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Volkswagen Touareg 2003 Service Manual

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Touareg 2003 ➤
Edition 11.2011
Service Department. Technical Information

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Summary of Contents for Volkswagen Touareg 2003

  • Page 1 Service Maintenance Touareg 2003 ➤ 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 K0058961120...

  • Page 3: Table Of Contents

    Touareg 2003 ➤ Maintenance - Edition 11.2011 Contents Engine list ............. .
  • Page 4 Touareg 2003 ➤ Maintenance - Edition 11.2011 4.36 Engine and components in engine compartment (from above and below): Perform visual check for leaks and damage ..........109 4.37...

  • Page 5: Engine List

    Touareg 2003 ➤ Maintenance - Edition 11.2011 Engine list This chapter provides information on the following subjects: ♦ Petrol engines ⇒ page 1 ♦ Diesel engines ⇒ page 2 Note To ease the search for an engine, the engine codes are listed in alphabetical order.
  • Page 6 Touareg 2003 ➤ Maintenance - Edition 11.2011 1) Under exceptional circumstances super unleaded, at least 95 RON, but with reduced output. Engines: ⇒ Petrol engine Petrol engine Petrol engine Capacity Engine code No. of cylinders/valves per cylinder 12/4 Output kW at 1 rpm...
  • Page 7 Touareg 2003 ➤ Maintenance - Edition 11.2011 Engines ⇒ Diesel engine Diesel engine Diesel engine Diesel engine Capacity Engine code Torque Nm at rpm 750/2000 400/2000 to 2300 450/1400 to 3250 750/2000 Bore ∅ mm 81.0 81.0 83.0 81.0 Stroke 95.5...
  • Page 8 Touareg 2003 ➤ Maintenance - Edition 11.2011 Engines: ⇒ Diesel engine Diesel engine Diesel engine Diesel engine Capacity Engine code CASA CASB Injection/ignition unit injector common rail common rail common rail Diesel particulate filter (DPF) yes/no Additive system Leakage diagnosis system (e.g.

  • Page 9: Service Work

    2.1.3 Time or distance dependent service For vehicles with time or distance dependent service with PR number „QG0/QG2“ the non-flexible service intervals are set by Volkswagen according to predetermined mileage or time values. 2. Service work...
  • Page 10 Touareg 2003 ➤ Maintenance - Edition 11.2011 For normal operating conditions achieving these service intervals is technically assured. Therefore the service intervals for time or distance dependent service are non-flexible. For vehicles ♦ Which were delivered without extended servicing intervals (ESI) (PR number „QG0“...

  • Page 11: Service Tables

    Service tables The following chapter contains the well-known service tables with the service specifications of the Volkswagen brand. Since, in the past, individual service specifications were set up in various mar‐ kets, mostly through severe operating conditions, these are listed in service tables with specific deviations.
  • Page 12 Touareg 2003 ➤ Maintenance - Edition 11.2011 Toothed belt change intervals ⇒ page 11 Spark plug change intervals ⇒ page 11 Other time or distance dependent additional work ⇒ page 12 Service intervals Caution Only applies to diesel engines: • In some countries, there is an elevated sulphur content in diesel fuel.
  • Page 13 Touareg 2003 ➤ Maintenance - Edition 11.2011 TOUAREG SERVICE INTERVALS 2008► From - to Engine/Engine code/ Service/intervals Indicated on PR No./Remarks service interval display SID (includes oil change) Since in‐ Diesel, in countries with ele‐ Oil change service troduc‐ vated sulphur content in fuel...
  • Page 14 Touareg 2003 ➤ Maintenance - Edition 11.2011 TOUAREG VW ENGINE OIL STANDARDS R5, V10 engines with diesel par‐ R5, V10 engines with diesel particu‐ 507 00 507 00 ticulate filter late filter 2007► 2007► V6 with diesel particulate filter V6 with diesel particulate filter...
  • Page 15 Touareg 2003 ➤ Maintenance - Edition 11.2011 For vehicles with diesel particulate filter biodiesel must not be used. Toothed belt change intervals • If the engine is fitted with toothed belt or timing chain can be found in the engine list.
  • Page 16 Touareg 2003 ➤ Maintenance - Edition 11.2011 Other time or distance dependent additional work Time or distance dependent additional work Interval Description of work – Diesel particulate filter: Read ash load At 90,000 km, ⇒ page 38 then every •...
  • Page 17 Touareg 2003 ➤ Maintenance - Edition 11.2011 Time or distance dependent additional work Interval Description of work – Fuel additive container: Extract residual fluid and replenish with new Every 4 years ⇒ page 32 additive fluid • Only valid for V10 TDI with diesel particulate filter and additive sys‐...
  • Page 18 Touareg 2003 ➤ Maintenance - Edition 11.2011 Interval Description of work Inspection service Every 30,000 km → Mainte‐ (does not appears on service interval display) nance tables or 2 years – Dust and pollen filter (cabin filter): Renew Every 15,000 km ⇒...
  • Page 19 Touareg 2003 ➤ Maintenance - Edition 11.2011 Interval Description of work – Air filter element: Renew and clean housing Every 30,000 km ⇒ page 86 or 2 years – Diesel fuel filter: Replace Every 30,000 km ⇒ page 73 – Spark plugs: Renew Every 30,000 km ⇒...

  • Page 20: General

    Touareg 2003 ➤ Maintenance - Edition 11.2011 General This chapter provides information on the following subjects: ♦ Raising vehicle with lifting platform or trolley jack ⇒ page 16 ♦ Sticker ⇒ page 17 ♦ Entries in service schedule ⇒ page 19 ♦...

  • Page 21: Sticker

    Touareg 2003 ➤ Maintenance - Edition 11.2011 3.1.2 Lifting points for lifting platform or trolley jack: Front lifting point: – Position support plate at reinforcement -arrow- of floor pan. WARNING Under no circumstances must vehicle be raised on vertical stiffener of side member.
  • Page 22 Touareg 2003 ➤ Maintenance - Edition 11.2011 Sticker from week 45/2009 – Service sticker „Your next service“: Enter a cross in position for next oil change service or inspection service or legal check such as legislative inspection or gas system check (next serv‐...

  • Page 23: Connecting Vehicle Diagnosis Tester

    Touareg 2003 ➤ Maintenance - Edition 11.2011 3.2.4 Entries in service schedule If a component is changed which has a change interval prescribed by the manufacturer, e.g. the toothed belt, the new change inter‐ val begins at the time the component is changed.
  • Page 24 Touareg 2003 ➤ Maintenance - Edition 11.2011 ♦ Vehicle diagnosis and service information system -VAS 5052- or subsequent units ♦ Diagnosis cable, 2 m -VAS 5052/3 A- Note Ensure that the selected vehicle diagnosis tester is only used with the respective diagnosis cable.

  • Page 25: Vehicle Identification Number

    Touareg 2003 ➤ Maintenance - Edition 11.2011 Open cover -1- and connect vehicle diagnosis tester . – Switch on vehicle diagnosis tester . – Switch on ignition. Now follow screen display to start desired functions. Vehicle identification number Location: windscreen The vehicle identification number -see enlargement- is located behind the windscreen on driver side.

  • Page 26: Vehicle Data Sticker

    Touareg 2003 ➤ Maintenance - Edition 11.2011 Vehicle data sticker Location: dash panel trim The vehicle data sticker -arrow- is mounted on the dash panel trim in the footwell on driver side. The vehicle data sticker is also found in the service schedule for the customer.

  • Page 27: Countries With Elevated Sulphur Content In Diesel Fuel

    Touareg 2003 ➤ Maintenance - Edition 11.2011 Countries with elevated sulphur content in diesel fuel Only applies to diesel engines: In some countries, there is an ele‐ vated sulphur content in diesel fuel. The high sulphur content leads to excessive wear of cylinders and it considerably reduces the cleanliness of pistons.

  • Page 28: Severe Operating Conditions

    Touareg 2003 ➤ Maintenance - Edition 11.2011 ♦ At ambient temperatures below -10 °C we recommend using winter diesel fuel. Note When using biodiesel observe the changed intervals for ♦ changing the diesel fuel filter ⇒ page 7 If it is planned not to use the vehicle for approx. two weeks, it ♦...
  • Page 29 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Switch on ignition. – Press button in centre console -arrow- and hold for 5 LOCK seconds. The „jacking up mode“ is displayed in the combi-instrument, a warning lamp flashes in button. LOCK After activating, the ignition can be switched off.

  • Page 30: Descriptions Of Work

    Touareg 2003 ➤ Maintenance - Edition 11.2011 Descriptions of work This chapter provides information on the following subjects: ♦ Removable towing bracket: Check and clean if necessary ⇒ page 28 ♦ Turbocharger: Lubricate control motor linkage ⇒ page 30 ♦ Swivel joints and axle bearings: Visual check ⇒...
  • Page 31 Touareg 2003 ➤ Maintenance - Edition 11.2011 ♦ Air filter: Clean housing and renew filter element ⇒ page 86 ♦ Oil level: Check ⇒ page 98 ♦ Engine oil: Drain or extract; renew oil filter and replenish en‐ gine oil ⇒...

  • Page 32: Removable Towing Bracket: Check And Clean If Necessary

    Touareg 2003 ➤ Maintenance - Edition 11.2011 ♦ Spark plugs: Renew ⇒ page 140 ♦ Static cornering light (cornering light) and driving light assist: Check function ⇒ page 151 Removable towing bracket: Check and clean if necessary This chapter describes how to check and repair a removable tow‐...
  • Page 33 Touareg 2003 ➤ Maintenance - Edition 11.2011 After ball head has been inserted, green mark on hand wheel must be aligned with white mark on ball head. Hand wheel must be entirely in contact. Afterwards, it must be possible to close the towing bracket lock by removing the key.

  • Page 34: Turbocharger: Lubricate Control Motor Linkage

    Touareg 2003 ➤ Maintenance - Edition 11.2011 – Insert cover -1-. Turbocharger: Lubricate control motor linkage Lubricating the control motor linkage includes: 1. - Turbocharger 1 control motor -V280- for cylinder bank 1 (right engine side). 2. - Turbocharger 2 control motor -V281- for cylinder bank 2 (left engine side).

  • Page 35: Swivel Joints And Axle Bearings: Visual Check

    Touareg 2003 ➤ Maintenance - Edition 11.2011 Fitting location: Front left, between steering and housing of front final drive, above coolant hoses -arrow A-. – Lubricate rotating point of control motor shaft and linkage -arrows A- and -B- by hand.

  • Page 36: Additive Container: Extract Fluid And Replenish With New Additive

    Touareg 2003 ➤ Maintenance - Edition 11.2011 Additive container: Extract fluid and re‐ plenish with new additive 4.4.1 Safety measures and handling instruc‐ tions when working on additive contain‐ er system WARNING Please note the following for all procedures: ♦ The diesel additive fluid is hazardous to health.
  • Page 37 Touareg 2003 ➤ Maintenance - Edition 11.2011 WARNING Please note the following for all procedures: ♦ The diesel additive must not drain into sewerage and not soak into the soil. If leaks occur, immediately bind and eliminate. ♦ The additive container is under pressure! Before opening the system, place a cloth around the connection and re‐...
  • Page 38 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Turn cover -B- at drain hose connection -C- approx. 90 de‐ grees anti-clockwise so that the connections are visible. The connections are located on tank filler neck -arrow A- Note Always note safety measures when working on additive contain‐...
  • Page 39 Touareg 2003 ➤ Maintenance - Edition 11.2011 4.4.5 Extracting and replenishing with fluid Special tools, testers, measuring instruments and auxiliary items required ♦ Extraction unit -VAS 6277/1- ♦ Filling device -VAS 6277/2- ♦ Overflow protection -VAS 6277/3- ♦ Hose clamp -3094-...
  • Page 40 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Connect compressed air supply -2- to extraction unit -VAS 6277/1- . – Extract fluid by carefully pulling metering lever -3-. WARNING ♦ Turn ventilation -1- in direction of the well ventilated room, do not inhale emitting vapours.
  • Page 41 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Seal valve -2- and disconnect filling hose using e.g. hose clamp -3094- . – Separate filling device -VAS 6277/2- and overflow protection -VAS 6277/3- from additive container connections -arrows A + B-.

  • Page 42: Diesel Particulate Filter: Reading The Ash Load

    Touareg 2003 ➤ Maintenance - Edition 11.2011 WARNING Remove spilt fluid with absorbing, non-flammable material (binding agent). Dispose of materials which are soaked with fluid, e.g. cloths or binding agents, in a suitable container which can be closed, observe hazardous material regulations! –...
  • Page 43 Touareg 2003 ➤ Maintenance - Edition 11.2011 Note Notes on invoicing can be found in „Technical product infor‐ ♦ mation“ in ELSA: Technical Service Handbook ♦ Technical solutions ♦ Power unit ♦ Function ♦ Engine problems when starting ♦ Engine does not start / transportation device active ♦...

  • Page 44: Battery: Check Battery Terminal Clamps For Secure Seating

    Touareg 2003 ➤ Maintenance - Edition 11.2011 – Pull a padded cover -A- over the relay cable connector. – Secure the padded cover with adhesive tape. – Unscrew earth cable -2- from battery cut-off relay -1-. – Unscrew retainer for battery cut-off relay from earth point -B-.
  • Page 45 Touareg 2003 ➤ Maintenance - Edition 11.2011 Battery under left front seat: checking battery terminal clamps for secure seating – Switch off ignition and all electrical consumers and remove ignition key. After waiting 60 seconds: – Remove trim from front and side of left front seat frame.
  • Page 46 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Open catches for battery box -arrows- and remove cover. – Check whether battery clamps are secure on battery terminals by moving battery earth cable -1- and battery positive wire -2- back and forth.
  • Page 47 Touareg 2003 ➤ Maintenance - Edition 11.2011 Special tools and workshop equipment required ♦ -V.A.G 1331- Torque wrench (5-50 Nm) – Tighten securing bolt on battery positive terminal clamp to 6 Nm. – Only after the positive terminal clamp -2- is secure may the negative terminal clamp -1- be placed on the battery negative terminal.
  • Page 48 Touareg 2003 ➤ Maintenance - Edition 11.2011 Special tools and workshop equipment required ♦ -V.A.G 1331- Torque wrench (5-50 Nm) – Tighten battery clamp -1- on battery negative terminal to 6 Nm. – Reinstall engine cover panel. – Renew securing bolts -arrows- of seat frame and tighten them to 45 Nm specified torque.
  • Page 49 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Remove fastenings -arrows- for retaining straps and remove battery cover with retaining straps. – Check whether battery clamps are secure on battery terminals by moving battery positive wire -1- and battery negative wire -2- back and forth.
  • Page 50 Touareg 2003 ➤ Maintenance - Edition 11.2011 Special tools and workshop equipment required ♦ -V.A.G 1331- Torque wrench (5-50 Nm) – Tighten securing bolt on battery positive terminal clamp -arrow- to 6 Nm. – Only after the positive terminal clamp is secure may the neg‐...

  • Page 51: Battery: Check Using Battery Tester With Printer Vas 5097A Or Vas 6161

    Touareg 2003 ➤ Maintenance - Edition 11.2011 Battery: Check using battery tester with printer VAS 5097A or VAS 6161 Note When a battery cut-off relay is installed, ensure that the battery is not charged via jump start points. Proceed as described in work‐...
  • Page 52 Touareg 2003 ➤ Maintenance - Edition 11.2011 ♦ Filling device -VAS 6542- ♦ Tank for used reducing agent (AdBlue®) ♦ Engine and gearbox jack -VAG 1383 A- ♦ Adapter plate -VAG 1383A-1- 4.10.1 General Properties ♦ The reducing agent (AdBlue ®...
  • Page 53 It is NOT therefore mixed with diesel fuel. ♦ The reducing agent tank is located in the luggage compart‐ ment. ♦ A refill container approved by Volkswagen must be used for ® replenishing the reducing agent (AdBlue ♦...
  • Page 54 Touareg 2003 ➤ Maintenance - Edition 11.2011 ♦ As of a remaining range of 1000 km, a warning buzzer sounds with „Check AdBlue! No engine starting in 1000 km“ ♦ As of a remaining range of 0 km, a three-fold warning buzzer sounds with „Check AdBlue! Engine starting no longer possi‐...
  • Page 55 Touareg 2003 ➤ Maintenance - Edition 11.2011 4.10.4 Work preparation for filling reducing agent tank Note Ensure that vehicle stays on an even ground. The reducing agent tank's filler aperture is located under the floor covering in the luggage compartment.
  • Page 56 Touareg 2003 ➤ Maintenance - Edition 11.2011 4.10.5 Filling reducing agent tank Components of filling device -VAS 6542- 1 - Connection for reducing agent container 2 - Union nut for reducing agent container 3 - Cut-off tap for breather hose (cut-off tap open: Lever points in...
  • Page 57 Touareg 2003 ➤ Maintenance - Edition 11.2011 1 - Reducing agent container 2 - Adapter plate -VAG 1383 A-1- 3 - Quick release coupling on breather hose A - Dimension -A- (60-80 cm) for height difference from reducing agent container to tank filler neck...
  • Page 58 Touareg 2003 ➤ Maintenance - Edition 11.2011 ♦ 9. Close cut-off tap of tank filling hose -6-. ♦ 10. Now close cut-off tap of breather hose -8- on container. ♦ 11. Separate quick-release coupling on breather hose -3-. ♦ 12. Drain excessive fluid into a suitable container -2- for re‐...
  • Page 59 Touareg 2003 ➤ Maintenance - Edition 11.2011 4.10.6 Work after filling reducing agent tank – Screw in tank cap -1- of tank filler neck until it engages. – Carefully insert sealing plug -1-. – Install spare wheel -2- (if available), tightening wing nut -3- hand-tight.

  • Page 60: Reducing Agent (Adblue ): Change

    Touareg 2003 ➤ Maintenance - Edition 11.2011 4.10.7 Cleaning the filling device -VAS 6542- – Open both cut-off taps and clean or flush through all parts of filling device -VAS 6542- under flowing water. 4.11 Reducing agent (AdBlue ): Change ®...
  • Page 61 Touareg 2003 ➤ Maintenance - Edition 11.2011 4.12.1 Checking condition of tyre For delivery inspection: – Check tyre treads and side walls for damage and remove for‐ eign bodies such as, for example, nails or glass splinters. WARNING If damage is determined, always check to see if a new tyre should be fitted.
  • Page 62 Touareg 2003 ➤ Maintenance - Edition 11.2011 4.12.4 General notes WARNING ♦ For safety reasons, only tyres of same type and tread pat‐ tern should be fitted on a vehicle! Approved wheel and tyre combinations, e.g. ⇒ Running gear; Rep. gr. 44 ; Touareg as of model year 2003 ♦...

  • Page 63: Storing Tyre Pressure Values

    Touareg 2003 ➤ Maintenance - Edition 11.2011 4.12.5 Tyre pressure: Checking and correcting if necessary Note The binding tyre pressures for the respective model can be found on a sticker attached to inside of tank flap or to B-pillar. Check tyre inflation pressure using tyre inflator -VAS 5216- , cor‐...
  • Page 64 Touareg 2003 ➤ Maintenance - Edition 11.2011 ♦ Pliers -3314- ♦ Torque wrench (40-200 Nm) -V.A.G 1332/- ♦ Electric hand torch and mirror Note The adapter to loosen and tighten the anti-theft wheel bolts can be found in the vehicle tool kit.
  • Page 65 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Mark position of wheel relative to brake disc. – Unbolt wheel bolts and remove wheel. – Measure thickness of inner and outer pads. a - Pad thickness without backplate Wear limit: 2 mm The brake pads have reached their wear limit at a pad thickness of 2 mm (without backplate) and must be renewed (repair meas‐...

  • Page 66: Brake System And Shock Absorbers: Perform Visual Check For Leaks And Damage

    Touareg 2003 ➤ Maintenance - Edition 11.2011 – Determine thickness of outer pad by checking visually. – Illuminate inner pad with an electric hand torch and mirror. – Determine thickness of inner pad by checking visually. a - Inner and outer pad thickness without backplate...

  • Page 67: Changing Brake Fluid

    Touareg 2003 ➤ Maintenance - Edition 11.2011 WARNING Faults found must always be rectified (repair measure). 4.16 Changing brake fluid Instructions for use and safety ⇒ page 63 Brake fluid specification ⇒ page 63 Changing brake fluid ⇒ page 63 4.16.1...
  • Page 68 Touareg 2003 ➤ Maintenance - Edition 11.2011 ♦ Brake filling and bleeding equipment -VAS 5234- ♦ Brake bleeding wrench -VAS 5519- ♦ Brake bleeding tool -VAS 6564- Observe ⇒ operating instructions for -VAS 5234- ! – Adjust correct pressure on brake filling and bleeding equip‐...
  • Page 69 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Unscrew cap -1- from brake fluid reservoir. – Extract as much brake fluid as possible using suction hose from -VAS 5234- or from -V.A.G 1869- or using a suction bottle if strainer is built in.

  • Page 70: Brake Fluid Level (Depending On Lining/Pad Wear): Check

    Touareg 2003 ➤ Maintenance - Edition 11.2011 – Push collector bottle bleed hose onto front bleeder screw , open bleeder screw and let appropriate quantity of brake fluid run out (see following table). Close bleed screw. Torque: »Running gear, brake systems« ⇒ Running gear, brake sys‐...

  • Page 71: Diesel Particulate Filter: Renew

    Touareg 2003 ➤ Maintenance - Edition 11.2011 4.17.1 Procedure, brake fluid level (dependent upon lining/pad wear): Check – Release securing bolts -1- and -2- and remove cover upwards. Please note the following: Brake fluid level at delivery inspection: – At delivery inspection the fluid level must be at MAX. marking -1-.

  • Page 72: Window Regulators: Check Positioning (Open And Close Functions)

    Touareg 2003 ➤ Maintenance - Edition 11.2011 Note Every time the diesel particulate filter is changed, the ash mass comparison adaption must be set to »0«, ⇒ Vehicle diagnostic tester 4.19 Window regulators: Check positioning (open and close functions) WARNING After batteries (in luggage compartment and/or left front seat) have been disconnected and reconnected, the roll-back func‐...

  • Page 73: Vehicles With Reversing Camera System: Check Number Plate

    Touareg 2003 ➤ Maintenance - Edition 11.2011 4.20 Vehicles with reversing camera system: Check number plate Note For vehicles with reversing camera system it is not permitted to install an additional number plate bracket or an additional number plate mounting. Additional information see ⇒ Electrical system ⇒...

  • Page 74: Front Airbag For The Front Passenger: Check Activation / Deactivation

    Touareg 2003 ➤ Maintenance - Edition 11.2011 Now it is confirmed on display that all sporadic faults have been cleared. Then the diagnosis log is sent „online“ or stored on the vehicle diagnosis tester . Note If the vehicle diagnosis tester is not connected to the network, ♦...

  • Page 75: Gearbox, Final Drive (Especially On Flanges) And Drive Shaft Bellows: Perform Visual Check For Leaks And Damage

    Touareg 2003 ➤ Maintenance - Edition 11.2011 4.23 Gearbox, final drive (especially on flang‐ es) and drive shaft bellows: Perform vis‐ ual check for leaks and damage 4.23.1 Protective bellows: Visual check Carry out the following procedure: – Check outer bellows and inner bellows -arrows- for leaks and damage.

  • Page 76: Diesel Fuel Filter: Drain

    Touareg 2003 ➤ Maintenance - Edition 11.2011 – Check poly V-belt -1- for: ♦ Substructure cracks (cracks, core ruptures, cross sectional breaks) ♦ Layer separation (top layer, cord strands) ♦ Base break-up ♦ Fraying of cord strands ♦ Flank wear (material wear, frayed flanks, brittle flanks -glassy flanks-, surface cracks) ♦...

  • Page 77: Diesel Fuel Filter: Renew (Diesel Engine)

    Touareg 2003 ➤ Maintenance - Edition 11.2011 4.27 Diesel fuel filter: Renew (Diesel engine) Replacing diesel fuel filter: 6-cylinder diesel engines ⇒ page 73 Replacing diesel fuel filter: 10-cylinder diesel engines ⇒ page 75 Replacing diesel fuel filter: 5-cylinder diesel engines ⇒...
  • Page 78 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Remove bolts -arrows B-. – Remove diesel fuel filter upper part -1- and fuel lines connec‐ ted. – Remove old seal -2- from diesel fuel filter upper part -arrows A-. – Pull diesel fuel filter element -4- out of diesel fuel filter lower part on retainer -3-.
  • Page 79 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Fit diesel fuel filter upper part and seal on diesel fuel filter lower part and screw in bolts approx. one turn. Caution Ensure correct installation position of fuel filter upper part to fuel filter lower part.
  • Page 80 Touareg 2003 ➤ Maintenance - Edition 11.2011 ♦ Diesel extractor -VAS 5226- Remove engine cover ⇒ page 106 Removing: – Remove plug -arrow- from water drainage connection of diesel fuel filter housing. – Extract diesel fuel from side water drainage connection of die‐...
  • Page 81 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Pull filter elements -3- off cover -1-. Note Observe disposal regulations! Installing: – Insert new filters -3- and renew seal -2-. – Install diesel fuel filter cover -1-. – Tighten diesel fuel filter cover bolts -arrows- to 8 Nm.
  • Page 82 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Install connection for fuel hoses. Note Renew seal between diesel fuel filter cover and connection for fuel hoses. – Tighten bolts -arrows- to 8 Nm. Bleeding fuel system To ensure the engine starts immediately after changing the diesel fuel filter, bleed the fuel system using vehicle diagnosis tester .
  • Page 83 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Note fuel line identification on diesel fuel filter. ♦ Return line (marked blue) -2- identified with „RT“ (return line to tank). ♦ Supply line (marked black) -3- identified with „VF“ (supply line to filter).

  • Page 84: Interior And Exterior Body: Performing Visual Check For Corrosion When Doors And Flaps Are Open

    Touareg 2003 ➤ Maintenance - Edition 11.2011 – Insert new filter -5-. – Secure diesel fuel filter -5- on bracket -4- with clip -1-. – Push lines onto diesel fuel filter connections and ensure se‐ cure seating. Bleeding fuel system To ensure the engine starts immediately after changing the diesel fuel filter, bleed the fuel system using vehicle diagnosis tester .

  • Page 85: Cooling System: Check Frost Protection And Coolant Level

    Touareg 2003 ➤ Maintenance - Edition 11.2011 – With ignition switched on press button -3-. – Select the symbol „N“ using the function buttons -2- in display -1- and confirm with – To set the compass zone, select with function buttons -2- the selected zone between „1 and 15“...
  • Page 86 Touareg 2003 ➤ Maintenance - Edition 11.2011 ♦ Refractometer -T10007 A- ♦ Cooling system charge unit -VAS 6096- ♦ Adapter -V.A.G 1274/8- 4. Descriptions of work...
  • Page 87 Touareg 2003 ➤ Maintenance - Edition 11.2011 Note From model year 2008 all engines are filled with coolant ad‐ ♦ ditive G12 Plus Plus (purple). Because of its positive charac‐ teristics, ensure that only G12 Plus Plus is used when replenishing.
  • Page 88 Touareg 2003 ➤ Maintenance - Edition 11.2011 The scale -1- of the refractometer is calibrated for coolant addi‐ tives G12; G12 Plus, G12 Plus Plus and G11. The scale -2- is only calibrated for coolant additive G13. – If frost protection is insufficient, drain quantity indicated in frost protection table and add coolant additive G12 Plus Plus ac‐...
  • Page 89 Touareg 2003 ➤ Maintenance - Edition 11.2011 Mixture ratio: Caution Only distilled water may be used for mixing. Tap or well water does not have the required quality to ensure the functionality of coolant. Frost protection to Coolant additive G12 Plus Plus Water -25 °C...

  • Page 90: Air Filter: Clean Housing And Renew Filter Element

    Touareg 2003 ➤ Maintenance - Edition 11.2011 – Unscrew cap -1- from expansion tank. ♦ Delivery inspection: Coolant level at max. marking. ♦ Inspection service: Coolant level between min. and max. marking. – If coolant is too low, add required amount according to mixture ratio.
  • Page 91 Touareg 2003 ➤ Maintenance - Edition 11.2011 4.31.1 Removing and installing filter element on 10-cylinder engines Remove engine cover ⇒ page 106 Removing Note The removal and installation of the left air filter element is descri‐ bed below. The right air filter element is removed and installed in the same manner.
  • Page 92 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Disconnect lines to air filter housing -arrow- as follows: – Press locking ring -1- off flange of line -3- using screwdriver -C-. – Press securing sleeve -2- in direction of arrow and pull line -A- off line -B- at the same time.
  • Page 93 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Secure air filter housing with spring clips -1-. – Push line -arrow- together again. – Then press locking ring -1- onto flange of line -3- until it can be heard to engage.
  • Page 94 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Insert securing pins so that marking on pin -1- and marking on air filter housing -2- align. – Install engine cover panel. 4.31.2 Removing and installing air filter ele‐ ment for 5-cylinder diesel engines Remove engine cover ⇒...
  • Page 95 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Turn pin until marking -1- aligns with marking on air filter hous‐ ing -3-. – Pull out securing pin upwards. – Pull off intake hose. – Disconnect lines to air filter housing -arrow- as follows: –...
  • Page 96 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Remove air filter element -A-. – If necessary, blow out air filter housing with compressed air and install new air filter element. Installing – Install air filter element. – Fit air filter housing upper part to filter housing lower part.
  • Page 97 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Then press locking ring -1- onto flange of line -3- until it can be heard to engage. – Install intake hose. Install intake hose securing pins as follows: – Insert securing pins so that marking on pin -1- and marking on air filter housing -2- align.
  • Page 98 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Disconnect lines to air filter housing -arrow- as follows: – On the rear line, press locking ring -1- off flange of line -3- using screwdriver -C-. – Press securing sleeve -2- in direction of arrow and pull line -A- off line -B- at the same time.
  • Page 99 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Secure air filter housing with spring clips -1-. – Bolt on throttle valve module -2- and tighten to 3 Nm. – Reconnect connector -3-. – Push line -arrow- together again. – Then press locking ring -1- onto flange of line -3- until it can be heard to engage.
  • Page 100 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Disconnect lines to air filter housing -arrow- as follows: – Press locking ring -1- off flange of line -3- using screwdriver -C-. – Press air filter upper part -1- off air filter lower part -3-.
  • Page 101 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Remove air filter element -A-. – If necessary, blow out air filter housing with compressed air and install new air filter element. Installing – Install air filter element -A-. – Insert air filter housing upper part with retaining lugs -arrows A- into holes of air filter housing lower part -arrows B-.

  • Page 102: Engine Oil Level: Check

    Touareg 2003 ➤ Maintenance - Edition 11.2011 – Secure air filter housing with spring clips -1-. – Bolt on throttle valve module -2- and tighten to 3 Nm. – Reconnect connector -3-. – Push line -arrow- together again. – Then press locking ring -1- onto flange of line -3- until it can be heard to engage.

  • Page 103: Engine Oil: Drain Or Extract; Renew Oil Filter And Replenish Engine Oil

    Touareg 2003 ➤ Maintenance - Edition 11.2011 4.33 Engine oil: Drain or extract; renew oil fil‐ ter and replenish engine oil Engine oil capacities: ⇒ Power unit ⇒ Rep. gr. 17 ⇒ Engine oil or in ⇒ Maintenance tables Draining or extracting engine oil ⇒...
  • Page 104 Touareg 2003 ➤ Maintenance - Edition 11.2011 4.33.2 Renewing oil filter Renewing oil filter on 5-cylinder diesel engine ⇒ page 100 Renewing oil filter on 6-cylinder petrol engine ⇒ page 103 Renewing oil filter on 6-cylinder diesel engine ⇒ page 105 Renewing oil filter on 8-cylinder petrol engine ⇒...
  • Page 105 Touareg 2003 ➤ Maintenance - Edition 11.2011 4.33.4 Renewing oil filer on 8-cylinder petrol engine, engine codes AXQ and BHX Removing Note Observe disposal regulations! ♦ Oil new O-rings before installing. ♦ – Remove oil drain plug -1- of threaded cover and drain oil.
  • Page 106 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Release sealing cap -arrow- using a 32 mm socket. – Remove sealing cap together with oil filter element. – Separate oil filter element -3- from sealing cap -1-. – Clean sealing surfaces on threaded cap and oil filter housing.
  • Page 107 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Renew filter element -3-. Installing – Install threaded cap -1- with new O-rings -2- and -4- and tight‐ en to 25 Nm. 4.33.7 Renewing oil filter on 6-cylinder petrol engine Note Observe disposal regulations! ♦...
  • Page 108 Touareg 2003 ➤ Maintenance - Edition 11.2011 ♦ Torque wrench (5 - 50 Nm) -V.A.G 1331- Removing Note Observe disposal regulations! ♦ Oil new O-rings before installing. ♦ Prevent engine oil from dripping onto components in engine ♦ compartment. – Remove oil drain plug -1- of threaded cover and drain oil.
  • Page 109 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Renew filter element -5-. – Install threaded cap -3- with new O-ring -4- and tighten to 25 – Fit oil drain plug -1- with new seal -2- and tighten to 10 Nm.

  • Page 110: Engine Cover Panel -Top-: Removing And Installing

    Touareg 2003 ➤ Maintenance - Edition 11.2011 – Separate oil filter element -3- from sealing cap -1-. – Clean sealing surfaces on threaded cap and oil filter housing. Installing – Renew oil filter element -3-. – Install sealing cap -1- with new O-rings -2- and -4- and tighten to 35 Nm.
  • Page 111 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Lever off cover -2-. – Pull engine cover out of fastenings -arrows- and take out up‐ wards. Centre engine cover for 6-cylinder petrol engine – Unclip engine compartment covers -1- and -2- and remove upwards.

  • Page 112: Removing And Installing Engine Cover -Bottom- (Noise Insulation)

    Touareg 2003 ➤ Maintenance - Edition 11.2011 – First pull engine cover off at front with both hands (from driver perspective) -arrows-, then lift at rear with both hands (in bulk‐ head area). Note Do not lift engine cover abruptly when pulling off.

  • Page 113: Engine And Components In Engine Compartment (From Above And Below): Perform Visual Check For Leaks And Damage

    Touareg 2003 ➤ Maintenance - Edition 11.2011 – First remove bolts -1- and then -2-. 4.35.2 Front and rear noise insulation – Remove bolts -A-. – First remove front noise insulation -3-. – Then remove bolts -B-. – Pull rear noise insulation -2- out of spring tabs -1-.

  • Page 114: Tyre Repair Set: Check Bottle For Damage And If Used; Check Date Of Tyre Sealant

    Touareg 2003 ➤ Maintenance - Edition 11.2011 Caution Arrange for defects to be rectified as repair measures. If fluid loss is greater than can be expected through normal use, determine source and rectify (repair measure). 4.37 Tyre repair set: Check bottle for damage and if used;...

  • Page 115: Wheel Securing Bolts: Tighten To Specified Torque

    Touareg 2003 ➤ Maintenance - Edition 11.2011 – Automatic gearbox: Selector lever position, shift lock/ignition key removal lock, shift behaviour, dash panel insert display. – Foot brake: Function, free travel and effectiveness, pulling to one side, juddering, squealing. – Parking brake: Sufficient effect for public roads after 5-7 clicks at latest.

  • Page 116: Reading Radio Code Using Vehicle Diagnosis Tester

    Touareg 2003 ➤ Maintenance - Edition 11.2011 ♦ Adapter set for tamper-proof wheel bolts -T10313- The adapter to loosen and tighten the anti-theft wheel bolts can be found in the vehicle tool kit. Note Ensure that wheel bolts are tightened diagonally and alternately...

  • Page 117: Radio/Navigation System: Activate Anti-Theft Coding

    – Switch off ignition and separate diagnosis connections. 4.41 Radio/navigation system: Activate anti- theft coding ♦ General information ⇒ page 113 ♦ Activate anti-theft coding on Volkswagen radio systems ⇒ page 114 ♦ Activate anti-theft coding on Volkswagen radio/navigation sys‐ tems ⇒ page 115 4.41.1 General information The anti-theft coding electronically prevents unauthorized per‐...
  • Page 118 Touareg 2003 ➤ Maintenance - Edition 11.2011 4.41.2 Activating anti-theft coding on Volkswa‐ gen radio systems Activate fixed code on DELTA radio system as follows: – Switch radio on. ”SAFE” appears on the digital display. – Enter radio code using station buttons 1 to 4.

  • Page 119: Power Assisted Steering: Check Oil/Fluid Level

    Touareg 2003 ➤ Maintenance - Edition 11.2011 4.41.3 Activating anti-theft coding on Volkswa‐ gen radio/navigation systems Activate fixed code on „RNS 510“ as follows: – Switch on radio navigation system using press button -1-. – Enter code by turning rotary/push button -2- until number re‐...

  • Page 120: Headlight Adjustment: Check And Adjust As Necessary

    Touareg 2003 ➤ Maintenance - Edition 11.2011 – Check fluid level: The fluid level must be in area of MIN. mark‐ ing (up to 2 mm above or below marking). Note If the fluid level is above the area specified, the excessive fluid ♦...
  • Page 121 Touareg 2003 ➤ Maintenance - Edition 11.2011 4.43.1 Checking headlight adjustment (using test screen without 15° setting line) Special tools and workshop equipment required ♦ Headlight adjustment unit -VAS 5046- ♦ Or ♦ Headlight adjustment unit -VAS 5047- ♦ Headlight adjustment unit -VAS 5208A- ♦...
  • Page 122 Touareg 2003 ➤ Maintenance - Edition 11.2011 Note If the vehicle is equipped with separate dipped and main ♦ beam, adjust main beam additionally. When adjusting main beam ensure that the adjustment unit is set to 0 %. For NAR vehicles the side adjustment of headlight is not per‐...
  • Page 123 Touareg 2003 ➤ Maintenance - Edition 11.2011 Note For certain export markets a manually regulated headlight range control is not offered, thus the -0- position is discontinued. Headlights: Please check the following: – Whether, with the dipped beam switched on, the horizontal...
  • Page 124 Touareg 2003 ➤ Maintenance - Edition 11.2011 Left headlight up to model year 2005 Lateral adjustment of left headlight 1 - Horizontal dipped beam adjustment 2 - Horizontal main beam adjustment – Turn lateral dipped beam adjustment bolt -1- and lateral main beam adjustment bolt -2- until the correct setting is achieved.
  • Page 125 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Observe notes displayed and confirm by selecting „Done“. – Switch on dipped beam and confirm with „Done“. – Adjust headlights as follows: Identification characteristic for headlights with cornering light sys‐ tem: Note An additional reflector with halogen lamp for the static cornering light is located between dipped beam and turn signal.
  • Page 126 Touareg 2003 ➤ Maintenance - Edition 11.2011 4.43.4 Headlights with halogen bulbs: Adjust Adjusting left headlight up to model year 2006 Lateral adjustment of left headlight 1 - Horizontal dipped beam adjustment 2 - Horizontal main beam adjustment – Turn lateral dipped beam adjustment bolt -1- and lateral main beam adjustment bolt -2- until the correct setting is achieved.
  • Page 127 Touareg 2003 ➤ Maintenance - Edition 11.2011 Fog light in bumper up to model year 2006 – Set the appropriate inclination on the headlight adjustment unit. • The inclination for fog lights is „2.0 %“. Note Percentage given is based on a projection distance of 10 metres.

  • Page 128: Sunroof: Check Function, Clean And Grease Guide Rails

    Touareg 2003 ➤ Maintenance - Edition 11.2011 – Turn height adjustment bolt until correct setting is attained, using hexagon key -arrow-. A lateral adjustment is not possible. Other additional lights Additionally retrofitted lights of other systems must be checked and set according to valid guidelines.
  • Page 129 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Check sliding sunroof drain holes -arrows- for dirt and clean if necessary. – Pour tap water into sliding sunroof drains and check if almost the same quantity of water flows out of the wheel housings.

  • Page 130: Window Wash/Wipe System And Headlight Washer System: Checking Operation And Checking For Damage, If Necessary Replenishing Fluid

    Touareg 2003 ➤ Maintenance - Edition 11.2011 – Drains -arrows- are located on the left and right side, inside the plenum chamber. – Check plenum chamber drains -arrows- for dirt and clean if necessary. – To check, pour tap water again through the sliding sunroof drain holes.
  • Page 131 -37/-38 °C 1 part 1 part Replenishing fluid: The fluid reservoir of the window washer system must be filled completely. Starting immediately, use only „Genuine Volkswagen Wind‐ screen Clear“ all-year-round when replenishing window wash/ wipe system. 4. Descriptions of work...
  • Page 132 „Genuine Volkswa‐ gen window cleaner“ ensures that the fan -type washer jets remain fully functional at low temperatures. Use Genuine Volkswagen Windscreen Clear „G 052 164“ also ♦ in the warmer periods of the year. The powerful cleanser re‐...
  • Page 133 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Adjust spray jet at adjuster -1- by hand upwards or down‐ wards. 4.46.3 Headlight washer system: Checking spray jet settings Caution Only control function of spray jets but do not adjust them.

  • Page 134: Wiper Blade Protection: Remove

    Touareg 2003 ➤ Maintenance - Edition 11.2011 4.46.5 Wiper blades: Checking park position, adjusting if necessary Windscreen of LHD vehicles: – Check park position. The distance -A- between wiper blade and lower edge of wind‐ screen must be 9 mm.
  • Page 135 Touareg 2003 ➤ Maintenance - Edition 11.2011 Version 1 On this wiper arm the blade protector is secured on the blade with two securing clips -arrows-. Perform the following procedure: – Set wipers in service position. This can be done by switching the ignition on and off once with bonnet closed.
  • Page 136 Touareg 2003 ➤ Maintenance - Edition 11.2011 This transport wiper arm is fitted without wind deflector. Perform the following procedure: – Set wipers in service position. This can be done by switching the ignition on and off once with bonnet closed. Then operate wiper lever and the wipers will stop in service position.

  • Page 137: Service Interval Display: Reset

    Touareg 2003 ➤ Maintenance - Edition 11.2011 – Set wipers in service position. This can be done by switching the ignition on and off once with bonnet closed. Then operate wiper lever and the wipers will stop in service position.

  • Page 138: Service Interval Display: Recode

    Touareg 2003 ➤ Maintenance - Edition 11.2011 ♦ „Dash panel insert“ -ARROW- ♦ „Resetting service interval display“ – Perform adaption according to the information of „GUIDED FUNCTIONS“. Ending adaption Indicated on display: – Press the »GoTo« button on display -arrow-.

  • Page 139: Track Rod Ends: Check Clearance, Security And Boots

    Touareg 2003 ➤ Maintenance - Edition 11.2011 If the vehicle identification has been performed correctly, confirm with button. > – Select one after the other: ♦ „Dash panel insert“ -ARROW- ♦ „Adapting service interval extension“. – Perform adaption according to the information of „GUIDED FUNCTIONS“.

  • Page 140: Transportation Mode: Switch Off

    Touareg 2003 ➤ Maintenance - Edition 11.2011 – Check mountings. – Check that boots -arrow- are not damaged and are seated correctly. 4.51 Transportation mode: Switch off – Connect vehicle diagnosis tester ⇒ page 19 – Switch on ignition. Indicated on display: Selecting operating mode –...

  • Page 141: Door Arrester: Grease

    Touareg 2003 ➤ Maintenance - Edition 11.2011 Indicated on display: – Press »GoTo« button on display -arrow-. Indicated on display: – Press the »End« button on display -arrow-. – Press »End« button in End menu. – Switch off ignition. Note The vehicle diagnosis tester must probably remain connected for further tests.

  • Page 142: Underbody: Visual Check For Damage To Underbody Sealant, Underbody Panels, Routing Of

    Touareg 2003 ➤ Maintenance - Edition 11.2011 4.54 Underbody: Visual check for damage to underbody sealant, underbody panels, routing of lines, plugs During visual check, also check floor pan, wheel housings and sills. Always ensure that all lines are secured in their mountings, all plugs are available and that there is no visible damage on the underbody.
  • Page 143 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Operate (press) button -1- or button -3- to change the menus, and to select (turn) knurled wheel -2-. – Press button -1- or button -3- until the menu point „CONVEN‐ IENCE SET-UP“ is shown marked.

  • Page 144: Transfer Box And Front And Rear Final Drive: Checking Oil Level, Replenishing If Necessary

    Touareg 2003 ➤ Maintenance - Edition 11.2011 – Operate (press) button -1- or button -3- to change the menus, and to select (turn) knurled wheel -2-. – Press button -1- or button -3- until the menu point „CONVEN‐ IENCE SET-UP“ is shown marked.
  • Page 145 Touareg 2003 ➤ Maintenance - Edition 11.2011 ♦ Torque wrench -V.A.G 1331/- ♦ Assembly tool -T10118- for 6-cylinder engine ♦ Puller -T10095 A- for 6-cylinder engine ♦ Puller -T40039- for 8-cylinder engine 4. Descriptions of work...
  • Page 146 Touareg 2003 ➤ Maintenance - Edition 11.2011 ♦ Spring-type clip pliers -VAS 6499- 4.58.1 Vehicles with 6-cylinder petrol engine Removing: Carry out the following procedure: – Unclip engine covers -1- and -2- and remove upwards. Release connection locking device: – Apply tool T10118 to connection locking device -arrow- and carefully pull upwards until connection locking device relea‐...
  • Page 147 Touareg 2003 ➤ Maintenance - Edition 11.2011 The flat side of the connector must align with the flat side of igni‐ tion coil with output stage -arrows-. – Slide puller T10095/a from the flat side of the connector in di‐...
  • Page 148 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Apply a thin bead of spark plug connector grease -G 052 141 A2- on the circumference of the sealing hose of the pencil-type ignition coil -arrow-. The grease bead must be 1 to 2 mm thick.
  • Page 149 Touareg 2003 ➤ Maintenance - Edition 11.2011 4.58.2 Vehicles with 8-cylinder petrol engine Removing: – Pull out dipstick. – Remove bracket for left engine cover -1-. – Unscrew bolts and retaining pin for engine cover -arrows-. Press connection locking device -arrows- in direction of arrow and pull connectors -A- off ignition coils with output stage.
  • Page 150 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Unscrew spark plugs using spark plug socket and extension -3122B- . Installing: – Screw in new spark plugs using spark plug socket and exten‐ sion 3122 B. Note Observe specified torque! Current values ⇒ Power unit ⇒...
  • Page 151 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Push on connectors -A- so that they engage. – Install left bracket for engine cover -1- and tighten to 10 Nm. 4.58.3 Vehicles with 12-cylinder petrol engine Removing: – Remove engine covers.
  • Page 152 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Pull off hose -1-. – Remove bolts -1- and -2- and carefully pull off intake manifold side part. – Remove bonded rubber seal -3-. – Disconnect connectors -1- at ignition coils with output stages -2-.
  • Page 153 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Unscrew spark plugs using spark plug socket and extension -3122 B- . Note Spark plug designation and torque setting ⇒ Power unit ⇒ ♦ Rep. gr. 28 ⇒ Ignition system, test data Observe disposal regulations! ♦...
  • Page 154 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Reinstall intake manifold side part -2-. Note Renew seal -3-. – When installing ensure that the seal -3- lies in the guide pins -1-. – Tighten bolts -1- and -2- to 8 Nm.

  • Page 155: Static Cornering Light (Cornering Light) And Driving Light Assist: Check Function

    Touareg 2003 ➤ Maintenance - Edition 11.2011 – Secure intake hose with clips -1- and -2- using spring-type clip pliers -VAS 6499- . – Install engine covers. 4.59 Static cornering light (cornering light) and driving light assist: Check function Static cornering light –...

  • Page 156: Exhaust Emissions Test

    Touareg 2003 ➤ Maintenance - Edition 11.2011 Exhaust emissions test Note Please observe the country specific legal regulations. ♦ The following exhaust emissions test description is applicable ♦ only in countries where no specific exhaust emission regula‐ tions have to be adhered to.
  • Page 157 Touareg 2003 ➤ Maintenance - Edition 11.2011 Note ♦ It is only possible to perform an exhaust emissions test when all units of the Emissions testing station -VAS 6300- are con‐ nected properly and combined with each other according to the instruction manual.
  • Page 158 The vehicle data input menu is displayed. – Enter vehicle data from vehicle registration document at posi‐ tions -1...8-. ♦ -1- Vehicle manufacturer: „e.g. VOLKSWAGEN - VW“ ♦ -2- Vehicle type: „e.g. Golf“ ♦ -3- Key number to 1: „e.g. 11“...
  • Page 159 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Enter displayed values on EET data sheet in column „Test values for exhaust emissions test“ on display as follows: Test speed (idling speed) Warm-up phase for catalytic converter Engine temperature Increased idling speed...
  • Page 160 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Follow instructions on display. – Switch off ignition. – Connect diagnosis cable connector to EOBD connection. – Switch on ignition. – Perform visual check of „MI lamp“. – If lamp lights up, press button „Lamp On“ -arrow C-.
  • Page 161 Touareg 2003 ➤ Maintenance - Edition 11.2011 It is automatically switched to test for readiness of operation. It is checked here if all tests for readiness of operation supported by the control unit have been performed. Note If all display values are set to zero, a regulating probe test is ♦...
  • Page 162 Touareg 2003 ➤ Maintenance - Edition 11.2011 Measurement at increased idling speed: It is automatically switched to display for measuring increased idling speed. – Follow instructions on display. Measurement starts when the engine speed has reached the re‐ quired level.

  • Page 163: Exhaust Emissions Test For Diesel Engines

    Touareg 2003 ➤ Maintenance - Edition 11.2011 Evaluation: When the exhaust emissions test is performed, the log is shown on display. The test result is displayed. Now remarks concerning the exhaust emissions test can be en‐ tered -arrow A-. They will then be included in the test log.
  • Page 164 Touareg 2003 ➤ Maintenance - Edition 11.2011 ♦ Engine speed adapter -VAS 5087 A- ♦ Or ♦ Engine speed adapter -VAS 6296- ♦ Data reader -V.A.G 1798- ♦ Or ♦ Data reader -V.A.G 1799- ♦ ⇒ Data sheets for exhaust emissions test...
  • Page 165 Touareg 2003 ➤ Maintenance - Edition 11.2011 Test conditions • Engine temperature at least 80 °C • No fault in event memory Connecting test units Connect diesel tester -V.A.G 1743- according to operating in‐ structions. Description, measuring process, function, setting up and opera‐...
  • Page 166 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Using the other wires from adapter -VAS 5087/1- make a con‐ nection to the vehicle battery, by connecting: ♦ Red clamp on positive ♦ Black clamp on negative. Note When using the engine speed adapter -VAS 5087 A- press ♦...
  • Page 167 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Confirm vehicle data entered or read using button. If the following is indicated on display: Visual check OK = y Not OK = n – Enter result of visual check. If the following is indicated on display: F1 Temperature measurement with sen- F2 Enter temp.
  • Page 168 Touareg 2003 ➤ Maintenance - Edition 11.2011 If the following is indicated on display: Idling speed 1st measurement 15 sec Speed ACT. xxxx rpm SPEC. xxx...xxxx rpm – The data reader accepts the actual figures within 15 seconds. If the following is indicated on display:...
  • Page 169 Touareg 2003 ➤ Maintenance - Edition 11.2011 If the following is indicated on display: Data transfer to diesel tester Depress accelerator quickly – Depress accelerator pedal fully and hold. If the following is indicated on display: Data transfer to diesel tester Neutral accel.

  • Page 170: Exhaust Emissions Test For Diesel Engines With Obd

    Touareg 2003 ➤ Maintenance - Edition 11.2011 Exhaust emissions test for diesel en‐ gines with OBD 5.3.1 Exhaust emissions test for diesel en‐ gines with OBD with emissions testing station VAS 6300 Caution • Observe „SAFETY AND DAMAGE AVOIDANCE PRE‐...
  • Page 171 Touareg 2003 ➤ Maintenance - Edition 11.2011 • Manual gearbox: Gear lever in neutral • Handbrake pulled on – Perform exhaust emissions test according to instructions on display. Initial screen: – Select button „Exhaust emissions test“ -arrow-. An overview is displayed to select the respective EET type.
  • Page 172 For new models the document previously known as the vehicle ♦ log book is now called the vehicle registration certificate part ♦ -1- Vehicle manufacturer: „e.g. VOLKSWAGEN - VW“ ♦ -2- Vehicle type: „e.g. Golf“ ♦ -3- Key number to 1: „e.g. 11“...
  • Page 173 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Select „Diesel OBD“ -arrow-. Specified data input for EET: There are different ways to enter the specified data: ♦ 1. Manual input ♦ 2. Bar code input of EET data sheet ♦ 3. ELSA web service...
  • Page 174 Touareg 2003 ➤ Maintenance - Edition 11.2011 All data required are shown on display -1-. – Press button -arrow- to continue the process. → Visual check: – Follow instructions on display. – Perform visual check. – If visual check is OK press „OK“ button. -arrow- Note When „not OK“...
  • Page 175 Touareg 2003 ➤ Maintenance - Edition 11.2011 – If lamp lights up, press button „Lamp On“ -arrow C-. Note If the MI lamp does not light up during visual check, the result of the exhaust emissions test is „Failed“. Visual check of MI lamp with engine running: –...
  • Page 176 Touareg 2003 ➤ Maintenance - Edition 11.2011 It is automatically switched to display for measuring rev limit. Measurement starts when the engine speed has reached the re‐ quired level. – Operate throttle until the measurement is carried out. To do this, immediately depress accelerator pedal.
  • Page 177 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Follow instructions on display -arrow B-. – Depress accelerator pedal fully when prompted and hold until the prompt for idling is shown on display. Free acceleration - phase 3: – Remove foot from accelerator pedal when the prompt for idling is shown on display -arrow B- and run engine at idling speed.
  • Page 178 Touareg 2003 ➤ Maintenance - Edition 11.2011 – Press button „Close“ -arrow B- to close the menu „Print pre‐ view “. – Follow instructions on display. – Take emission probe out of exhaust tail pipe. – Then press button -arrow B-.

  • Page 179: Glossary

    Touareg 2003 ➤ Maintenance - Edition 11.2011 Glossary These explanations only apply to „Maintenance Manual“. They are not necessarily generally valid! Term Explanation Anti-lock brake system: the ABS is a regulating system in the brake system, that pre‐ vents locking when braking. This helps to maintain directional stability and steerability.

  • Page 180: Touareg

    Touareg 2003 ➤ Maintenance - Edition 11.2011 Term Explanation The LongLife service is not factory-activated. This means vehicles have a non-flexible service interval display (time and distance dependent service intervals) and are fitted with the following components: ♦ Non-flexible service interval display in dash panel insert ♦...

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