Volkswagen Touran 2003 Manuals

Manuals and User Guides for Volkswagen Touran 2003. We have 1 Volkswagen Touran 2003 manual available for free PDF download: Workshop Manual

Volkswagen Touran 2003 Workshop Manual (299 pages)

Brand: Volkswagen | Category: Automobile | Size: 7 MB

Table of Contents
3
Technical Data
7
Engine Number
7
Engine Data
7
Removing and Installing Engine
9
Removing Engine
10
Securing Engine to Assembly Stand
17
Notes on Installing
19
Assembly Mountings
20
Crankshaft Group
21
Dismantling and Assembling Engine
21
Assembly Overview - Poly V-Belt Drive
21
Removing and Installing Poly V-Belt
22
Assembly Overview - Toothed Belt Drive
24
Assembly Overview - Crankcase
29
Removing and Installing Sealing Flange and Flywheel
30
Renewing Crankshaft Sealing Flange - Flywheel End
31
Renewing Crankshaft Oil Seal - Pulley End
39
Removing and Installing Sealing Flange - Pulley End
41
Removing and Installing Engine Speed Sender G28
43
Pistons and Conrods
45
Assembly Overview - Pistons and Conrods
45
Piston and Cylinder Dimensions
46
Checking Piston Projection at TDC
46
Piston Rings, Cylinder Bore and Piston Installation Position
48
Crankshaft
50
Assembly Overview - Crankshaft
50
Crankshaft Dimensions
50
Pulling Needle Bearing out of and Driving into Crankshaft
51
Cylinder Head, Valve Gear
53
Cylinder Head
53
Assembly Overview - Cylinder Head
53
Removing and Installing Cylinder Head Cover
55
Removing, Installing and Tensioning Toothed Belt
57
Removing and Installing Cylinder Head
72
Checking Compression
77
Valve Gear
78
Assembly Overview - Valve Gear
78
Removing and Installing Roller Rocker Finger
80
Valves
82
Removing and Installing Camshafts
85
Removing and Installing Camshaft Oil Seal
90
Lubrication
92
Engine Oil
92
Oil Capacities - Golf, Golf Plus, Touran
92
Oil Capacities - Passat
92
Checking Engine Oil Level
92
Parts of Lubrication System (Golf, Golf Plus, Touran)
93
Assembly Overview - Oil Pump, Sump
93
Removing and Installing Oil Sump
95
Parts of Lubrication System (Passat)
98
Assembly Overview - Oil Pump, Sump, Balancer Shaft Module with Chain Drive
99
Removing and Installing Oil Pump (for Balancer Shaft Module with Chain Drive)
101
Removing and Installing Balancer Shaft Module with Chain Drive
104
Retrofitting Spur Gear Drive for Balancer Shaft Module
107
Assembly Overview - Oil Pump, Sump, Balancer Shaft Module with Spur Gear Drive
110
Removing and Installing Oil Pump (for Balancer Shaft Module with Spur Gear Drive)
113
Removing Balancer Shaft Module with Spur Gear Drive
113
Renewing Spur Gear for Crankshaft
114
Installing Balancer Shaft Module
117
Removing and Installing Oil Sump
123
Oil Filter Bracket, Oil Cooler, Oil Pressure and Oil Supply Line
126
Assembly Overview - Oil Filter Bracket and Oil Cooler
126
Checking Oil Pressure and Oil Pressure Switch
127
Assembly Overview - Oil Supply Line to Turbocharger
129
Removing and Installing Oil Supply Line to Turbocharger
129
Cooling
131
Parts of Cooling System
131
Parts of Cooling System, Body Side
132
Assembly Overview - Parts of Cooling System, Engine Side (Golf, Golf Plus, Touran)
133
Assembly Overview - Parts of Cooling System, Engine Side (Passat)
135
Coolant Hose Schematic Diagram
137
Draining and Filling Coolant
140
Removing and Installing Fan Support with Fans
145
Removing and Installing Radiator
146
Removing and Installing Coolant Pump
148
Removing and Installing Thermostat
150
Checking Cooling System for Leaks
152
Checking Oil Cooler for Leaks
154
Fuel Supply System
156
Safety Precautions
156
Safety Precautions When Working on Fuel Supply System
156
Rules for Cleanliness
157
Rules for Cleanliness When Working on Fuel Supply System
157
Parts of Fuel Supply System (Golf, Golf Plus)
158
Fuel Tank, Vehicles with Front-Wheel Drive
158
Fuel Tank, Vehicles with Four-Wheel Drive
162
Emptying Fuel Tank
168
Removing and Installing Fuel Delivery Unit
170
Removing and Installing Fuel Gauge Sender
172
Checking Fuel Pump
172
Assembly Overview - Fuel Filter
177
Removing and Installing Fuel Cooler
179
Parts of Fuel Supply System (Touran)
181
Assembly Overview - Fuel Tank with Attachments
182
Emptying Fuel Tank
183
Removing and Installing Fuel Tank
186
Assembly Overview - Fuel Filter
188
Removing and Installing Fuel Cooler
189
Removing and Installing Fuel Delivery Unit
190
Removing and Installing Fuel Gauge Sender
192
Checking Fuel Pump
192
Parts of Fuel Supply System (Passat)
198
Fuel Tank, Vehicles with Four-Wheel Drive
198
Emptying Fuel Tank, Vehicles with Four-Wheel Drive
208
Fuel Tank, Vehicles with Front-Wheel Drive
212
Emptying Fuel Tank, Vehicles with Front-Wheel Drive
219
Checking Fuel Pump
221
Assembly Overview - Fuel Filter
225
Removing and Installing Fuel Cooler
227
Accelerator Mechanism
229
Assembly Overview - Accelerator Mechanism
229
Tandem Pump
231
Checking Tandem Pump
231
Removing and Installing Tandem Pump
233
Turbocharging/Supercharging
236
Charge Air System with Turbocharger
236
Safety Precautions
236
Rules for Cleanliness
236
Hose Connections
237
Assembly Overview - Turbocharger with Attachments
238
Removing and Installing Turbocharger
241
Assembly Overview - Charge Air Cooling
243
Checking Charge Air System for Leaks
244
Vacuum Hose Schematic Diagram
246
Mixture Preparation - Injection
248
Diesel Direct Injection System
248
Safety Precautions
248
Rules for Cleanliness
249
Assembly Overview - Intake Manifold with Attachments
250
Assembly Overview - Pre-Wired Wiring Harness for Unit Injectors and Glow Plugs
252
Removing and Installing Pre-Wired Wiring Harness for Unit Injectors and Glow Plugs
252
Assembly Overview - Unit Injector
255
Removing and Installing Unit Injector
257
Cleaning Unit Injectors (Engine Codes BMN, BKP, BMA, BUZ and BMR)
261
Removing and Installing O-Rings for Unit Injector
263
Assembly Overview - Air Filter
265
Engine Control Unit (Golf)
266
Removing and Installing Engine Control Unit
266
Removing and Installing Anti-Theft Engine Control Unit
266
Engine Control Unit (Golf Plus, Touran)
270
Removing and Installing Engine Control Unit
270
Removing and Installing Anti-Theft Engine Control Unit
271
Engine Control Unit (Passat)
274
Removing and Installing Engine Control Unit
274
Removing and Installing Anti-Theft Engine Control Unit
275
Exhaust System
279
Front Exhaust Pipe
279
Assembly Overview - Front Exhaust Pipe with Catalytic Converter
279
Assembly Overview - Front Exhaust Pipe with Particulate Filter
280
Silencer (Golf, Golf Plus)
283
Assembly Overview - Silencer, Vehicles with Front-Wheel Drive
283
Assembly Overview - Silencer, Vehicles with Four-Wheel Drive
284
Cutting Exhaust Pipe
284
Installation Position and Specified Torque of the Clamp
285
Aligning Exhaust System Free of Stress
286
Silencer (Touran)
288
Assembly Overview - Silencers
288
Cutting Exhaust Pipe
289
Aligning Exhaust System Free of Stress
289
Silencer (Passat)
290
Assembly Overview - Silencer, Vehicles with Front-Wheel Drive
290
Assembly Overview - Silencer, Vehicles with Four-Wheel Drive
291
Aligning Exhaust System Free of Stress
291
Exhaust Gas Recirculation System
293
Assembly Overview - Exhaust Gas Recirculation
293
Glow Plug System
296
Optical Characteristics of Metal or Ceramic Glow Plugs
296
Removing and Installing Metal Glow Plug
296
Removing and Installing Ceramic Glow Plugs
298

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Volkswagen Touran 2003 Manuals

Volkswagen Touran 2003 Workshop Manual (299 pages)

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