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Touran 2003
Workshop manual
Volkswagen Touran 2003 Workshop Manual
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Contents
Table of Contents
Bookmarks
Table of Contents
Table of Contents
Technical Data
Engine Number
Engine Data
Removing and Installing Engine
Removing Engine
Securing Engine to Assembly Stand
Notes on Installing
Assembly Mountings
Crankshaft Group
Dismantling and Assembling Engine
Assembly Overview - Poly V-Belt Drive
Removing and Installing Poly V-Belt
Assembly Overview - Toothed Belt Drive
Assembly Overview - Crankcase
Removing and Installing Sealing Flange and Flywheel
Renewing Crankshaft Sealing Flange - Flywheel End
Renewing Crankshaft Oil Seal - Pulley End
Removing and Installing Sealing Flange - Pulley End
Removing and Installing Engine Speed Sender G28
Pistons and Conrods
Assembly Overview - Pistons and Conrods
Piston and Cylinder Dimensions
Checking Piston Projection at TDC
Piston Rings, Cylinder Bore and Piston Installation Position
Crankshaft
Assembly Overview - Crankshaft
Crankshaft Dimensions
Pulling Needle Bearing out of and Driving into Crankshaft
Cylinder Head, Valve Gear
Cylinder Head
Assembly Overview - Cylinder Head
Removing and Installing Cylinder Head Cover
Removing, Installing and Tensioning Toothed Belt
Removing and Installing Cylinder Head
Checking Compression
Valve Gear
Assembly Overview - Valve Gear
Removing and Installing Roller Rocker Finger
Valves
Removing and Installing Camshafts
Removing and Installing Camshaft Oil Seal
Lubrication
Engine Oil
Oil Capacities - Golf, Golf Plus, Touran
Oil Capacities - Passat
Checking Engine Oil Level
Parts of Lubrication System (Golf, Golf Plus, Touran)
Assembly Overview - Oil Pump, Sump
Removing and Installing Oil Sump
Parts of Lubrication System (Passat)
Assembly Overview - Oil Pump, Sump, Balancer Shaft Module with Chain Drive
Removing and Installing Oil Pump (for Balancer Shaft Module with Chain Drive)
Removing and Installing Balancer Shaft Module with Chain Drive
Retrofitting Spur Gear Drive for Balancer Shaft Module
Assembly Overview - Oil Pump, Sump, Balancer Shaft Module with Spur Gear Drive
Removing and Installing Oil Pump (for Balancer Shaft Module with Spur Gear Drive)
Removing Balancer Shaft Module with Spur Gear Drive
Renewing Spur Gear for Crankshaft
Installing Balancer Shaft Module
Removing and Installing Oil Sump
Oil Filter Bracket, Oil Cooler, Oil Pressure and Oil Supply Line
Assembly Overview - Oil Filter Bracket and Oil Cooler
Checking Oil Pressure and Oil Pressure Switch
Assembly Overview - Oil Supply Line to Turbocharger
Removing and Installing Oil Supply Line to Turbocharger
Cooling
Parts of Cooling System
Parts of Cooling System, Body Side
Assembly Overview - Parts of Cooling System, Engine Side (Golf, Golf Plus, Touran)
Assembly Overview - Parts of Cooling System, Engine Side (Passat)
Coolant Hose Schematic Diagram
Draining and Filling Coolant
Removing and Installing Fan Support with Fans
Removing and Installing Radiator
Removing and Installing Coolant Pump
Removing and Installing Thermostat
Checking Cooling System for Leaks
Checking Oil Cooler for Leaks
Fuel Supply System
Safety Precautions
Safety Precautions When Working on Fuel Supply System
Rules for Cleanliness
Rules for Cleanliness When Working on Fuel Supply System
Parts of Fuel Supply System (Golf, Golf Plus)
Fuel Tank, Vehicles with Front-Wheel Drive
Fuel Tank, Vehicles with Four-Wheel Drive
Emptying Fuel Tank
Removing and Installing Fuel Delivery Unit
Removing and Installing Fuel Gauge Sender
Checking Fuel Pump
Assembly Overview - Fuel Filter
Removing and Installing Fuel Cooler
Parts of Fuel Supply System (Touran)
Assembly Overview - Fuel Tank with Attachments
Emptying Fuel Tank
Removing and Installing Fuel Tank
Assembly Overview - Fuel Filter
Removing and Installing Fuel Cooler
Removing and Installing Fuel Delivery Unit
Removing and Installing Fuel Gauge Sender
Checking Fuel Pump
Parts of Fuel Supply System (Passat)
Fuel Tank, Vehicles with Four-Wheel Drive
Emptying Fuel Tank, Vehicles with Four-Wheel Drive
Fuel Tank, Vehicles with Front-Wheel Drive
Emptying Fuel Tank, Vehicles with Front-Wheel Drive
Checking Fuel Pump
Assembly Overview - Fuel Filter
Removing and Installing Fuel Cooler
Accelerator Mechanism
Assembly Overview - Accelerator Mechanism
Tandem Pump
Checking Tandem Pump
Removing and Installing Tandem Pump
Turbocharging/Supercharging
Charge Air System with Turbocharger
Safety Precautions
Rules for Cleanliness
Hose Connections
Assembly Overview - Turbocharger with Attachments
Removing and Installing Turbocharger
Assembly Overview - Charge Air Cooling
Checking Charge Air System for Leaks
Vacuum Hose Schematic Diagram
Mixture Preparation - Injection
Diesel Direct Injection System
Safety Precautions
Rules for Cleanliness
Assembly Overview - Intake Manifold with Attachments
Assembly Overview - Pre-Wired Wiring Harness for Unit Injectors and Glow Plugs
Removing and Installing Pre-Wired Wiring Harness for Unit Injectors and Glow Plugs
Assembly Overview - Unit Injector
Removing and Installing Unit Injector
Cleaning Unit Injectors (Engine Codes BMN, BKP, BMA, BUZ and BMR)
Removing and Installing O-Rings for Unit Injector
Assembly Overview - Air Filter
Engine Control Unit (Golf)
Removing and Installing Engine Control Unit
Removing and Installing Anti-Theft Engine Control Unit
Engine Control Unit (Golf Plus, Touran)
Removing and Installing Engine Control Unit
Removing and Installing Anti-Theft Engine Control Unit
Engine Control Unit (Passat)
Removing and Installing Engine Control Unit
Removing and Installing Anti-Theft Engine Control Unit
Exhaust System
Front Exhaust Pipe
Assembly Overview - Front Exhaust Pipe with Catalytic Converter
Assembly Overview - Front Exhaust Pipe with Particulate Filter
Silencer (Golf, Golf Plus)
Assembly Overview - Silencer, Vehicles with Front-Wheel Drive
Assembly Overview - Silencer, Vehicles with Four-Wheel Drive
Cutting Exhaust Pipe
Installation Position and Specified Torque of the Clamp
Aligning Exhaust System Free of Stress
Silencer (Touran)
Assembly Overview - Silencers
Cutting Exhaust Pipe
Aligning Exhaust System Free of Stress
Silencer (Passat)
Assembly Overview - Silencer, Vehicles with Front-Wheel Drive
Assembly Overview - Silencer, Vehicles with Four-Wheel Drive
Aligning Exhaust System Free of Stress
Exhaust Gas Recirculation System
Assembly Overview - Exhaust Gas Recirculation
Glow Plug System
Optical Characteristics of Metal or Ceramic Glow Plugs
Removing and Installing Metal Glow Plug
Removing and Installing Ceramic Glow Plugs
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Table of Contents
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Engine Number
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Technical Data
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Engine Oil
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Service
Workshop Manual
Golf 2004 ➤
Golf Plus 2005 ➤
Passat 2006 ➤
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 4 valve)
Engine ID
Edition 02.2011
Service Department. Technical Information
AZV BKD BMN BKP BMA BVE BMR BUZ BWV
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