end of the valve stem must be flush with the guide. On account of differing stem diame‐...

  • Page 73

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Note If the valve is to be renewed as part of a repair, use a new valve for the calculation. – Measure distance -a- between end of valve stem and upper edge of cylinder head.

  • Page 74: Lubrication

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 17 – Lubrication Removing and installing parts of lu‐ brication system Dismantling and assembling oil filter housing ⇒ page 69 Removing and installing sump ⇒ page 70 Removing and installing oil pump ⇒...

  • Page 75: Dismantling And Assembling Oil Filter Housing

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Markings on oil dipstick 1 - Max. mark 2 - Min. mark a - Area above hatched field up to max. mark: Do not top up with engine oil! b - Engine oil level within hatched zone: Engine oil can be topped- c - Area from min.

  • Page 76: Removing And Installing Oil Sump

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 17 - 50 Nm + / 4 turn (90°) further ❑ Renew. 18 - Engine mounting Removing and installing oil sump Note The sump (upper and lower parts) can be removed or installed only with the oil filter housing removed ⇒...

  • Page 77

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 21 - 10 Nm 22 - 25 Nm 23 - Oil suction pipe ❑ For sump, upper part Installation position of oil pump chain drive sprocket – Fit chain sprocket onto oil pump shaft. The flattened side -arrow- faces oil pump shaft and the inscription on the chain sprocket faces towards front.

  • Page 78

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Unscrew bracket for coolant drain pipe -from- upper part of sump. If necessary, slightly loosen banjo bolt -1-. – Now unscrew lower part and upper part of sump. – Loosen sump with light blows of a rubber headed hammer or light leverage with a lever, if necessary.

  • Page 79

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Run bead along inner side of bolt holes -arrows-. Note The sealant bead must not be thicker, otherwise excess sealing compound will enter the oil sump and may block the oil suction line strainer.

  • Page 80: Oil Pump

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Bolt coolant drain pipe to sump upper part -arrow- to 10 Nm and then bolt to cylinder block -1- to 30 Nm. Note Let sealing compound dry for approx. 30 minutes after installing oil sump.

  • Page 81: Checking Oil Pressure And Oil Pressure Switch

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Checking oil pressure and oil pressure switch Special tools and workshop equipment required ♦ Oil pressure tester -V.A.G 1342- ♦ Adapter -V.A.G 1342/14- ♦ Voltage tester -V.A.G 1527B- ♦ Auxiliary measuring set - V.A.G 1594C-...

  • Page 82

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Checking oil pressure switch – Remove oil pressure switch -F1- and screw into tester. – Screw oil pressure tester -V.A.G 1342- with adapter - V.A.G 1342/14- into oil filter housing in place of oil pressure switch.

  • Page 83: Cooling

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 19 – Cooling Removing and installing parts of cool‐ ing system Caution When doing any repair work, especially in the engine compart‐ ment, pay attention to the following due to the cramped condi‐...

  • Page 84: Assembly Overview - Radiator

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Assembly overview - radiator 1 - Coolant pipe ❑ Secured to fan support with spacers. 2 - To expansion tank 3 - Coolant hose ❑ Secured to top of front end with retaining clips.

  • Page 85: Assembly Overview - Radiator Fan

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Assembly overview - radiator fan 1 - Radiator fan -V7- 2 - Fan support ❑ Clipped onto radiator. ❑ Check for secure seat‐ ing. 3 - 10 Nm 4 - 10 Nm...

  • Page 86

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Unscrew coolant pipe from fan support -arrow-. – Loosen spring-type clips on coolant pipe and swivel it upwards together with spacers. – Disconnect connectors from radiator, loosen cable clamps on fan support and lay wiring harness to side.

  • Page 87: Assembly Overview - Parts Of Cooling System, Engine Side, Front

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Assembly overview - parts of cooling system, engine side, front 1 - Thermostat housing 2 - Coolant pump ❑ Check for ease of move‐ ment. ❑ Removing and installing ⇒ page 89...

  • Page 88: Touareg

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 1 - Coolant pipe ❑ Between left and right cylinder head ❑ With junction to heat ex‐ changer for heating, ex‐ pansion tank and upper coolant hose. 2 - O-ring ❑ Renew.

  • Page 89: Assembly Overview - Parts Of Cooling System, Body Side

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Assembly overview - parts of cooling system, body side 1 - Expansion tank ❑ Test cooling system for leaks using cooling sys‐ tem tester -V.A.G 1274- and adapter for cooling system tester -V.A.G 1274/8- .

  • Page 90: Coolant Hose Schematic Diagram

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Coolant hose schematic diagram 1 - Radiator/cooler 2 - Upper coolant hose 3 - Lower coolant hose 4 - Coolant pump -V36- 5 - Non-return valve ❑ Note installation posi‐ tion.

  • Page 91: Checking Water Pump V36

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Checking water pump -V36- Special tools and workshop equipment required ♦ Voltage tester -V.A.G 1527/B- ♦ Auxiliary measuring set -V.A.G 1594/C- ♦ Current flow diagram Test prerequisite • Fuse -16- -arrow- must be OK.

  • Page 92: Draining And Filling Coolant

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Connect contact -1- of water pump -V36- to battery positive (+) and contact -2- to earth (-) using auxiliary cables from aux‐ iliary measuring set -V.A.G 1594C- . Pump must run.

  • Page 93

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Draining WARNING Steam may escape when expansion tank is opened. Wear eye protection and protective clothing to avoid eye injuries and scalding. Cover cap with cloth and open carefully. – Open cap on coolant expansion tank.

  • Page 94: Removing And Installing Radiator

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Note Use only coolant additive G12 plus in accordance with ♦ „TL VW 774 F“. Identification: purple colour. G 12 plus and coolant additives marked „Conforming to ♦ TL VW 774 F“ prevent frost and corrosion damage and scaling and also raise boiling point of coolant.

  • Page 95: Removing And Installing Coolant Pump And Thermostat

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 ♦ Torque wrench -V.A.G 1331- Removing – Drain coolant ⇒ page 86 – Pull out retaining clips from quick-release coupling for coolant hose at top and bottom and detach coolant hoses from radia‐...

  • Page 96

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 ♦ Torque wrench -V.A.G 1331- Removing – Drain coolant ⇒ page 86 – Remove upper coolant hose from thermostat housing. – Remove radiator fans with radiator fan support ⇒ page 79 –...

  • Page 97: Checking Cooling System For Leaks

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Remove toothed belt guard securing nuts -1-. – Then unscrew all coolant pump securing bolts -arrows-. Installation is carried out in the reverse order. When installing, note the following: – Insert coolant pump with gasket.

  • Page 98

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – To do this screw the cooling system tester -V.A.G 1274- and the adapter for cooling system tester -V.A.G 1274/9- on seal‐ ing cap as shown. – Operate pump on tester and create a pressure of between 1.6 bar.

  • Page 99: Fuel Supply System

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 20 – Fuel supply system Parts of fuel supply system Caution When doing any repair work, especially in the engine compart‐ ment, pay attention to the following due to the cramped condi‐...

  • Page 100: Assembly Overview - Fuel Tank With Attachments

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Assembly overview - fuel tank with attachments 1 - Fuel filler neck 2 - To activated charcoal filter. 3 - Fuel tank ❑ When removing, sup‐ port using engine and gearbox jack -V.A.G 1383 A- .

  • Page 101

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 ❑ Checking fuel pump ⇒ page 107 15 - Fuel gauge sender -G- ❑ Right side. ❑ Round, ball float ❑ Checking: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.

  • Page 102: Assembly Overview - Fuel Filter

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Assembly overview - fuel filter 1 - Connection ❑ For breather line. 2 - Flange ❑ Left side. ❑ With fuel filter housing ❑ Note installation posi‐ tion on fuel tank ⇒...

  • Page 103

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Prerequisites • Fuel tank must be emptied ⇒ page 100 , Emptying fuel tank. • Fuses -13- and -14- -arrow- must be removed from their sock‐ ets. Procedure WARNING Fuel supply lines are under pressure! Wear eye protection and gloves to avoid injuries and skin contact.

  • Page 104: Schematic Diagram Of Fuel Lines And Components In Fuel Tank

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Individual parts of flange, right side 1 - Connectors for fuel pump and fuel gauge sender 2 - Fuel pressure regulator (4 bar) 3 - Earth wire 4 - Pressure regulator inlet (from fuel filter)

  • Page 105: Safety Precautions When Working On Fuel Supply System

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 ❑ To fuel delivery unit on right side 15 - Suction-jet pump ❑ Left side. 16 - Fuel delivery unit ❑ Left side. Installation position of fuel delivery unit flange Insert left or right flange with marking -arrow- in direction of travel.

  • Page 106: Emptying Fuel Tank

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 ♦ Thoroughly clean all unions and surrounding areas before dis‐ connecting. ♦ Place removed parts on a clean surface and cover. Use only lint-free cloths. ♦ Carefully cover opened components or seal if repairs cannot be carried out immediately.

  • Page 107

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Push suction hose -arrow- of fuel extractor -VAS 5190- about 170...180 cm into fuel filler neck and extract fuel. Note When no more fuel is extracted, the tank is emptied just enough for the flanges to be opened without danger.

  • Page 108: Removing And Installing Fuel Delivery Unit, Fuel Gauge Sender And Suction-jet Pumps

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – When breather lines are pulled off, buttons of hose couplings sometimes cannot be pressed in. Use assembly tool -T10118- -arrow- to press in button. For further work on inside of fuel tank, flanges may remain re‐...

  • Page 109

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Pull off connectors -1- and -2- as well as hose couplings -3- and -4- below right flange. – Remove flange with pressure regulator. – Unclip black filler hose -arrow- from fuel delivery unit housing on left and right sides of fuel tank.

  • Page 110: Removing And Installing Fuel Tank With Attached Components

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Removing and installing fuel tank with attached components Special tools and workshop equipment required ♦ Fuel extractor -VAS 5190- ♦ Special wrench -T10202- ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- ♦...

  • Page 111

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Disconnect fuel supply line -arrow- in engine compartment. Once the fuel pressure has been reduced: – Remove silencers and mountings . – Remove rear propshaft tube ⇒ Transfer box and final drive;...

  • Page 112

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Remove securing bolts for filler neck -1- and activated char‐ coal filter -2- in wheel housing. – Now bend filler neck slightly downwards and pull off breather line connections to activated charcoal filter.

  • Page 113: Checking Fuel Pumps

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 ♦ Connections for breather and fuel lines must engage audibly when joined. ♦ Install breather and fuel hoses free of kinks. ♦ Secure fuel hoses with spring-type clips. ♦ Ensure that fuel hose connections are tight.

  • Page 114: Checking Delivery Rate Of Pumps

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 1.11 Checking delivery rate of pumps Checking delivery rate of right pump ⇒ page 109 Checking delivery rate of left pump ⇒ page 109 Test prerequisites • Fuses -13- and -14- -arrow- must be removed from their sock‐...

  • Page 115

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 1.11.1 Checking delivery quantity of right pump – Connect remote control -V.A.G 1348/3 A- with adapter cable - Phaeton -V.A.G 1348/3-3- to connection -arrow- of fuel pump relay for right fuel delivery unit.

  • Page 116

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Cut carpet open from point -A- to point -B- in the pre-cut area -arrows-. – Remove nuts -1- from cover. If necessary, unscrew backrest mounting -2- or support mounting ⇒ General body repairs, interior;...

  • Page 117: Checking Non-return Valve Of Right Pump

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Connect multimeter -V.A.G 1715- pick-up clamp to wiring of 4- pin connector contact -1- -arrow- of wiring harness to right fuel delivery unit. Note The hand-held multimeter -V.A.G 1526D- with pickup clamp - V.A.G 1526B/2- can also be used.

  • Page 118

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Now unscrew locking ring from flange (fuel filter) using wrench -T10202- . – Carefully lever flange and raise it slightly. – Disconnect connectors next to fuel filter. – Then detach fuel supply hose -2- leading from right fuel deliv‐...

  • Page 119: Checking Non-return Valve Of Left Pump

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Now connect remote control -V.A.G 1348/3A- with adapter - V.A.G 1348/3-3- to connection -arrow- of fuel pump relay for right fuel delivery unit. – Operate remote control at short intervals until a pressure of approx.

  • Page 120

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Close pressure gauge shut-off tap -arrow- (lever at right an‐ gles to direction of flow). – Connect pressure tester -V.A.G 1318- with adapter - V.A.G 1318/7- , adapter -V.A.G 1318/13- and adapter - V.A.G 1318/24- as shown.

  • Page 121: Electronic Power Control (epc)

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Electronic power control (EPC) 1 - Bearing bracket ❑ Removing and instal‐ ling: ⇒ Brake systems; Rep. gr. 46 ; Assembly overview - brake pedal (LHD) . 2 - Connector ❑ Black, 6-pin.

  • Page 122

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 When the engine is running (under load), the engine control unit can open or close the throttle valve independently of the accel‐ erator position sender. This means that the throttle valve can already be completely open even though the accelerator is only depressed half way.

  • Page 123: Activated Charcoal Filter System

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Activated charcoal filter system Function Depending on the air pressure and ambient temperature, fuel va‐ pour will form above the level of fuel in the tank. The activated charcoal filter system prevents these HC emissions escaping to the atmosphere.

  • Page 124: Assembly Overview - Activated Charcoal Filter System

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Assembly overview - activated charcoal filter system 1 - Expansion tank 2 - Gravity valve 3 - To gravity valve 4 - Pressure retention valve ❑ Function ⇒ page 118 5 - 9 Nm...

  • Page 125

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 ♦ Hose clips up to 25 mm Ø -3094- ♦ Tester -V.A.G 1371- Procedure: – Remove rear right wheel and wheel housing liner. – Clamp off hose -arrow- between activated charcoal filter and air filter using a hose clamp -3094- .

  • Page 126

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Connect tester -V.A.G 1371- to breather line -arrow- as shown in illustration. – Connect valve adapter of tester -V.A.G 1371- to tyre valve. – Regulate the pressure to 35 mbar with valve -A-. When the pressure has stabilised, it must not drop below 30 mbar after 5 minutes.

  • Page 127

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – With valve -A- is open, check fuel tank for leaks by hearing, touching, with commercially available leak detector spray or ultrasonic tester -V.A.G 1842- . Caution After completing work check tyre pressure!

  • Page 128: Activated Charcoal Filter System (vehicles For Usa And Canada)

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Activated charcoal filter system (ve‐ hicles for USA and Canada) Assembly overview - activated charcoal filter system ⇒ page 123 Checking fuel system for leaks ⇒ page 124 Function Fuel vapour forms above the surface of the fuel in the fuel tank;...

  • Page 129: Assembly Overview - Activated Charcoal Filter System

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Note Hose connections are secured with either spring-type or ♦ clamp-type clips. Use spring-type clip pliers -VAS 6340- for installation of spring- ♦ type clips or space-saving hose clip pliers -VAS 6362- .

  • Page 130: Checking Fuel System For Leaks

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 14 - Securing bolts ❑ Qty. 3 ❑ 9 Nm 15 - Breather line ❑ To vacuum connection on intake manifold ❑ Check for secure seating. 16 - Connector ❑ Black, 2-pin.

  • Page 131

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Check on fuel system tester -KLI 9210- if there is enough fluid in smoke generator. – Set valve -D- to „Hold“. – Open nitrogen bottle -H-. – Connect test hose -G- to self-test connection -B-.

  • Page 132

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Connect vehicle system tester to vehicle. – Start engine and run at idling speed. – On vehicle system tester, select operating mode – Now select diagnostic mode 8 „Tank leak test“.

  • Page 133

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Repeat pressure test by setting valve -D- again to „Test“. – Observe pressure gauge and flow meter. When the through‐ put quantity decreases and the pressure increases to 25 mbar (10 in.

  • Page 134

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 If smoke still escapes from air filter: – Clamp off hose between fuel system diagnostic pump -V144- and air filter -arrow-. Also refer to ⇒ Item C (page 128) – Observe air filter. If smoke no longer escapes, shut-off valve in fuel system diagnostic pump -V144- is leaking.

  • Page 135

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 C - Clamp off in this area ❑ 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: •...

  • Page 136

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 ♦ Turbocharger tester -V.A.G 1397A- ♦ 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.

  • Page 137: Mixture Preparation - Injection

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 24 – Mixture preparation - injection 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.

  • Page 138: Assembly Overview - Intake Manifold

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 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.

  • Page 139: Assembly Overview - Fuel Rail

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Assembly overview - fuel rail 1 - Threaded connection, 22 ❑ Counterhold when tight‐ ening. ❑ For fuel supply. 2 - Fuel supply hose ❑ Check for secure seat‐ ing. ❑ Secure with spring-type clip.

  • Page 140

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 1 - Intake hose 2 - Spring-type clip 3 - Intake hose 4 - 6 Nm 5 - Air mass meter -G70- with intake air temperature sender - G42- 6 - Seal ❑...

  • Page 141

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 1.3.1 Disconnecting connecting line to air sus‐ pension compressor – Disconnect connecting line on right air filter -arrow- as follows: – Carefully lever off green securing ring -1- using a screwdriver.

  • Page 142: Assembly Overview - Vacuum Hose Assembly On Intake Manifold

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Assembly overview - vacuum hose assembly on intake manifold 1 - Combination valve ❑ For injection of secon‐ dary air 2 - To secondary air pump mo‐ tor -V101- 3 - Connecting hose ❑...

  • Page 143: Safety Precautions

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Safety precautions ♦ For safety reasons, fuse nos. -13- and -14- -arrows- must be removed from the fuse holder before opening the fuel system. Otherwise, the fuel pump could be activated by the driver's door contact switch.

  • Page 144

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Engine codes Engine control unit System designation Motronic ME 7.1 Motronic ME 7.1 Part number ⇒ Spare parts cata‐ ⇒ Spare parts cata‐ logue logue Governed speed from approx. 6500 from approx. 6500 3) Not adjustable.

  • Page 145: Checking Components

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Checking components Checking injectors ⇒ page 139 Checking fuel pressure regulator and holding pressure ⇒ page 142 Checking injectors Checking injectors for leaks and quantity injected ⇒ page 139 Special tools and workshop equipment required ♦...

  • Page 146

    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.

  • Page 147

    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: – 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.

  • Page 148: Checking Fuel Pressure Regulator And Holding Pressure

    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.

  • Page 149

    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.

  • Page 150

    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 ⇒...

  • Page 151: Engine Control Unit

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Engine control unit Removing and installing engine control unit ⇒ page 145 Reading and clearing engine control unit fault memory ⇒ page 145 Removing and installing engine control unit If you wish to replace the engine control unit, connect the vehicle diagnosis, testing and information system -VAS 5051B- and carry out the guided function „Renew control unit“.

  • Page 152

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Connect connector of diagnosis cable -VAS 5051/1- or - VAS 5051/3- to diagnostic connection. – Start engine and run at idling speed. Only when engine does not start: – Switch on ignition.

  • Page 153: Exhaust System

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 26 – Exhaust system Removing and installing parts of ex‐ haust system Assembly overview - exhaust manifold with starter catalytic con‐ verters and attachments ⇒ page 148 Assembly overview - silencers with mountings ⇒...

  • Page 154: Assembly Overview - Exhaust Manifold With Starter Catalytic Converters And Attachments

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Assembly overview - exhaust manifold with starter catalytic converters and attachments 1 - Nut, 25 Nm 2 - Nut, 25 Nm 3 - Exhaust manifold ❑ For cylinder bank 1. ❑ Removal only possible with engine removed.

  • Page 155: Removing And Installing Lambda Probes

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 19 - Catalytic converter 20 - Starter catalytic converter ❑ Installed in exhaust gas stream of cylinder bank 2. 21 - 25 Nm 22 - Bracket ❑ For supporting gearbox on left.

  • Page 156

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 ♦ Open ring spanner with 3/8" drive (flared spanner) ♦ Lambda probe open ring spanner set -3337- Removing: – Remove cover for engine and intake manifold. – Remove intake hoses -1- and -2-. Loosen hose clip for crank‐...

  • Page 157

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Lambda probe 2 -G108- (bank 2, probe 1): – Unscrew Lambda probe 2 -G108- -item 1-. Lambda probe -G39- (bank 1, probe 1): – Unscrew Lambda probe -G39- -item 2-. Lambda probe 2 after catalytic converter -G131- (bank 2, probe...

  • Page 158

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Lambda probe after catalytic converter -G130- (bank 1, probe 2): – Unbolt heat shield for front propshaft -arrows-. – Unscrew Lambda probe after catalytic converter -G130- -item 1-. Installing: – If reusing Lambda probe, lubricate threads with high temper‐...

  • Page 159: Assembly Overview - Silencers With Mountings

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Assembly overview - silencers with mountings 1 - Exhaust tailpipe 2 - Rear silencer ❑ Centre and rear silenc‐ ers are installed as a single component dur‐ ing production. In case of repair, the centre and rear silencers are sup‐...

  • Page 160

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 13 - To exhaust manifold 14 - Centre silencer ❑ Centre and rear silencers are installed as a single component during production. In case of repair, the centre and rear silencers are supplied separately, with a double repair clamp for connecting.

  • Page 161: Secondary Air System

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 Secondary air system Function The secondary air system blows air in behind the exhaust valves for max. 65 seconds after a cold start (+15°C … +35°C coolant temperature). This produces an oxygen rich exhaust gas, causing afterburning and reducing the heat-up phase of the catalytic con‐...

  • Page 162

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 1 - Combination valve ❑ For cylinder bank 1. 2 - 10 Nm 3 - To secondary air inlet valve -N112- 4 - Combination valve ❑ For cylinder bank 2. 5 - Gasket 6 - Connecting hose ❑...

  • Page 163: Ignition System

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 28 – Ignition system Repairing ignition system General notes on ignition system ♦ For trouble-free operation of electrical components, a voltage of at least 11.5 V is necessary. ♦ Certain tests may lead to a fault being detected by the control unit and stored.

  • Page 164: Safety Precautions

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 10 - Spark plug, 30 Nm ❑ Remove and install with spark plug socket and extension 3122 B. ❑ Type and electrode gap ⇒ page 159 , test data, spark plugs 11 - Knock sensor 2 -G66- ❑...

  • Page 165: Test Data, Spark Plugs

    Touareg 2003 ➤ 8-cylinder injection engine - Edition 11.2011 – Press in catch of respective connector -A- to be removed in -direction of arrow- and disconnect connector. – Before disconnecting connectors of cylinders 5 to 8 remove bracket -1- by unscrewing bolts -arrows-.

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