Volkswagen Touareg 2003 Workshop Manual PDF

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

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Repair Group
00 - Technical data
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10 - Removing and installing engine
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13 - Crankshaft group
15 - Cylinder head, valve gear
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17 - Lubrication
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19 - Cooling
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20 - Fuel supply system
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24 - Mixture preparation - injection
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26 - Exhaust system
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28 - Ignition system
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. 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

Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Assembly overview - part I, toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 Assembly overview - part II, cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.4 Checking alignment of poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2 Removing and installing sealing flange and drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.3 Removing and installing sealing flange at drive plate end . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.4 Renewing crankshaft oil seal, vibration damper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.2 Removing and installing right cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.3 Removing and installing left cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.4 Removing, installing and tensioning toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.5 Removing and installing left cylinder shead AG. Volkswagen
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1.6 Removing and installing right cylinder
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1.7 Checking compression . h. o.ris. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .nt.ee. . . . . . . . . . . . . . . . 48
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2 Repairing valve gear s.s.a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.c . . . . . . . . . . . . . 50
2.1 Camshafts, checking axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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2.2 Renewing camshaft oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

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2.3 Renewing Hall sender seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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2.4 Removing and installing camshafts and variable camshaft timing adjusters . . . . . . . . . . . . 56
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2.5 Removing and installing roller rocker finger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

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2.6 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

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2.7 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

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2.8 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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1 Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

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1.1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

1.2 Oil capacities: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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1.3 Dismantling and assembling oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

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1.4 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

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1.5 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
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1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

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1.1 Assembly overview - radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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1.2 Assembly overview - radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.3 Removing and installing fan support with fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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1.4 Assembly overview - parts of cooling system, engine side, front . . . . . . . . . . . . . . . . . . . . 81
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Contents i
Touareg 2003 ➤
1.5 Assembly overview - parts of cooling system, engine side, rear . . . . . . . . . . . . . . . . . . . . 81

1.6 Assembly overview - parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.7 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.8 Checking water pump V36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.9 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.10 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.11 Removing and installing coolant pump and thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.12 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

1 Parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.1 Assembly overview - fuel tank with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.2 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.3 Renewing fuel filter . . . . . . . . . . . . . . . . . . g. e.n.A.G.. V
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1.4 Schematic diagram of fuel lines and ycomponentsV olks in fuel tank . . .s.no. t .gu. . . . . . . . . . . . . . . . 98
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1.5 Safety precautions when working ris on fuel supply system . . . . . . . . . . . . n. te.e. . . . . . . . . . . .
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1.6 Rules for cleanliness . . . . .a.uth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o. r .a . . . . . . . . . . 99
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1.7 Emptying fuel tank . . . . . .s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
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1.8 Removing and installing fuel delivery unit, fuel gauge sender and suction-jet pumps . . . . 102
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1.9 Removing and installing fuel tank with attached components . . . . . . . . . . . . . . . . . . . . . . 104
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1.10 Checking fuel pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
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1.11 Checking delivery rate of pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
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1.12 Checking non-return valve of right pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
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1.13 Checking non-return valve of left pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
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2 Electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3.1 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
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3.2 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
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4 Activated charcoal filter system (vehicles for USA and Canada) . . . . . . . . . . . . . . . . . . . . 122
4.1 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
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4.2 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
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24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

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1 Repairing injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

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1.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

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1.2 Assembly overview - fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

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1.3 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.4 Assembly overview - vacuum hose assembly on intake manifold . . . . . . . . . . . . . . . . . . . . 136
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1.5 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
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1.6 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
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1.7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

2 Checking components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2.1 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2.2 Checking fuel pressure regulator and holding pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
3 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.2 Reading and erasing engine control unit fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.1 Assembly overview - exhaust manifold with starter catalytic converters and attachments
........................................................................ 148
1.2 Removing and installing Lambda probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.3 Assembly overview - silencers with mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
2 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
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Touareg 2003 ➤
2.1 Assembly overview - removing and installing parts of secondary air system . . . . . . . . . . . . 155
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

1 Repairing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.1 Assembly overview - parts of ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.3 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.4 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
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wage - Edition 11.2011
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Technical data
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1 Technical data
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Engine data ⇒ page 1
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The engine number („engine code“ and „serial number“) is stam‐
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The engine code is also included on the vehicle data sticker.
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1.1 Engine data
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Issued 11.2011; Version 6.0
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Engine code AXQ BHX

Manufactured 03.03 ► 03.03 ►
Cylinder arrangement V-engine V-engine
Cylinder angle 90° 90°
Capacity l 4.2 4.2
Output kW at rpm 228/6200 228/6200
Torque Nm at rpm 410/3200 410/3200
Bore ∅ mm 84.5 84.5
Stroke mm 93.0 93.0
Compression ratio 11.0 11.0
Valves per cylinder 5 5
Injection, ignition Motronic ME 7.1 Motronic ME 7.1
Firing order 1-5-4-8-6-3-7-2 1-5-4-8-6-3-7-2
Knock control 2 knock sensors 2 knock sensors
Lambda control 4 probes 4 probes
Leak diagnosis system Only vehicles for USA and yes
Canada
Catalytic converter yes yes
Exhaust gas recirculation no no
Turbocharging/supercharging no no
Secondary air system yes yes
Electronic power control yes yes
Variable intake manifold yes yes
Camshaft timing control yes yes
RON min. 98 unleaded1) 98 unleaded1)
1) In exceptional circumstances min. 95 RON, however with reduced perform‐

ance.
1. Technical data 1
Touareg 2003 ➤
10 – Removing and installing engine

1 Removing and installing engine
Removing engine ⇒ page 3 .
Securing engine on engine and gearbox support -VAS 6095-
⇒ page 9 .
Notes on installing ⇒ page 10 .
Special tools and workshop

equipment required
♦ Lifting tackle -VAS 3033-
♦ Drip tray -V.A.G 1306-
♦ Engine and gearbox sup‐
port -VAS 6095-
♦ Workshop hoist -VAS
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♦ Scissor-type assembly d byV ua
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platform -VAS 6131- ir se tee
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♦ Engine and gearbox jack - ss
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Not illustrated:
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♦ Left support -VAS 6131/6-1-

♦ Right support -VAS 6131/6-2-
♦ Left running gear support -VAS 6131/6-3-
♦ Right running gear support -VAS 6131/6-4-
♦ Support (Qty. 2) -VAS 6131/6-5-
♦ Support (Qty. 2) -VAS 6131/6-6-
♦ Support -VAS 6131/8-
2 Rep. gr.10 - Removing and installing engine

Touareg 2003 ➤
♦ Stepladder -VAS 5085-

♦ Torque wrench (5…50 Nm) -V.A.G 1331-
1.1 Removing engine

The engine is removed from below with the gearbox
– Read fault memories of all control Aunits
G. Volkbefore removal:
swagen A ⇒
Diagnostic tester VAS 5051; agen
Guided
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fault finding; Vehicle
es n sys‐
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♦ To enable the propshaft to rotate freely, move selector lever

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to the „N“ position.
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♦ Leave key in ignition to prevent steering wheel lock from en‐
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gaging.
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spec
♦ It is advisable to remove the front wheels before beginning
engine removal. The vehicle can then be lowered on hoist until
t to the co
the brake disc splash plates are just above the floor. This pro‐
vides the most ergonomic working position regarding acces‐
sibility of engine compartment components.
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♦ Some components cannot be removed, or removed only with
s
difficulty, with the engine installed. Therefore, you should de‐
s o
termine all defective components before removing engine and
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renew them while engine is removed.
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♦ To prevent damage to removed components, place them in

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the container for removed parts -V.A.G 1698- .

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♦ All cable ties which are opened or cut through when engine is
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removed must be replaced in the same position when engine

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is installed.
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Disconnecting battery
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The procedure must be strictly followed!
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– Switch off ignition and all electrical consumers.
– First disconnect battery under driver seat ⇒ Electrical system;
Rep. gr. 27 ; Disconnecting and reconnecting batteries .
Procedure
– Remove left and right wiper arms: ⇒ Electrical system; Rep.
gr. 29 ; Removing and installing wiper system .
– Pull engine compartment seal off bulkhead.
– Remove covers -A-, -B- and -C- from engine compartment.
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.
– Wrap a cloth around the joint to catch fuel which flows out.
1. Removing and installing engine 3

Touareg 2003 ➤
– Disconnect fuel supply line -arrow-. agen

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– Disconnect breather line -arrow- to solenoid valve in engine
compartment.
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– Disconnect small connector -A- from engine control unit -1-
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and disconnect earth connection -arrow- of wiring harness.
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– Open fuse box cover in plenum chamber on left and separate

connectors -A-, -B- and -C-.
– Remove wiring harness from plenum chamber and lay it on
engine.

Touareg 2003 ➤
– 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.
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– Separate connectors -1- to -4- for Lambda probes and lay
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connectors on engine.
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Note
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Connector for cylinder bank 1 = black, connector for cylinder bank
2 = brown
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– Remove intake hose on right leading to throttle valve module.
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– Pull intake hose leading to secondary air pump motor -V101-

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off upper part of air filter and remove upper part of air filter.
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– Remove air filter element.
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– Then pull connecting line -arrow- to air suspension compres‐

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sor off right air filter housing downwards ⇒ page 135 .

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– Unclip gearbox breather hose from air filter housing. C py
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– Remove bracket for engine cover on right ⇒ page 134 . cop Vo
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– Pull lower part of air filter from air duct ⇒ Item 10 (page 134)
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on right and remove it.

– Extract refrigerant from air conditioning system: ⇒ Heating, air
conditioning; Rep. gr. 87
– Remove insulation tray: ⇒ General body repairs, exterior;
Rep. gr. 50 ; Body - front; Assembly overview - noise insulation
– Loosen double clamp between catalytic converter and centre
silencer and slide clamp forward.
– Support exhaust system between rear silencer and centre si‐
lencer using engine and gearbox jack -V.A.G 1383 A- , un‐
screw mountings and lower exhaust system.
– Remove rear propshaft tube ⇒ Transfer box and final drive;
Rep. gr. 39 ; Removing and installing propshaft .
– Remove front wheels.
– Remove front wheel housing liners ⇒ General body repairs,
exterior; Rep. gr. 66 ; Exterior equipment; Removing and in‐
stalling wheel housing liner; Front wheel housing liner
– Disconnect hose connection to vacuum reservoir in front left
wheel housing.

Touareg 2003 ➤
– 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 ⇒ Automatic gearbox;
Rep. gr. 37 ; Controls, housing .
– Separate brake lines at brake hoses in wheel housings and
collect brake fluid which runs out. ⇒ Brake system; Rep. gr.
46 ; Repairing front wheel brake
– Separate all connectors between body and front axle in wheel
housings. agen
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– Unbolt connecting elines
d b of air suspension at suspensionustrut.
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– Remove gearbox transverse support -A-.

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WARNING
s
Steam may escape when expansion tank is opened. Wear eye

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protection and protective clothing to avoid eye injuries and

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scalding. Cover cap with cloth and open carefully.

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– Open and close expansion tank cap to release pressure in

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cooling system.
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– Drain coolant ⇒ page 86 .

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– Disconnect hose connection to heat exchanger working from
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left wheel housing side and collect escaping coolant. t. C rig
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– Disconnect upper coolant hose from radiator and lower cool‐
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ant hose from coolant pipe.
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Touareg 2003 ➤
– 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.
– Disconnect coolant hose -3- and unscrew coolant pump with
bracket -2-.
– Now unscrew one of the rear securing bolts -3-.
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– Secure subframe to body ⇒ Running ed by gear, axles, steering; ara
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Rep. gr. 40 ; l - Assembly overview
thor - subframe, lower sus‐ eo
pension links, anti-roll bars a.u ra
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– Then proceed with other securing bolt -3- in the same way.
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– On each side of vehicle, remove the two hard-to-access sus‐ y li

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pension strut bolts working from plenum chamber side ⇒ ility
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Running gear, axles, steering; Rep. gr. 40 ; Front suspension .

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Preparing scissor-type assembly platform -VAS 6131- for further

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procedure:
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Touareg 2003 ➤
– 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. Right support -2-:
G4, H4 and H5
– Bolt both suspension supports -3- -VAS 6131/6-3- and
6131/6-4 to the assembly platform in the following positions:
left suspension support -3-: A6 and C6. Right running gear
support -3-: F6 and H6
– Screw the suspension support turntables down.
– Place supports -4- (VAS 6131/6-5) for subframe and -5- (VAS
6131/6-6) for gearbox console in appropriate positions on as‐
sembly platform.
– Position assembly platform horizontal under engine/gearbox

assembly. Supports -1- must be guided into corresponding
receptacles on left and right -arrow-.
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– At the same time, guide right and left mountings for gearbox
es, in part or in w
bracket into corresponding holes -arrow-. When all four sup‐
t to the co
ports are in the receptacle holes without pressure:
– Screw the two rotating plates of running gear supports under
rrectness of i
the suspension links applying a small amount of pre-tension.
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– Guide supports -2- into their respective receptacles in sub‐

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frame, correcting support height as necessary with knurled

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Touareg 2003 ➤
– 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‐
serving the clearance.
Procedure
– Support gearbox on assembly platform using -VAS 6131/7-6- .
– Unscrew one of the lower gearbox securing bolts.
– Insert angled guide pin of -VAS 6131/8- into threaded hole
from engine side.
– Bolt supports stress free to assembly platform.
– Now remove all gearbox securing bolts.
Note
Separating engine and gearbox: ⇒ Operating instructions for

scissor-type assembly platform VAS 6131 .
1.1.1 Securing engine on engine and gearbox

support -VAS 6095-
Special tools and workshop equipment required
♦ Shackle -10 - 222 A /12- AG. Volkswagen AG d
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Secure engine to engine and gearbox support -VAS 6095- to car‐

ry out repairs.
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Note
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To prevent damage to engine when lifting down, additionally use

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shackles -10 - 222 A /12- .

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Vehicles with automatic gearbox

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– Secure torque converter against „falling out“ after separating

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engine from gearbox.

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Continuation for all vehicles
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– Bolt shackles -10 - 222 A /12- to each lifting eye of engine.
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Touareg 2003 ➤
– 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- . Then bolt sup‐
port to cylinder block as shown in the illustration using univer‐
sal fastening elements.
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1.1.2 Notes on installing

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Note
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When fitting engine and gearbox to body, it is essential to position

es, in part or in w
engine carrier against body with the aid of scissor-type assembly

t to the co
platform -VAS 6131- . »Pulling up« engine carrier with securing

bolts will damage threads.
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Procedure
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Install in reverse order. In the process, note the following:

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When the engine has been separated from the gearbox:

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at
– Check whether dowel sleeves for centring engine/gearbox are

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in cylinder block and install if necessary ⇒ 5-speed automatic

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gearbox 09D, four-wheel drive; Rep. gr. 37 ; Removing and

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ate
installing gearbox .
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If subframe with engine carrier has been removed from assembly

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platform:
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Touareg 2003 ➤
– 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- .
– Before installing assembly, install exhaust manifold with cat‐
alytic converters to engine.
Caution
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant, refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ To avoid damage to lines, ensure sufficient clearance to
all moving or hot components.
Vehicles with automatic gearbox

– When installing engine, first raise scissor-type assembly plat‐
form only sufficiently to clip selector lever cable ninAGposition.
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– Reconnect all electrical connections, lines,
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nectors which were separated during
ris removal.
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– Top up ATF level ⇒ 5-speedssautomatic
au gearbox 09D, four- ra
c
wheel drive; Rep. gr. 37 ; Checking ATF level and topping-
ce
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– Reconnect air conditioning lines: ⇒ Heating, air conditioning y li

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system; Rep. gr. 87 ; Repairing components of refrigerant cir‐ ility
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– Recharge air conditioning system with refrigerant: ⇒ Heating,

spec
air conditioning system; Rep. gr. 87 ; Repairing components

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of refrigerant circuit .
t to the co
– Replenish oil in power-assisted steering: ⇒ Running gear,

axles, steering, front and four-wheel drive; Rep. gr. 48 ;
rrectness of i
Checking power-assisted steering system oil level .

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– Replenish coolant ⇒ page 86 .

– Replenish engine oil if necessary.
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– Connect battery.
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Note
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Perform wheel alignment after the installation of subframe ⇒

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Running gear, axles, steering, front and four-wheel drive; Rep.

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– Connect Vehicle diagnosis, testing and information system -
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VAS 5052- .
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– Carry out vehicle system test ⇒ Vehicle diagnostic tester „Gui‐

ded fault finding“.
– Finish the vehicle system test so that any fault entries stored
during assembly can be deleted automatically.

Touareg 2003 ➤
– 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.
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M8 25 Nm
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M12 60 Nm
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Deviations
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Engine bracket to engine M10 75 Nm
mounting (nut)
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Engine mounting to en‐ M10 60 Nm
gine carrier (bolt)
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Engine carrier to body M12 100 Nm + 1/2 turn (180°).
(bolt)
ss
Drive shafts to gearbox ⇒ Running gear, axles, steer‐
o
cial p
f
ing - front and four-wheel
inform
drive; Rep. gr. 40 ; Repairing
mer
drive shaft
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Gearbox carrier to body ⇒ Differential and final drive;

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Rep. gr. 34 ; Installing gear‐

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box carrier and console .

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Drive shafts to gearbox ⇒ Running gear, axles, steer‐

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fo
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ing; Rep. gr. 40 ; Front wheel

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

Touareg 2003 ➤
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‐
ance. Even if the bearing shells are not renewed bearing
damage could occur due to a different bearing clearance. If the
bearing cap bolts are loosened, the cylinder block must be re‐
placed complete with the crankshaft and pistons. Measuring
the main bearing clearance is not possible with normal work‐
shop equipment.
Note
♦ Secure engine to engine and gearbox support -VAS 6095- to carry out repairs.
♦ Engine must not be set down on oil sump, as this will damage the liquid gasket between the upper and lower
sump.
♦ Finding metal shavings or a large quantity of small metal particles during engine repair could indicate that
the crankshaft bearings or conrod bearings are damaged. To prevent this from causing further damage,
perform the following repairs:
♦ Thoroughly clean oil passages,
♦ Renew oil return valve,
♦ Renew oil spray jets,
♦ Renew oil cooler,
♦ Renew oil filter.
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14 Rep. gr.13 - Crankshaft group

Touareg 2003 ➤
1.1 Assembly overview - part I, toothed belt drive
1 - 10 Nm
2 - Bearing sleeve
3 - 20 Nm + 1/4 turn (90°) fur‐
ther
❑ Renew.
4 - Washer
❑ For tensioning roller.
5 - 40 Nm
6 - Tensioning roller
7 - Tensioning lever
8 - 22 Nm
9 - 55 Nm
❑ Renew.
❑ Oil threads and bolt
head contact surface.
10 - Securing plate
❑ Renew.
❑ Observe installation po‐
sition: side with lettering
faces to rear.
11 - Right camshaft pulley
❑ Pull off camshaft with
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12 - 10 Nm
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❑ Insert with locking fluid -

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13 - Toothed belt guard, rear right

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14 - Idler roller
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15 - Pin, 6 Nm
16 - 15 Nm
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17 - Coolant pump
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❑ Removing and installing ⇒ page 89

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18 - Gasket
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❑ Renew.
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19 - Toothed belt guard, rear left

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20 - 10 Nm
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❑ Insert with locking fluid -D 000 600 A2- .

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21 - 10 Nm t. Cop py
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22 - Left camshaft pulley pyri by
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❑ Pull off camshaft with two arm puller -T40001- and claw -T40001/2- . cted agen
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Touareg 2003 ➤
❑ 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
❑ Renew.
❑ Oil threads and bolt head contact surface.
25 - Toothed belt
❑ Mark direction of rotation before removing.
❑ Check for wear.
❑ Do not kink.
❑ Removing, installing and tensioning ⇒ page 34 .
26 - Eccentric roller
27 - 45 Nm
28 - Crankshaft toothed belt pulley
❑ Fitting possible in one position only.
❑ For removal lock crankshaft using locking pin -3242- ⇒ page 22 ; Removing and installing drive plate.
29 - 200 Nm + 1/2 turn (180°) further
❑ Renew.
❑ Do not oil.
❑ Turning further can be done in several stages.
30 - Washer AG. Volkswagen AG d
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❑ For tensioning lever
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Touareg 2003 ➤
1.2 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
❑ With seal.
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6 - Oil return supply valve rised ara
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7 - O-ring
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9 - Knock sensor 1 (G61)
t to the co
10 - Knock sensor 2 (G66)
rrectness of i
11 - Plug, 35 Nm
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12 - Seal
❑ Renew.
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13 - Engine bracket
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❑ Engine bracket and
com
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specified torques
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⇒ page 18
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16 - 10 Nm
AG.
17 - Coolant drain pipe

18 - Cylinder block
19 - Thermostat
20 - Thermostat housing
21 - Oil return supply valve
❑ For cylinder head, left

Touareg 2003 ➤
Specified torque for engine bracket

Specified torque for securing bolt -1-: 60 Nm.
Specified torque for securing nut -2-: 75 Nm.
1.3 Removing and installing poly V-belt

♦ Locking pin -T10060 A-
Removing poly V-belt

– Remove noise insulation tray.
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– Mark direction of rotation of poly VV-belt.
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♦ Before installing poly V-belt, ensure that all ancillary assem‐

blies (alternator, air conditioner compressor, vane pump) are

t to the co
secured tightly.
♦ Check that idler roller turns easily.
rrectne
♦ When installing poly V-belt, check direction of belt rotation and

proper seating of belt in pulleys.
ss o
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Touareg 2003 ➤
– Fit poly V-belt as illustrated.

After completing repairs always:
– Start engine and check that belt runs properly.
1.4 Checking alignment of poly V-belt
Note
Alignment of poly V-belt must always be checked to prevent dam‐

age if power-assisted steering vane pump, air conditioning sys‐
tem compressor or the respective brackets for power-assisted
steering or air conditioning system compressor have been re‐
newed.

♦ Aligning gauge -3201-
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Procedure
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– Remove power-assisted steering vane pump pulley.

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– Remove poly V-belt ⇒ page 18 .

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Touareg 2003 ➤
– 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.
If belt pulleys do not align
– Compensate misalignment of pulleys using shims with thick‐

nesses of 0.6, 0.8, 1.0, 1.2, and 1.4 mm.
– Check alignment of belt pulleys again with aligning gauge
-3201-
– Install idler roller. Specified torque: 25 Nm
– Install poly V-belt ⇒ page 18 .
– Tighten power-assisted steering belt pulley securing bolts to
22 Nm.
AG. Volkswagen AG d
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Touareg 2003 ➤
2 Removing and installing sealing

flange and drive plate
Note
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Removing and installing drive plate ⇒ page 22 .
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Removing and installing sealing flange at drive plate end
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⇒ page 24
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Renewing crankshaft oil seal, vibration damper end
wit
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⇒ page 26
hole
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2.1 Assembly overview
es, in part or in w
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1 - Gasket
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❑ Renew.
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2 - Sealing flange
❑ With seal.
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❑ Remove sump in order

m
to remove and install
at
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⇒ page 70 .
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his
ate
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AG.
ing lip.
❑ Use support sleeve sup‐
plied when installing.
❑ Only remove supporting
sleeve after sealing
flange has been slid on‐
to crankshaft journal.
❑ If the sealing flange has
not been renewed use
fitting tool -T10122- for
installing ⇒ page 26 ,
Removing and installing
sealing flange at drive
plate end.
❑ Removing and installing
⇒ page 24 .
3 - Shim
❑ 2 mm thick
4 - Drive plate
❑ Use locking pin -3242- to loosen and tighten ⇒ page 22 ; Removing and installing drive plate.
5 - Washer
❑ 3.4 mm thick
2. Removing and installing sealing flange and drive plate 21

Touareg 2003 ➤
8-cylinder injection engine - EditionA11.2011
G. Volkswagen A n G do
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6 - 30 Nm + 1/4 turn (90°) further ed
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❑ Renew. au
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7 - 10 Nm
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8 - 15 Nm
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9 - Cylinder block
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10 - Oil sump
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spec
11 - Securing bolt
t to the co
❑ M7 = 15 Nm
❑ M8 = 22 Nm
rrectne
12 - Timing chain
s
❑ Mark with arrow pointing in direction of rotation before removing (e.g. using paint).
s o
cial p
f
❑ Do not mark with a centre punch mark, notch or anything similar!
inform
mer
13 - Chain sprocket
atio
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❑ For crankshaft.
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14 - Thrust washer
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❑ In case of signs of abnormal wear remove and reverse or renew.

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16 - Sealing flange at belt pulley end by c lksw
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❑ Remove sump in order to remove and install ⇒ page 70 .
❑ Must seat on dowel sleeves.
❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
17 - O-ring
❑ Renew.
18 - Spray nozzle valve, 35 Nm
19 - Seal
❑ Renew. ⇒ page 26 .
20 - Crankshaft toothed belt pulley
❑ Fitting possible in one position only.
21 - 200 Nm + 1/2 turn (180°) further
❑ Renew.
❑ Do not oil.
❑ Turning further can be done in several stages.
22 - Vibration damper/belt pulley
❑ For poly V-belt.
23 - 22 Nm
24 - 25 Nm
25 - Cover
2.2 Removing and installing drive plate


Touareg 2003 ➤
♦ Locking pin -3242-
Removing
– Remove engine ⇒ page 3 .
– Separate engine from gearbox.
– Set engine to TDC. For this, notches -A- and -B- must align.
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– Remove screw plug -arrow-.

es, in part or in w
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Note
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There is a TDC drilling in the crankshaft directly behind the plug

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23
agen
Prote AG.
2. Removing and installing sealing flange and drive plate
Touareg 2003 ➤
– Screw locking pin -3242- into crankshaft.

n AG. Volkswagen A
– Loosen drive plate securing
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– Remove drive riplate
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Installation is carried out in the reverse order. When installing,

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– Fit shim -1- of „2.0 mm thickness“ onto crankshaft journal.
– Then, install drive plate and washer -2- of „3.4 mm thickness“.
rrectness of i
– Insert new securing bolts and tighten by hand.
l purpos
– Tighten securing bolt to 30 Nm + 1/4 turn (The additional turn

may be performed in several steps.)
nform
ercia
– Unscrew locking pin -3242- .

m
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– Install sealing plug with a new seal. Specified torque: 35 Nm
ion
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2.3 Removing and installing sealing flange

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Removing ⇒ page 25 .
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Installing ⇒ page 25 .
♦ Fitting tool -T10122-

Touareg 2003 ➤
2.3.1 Removing
– Separate engine from gearbox.
– Remove drive plate ⇒ page 22 .
– Remove sump ⇒ page 70 .
– Remove sealing flange -arrow- from cylinder block.
– Remove existing gasket.
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2.3.2 Installing d b ara
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Note
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♦ In the following work procedure the seal is illustrated without
ab
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sealing flange.
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h re
hole
completely. Use protective sleeve supplied when installing. spec

es, in part or in w
t to the co
– Clean sealing surfaces on sealing flange and cylinder block.

They must be free of oil and grease.
rrectness of i
– Remove oil residue from crankshaft journal using clean cloth.

l purpos
– Fit new gasket -1- onto dowel sleeves on cylinder block.

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Prote AG.

Touareg 2003 ➤
– 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. gen AG
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– Bolt sealing flange to cylinder block. Specified torque:
db
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10 Nm gu
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– Install sump ⇒ page 70 . utho eo
ra
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ss
– Install drive plate ⇒ page 22 .
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– Install engine ⇒ page 3 .
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2.4 Renewing crankshaft oil seal, vibration
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damper end
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♦ Thrust piece -T40007-

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Removing
– Remove noise insulation tray.
– Remove toothed belt ⇒ page 34 .
– Unscrew centre bolt -2- from crankshaft toothed belt pulley
-1- and remove crankshaft toothed belt pulley from crankshaft
journal.
– Then remove seal using extractor hook -T20143/1- .

AG. Volkswagen AG d Touareg 2003 ➤
agen oes
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yV gu
db ara
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– Remove thrust washer from crankshaftujournal
tho and mark thrust eo
ra
washer front face -arrow- using a waterproof
ss a felt-tip marker. c
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nl
Installing
pt
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– Remove oil residue from crankshaft journal and thrust washer
erm
ab
using a clean cloth.
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spec
es, in part or in w
t to the co
rrectness of i
– Press new seal in to stop using thrust piece -T40007- .
l purpos
– Reverse thrust washer and fit it on crankshaft journal with

marked front face towards engine.
nf
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orm
– Install crankshaft toothed belt pulley using a new centre bolt.
m
atio
m
Specified torque: 200 Nm + 1/2 turn (180°) further.

o
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– Install toothed belt. ⇒ page 34

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– Install noise insulation tray.
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Prote AG.

Touareg 2003 ➤
15 – Cylinder head, valve gear

1 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 34 .
Removing and installing left cylinder head ⇒ page 40 .
Removing and installing right cylinder head ⇒ page 44 .
Checking compression ⇒ page 48 .
Note
♦ To remove cylinder head, engine must first be removed

⇒ page 3 .
♦ If an exchange cylinder head is installed, all the contact sur‐
faces between the support elements, roller rocker fingers and
the running surfaces of the cam shafts must be oiled before
the cylinder head cover is installed.
♦ The plastic protectors fitted to protect the open valves must be
removed only immediately before the cylinder head is fitted.
♦ When cylinder head or cylinder head gasket is renewed, the
complete coolant must be renewed.
♦ Removing and installing intake manifold ⇒ page 132 ; Re‐
moving and installing cylinder head cover. AG. Volkswagen AG d
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28 Rep. gr.15 - Cylinder head, valve gear

Touareg 2003 ➤
1 - Cap
❑ Renew seal if damaged.
2 - Boot
❑ Renew if damaged.
3 - Oil filler neck
❑ Renew seal if damaged.
4 - Connecting hose
tion.
5 - Cylinder head cover
left cylinder head cover n AG. Volkswagen AG do
⇒ page 32 . lkswage es n
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❑ Removing and installing ir se
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right cylinder head cov‐ utho tee
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❑ Renew if damaged or
ole,
spec
leaking.
t to the co
7 - 10 Nm
❑ Observe tightening se‐
quence.
rrectne
left cylinder head cover
ss
⇒ page 32 .
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right cylinder head cov‐ nform
mer
er ⇒ page 30 .
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8 - Cylinder head cover gasket

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❑ Ensure proper seating of lugs in cylinder head cover.

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❑ Renew if damaged or leaking.

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❑ Removing and installing left cylinder head cover ⇒ page 32 .
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❑ Removing and installing right cylinder head cover ⇒ page 30 .
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9 - Baffle plate
10 - 5 Nm
11 - Coolant pipe
12 - Gasket
❑ Renew.
13 - Sealing grommet
❑ Insert in cylinder head cover.
14 - Cylinder head bolt
❑ Renew.
❑ Follow installation instructions and sequence when loosening and tightening.
1. Cylinder head 29
olkswagen AG
Touareg 2003 ➤ wage
n AG. V does
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8-cylinder injection engine - Edition 11.2011 d by V gu
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❑ Removing and installing right cylinder head
aut ⇒ page 44 .
ho eo
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ss ⇒ page 40 . c
❑ Removing and installing left cylinder head
ce
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15 - Cylinder head
an
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❑ Check for distortion ⇒ page 30 .
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❑ Removing and installing right cylinder head ⇒ page 44 .
wit
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❑ Removing and installing left cylinder head ⇒ page 40 .
h re
hole
spec
❑ After renewing, renew entire coolant.
es, in part or in w
t to the co
16 - Cylinder head gasket
❑ Metal gasket.
❑ Renew.
rrectness of i
❑ Must seat on dowel pins.
l purpos
nform
ercia
17 - 10 Nm
m
18 - Combination valve
at
om
ion
❑ For secondary air system
c
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19 - Coolant pipe
a
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20 - O-ring
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❑ Renew.
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21 - 20 Nm
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22 - Lifting eye
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23 - Seal
Checking cylinder head for distortion

♦ Straight edge
♦ Feeler gauges
Max. permissible distortion: 0.1 mm.
1.2 Removing and installing right cylinder

head cover

Touareg 2003 ➤
♦ Not illustrated:
♦ Cable ties
♦ Sealant -D 454 300 A2-
Removing
Caution

tions:
sitions. AG. Volkswagen A gen G do
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♦ To avoid damagebytoVolines,
lk ensure sufficient clearance
not
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– All cable ties which are opened or cut open when engine is
ce
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is installed.
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ab
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ility
– Remove intake hose between air filter and throttle valve con‐
ot
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hole
– Disconnect connectors -1- from ignition coils.

spec
es, in part or in w
t to the co
– Remove ignition coils -2- ⇒ page 158 .

– Detach line -3- for secondary air system from cylinder head
cover.
rrectness of i
– Disconnect crankcase breather hose.

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tion in
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te o
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t.
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rig ht
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Prote AG.
1. Cylinder head 31
Touareg 2003 ➤
– Loosen securing bolts in the sequence -12- to -1- and remove

cylinder head cover.
Installing
note the following:
Note
♦ Renew gasket if damaged or leaking.

♦ Before installing ensure that all seals between cylinder head
cover and cylinder head are installed correctly and not dam‐
aged.
– Lightly coat transitions -arrows- on sealing surface of cylinder

head with sealant -D 454 300 A2- .
– Carefully install cylinder head cover.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
h
aut ra
ss c
ce
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nl
pt
du
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itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Tighten securing bolts in the sequence -1- to -12-. Specified

torque: 10 Nm
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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pyri by
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Prote AG.
1.3 Removing and installing left cylinder
head cover

Touareg 2003 ➤
AG. Volkswagen AG d
agen oes
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ility
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hole
spec
♦ Not illustrated:
es, in part or in w
t to the co
♦ Cable ties
♦ Sealant -D 454 300 A2-
rrectness of i
Removing
l purpos
Caution
nform
ercia

m
a
com
tion in
tions:
r
te o
thi
s
iva
do
r

rp
cum
fo

en
ng
t.
yi
sitions.
Co
Cop py
t. rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote AG.
is installed.
– Remove intake hose between air filter and throttle valve con‐
trol module.
– Remove bracket -3-.
– Disconnect connectors -4- from ignition coils.
– Remove ignition coils ⇒ page 158 .
– Disconnect crankcase breather hoses -1- and -2-.
1. Cylinder head 33
Touareg 2003 ➤
– Loosen securing bolts in the sequence -12- to -1- and remove

cylinder head cover.
Installing
note the following:
Note
♦ Renew gasket if damaged or leaking.

♦ Before installing ensure that all seals between cylinder head
cover and cylinder head are installed correctly and not dam‐
aged.
– Lightly coat transitions -arrows- on sealing surface of cylinder

head with sealant -D 454 300 A2- .
– Carefully install cylinder head cover.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
tho eo
– Tighten securing bolts in the sequence -1- to -12-. Specified
s au ra
c
torque: 10 Nm s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
1.4 Removing, installing and tensioning

toothed belt
nform
ercia
m
a
com
tio
Installing and tensioning ⇒ page 38

n in
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te o
thi
s
iva
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
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Prote AG.

Touareg 2003 ➤

equipment required
♦ Locking pin -3242-
♦ Two-arm puller -T40001-
♦ Camshaft clamp -T40005-
♦ Tensioner wrench -
T40009-
♦ Locking pin -T40011-
♦ Reversible ratchet -VAS
5122-
♦ Torque wrench -V.A.G
1410-
1331-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
1.4.1 Removing
es, in part or in w
t to the co
Caution
rrectness of i

l purpos

tions:
nf
ercia
rm
m

atio
m

o
n in
c
sitions.
or
thi
te
sd
iva

o
r
rp
cu

o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh
– Remove insulation tray ⇒ General body repairs, exterior; Rep.
ht
pyri by
Vo
gr. 50 ; Noise insulation
o
by c lksw
cted agen
Prote AG.
– Remove radiator fans with radiator fan support ⇒ page 79 .
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front; Lock carrier service posi‐
tion .
1. Cylinder head 35
Touareg 2003 ➤
– 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.
– Turn crankshaft to TDC. Mark on toothed belt guard -A- must
align with mark on V-belt pulley -B-.
– Check position of camshaft sprockets. The larger holes in se‐

curing plates -arrows- must be positioned to the inside and
must be aligned with the horizontal camshaft centre line.
Note
If the larger holes in the securing plates are positioned to the out‐
side of the camshaft sprockets, the crankshaft must be turned one
revolution further in direction of engine rotation.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
tho eo
– Remove sealing plug s au-arrow- from left side of cylinder block. ra
c
The TDC drilling insthe crankshaft must be visible (or able to
ce
le
be felt) in the sealing plug hole.

un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Carefully screw locking pin -3242- into drilling to stop in order

prevent crankshaft from turning.
nform
ercia
– Remove middle part of toothed belt guard.

m
– Remove vibration damper.

com
tion in
r
te o
thi
s
iva
Note
do
r
rp
cum
fo
en
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The vibration damper is secured to the crankshaft with 8 securing

n
t.
yi Co
op
bolts. C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
– 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.
– Remove cover.
Note
♦ The toothed belt tensioning element is provided with oil damp‐

ing. It can therefore only be pushed back slowly.
♦ Use locking pin -T40011- for securing the tensioning element.
– If necessary, before tensioning align holes in housing and in

piston of tensioning element using long nose pliers or thin wire.
– Turn tensioning lever of toothed belt tensioning roller -1- in
-direction of arrow- using hexagon key.
kswage es n
– Secure tensioning element with locking pin -T40011-
byV
ol
when the ot g
ua
tensioning lever of the toothed belt tensioning
ir se
d element -2- has ran
tee
been pushed back so that the holes uinth the housing and the
o
or
pistons align. ss
a ac
ce
le
un
pt
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d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Insert camshaft clamp -T40005- into camshaft securing plates

rrectness of i
and loosen securing bolts by approx. 5 turns.

l purpos
– Remove camshaft clamp -T40005- again.

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Cylinder head 37
Touareg 2003 ➤
– Now pull camshaft sprockets off camshaft tapers using two-

arm puller -T40001- and hook -T40001/2- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Loosen tensioning roller -arrow- and remove toothed belt.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
1.4.2 Installing and tensioning

om
ion
c
in t
or
– Note marking for direction of rotation when reinstalling the ex‐

his
ate
isting toothed belt.

do
priv
cum
or
– First, fit toothed belt to crankshaft toothed belt pulley -1-, then
f
en
ng
t.
yi
to idler roller of toothed belt tensioner -2- and then to tension‐
Co
op py
ing roller -3-. After that, fit toothed belt to camshaft sprockets t. C rig
gh ht
and coolant pump pulley as shown in the illustration. pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
It should just be possible to turn the camshaft sprockets on the

camshaft tapers.
– Fit camshaft clamp -T40005- onto camshaft pulleys again.

Touareg 2003 ➤
– 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.
– Tighten bolt -1- to 45 Nm in this position.
– Then remove 5 mm drill.
-direction of arrow- using hexagon key.
– When piston of toothed belt tensioning element -2- has been

pushed back by tensioning lever, pull out locking pin -
T40011- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
direction of -arrow-, using hexagon key and place a 7 mm drill

wit
, is n
between housing and tensioning lever. h re

hole
spec
– Tighten camshaft sprockets to 55 Nm.
es, in part or in w
t to the co
– Remove camshaft clamp -T40005- again.

– Pull out drill inserted between housing and tensioning lever.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Cylinder head 39
Touareg 2003 ➤
– 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.
Further assembly is basically the reverse of the dismantling se‐
quence.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
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wit
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1.5 Removing and installing left cylinder
h re
hole
spec
head
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤

equipment required
♦ Torque wrench (5…50 Nm)
-V.A.G 1331-
♦ Torque wrench (40…200
Nm) -V.A.G 1332-
♦ Spring-type clip pliers -VAS
5024A-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Not illustrated:
rrectness of i
l purpos
♦ Cable ties
Prerequisite
nform
ercia
• The engine must be no more than warm to touch.

m
at
om
io
1.5.1 Removing
n
c
in t
or
his
ate

do
priv
cum
for
en
ng
t.
Caution
Cop
yi Co
py
t. rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote
tions:
AG.
sitions.
1. Cylinder head 41
Touareg 2003 ➤
is installed.
– Remove front exhaust pipe from exhaust manifold
⇒ page 148 .
wage es n
– Unbolt guide tube for oil dipstick -arrow- from cylinder head.y Volks ot g
ua
b
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Disconnect connectors -2- and -3-.
rrectness of i
l purpos
– Remove camshaft pulley ⇒ page 34 , Removing, installing and

tensioning toothed belt.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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cu
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f
en
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t.
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Cop py
t. rig
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– Loosen securing bolts -1- and -2- and remove rear toothed belt
ht
pyri by
Vo
o
guard. by c lksw
cted agen
Prote AG.
– Disconnect vacuum hose -1- from combination valve.

– Remove bolts -2-.
– Disconnect connector -3-.
– Unscrew bolts -4- and remove oil pipe.
– Remove bolts -5- and remove combination valve.

Touareg 2003 ➤
– Remove bolts securing coolant pipe -arrow-.

– Disconnect connectors from knock sensors.
– Pull connectors off all injectors.

– Disconnect hose -2-.
– Remove coolant pipe.
– Remove intake manifold ⇒ page 132 .
– Remove cylinder head cover ⇒ page 32 .
– Loosen cylinder head bolts in the sequence given starting at

the outside and working inwards and Athen
G. Voremove completely.
lkswagen A G do gen
es n swa
– Carefully remove cylinderbyhead.
Vol
k ot g
ua
ed ran
– Place clean cloths in oris
cylinders so that no dirt or emery cloth tee
th or
particles can get sin between cylinder wall and piston.
au ac
s
ce
le
– Also prevent dirt and emery cloth particles from getting into
un
pt
an
coolant.
d
itte
y li
erm
ab
– Now carefully clean sealing surfaces of cylinder head and cyl‐

ility
ot p
inder block. When doing this, ensure that surfaces are not
wit
is n
scored or scratched (if abrasive paper is used, grade must not

h re
ole,
be less than 100).

spec
t to the co
1.5.2 Installing
– Carefully remove metal particles, emery residue and cloths.
rrectnes
Note
s o
cial p
f in
♦ Do not remove new cylinder head gasket from its packing until
form
mer
immediately before installing.

atio
om
♦ Handle new gasket with extreme care. Damage will cause

n
c
i
or
leakage.
thi
te
sd
iva
o
pr
cum
– Fit new cylinder head gasket. Inscription (Part No.) must be

r
fo
en
ng
readable.
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Cylinder head 43
Touareg 2003 ➤
– 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.
– 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 1/4 turn (90°) further using a rigid wrench.
– Then tighten all bolts again 1/4 turn (90°) further.
Adjusting valve timing ⇒ page 34 .

– Installing cylinder head cover ⇒ page 32 .
– Install intake manifold ⇒ page 132 .
quence.
Note
It is not necessary to retighten cylinder head bolts after repairs. agen

AG. Volkswagen AG d
oes
olksw not
byV gu
ara
ed
is nte
1.6 Removing and installing right cylinder or eo
h
aut ra
head ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤

equipment required
-V.A.G 1331-
♦ Torque wrench (40…200
Nm) -V.A.G 1332-
5024A-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
Not illustrated: hor eo
aut ra
ss c
♦ Cable ties
ce
le
un
pt
an
d
itte
Prerequisite
y li
rm
ab
pe
ility
• The engine must be no more than warm to touch.

ot
wit
, is n
1.6.1 Removing
h re
hole
spec

es, in part or in w
t to the co
Caution
rrectness of i

l purpos

tions:
nform
ercia
m
a
com

ion in
sitions.
r
te o
thi
s
iva

do
r

rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
45
op Vo
by c lksw
Prote
cted AG.
agen 1. Cylinder head
Touareg 2003 ➤
is installed.
– Remove front exhaust pipe from exhaust manifold
⇒ page 148 .
– Disconnect connectors -1-, -2- and -3-.
– Remove camshaft pulley ⇒ page 34 , Removing, installing and
tensioning toothed belt.

– Loosen securing bolts -arrows- and remove rear toothed belt
guard.
– Disconnect connectors from knock sensors.
– Pull connectors off all injectors.
kswage es n
– Remove bolts securing coolant pipe -arrow-. byV
ol ot g
ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co

rrectness of i
– Disconnect hose -2-.

l purpos

nform
ercia

m
– Disconnect vacuum hose -7- from combination valve.

at
om
ion
c
in t

or
his
ate

do
priv
cum
or
– Remove coolant pipe.

f
en
ng
t.
yi Co
op
– Remove intake manifold ⇒ page 132 .
C py
t. rig
gh ht
yri by
– Remove cylinder head cover ⇒ page 30 . cop Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
– 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.
– Also prevent dirt and emery cloth particles from getting into
coolant.
– Now carefully clean sealing surfaces of cylinder head and cyl‐
inder block. When doing this, ensure that surfaces are not
scored or scratched (if abrasive paper is used, grade must not
be less than 100).
1.6.2 Installing
– Carefully remove metal particles, emery residue and cloths.
Note
♦ Do not remove new cylinder head gasket from its packing until
immediately before installing.
♦ Handle new gasket with extreme care. Damage will cause
leakage.
– Fit new cylinder head gasket. Inscription (Part No.) must be

readable.
AG. Volkswagen AG d
agen
– Ensure dowel sleeves -arrows- are inserted
olks into cylinder block
w oes
not
yV gu
holes and the cylinder head gasketedis located.
b ara
nte
is
or eo
– Fit cylinder head, screw in newautcylinder
h
head bolts and tighten ra
hand tight. ss c ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Cylinder head 47
Touareg 2003 ➤
– Tighten cylinder head bolts in tightening sequence shown

working from inside to outside.
– Pre-tighten all bolts to 35 Nm.
AG. Volkswagen AG d
agen oes
– Then tighten all bolts to 60 Nm. olksw not
byV gu
ara
ed
– 1
Then tighten all bolts /4 turn (90°) further using a rigid twrench.
horis nte
eo
au ra
s c
– Then tighten all bolts again /4 turn (90°) further.
1 s
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Installing cylinder head cover ⇒ page 30 .
ility
ot p
wit
, is n
– Install intake manifold ⇒ page 132 .
h re
hole
spec
es, in part or in w
quence.
t to the co
Note
rrectness of i
It is not necessary to retighten cylinder head bolts after repairs.
l purpos
nform
ercia
1.7 Checking compression

m
at
om
ion
c
in t
r

o
his
e
equipment required
at
do
priv
cum
or
♦ Spark plug socket and ex‐

f
en
g
tension -3122 B-
n
t.
yi Co
Cop py
♦ Torque wrench (5…50 Nm) ht. rig
rig ht
-V.A.G 1331-
py by
co Vo
by lksw
cted agen
♦ Compression tester -
Prote AG.
V.A.G 1763-

Touareg 2003 ➤
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.
• If the vehicle is equipped with an air conditioner, it must be
switched off.
• The selector lever of the must be in „P“or „N“ position.
Test procedure
– Remove ignition coils with output stages ⇒ page 158 .
– Disconnect all connectors from injectors.
Volkswa
– Remove spark plugssusing
agen spark plug socket
AG. gen AG
doesand extension
k w
-3122B- . by
Vol not
gu
a
d ran
se
– Check compression
tho
ri using compression tester -V.A.G 1763-
tee
o .
au ra
c
ss
ce
le
un
pt
Note
an
d
itte
y li
rm
ab
Using compression tester ⇒ operating instructions .
pe
ility
ot
wit
, is n
h re
– Have a second mechanic fully depress accelerator and crank
hole
engine.
spec
es, in part or in w
– Operate starter until tester shows no further pressure in‐

t to the co
crease.
Compression pressures:
rrectness of i
New: 10…15 bar

l purpos
Wear limit: 7.0 bar.

nform
ercia
Maximum permissible difference between all cylinders: 3 bar

m
– Insert spark plugs using spark plug socket and extension

com
tio
-3122B- and tighten to 30 Nm.

n in
r
te o
thi
After the test has been completed:

s
iva
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– Connect Vehicle diagnosis, testing and information system -

fo
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VAS 5052- .
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Cop py
– Carry out vehicle system test ⇒ Vehicle diagnostic tester „Gui‐
ht. rig
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cted agen
– Finish the vehicle system test so that any fault entries stored
Prote AG.
during assembly can be deleted automatically.

– 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.
1. Cylinder head 49
Touareg 2003 ➤
2 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 56
Removing and installing roller rocker finger ⇒ page 62 .
Renewing valve stem seals ⇒ page 62 .
Checking valve guides ⇒ page 65 .
Reworking valve seats ⇒ page 66 .
lkswage es n
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1 - Double bearing d bycap ua
ran
ir se
❑ Whenuthinstalling, seal
o tee
or
parting
ss
a surfaces of outer ac
bearing caps with seal‐
ce
e
nl
ant -AMV 188 001 02-

pt
du
an
itte
⇒ page 61 .
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erm
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ility
2 - 5 Nm + 1/4 turn (90°) further

ot p
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❑ Renew.
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hole
spec
3 - Support element
es, in part or in w
t to the co
❑ Before installing, check

camshaft axial clear‐
ance ⇒ page 53 .
rrectness of i
❑ Do not interchange.
l purpos
❑ With hydraulic valve

clearance compensa‐
tion.
nform
ercia
4 - Exhaust camshaft
m
at
om
❑ Checking radial clear‐

on
c
ance with Plastigage;

in t
or
his
e
wear limit: 0.1 mm.

at
do
riv
❑ Runout: max. 0.01 mm.

p
cum
for
en
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❑ Checking axial clear‐

n
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ance ⇒ page 53 . Cop py
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ht
pyri by
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⇒ page 56
c by lksw
cted agen
Prote AG.
5 - Inlet camshaft bearing cap
⇒ page 56 , Removing
and installing camshafts
and variable camshaft
timing adjuster.
6 - Exhaust camshaft bearing
cap
❑ Removing and installing ⇒ page 56 , Removing and installing camshafts and variable camshaft timing
adjuster.
7 - 5 Nm + 1/4 turn (90°) further
❑ Renew.
8 - Double bearing cap

Touareg 2003 ➤
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 61 .
11 - Roller rocker finger

❑ For exhaust camshaft.
❑ Before installing, check camshaft axial clearance ⇒ page 53 .
❑ Check roller bearing for ease of movement.
❑ Oil contact surface.
12 - Camshaft timing chain
❑ Before removing, mark direction of rotation (installation position) ⇒ page 56 ; Removing and installing
camshafts and variable camshaft timing adjusters.
13 - Roller rocker finger
❑ For inlet camshaft.
❑ Before installing, check camshaft axial clearance ⇒ page 53 .
❑ Check roller bearing for ease of movement.
❑ Oil contact surface.
14 - Inlet camshaft n AG. Volkswagen AG do
wage es n
❑ Checking radial clearanceyV
olks with Plastigage; wear olimit:
t gu 0.1 mm.
d b ara
❑ Runout: max. oris0.01 mm.
e nte
th eo
❑ Checkings axial clearance ⇒ page 53 .
au ra
c
s
ce
e
nl
pt
du
an
15 - 5 Nm + 1/4 turn (90°) further

itte
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erm
ab
❑ Renew.
ility
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wit
, is n
16 - Camshaft adjuster
h re
hole
❑ Rotate engine only with camshaft adjuster installed.

spec
es, in part or in w
❑ Removing and installing ⇒ page 56 , Removing and installing camshafts and variable camshaft timing
t to the co
adjuster.
17 - Gasket
rrectness of i
❑ Renew.
l purpos
18 - Valve cotters
19 - Valve spring plate
nf
ercia
orm
20 - Valve spring
m
atio
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thi
❑ Removing and installing ⇒ page 62 , Renewing valve stem seals.

te
sd
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21 - Valve stem seal

rp
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❑ Renew. ⇒ page 62 .
t.
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op py
22 - Gasket
. C rig
ht ht
rig by
py
❑ Renew. co Vo
by lksw
cted agen
Prote AG.
23 - Cylinder head
❑ Check for distortion ⇒ page 30 .
2. Repairing valve gear 51

Touareg 2003 ➤
❑ Removing and installing right cylinder head ⇒ page 44 .
❑ Removing and installing left cylinder head ⇒ page 40 .
24 - Exhaust valve
❑ Do not rework, only lapping-in is permitted.
❑ Valve dimensions ⇒ page 53
25 - Inlet valve
❑ Do not rework, only lapping-in is permitted.
❑ Valve dimensions ⇒ page 53
26 - Seal
❑ For Hall sender.
27 - Hall sender screen
28 - Washer
❑ Conical.
29 - 23 Nm
30 - Hall sender
31 - 10 Nm
32 - Shaft
❑ For roller rocker finger, inlet side
❑ Removing and installing ⇒ page 62 , Removing and installing roller rocker finger.
33 - 10 Nm
34 - 10 Nm
olkswagen AG
en AG. V
35 - Shaft olks
wag does
not
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❑ For roller rocker ifinger,
sed b exhaust side ara
nte
or
❑ Removing and au installing ⇒ page 62 , Removing and installing r roller
th eo
a rocker finger.
ss c
36 - 55 Nm
ce
le
un
pt
an
d
37 - Camshaft pulley
itte
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rm
ab
❑ Removing and installing ⇒ page 34 Removing, installing and tensioning toothed belt.
pe
ility
ot
wit
38 - Seal
, is n
h re
❑ For camshaft.
hole
spec
❑ Removing and installing ⇒ page 54 .

es, in part or in w
t to the co
39 - O-ring
❑ Renew.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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cum
fo
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
Valve dimensions
Note
Valves must not be reworked. Only lapping-in is permitted.
Valve dimensions
Dimension Inlet valve Exhaust valve
-∅ a- mm 26.8...27.0 29.8...30.0
-∅ b- mm 5.96...5.97 5.94...5.95
-c- mm 104.84...105.34 103.64...104.14
-α- ∠° 45 45
Note
Worn sodium filled exhaust valves must not be disposed of with‐

out first preparing the valves.
agen
AG. Volkswagen AG d
oe
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WARNING eo
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Wear eye protection and protective clothing to avoid eye inju‐

nl
pt
du
ries and chemical burns!

an
itte
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ility
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– They must be cut through in the centre of the stem with a

, is n
h re
hacksaw. When doing this they must not come in contact with
hole
water!
spec
es, in part or in w
t to the co
– When valves have been prepared as described, throw a max‐

imum of ten valves into a bucket filled with water and step
back!
rrectness of i
– Due to the contact with water a sudden chemical reaction will

be initiated and the sodium fill will be burnt.
l purpos
– After this treatment, the valves can be scrapped as normal

nform
scrap.
mercia
at
om
2.1 Camshafts, checking axial clearance

ion
c
in t
or
his
e

at
do
priv
♦ Universal dial gauge bracket -VW 387-

um
for
en
ng
t.
yi
♦ Dial gauge
Co
Cop py
t. rig
gh
Test procedure
ht
pyri by
Vo
co lksw
by
Perform measurements with support elements and roller rocker
cted agen
Prote AG.
fingers removed.

Touareg 2003 ➤
– 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.
Exhaust camshaft
AG. Volkswagen AG d
agen oes
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d by ara
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or eo
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aut ra
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un
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ab
ility
ot p
– Attach dial gauge with universal dial gauge bracket to cylinder
wit
is n
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head, as shown.
ole,
spec
Wear limit for axial clearance: max. 0.20 mm.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
2.2 Renewing camshaft oil seals

i
or
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te
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pr
cum
r
fo
en
ng
♦ Oil seal extractor -3240-

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
♦ Fitting tool -3241-

Removing
– Remove toothed belt and camshaft sprockets ⇒ page 34 .

Touareg 2003 ➤
– 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‐
tion and, exerting firm pressure, screw it into oil seal as far as
possible.
– Loosen knurled screw and turn inner part against camshaftwagen AG. Volkswagen AG doe
until oil seal is pulled out. yV
olks s no
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b ara
ed
– Clamp flats of oil seal extractor in vice. Removehooil
ris seal with nte
e
pliers. sa
ut or
ac
s
Installing
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
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– Fit seal and press it in to stop using pressure sleeve -3241/1-
hole
spec
and bolt -3241/6- .
es, in part or in w
t to the co
– Install toothed belt and camshaft sprockets ⇒ page 34 .
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
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sd
a
2.3 Renewing Hall sender seals

iv
o
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en
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t.
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op py
♦ Oil seal extractor -2085- t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Fitting sleeves -3241-

Procedure
Left cylinder head
– Disconnect connectors from ignition coils and injectors and lay
wiring harness to side.
– Pull connector off Hall sender.
– Remove Hall sender housing with Hall sender screen and tap‐
er.
Right cylinder head
– Remove right toothed belt guard.
– Pull connector off Hall sender.

Touareg 2003 ➤
– Unscrew bolts -1- from Hall sender. lkswage es n
o ot g
yV ua
– Unscrew bolt -2- from rear of toothed belt guard. ir se
d b ran
tee
tho
or
– Slightly pull rear of toothed belt guard towards frontau and re‐ ac
ss
move Hall sender housing with Hall sender screen and taper.
ce
le
un
pt
Continuation for both cylinder heads
an
d
itte
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ab
pe
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Screw in pin -2085/1- as shown in the illustration.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
– Unscrew inner part of oil seal extractor -2085- several turns
t. rig
gh ht
yri
out of the outer part and lock with knurled screw. p by
co Vo
by lksw
cted agen
– Lubricate threaded head of oil seal extractor, place it in posi‐ Prote AG.
tion and, exerting firm pressure, screw it into oil seal as far as
possible.
– Loosen knurled screw and turn inner part against pin -2085/1-
until seal is pulled out.
– Clamp flats of oil seal extractor in vice. Remove oil seal with
pliers.
– Then press in new seal to stop until it is flush using fitting

sleeve -3241/1- and bolt -3241/3- .
quence.
2.4 Removing and installing camshafts and

variable camshaft timing adjusters

Touareg 2003 ➤
♦ Chain tensioner retainer -3366-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
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♦ Torque wrench (5…50 Nm) -V.A.G 1331- s
ce
le
un
pt
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d
itte
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pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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♦ Sealant -AMV 188 001 02-
nform
ercia
2.4.1 Removing
m
a
com
tion in
– Set engine to TDC ⇒ page 34 .
r
te o
thi
– Remove toothed belt and camshaft sprocket ⇒ page 34 ; Re‐
s
iva
moving, installing and tensioning toothed belt. do

r
rp
cum
fo
en
g
Left cylinder head

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c
– Loosen securing bolts -1- and -2- and remove rear toothed belt
lksw
cted agen
guard.
Prote AG.
Right cylinder head


Touareg 2003 ➤

– Loosen securing bolts -arrows- and remove rear toothed belt
guard.
Continuation for both cylinder heads
– Disconnect connector from Hall sender and remove Hall send‐
er housing with Hall sender screen and taper.
– Check TDC position of camshafts. The markings

en AG. V
olkson
wagthe
en Acam‐
G
shafts must be in line with the arrowolkson
wagboth bearing caps does not
-arrows-. ed
by
V gu
ara
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or
When reusing existing camshaft
au
th timing chain eo
ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
– Mark camshaft timing chain -arrows- before removing (e.g.

m
atio
m
with paint, arrow pointing in direction of rotation).

o
n in
or c
thi
te
sd
iva
Note
o
r
rp
cu
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m
f
en
ng
t.
Do not mark chain by way of centre punch, notch or the like.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
– Hold camshaft adjuster in position using retainer for chain ten‐

sioner -3366- .
AG. Volkswagen AG d
agen oes
ksw
Note by Vol not
gu
ara
d
rise nte
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Camshaft aadjuster
ut
h
can be damaged if chain tensioner is tightened ra
too far. ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Mark installation position of all bearing caps (e.g. using a wa‐
es, in part or in w
terproof felt-tip marker) with numbers as shown in the illustra‐
t to the co
tion regardless of the existing markings on the bearing caps.
– Unscrew securing bolts for camshaft adjuster.
rrectness of i
– Remove bearing cap -1-.
l purpos
– Remove bearing caps -2-, -4-, -6-, -8- and -9- and place them
on a clean surface in sequence given.
nform
ercia
– Loosen bearing caps -3-, -5- and -7- alternately and diagonally
m
and then remove.
a
com
tion in
– Carefully remove camshafts with camshaft adjusters and
r
te o
thi
place them on a clean surface.
s
iva
do
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rp
cum
fo
2.4.2 Installing
en
ng
t.
yi Co
Cop py
– Renew half-round sealing plug.
t. rig
gh ht
pyri by
Vo
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– Renew gasket for camshaft adjuster.
c by lksw
cted agen
Prote AG.
– Coat hatched area lightly with sealant -AMV 188 001 02- .
– Fit camshaft timing chain onto camshaft drive gears as de‐
scribed below.
When reusing existing camshaft timing chain

Touareg 2003 ➤
– 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- Arollers
G. Volkswagen AG d
agen
on the chain sprockets. Chain rollers -1- and -16- o are
lksw offset from
oes
not
1 yV gu
notches -A- and -B- by /2 the width of one stooth
ed b towards left. ara
n ri tee
ho
Continuation aut or
ac
ss
ce
e
– Fit camshaft adjuster to camshaft timing chain.

nl
pt
du
an
itte
– Carefully position camshafts with camshaft timing chain and
y li
erm
ab
camshaft adjuster in cylinder head.
ility
ot p
wit
– Oil the camshaft running surfaces.
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
Dowel sleeves for bearing caps and camshaft adjuster must be
fitted in cylinder head.
rrectness of i
l purpos
– Install bearing caps -3-, -5- and -7- to locations as marked and
tighten new bolts alternately and diagonally. Specified torque:
nf
ercia
5 Nm + 1/4 turn (90°) further.

orm
m
atio
m
– Tighten camshaft adjuster -10-. Specified torque: 5 Nm + 1/4

o
n in
or c
turn (90°) further.

thi
te
sd
iva
– Install chain tensioner.

o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
– 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‐

sure correct alignment of markings.
– Lightly coat double bearing cap -6- and bearing cap -1- with
sealant -AMV 188 001 02- ⇒ page 61 and install bearing
caps. Specified torque: 5 Nm + 1/4 turn (90°) further.
– Install remaining bearing caps. Specified torque: 5 Nm + 1/4
turn (90°) further. wage
e ks s no
Vol t gu
– Renew camshaft seals ⇒ page 54 . ed by ara
ris nte
– Renew Hall sender seals ⇒ page 55 . utho eo
ra
a c
ss
– Carefully drive in cap ⇒ Item 9 (page 50) using thrust piece of
ce
le
un
pt
fitting sleeves -3202- .
an
d
itte
y li
erm
ab
ility
quence.
ot p
wit
is n
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ole,
spec
Note
t to the co
♦ After installing camshafts wait for approx. 30 minutes before
starting engine. Hydraulic compensating elements must settle.
(Valves will otherwise contact piston).
♦ After working on valve mechanism, carefully turn engine by rrectne
hand to ensure that no valve strikes piston when engine is
ss o
started.
cial p
f inform
mer
atio
Lightly coat parting surfaces of front and rear bearing caps with
om
sealant -AMV 188 001 02- before installing.

c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
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co lksw
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cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
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d by ara
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r
Touareg 2003 ➤ ut
ho eo
ra
a
ss - Edition 11.2011 c
ce
le
un
pt
an
d
2.5 Removing and installing roller rocker fin‐
itte
y li
erm
ab
ger
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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cum
Procedure
r
fo
en
ng
t.
yi Co
– Remove engine ⇒ page 2 . t. Cop py
rig
gh ht
– Remove camshafts with camshaft adjuster ⇒ page 56 . yri
p by
o Vo
by c lksw
cted
– Mark allocation of roller rocker fingers and roller rocker finger
agen
Prote AG.
shafts in order to ensure correct reinstallation.
– Remove securing bolts -arrows-.
– Then, screw in M6 bolts into shaft holes and pull shafts out of
cylinder head.
– Remove roller rocker fingers.
Note
♦ O-rings for shafts must always be renewed.

♦ Oil bearing points of roller rocker fingers.
– When installing, tighten shaft securing bolts to 10 Nm.

quence.
2.6 Renewing valve stem seals


Touareg 2003 ➤

equipment required
♦ Spark plug socket and ex‐
tension -3122 B-
♦ Valve stem seal puller
-3364-
♦ Valve stem seal fitting tool
-3365-
♦ Adapter -T40012-
-V.A.G 1331-
♦ Dismantling and assem‐
bling device for valve cot‐
ters -VAS 5161-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
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ility
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wit
, is n
h re
hole
spec
es, in part or in w
2.6.1 Removing
t to the co

rrectness of i
– Remove camshafts with camshaft adjuster ⇒ page 56 .

l purpos
– Remove spark plugs using spark plug socket and extension

-3122B- .
nform
ercia
– Swivel roller rocker fingers upwards and secure them with a

rubber strap.
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
– 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‐
ters loose using a plastic hammer.
– Screw toothed piece -VAS 5161/6- with -VAS 5161/5- into

guide plate -VAS 5161/7- .
– Insert assembly cartridge -VAS 5161/8- into guide plate -VAS
5161/7- . swage
es n
olk ot g
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– Screw adapter -T40012- into spark plug thread, connect d to
b ua
ran
ir se
compressed air line with commercially available adapter
tho and tee
or
apply constant pressure (at least 6 bar). au ac
ss
ce
le
– Attach pressure fork -VAS 5161/2- to snap-in device -VAS

un
pt
5161/6- and push assembly cartridge down.
an
d
itte
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erm
ab
– At the same time, turn knurled screw of assembly cartridge
ility
ot p
clockwise until tips engage in valve cotters.
wit
is n
h re
– Move knurled screw back and forth lightly to press apart valve
ole,
spec
cotters and to capture them in the assembly cartridge.
t to the co
– Release pressure fork and remove assembly cartridge from
guide plate.
– Remove guide plate from cylinder head.
rrectness
Note
o
cial p
f inform
The compressed air line remains connected.
mer
atio
om
n
c
i
or
n
– Pull off valve stem seals using valve stem seal puller -3364- . thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
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.
– Remove plastic sleeve -A-.
If the valve cotters have been removed from the assembly item
then they must be inserted into the insertion device -VAS
5161/18- .
Note
Larger diameter faces upwards. AG. Volkswagen AG d

agen oes
olksw not
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– Insert valve spring and valve spring plate. ise
d b ara
nte
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h
– Secure guide plate -VAS 5161/7- back to cylinder
s aut
head. ra
c
s
ce
le
un
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an
d
itte
– Insert assembly cartridge -VAS 5161/8- into guide plate.
y li
rm
ab
pe
ility
– Press pressure fork down and pull knurled screw upwards.
ot
This causes the valve cotters to be inserted.
wit
, is n
h re
hole
– Release pressure fork with knurled screw still in pulled posi‐
spec
tion.
es, in part or in w
t to the co
– Install camshafts with camshaft adjuster ⇒ page 56 .
rrectness of i
l purpos
Note
nform
ercia
♦ After installing camshafts wait for approx. 30 minutes before

starting engine. Hydraulic compensating elements must settle.
m
(Valves will otherwise contact piston).

com
tion in
r
♦ After working on valve mechanism, carefully turn engine by

te o
thi
s
hand to ensure that no valve strikes piston when engine is

iva
do
r
started.
rp
cum
fo
en
ng
t.
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Cop py
2.7 Checking valve guides
t. rig
gh ht
pyri by
Vo
co lksw
by
Special tools and workshop equipment required cted agen
Prote AG.

Touareg 2003 ➤
♦ 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‐
ters, only use inlet valve in inlet guide and exhaust valve in
exhaust guide.
– Determine rock. Wear limit: 0.8 mm
If rock tolerance is exceeded: AG. Volkswagen AG d
agen oes
lksw not
– Renew cylinder head. d byV
o gu
ara
ise nte
or eo
h
aut ra
ss c
ce
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un
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an
d
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rm
ab
2.8 Reworking valve seats

pe
ility
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hole
spec
♦ Depth gauge
es, in part or in w
t to the co
♦ Valve seat refacing tool

Procedure
rrectness of i
l purpos
Note
♦ When repairing engines with leaking valves, it is not sufficient

nform
ercia
to rework or renew valve seats and valves. Particularly on high

m
mileage engines, it is necessary also to check valve guides for

a
com
tio
wear ⇒ page 65 .
n in
r
te o
thi
♦ Valve seats are only to be reworked to the extent required to

s
iva
do
yield a proper surface appearance. Before beginning to rework

r
rp
cum
valve seats, calculate the maximum permissible reworking di‐

fo
en
g
mensions. If the reworking dimension is exceeded, the hy‐

n
t.
yi Co
op
draulic valve clearance compensation can no longer be C py
ht. rig
guaranteed and the cylinder head must be renewed. rig ht
py by
co Vo
by lksw
cted agen
Prote
– Remove camshafts ⇒ page 56 .
AG.
The max. permissible reworking dimension is calculated as fol‐

lows:
– Insert valve and press firmly against seat.

Touareg 2003 ➤
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.
– Calculate maximum permissible reworking dimension from
measured distance -a- and minimum dimension.
Volkswa n AG. gen AG
wage does
Minimum dimension: Volks not
gu
by ara
ed nte
Inlet valves (outer) oris mm 34.0 eo
th
au ra
Inlet valve (centre)
ss mm 33.7 c
ce
le
Exhaust valves mm 34.4

un
pt
an
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Measured distance -a- minus minimum dimension = maximum
rm
ab
pe
ility
permissible reworking dimension.
ot
wit
, is n
Example:
h re
hole
spec
Measured distance 34.4 mm
es, in part or in w
t to the co
— Minimum dimension 34.0 mm
= Max. permissible reworking dimension 0.4 mm
rrectness of i
l purpos
Note
If the max. permissible reworking dimension is 0 mm or below 0 nform

ercia
mm, repeat measurement using new valves. If the result does not
m
change renew cylinder head.

a
com
tion in
r
te o
thi
s
Reworking valve seats

iva
do
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rp
cum
fo
Reworking inlet valve seat

en
ng
t.
yi Co
a - = ∅ 26.2 mm Cop py
t. rig
gh ht
yri
b - = 1.5…1.8 mm p by
co Vo
by lksw
cted agen
Z - = bottom surface of cylinder head Prote AG.
α - 45° valve seat angle

β - 30° upper correction angle
γ - 60° lower correction angle
Reworking exhaust valve seat
a - = ∅ 29.0 mm
b - = approx. 1.8 mm
Z - = bottom surface of cylinder head
α - 45° valve seat angle
β - 30° upper correction angle
γ - 60° lower correction angle

Touareg 2003 ➤
17 – Lubrication
1 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 71 .
Removing and installing drive chain for oil pump ⇒ page 74
Checking oil pressure and oil pressure switch ⇒ page 75
Note
If large quantities of metal shavings or particles are found when

repairing the engine, the oil passages must be cleaned, and the
oil cooler renewed in order to aprevent
n AG. Vofurther
lkswagedamage
n AG d occurring
later ⇒ page 69 . lksw ge oes
not
Vo g
by ua
ed ran
ris tee
Removing and installing
utho oil return valves ⇒ Item 6 (page 17) , and or
⇒ Item 21 (page
ss 17) .
a ac
ce
e
nl
1.1 Engine oil

pt
du
an
itte
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erm
ab
Engine oil specifications:

ility
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wit
Use „long-life engine oil“ conforming to VW standard „503 00“ or

, is n
h re
„504 00“.
hole
spec
es, in part or in w
t to the co
Note
♦ The engine is factory-filled with oil which is designed for long

rrectness of i
service intervals.
l purpos
♦ Engine oils conforming to VW standard 501 01 or 502 00 can

continue to be used. These oils must be changed every 12
months or 15,000 kilometres. The service interval display must
nf
ercia
be programmed accordingly. Procedure: ⇒ Maintenance ;

rm
m
atio
Booklet 17.1
om
n in
c
♦ Engine oil „ILSAC GF3 with viscosity class SAE5W-40“ may

or
thi
e
be used to change or top up oil.

t
sd
iva
o
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rp
cu
♦ Engine oil „ILSAC GF3 with viscosity class SAE5W-30“ may

o
m
f
en
ng
be used only to top up oil.

t.
yi Co
Cop py
t. rig
gh ht
1.2 Oil capacities:
pyri by
Vo
co lksw
by
cted agen
Prote
With oil filter 7.5 l
AG.
68 Rep. gr.17 - Lubrication

Touareg 2003 ➤
AG. Volkswagen AG d 8-cylinder injection engine - Edition 11.2011
agen oes
olksw not
V
Markings onedoil by dipstick gu
ara
ris nte
o
1 - Max.aut mark
h eo
ra
ss c
2 - Min. mark
ce
le
un
pt
an
d
a - Area above hatched field up to max. mark: Do not top up with

itte
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engine oil!
erm
ab
ility
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b - Engine oil level within hatched zone: Engine oil can be topped-
wit
is n
up.
h re
ole,
spec
c - Area from min. mark up to hatched field: Must be topped up,
max. 0.5 l of engine oil!
t to the co
rrectne
1.3 Dismantling and assembling oil filter
housing
ss o
Assembly overview
cial p
f inform
mer
atio
m
Note
o
n
c
i
or
n thi
e
The oil filter housing can be removed or installed only with the
t
sd
va
engine removed ⇒ page 2 .

i
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cum
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en
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t.
yi Co
Cop py
. rig
1 - Dowel sleeve
ht ht
rig by
copy Vo
2 - Gasket
by lksw
cted agen
Prote AG.
❑ For oil passage
❑ Renew.
3 - 10 Nm
4 - Oil cooler seal
❑ For oil passage
5 - 20 Nm
❑ Renew.
6 - Oil cooler
7 - Oil filter element
❑ Observe change inter‐
vals ⇒ Maintenance ;
Booklet 17.1
8 - Oil filter lower part, 25 Nm
9 - Oil drain plug, 10 Nm
10 - Seal
11 - Oil cooler seal
❑ For coolant passage
12 - Oil filter housing
13 - 25 Nm
14 - Coolant drain plug, 10 Nm
15 - Coolant pipe
16 - 1.4 bar oil pressure switch
-F1- , 20 Nm
❑ Checking ⇒ page 75 .
1. Removing and installing parts of lubrication system 69

Touareg 2003 ➤
17 - 50 Nm + 1/4 turn (90°) further

❑ Renew.
AG. Volkswagen AG d
agen oes
18 - Engine mounting Volksw not
gu
d by ara
ise nte
or eo
h
aut ra
1.4 Removing and installing oil sump ss c
ce
le
un
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an
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ab
Note
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ility
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The sump (upper and lower parts) can be removed or installed
h re
only with the oil filter housing removed ⇒ page 69 .
hole
spec
es, in part or in w
t to the co
1 - Oil pump
rrectness of i
⇒ page 71
l purpos
2 - Pipe connection
3 - 10 Nm
nform
ercia
4 - Chain tensioner
m
a
com
tio
❑ Secure with locking pin -
n in
r
T40011- before remov‐

te o
thi
s
al.
iva
do
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rp
cum
5 - 10 Nm
fo
en
ng
t.
yi Co
6 - Chain sprocket Cop py
t. rig
gh
ht
pyri by
Vo
o
tion ⇒ page 71 . by c lksw
cted agen
Prote AG.
7 - 34 Nm
8 - Drive chain
❑ For oil pump.
❑ Removing drive chain
⇒ page 74 .
9 - 30 Nm
10 - Sump, upper part
11 - Sump, lower part
12 - 10 Nm
13 - Oil level and oil tempera‐
ture sender -G266-
14 - 10 Nm
❑ For sump, lower part
16 - Seal
❑ Renew.
17 - 15 Nm
❑ For sump, upper part
19 - 22 Nm
20 - Seal
❑ Renew.

AG. Volkswagen AG d
agen oes
olksw not
d byV gu
ara Touareg 2003 ➤
e
horis 8-cylinder nte injection
eo engine - Edition 11.2011
aut ra
ss c
21 - 10 Nm
ce
le
un
pt
an
22 - 25 Nm
d
itte
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erm
ab
23 - Oil suction pipe
ility
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❑ For sump, upper part
wit
is n
h re
ole,
spec
Installation position of oil pump chain drive sprocket
t to the co
– Fit chain sprocket onto oil pump shaft. The flattened side
-arrow- faces oil pump shaft and the inscription on the chain
rrectne
sprocket faces towards front.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
1.4.1 Removing and installing oil pump
en
ng
t.
yi Co
Cop py
. rig
ht ht
rig by
copy Vo
♦ Engine and gearbox support -VAS 6095-
by lksw
cted agen
Prote AG.
♦ Locking pin -T40011-
♦ Silicone sealant D176 501A1
♦ Eye protection
Prerequisites
• Engine removed
• Engine is secured on engine and gearbox support -VAS
6095- .
Removing
– Drain engine oil from lower part and upper part of sump.
Note
Observe environmental regulations for disposal.
– Remove engine mounting on right ⇒ Item 18 (page 70) .

– Now the oil filter housing can be removed
⇒ Item 12 (page 69) .
– Unscrew bracket for dipstick guide tube -1- from cylinder head
and pull out guide tube.

lkswage es n
o ot g
Touareg 2003 ➤ byV ua
d ran
ir se
8-cylinder injection engine - Edition 11.2011 tho tee
or
au ac
ss
– Unscrew bracket for coolant drain pipe -from- upper part of
ce
le
un
pt
sump. If necessary, slightly loosen banjo bolt -1-.
an
d
itte
y li
rm
– Now unscrew lower part and upper part of sump.
ab
pe
ility
ot
– Loosen sump with light blows of a rubber headed hammer or
wit
, is n
light leverage with a lever, if necessary.
h re
hole
spec
– Press chain tensioner together -in direction of arrow- and se‐
es, in part or in w
cure it with pin -T40011- -1-.
t to the co
rrectness of i
l purpos
– Now unscrew chain sprocket -2- from oil pump.
nform
ercia
– Unscrew the three oil pump securing bolts m
⇒ Item 9 (page 70) and the oil suction pipe securing bolts
a
com
tio
⇒ Item 22 (page 71) .
n in
r
te o
thi
– Now oil pump can be removed.
s
iva
do
r
rp
c
– Remove sealant residue from cylinder block.
um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove sealant residue on lower part and upper part of sump

using a rotating brush, e.g. an electric drill with a plastic brush
attachment (wear safety goggles).
– Clean sealing surfaces. They must be free of oil and grease.
Installing
– Reinstall oil pump.
– Bolt chain sprocket to oil pump ⇒ page 71 .
– Remove locking pin -T40011- from chain tensioner.
– Now install upper part of sump as follows:
Note
♦ Observe expiry date of sealing compound.

♦ The sump must be installed within 5 minutes of applying sili‐
cone sealing compound.
– Cut off tube nozzle at front marking (∅ of nozzle approx. 1

mm).
– Coat clean sealing surface on upper part of sump with silicone
sealant as shown in the illustration. The sealant bead must be
1.5 mm thick

Touareg 2003 ➤
Run bead along inner side of bolt holes -arrows-.
Note
olkswagen AG
en AG. V
The sealant bead must not be thicker, otherwise olkexcess
swa
g
sealing does
not
compound will enter the oil sump and mayeblock
d by V the oil suction gu
ara
line strainer. tho
ris nte
eo
au ra
c
ss
– Fit upper part of sump immediately and lightly tighten all sump
ce
le
un
pt
bolts „diagonally“.
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Then „diagonally“ tighten sump bolts -1- to 15 Nm and bolts
l purpos
-2- to 22 Nm.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Now apply an approx. 1.5 mm bead of sealing compound

-arrow- onto the clean sealing flange of the lower part of the oil
sump as shown on illustration.
– Fit lower part of sump immediately and lightly tighten all sump
bolts „diagonally“.
– Then „diagonally“ tighten oil sump bolts to 10 Nm.
– Insert dipstick guide tube.

Touareg 2003 ➤
– 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. Only then fill with engine oil.

AG. Volkswagen AG d
quence. lkswagen oes
n o ot g
yV ua
edb ran
ris tee
ho
aut or
ac
1.4.2 ss Removing and installing drive chain for
ce
e
nl
oil pump
pt
du
an
itte
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erm
ab
♦ Engine removed
ility
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♦ Engine is secured on engine and gearbox support -VAS
wit
, is n
h re
6095- .
hole
spec
es, in part or in w
t to the co
– Drain engine oil from lower part and upper part of sump.
Note rrectness of i
l purpos
Observe environmental regulations for disposal.

nf
ercia
or
– Remove lower part and upper part of sump.

m
m
atio
m
– Remove front sealing flange ⇒ page 21 .

o
n in
or c
thi
e
– Mark front face of thrust washer ⇒ Item 14 (page 22) using a

t
sd
iva
coloured felt-tip marker.

o
r
rp
cu
o
m
f
– Remove oil pump ⇒ page 71 .

en
ng
t.
yi Co
op py
– Remove thrust washer from crankshaft journal. t. C rig
gh ht
pyri by
– Mark direction of rotation of drive chain using a coloured felt-
co Vo
by lksw
cted
tip marker.
agen
Prote AG.
– Remove drive chain for oil pump.

The assembly is basically a reverse of the dismantling sequence.
When doing this note installation position of chain sprocket
⇒ page 71 .

Touareg 2003 ➤
1.5 Checking oil pressure and oil pressure switch

AG. Volkswagen AG d
Special tools and workshop agen oes
olksw not
equipment required byV gu
ara
ed
ris nte
o
♦ Oil pressure tester -V.A.G aut
h eo
ra
1342- ss c
ce
le
un
pt
♦ Adapter -V.A.G 1342/14-
an
d
itte
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♦ Voltage tester -V.A.G
rm
ab
pe
ility
1527B-
ot
wit
, is n
♦ Auxiliary measuring set -
h re
hole
V.A.G 1594C-
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Test prerequisites
• Engine oil level OK.
• Oil pressure warning lamp -K3- must light up for approx. 3
seconds when ignition is switched on
• Engine oil temperature at least 80 °C (radiator fan must have
run once)
Checking oil pressure
– Check oil pressure at different revolutions: 2000 rpm: 3.0…5.5
bar, above 2000 rpm: maximal 7.0 bar.
If the specifications are not obtained
– Rectify mechanical damage, e.g. bearing damage.
At higher engine speeds, the oil pressure must not exceed 7.0
bar.
If the specification is exceeded:
– Renew oil pump, if necessary ⇒ page 71 .

Touareg 2003 ➤
AG. Volkswagen AG d
agen oes
lksw not
Checking oil pressure switch d by
Vo gu
ara
ise nte
r
– Remove oil pressure switch -F1- and screw into tester. ut
ho eo
ra
s a c
– Screw oil pressure tester -V.A.G 1342- with adapter - s
ce
le
V.A.G 1342/14- into oil filter housing in place of oil pressure
un
pt
an
d
switch. ⇒ Item 16 (page 69) .
itte
y li
rm
ab
pe
ility
ot
wit
Note
, is n
h re
hole
spec
Observe installation position of adapter: the conical connecting
es, in part or in w
piece of adapter must be screwed into pressure hose of tester.
t to the co
– Connect brown wire of tester to earth (-).
rrectness of i
– Connect voltage tester -V.A.G 1527B- using test cables from
l purpos
-V.A.G 1594 C- to battery positive (+) and oil pressure switch.
LED must not light up.
nform
ercia
If the LED lights up:

m
– Renew oil pressure switch -F1- .
a
com
tion in
If LED does not light up:
r
te o
thi
s
iva
– Start engine and run at idling speed. At 1.2…1.6 bar the LED
do
r
rp
c
must light up, otherwise renew oil pressure switch -F1- .
um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
19 – Cooling
1 Removing and installing parts of cool‐
ing system
Caution

tions:
sitions.
Note
♦ When the engine is warm, the cooling system is under pres‐

sure. If necessary, release pressure before beginning repair
work.
♦ Hoses are secured with spring-type clips. In case of repair,
only use spring-type clips.
wage
♦ Spring-type clip pliers -VAS 6340- are recommended for in‐y Volks
es n
ot g
stallation of spring-type clips. ed
b ua
ran
oris tee
h
♦ When installing coolant hoses, route stress-free sos athat
ut they or
ac
do not come into contact with other components (observe
s
ce
e
markings on coolant connection and hose).

nl
pt
du
an
itte
y li
erm
ab
Test for leaks in cooling system using cooling system tester -
ility
ot p
V.A.G 1274- and adapter for cooling system tester -V.A.G 1274/8-
wit
, is n
and adapter for cooling system tester -V.A.G 1274/9- .
h re
hole
Assembly overview - radiator ⇒ page 78
spec
es, in part or in w
t to the co
Assembly overview - radiator fan ⇒ page 79 .
Removing and installing fan support with fan ⇒ page 79 .
rrectness of i
Assembly overview - parts of cooling system, engine side, front
⇒ page 81 .
l purpos
Assembly overview - parts of cooling system, engine side, rear

⇒ page 81 .
nf
ercia
orm
Assembly overview - parts of cooling system, body side

m
atio
m
⇒ page 83 .
o
n in
or c
Draining and filling with coolant ⇒ page 86 .

thi
te
sd
iva
Coolant hose schematic diagram ⇒ page 84

r
rp
cu
o
m
f
en
ng
Coolant mixture ratios ⇒ page 86 , draining and filling with cool‐

t.
yi Co
op
ant. C py
t. rig
gh ht
yri
Removing and installing coolant pump and thermostat
p by
o Vo
by c lksw
⇒ page 89 . Prote
cted AG.
agen
1. Removing and installing parts of cooling system 77

Touareg 2003 ➤
1.1 Assembly overview - radiator
1 - Coolant pipe
❑ Secured to fan support
AG. Volkswagen AG d
with spacers. ksw
agen oes
n ol ot g
yV ua
2 - To expansionisetank
db ran
r tee
ho
3 - Coolant shose
au
t or
ac
s
❑ Secured to top of front
ce
le
un
pt
end with retaining clips.
an
d
itte
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4 - Upper coolant hose
erm
ab
ility
ot p
❑ Secured to radiator with
wit
is n
quick-release coupling.
h re
ole,
❑ Check for secure seat‐
spec
ing.
t to the co
❑ With junction for coolant
hose leading to expan‐
sion tank.
rrectne
5 - Radiator/cooler
s
s o
⇒ page 88
cial p
f inform
❑ After renewing, renew
mer
entire coolant.
atio
om
6 - Condenser
c
i
or
n thi
te
sd
7 - Oil cooler
iva
o
pr
❑ For gear oil

um
r
fo
en
ng
t.
yi
8 - Oil cooler
Co
Cop py
ht. rig
❑ For power-assisted rig ht
py by
steering co Vo
by lksw
cted agen
Prote AG.
9 - Lock carrier
10 - 10 Nm
11 - Low-temperature cooler
❑ For fuel cooling
❑ Only with certain equipment
12 - 10 Nm
13 - Rubber bush
❑ For lock carrier
14 - Retaining clip
❑ Check for secure seating.
15 - Rubber bush
16 - Lower coolant hose
❑ Secured to radiator with quick-release coupling.
17 - To coolant pump -V36-
18 - Coolant outlet temperature sender -G83-
19 - To coolant pump.
20 - To coolant pipe on top/side.
❑ Bolted to cylinder head bank 1.
78 Rep. gr.19 - Cooling

Touareg 2003 ➤
1.2 Assembly overview - radiator fan
1 - Radiator fan -V7-

2 - Fan support
❑ Clipped onto radiator.
ing.
3 - 10 Nm
4 - 10 Nm
5 - Radiator fan 2 -V177- agen
AG. Volkswagen AG d
oes
olksw not
6 - Radiator fan control unit - byV gu
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7 - 10 Nm ss c
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ility
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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at
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ion
c
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ate
do
priv
cum
for
en
ng
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
1.3 Removing and installing fan support
cted agen
Prote AG.
with fan
♦ Spring-type clip pliers -VAS 5024A-
Removing
WARNING

– Open and close cap on coolant expansion tank.

– Release coolant hose retaining clips from front end using a
screwdriver.

Touareg 2003 ➤
– Unscrew coolant pipe from fan support -arrow-.

en AG. V
olkswagen AG
ag does
ksw not
– Loosen spring-type clips on coolant Vol
by pipe and swivel it upwards gu
ara
together with spacers. ris
ed
nte
ho eo
ut
– Disconnect connectors from
ss radiator, loosen cable clamps
a on ra
c
fan support and lay wiring harness to side.
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
– Pull retaining ring -1- of rubber mounting on left and right in
direction of arrow off brake vacuum pump -V192- and lay
pump to side.
rrectne
– Then release locking mechanisms on left and right of radiator
s
using a screwdriver -arrows- and lift out complete fan support
s o
upwards.
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤

agen
AG. Vo-lkparts
swagen Aof
G docooling system, engine side, front
ksw es n
Vol ot g
d by ua
ran
e
1- Thermostat housing
tho
ris tee
or
au ac
2- Coolant pump
ss
ce
e
nl
❑ Check for ease of move‐
pt
du
an
ment.
itte
y li
erm
ab
ility
ot p
⇒ page 89
wit
, is n
h re
hole
spec
4 - To radiator
es, in part or in w
t to the co
6 - Radiator outlet coolant tem‐
rrectness of i
perature sender -G83-
l purpos
❑ Before removing, re‐

lease pressure in cool‐
ing system if necessary.
nf
ercia
or
7 - Retaining clip
m
m
atio
m

o
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c
ing.
or
thi
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sd
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8 - O-ring
o
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cu
o
❑ Renew if damaged. m
f
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t.
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op
9 - To bottom of radiator C py
t. rig
gh ht
yri
10 - Connection
p by
o Vo
by c lksw
cted
❑ Secured to radiator with
agen
Prote AG.
quick-release coupling.
ing.
11 - Coolant pump -V36-
❑ Fitting location of pump:
bolted to longitudinal
member on right.
12 - Bracket
13 - 23 Nm
14 - Non-return valve
❑ Arrow points towards engine.
15 - Coolant hose
16 - Coolant pipe
17 - Coolant pipe
18 - Coolant pipe, on side
19 - 10 Nm
1.5 Assembly overview - parts of cooling

system, engine side, rear
Assembly overview

Touareg 2003 ➤
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.
3 - Coolant temperature send‐
er -G62-
❑ With coolant tempera‐
ture display sender -
G2- .
❑ For engine control unit.
❑ Before removing, re‐
lease pressure in cool‐
ing system if necessary.
4 - Coolant pipe
5 - To thermostat.
AG. Volkswagen AG d
6 - 20 Nm lksw
agen oes
not
o
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7 - Gasket rised b ara
nte
ho eo
8 - Coolant pipe aut ra
ss c
❑ From cylinder head
ce
e
nl
pt
bank 1
du
an
itte
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erm
9 - Coolant pipe
ab
ility
ot p
❑ To oil filter housing
wit
, is n
h re
10 - To expansion tank
hole
spec
11 - To expansion tank
es, in part or in w
t to the co
12 - Coolant pipe
13 - 10 Nm
rrectness of i
14 - To upper coolant hose
l purpos
15 - 10 Nm
nform
ercia
16 - Coolant pipe, on side

m
❑ On cylinder head bank 1 at

om
ion
c
17 - Coolant hose
in t
or
his
ate
18 - From heat exchanger for heater unit

do
priv
cum
or
19 - To heat exchanger for heater unit.

f
en
ng
t.
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op
20 - Coolant pipe C py
ht. rig
rig ht
21 - 10 Nm
py by
co Vo
by lksw
cted agen
22 - Retaining clip
Prote AG.

23 - Connection
❑ To expansion tank
24 - 10 Nm

Touareg 2003 ➤
1.6 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- .
2 - Cap
❑ Check using cooling
system tester -V.A.G
1274- and adapter for
cooling system tester -
V.A.G 1274/9- .
❑ Test pressure: 1.4…1.6
bar.
3 - Connector
❑ For coolant shortage in‐
dicator
4 - Spring-type clip
ing.
AG. Volkswagen AG d
5 - Coolant hose ksw
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not
Vol
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6 - To connection ise
d b ara
nte
or eo
h
7 - To coolant pipe s aut ra
c
s
8 - Overflow hose
ce
le
un
pt
an
d
itte
9 - 10 Nm y li
erm
ab
10 - Coolant pipe ility
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11 - To upper coolant hose

h re
ole,
spec
12 - 8 Nm
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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te
sd
iva
o
pr
cum
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fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
1.7 Coolant hose schematic diagram
1 - Radiator/cooler
4 - Coolant pump -V36-
tion.
❑ Arrow points in direction
AG. Volkswagen AG d
of flow. ksw
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not
ol
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6 - Coolant pipe ised b ara
nte
or
❑ Secured to cylinder auth eo
ra
head bank 1. ss c
ce
e
nl
pt
7 - Alternator
du
an
itte
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8 - Oil cooler
erm
ab
ility
ot p
❑ For engine oil.
wit
, is n
h re
9 - Expansion tank
hole
spec
10 - Heat exchanger for heater
es, in part or in w
t to the co
unit
11 - Coolant pipe
rrectness of i
❑ Secured between cylin‐
der head bank 1 and cyl‐
l purpos
inder head bank 2.

12 - Coolant temperature
nf
ercia
sender -G62-
orm
m
atio
13 - Cylinder bank 2.
om
n in
or c
14 - Cylinder bank 1.
thi
te
sd
iva
15 - Coolant pipe
o
r
rp
cu
o
❑ Connected to cylinder
f
en
ng
t.
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head bank 1.
Co
Cop py
ht. rig
16 - Coolant pipe rig ht
py by
co Vo
lksw
❑ To thermostat housing
by
cted agen
Prote AG.
17 - Coolant pump
18 - Thermostat housing
Fitting location of water pump -V36-

The water pump -V36- -2- is clipped to the bracket with damping
rings and is bolted to the longitudinal member on right together
with the bracket.

Touareg 2003 ➤
1.8 Checking water pump -V36-

♦ Voltage tester -V.A.G 1527/B-
♦ Auxiliary measuring set -V.A.G 1594/C-
AG. Volkswagen AG d
agen oes
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♦ Current flow diagram by Vol
gu
ara
d
ise nte
Test prerequisite thor eo
au ra
s c
• Fuse -16- -arrow- must be OK. s ce
e
nl
pt
du
Test procedure
an
itte
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erm
ab
ility
ot p
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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– Pull 2-pin connector -1- off coolant pump -V36- -2-.

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
– Connect contact -1- of water pump -V36- Vto battery positive

(+) and contact -2- to earth (-) using
a n AG. olkcables
geauxiliary
swagen AG
from
doesaux‐
ksw
iliary measuring set -V.A.Gby1594C-
Vol . Pump must run. not
gu
a d ran
se
If the pump does not start
tho operating:
ri tee
or
au ac
– Renew water pump
ss -V36- .
ce
le
un
pt
an
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rm
ab
pe
ility
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hole
spec
es, in part or in w
t to the co
1.9 Draining and filling coolant
rrectness of i
l purpos
equipment required
♦ Refractometer -T10007-
nform
ercia

m
a
com
t
ion in
5024A-
r
te o
thi
s
iva
♦ Adapter for cooling system
do
r
rp
c
tester -V.A.G 1274/8-
um
fo
en
ng
t.
yi
Co
op py
1331- t. C rig
gh ht
pyri by
♦ Cooling system charge unit
co Vo
by lksw
cted agen
-VAS 6096- Prote AG.

Touareg 2003 ➤
Draining
WARNING

– Open cap on coolant expansion tank.

– Remove noise insulation. ⇒ General body repairs, exterior;
AG. Volkswagen AG d
Rep. gr. 50 ; Body - front; Assembly overviewolks-wnoise
agen insula‐ oes
not
tion . d byV gu
ar
e an
ris tee
– Place drip tray -V.A.G 1306- under uvehicle.
tho or
sa ac
– Disconnect coolant hoses -1- from
s
water pump -V36- .
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
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Follow disposal regulations for coolant!
h re
hole
spec
Filling
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
AG. Volkswagen AG d
agen
Note olksw
oes
not
byV gu
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♦ Use only coolant additive
ut
h G12 plus in accordance with
or eo
„TL VW 774 F“. Identification:
ss a purple colour. ra
c
ce
e
♦ G 12 plus and coolant additives marked „Conforming to
nl
pt
du
an
TL VW 774 F“ prevent frost and corrosion damage and scaling
itte
y li
and also raise boiling point of coolant. Therefore, the cooling
erm
ab
system must be filled all year round with frost and corrosion
ility
ot p
protection additives.
wit
, is n
h re
♦ Because of its higher boiling point, the coolant improves en‐
hole
spec
gine reliability under heavy loads, particularly in countries with
es, in part or in w
tropical climates.
t to the co
♦ Frost protection is required down to about -25°C (in countries
with arctic climates: down to about -35°C).
rrectness of i
♦ The coolant concentration must not be reduced by adding wa‐
l purpos
ter even in warmer seasons and in warmer countries. The

coolant additive concentration must be at least 40%.
nf
ercia
♦ If for climatic reasons greater frost protection is required, the
orm
amount of G 12 can be increased, but only up to 60 % (frost
m
atio
m
protection to about -40 °C). Otherwise frost protection and

o
n in
c
cooling effectiveness are reduced again.

or
thi
te
sd
a
♦ If radiator, heat exchanger, cylinder head or cylinder head

iv
o
r
rp
cu
gasket is renewed, do not reuse old coolant.
o
m
f
en
ng
t.
yi
♦ The Refractometer -T10007- is recommended for determining
Co
op py
the current anti-freeze density.
. C rig
ht ht
rig by
copy Vo
by lksw
Recommended mixture ratios:
cted agen
Prote AG.
Frost protection Anti-freeze G 122) Water2)

to quantity
-25 °C 4.0 l 4.0 l 5.0 l
-35 °C 4.5 l 4.5 l 4.5 l
2) The quantity of coolant can vary depending upon vehicle equipment.
– Install coolant hoses and secure.
– Screw adapter for cooling system tester -V.A.G 1274/8- onto

expansion tank.
– Fill coolant circuit using cooling system charge unit -VAS
6096- ⇒ Operating instructions for cooling system charge unit
VAS 6096 .
1.10 Removing and installing radiator


agen
AG. Volkswagen AG d
oe
Touareg 2003 ➤
olksw 8-cylinder sinjection
not engine - Edition 11.2011
byV gu
ara
ed
ris nte
♦ Torque wrench -V.A.G 1331-
au
tho eo
ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing
nf
ercia
or
– Pull out retaining clips from quick-release coupling for coolant
m
m
atio
hose at top and bottom and detach coolant hoses from radia‐
om
n in
tor.
or c
thi
e
– Remove front bumper ⇒ General body repairs, exterior; Rep.

t
sd
iva
o
gr. 63 ; Assembly overview - front bumper
r
rp
cu
o
m
f
en
ng
– Remove fans with fan support ⇒ page 79 .

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Loosen securing clips for condenser and ATF cooler.

– Remove upper securing bolts for radiator and remove radiator
upwards.
Installing
note the following:
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Install front bumper: ⇒ General body repairs, exterior; Rep.
gr. 63 ; Assembly overview - front bumper
– Check headlight adjustment and correct if necessary ⇒ Main‐
tenance ; Booklet 17.1 .
1.11 Removing and installing coolant pump

and thermostat

Touareg 2003 ➤
AG. Volkswagen AG d
agen oes
♦ Torque wrench -V.A.G 1331- olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing
rrectness of i
l purpos
– Remove upper coolant hose from thermostat housing.
nform
ercia
– Remove radiator fans with radiator fan support ⇒ page 79 .

m
a
com
– Remove poly V-belt ⇒ page 18 .
tion in
r
te o
thi
s
iva
do
If thermostat must be renewed:
r
rp
cum
fo
en
g
– Unscrew securing bolts of thermostat housing -arrows-.

n
t.
yi Co
Cop py
– First remove seal and then thermostat.
t. rig
gh ht
pyri by
Vo
o
Installing
c by lksw
cted agen
Prote AG.
– Insert thermostat with bleeder valve -arrow- facing upwards.

– Moisten new O-ring with coolant and install it.
– Install thermostat housing by first screwing in all securing bolts
by hand and then tightening all bolts to specified torque of 10
Nm.
If coolant pump must be renewed:

Touareg 2003 ➤
– Remove toothed belt guard securing nuts -1-.

– Then unscrew all coolant pump securing bolts -arrows-.
note the following:
– Insert coolant pump with gasket.
– Screw in all securing bolts by hand and tighten to specified
torque. Specified torque: 15 Nm
– Reinstall toothed belt ⇒ page 34 .
1.12 Checking cooling system for leaks

♦ Cooling system tester -V.A.G 1274-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
♦ Adapter for cooling system tester -V.A.G 1274/8-

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
♦ Adapter for cooling system tester -V.A.G 1274/9-
yi Co
Cop py
t. rig
– Screw cooling system tester -V.A.G 1274- with adapter -V.A.G
gh ht
yri by
1274/8- onto expansion tank.
op Vo
by c lksw
cted agen
Prote AG.
– Operate pump on tester and build-up pressure of between 1.4
and 1.6 bar.
– Check cooling system tester for leaks.
– In addition, check sealing cap.

Touareg 2003 ➤
– 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.
– The pressure relief valve in the sealing cap must remain
closed for the time being.
– If valve opens before test is complete, renew sealing cap.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
92
Prote AG.
Rep. gr.19 - Cooling
Touareg 2003 ➤
20 – Fuel supply system

1 Parts of fuel supply system
Caution

tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐ agen AG. Volkswagen AG do
vated charcoal filter system, coolant, refrigerant, brake olks
w es n
ot g
yV
fluid and vacuum) and electrical wiring in their original
ed b po‐ ua
ran
sitions. thoris tee
o
au ra
♦ To avoid damage to lines, ensure sufficientss clearance to c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
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Note
h re
hole
spec
♦ Hose connections are secured with couplings or spring-type
es, in part or in w
or clamp-type clips.
t to the co
♦ Always renew clamp-type clips with spring-type clips.
rrectness of i
♦ Fuel hoses on engine must be secured with spring-type clips
only. The use of clamp or screw-type clips is not permissible.
l purpos
♦ Spring-type clip pliers -VAS 6340- or spring-type clip pliers -

VAS 5024 A- are recommended for installation of spring-type
nform
ercia
clips.
m
at
om
io
Observe safety precautions ⇒ page 99 .
n
c
in t
or
his
e
Observe rules for cleanliness ⇒ page 99 .

at
do
priv
cum
Assembly overview - fuel tank with attachments ⇒ page 94 .
for
en
ng
t.
yi Co
Assembly overview - fuel filter ⇒ page 96 . . Cop py
rig
ht ht
Renewing fuel filter ⇒ page 96
rig by
copy Vo
by lksw
cted
Schematic diagram of fuel lines and components in fuel tank
agen
Prote AG.
⇒ page 98 .
Draining fuel tank ⇒ page 100
Removing and installing fuel delivery unit, fuel gauge sender and
suction-jet pumps ⇒ page 102
Removing and installing fuel tank with attachments
⇒ page 104 .
Checking fuel pumps ⇒ page 107
1. Parts of fuel supply system 93

Touareg 2003 ➤
1.1 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- .
4 - Flange
❑ Left side.
❑ With fuel filter
❑ The fuel tank must not
be more than 1/2 full
when removing.
5 - Locking ring, 110 Nm
❑ Remove and install us‐
ing wrench -T10202- .
ing.
6 - Fuel delivery unit
❑ Left side.
❑ Checking fuel pump
⇒ page 107 .
7 - Fuel gauge sender 3 -
G237-
❑ Left side.
❑ Flat, square float AG. Volkswagen AG d
agen oes
olksw not
❑ Clipped into bottom of ed byV gu
ara
tank. horis nte
eo
ut ra
❑ Checking: ⇒ Current ss a c
flow diagrams, Electri‐
ce
le
un
pt
cal fault finding and Fit‐

an
d
itte
ting locations.
y li
erm
ab
ility
8 - Suction-jet pump
ot p
wit
is n
❑ Left side.
h re
ole,
❑ Clipped into bottom of tank.

spec
9 - Protective cover
t to the co
❑ For bottom of fuel tank.

10 - Securing strap
rrectne

s

s o
cial p
f i
11 - 20 Nm + 1/4 turn (90°) further

nform
mer
atio
12 - Protective cover
om
n
c
❑ For top of fuel tank

i
or
n thi
te
sd
a
iv
o
pr
cum
r
❑ Right side.
fo
en
ng
t.
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❑ Checking fuel pump ⇒ page 107 .
Co
Cop py
ht. rig
14 - Fuel delivery unit rig ht
py by
co Vo
❑ Right side.
by lksw
cted agen
Prote AG.
94 Rep. gr.20 - Fuel supply system

Touareg 2003 ➤
❑ 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.
16 - Flange
❑ Right side.
❑ The fuel tank must not be more than 1/2 full when removing.
❑ With fuel pressure regulator
❑ With gravity valve
❑ Individual parts ⇒ page 98
❑ Note installation position on fuel tank ⇒ page 99 .
G. Volkswagen AG d
17 - Breather line ksw
agen
A
oes
not
Vol
ed
by gu
ara
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18 - Expansion tank ho eo
aut ra
ss c
19 - Gravity valve
ce
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nl
pt
du
an
20 - To pressure retention valve
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
1.2 Assembly overview - fuel filter
1 - Connection
❑ For breather line.
2 - Flange
❑ Left side.
❑ With fuel filter housing
tion on fuel tank
⇒ page 99 .
3 - Filter element
4 - Seal
❑ Renew.
5 - Earth wire
6 - 10 Nm
7 - Supply line
❑ To fuel pressure regula‐
tor.
8 - Connection
AG. Volkswagen AG d
❑ Filter feed from left fuel agen oes
olksw not
V
delivery unit ed by gu
ara
ris nte
o
9 - Connection aut
h eo
ra
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❑ Filter feed from right fuel s
ce
e
nl
delivery unit
pt
du
an
itte
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10 - Earth connection
erm
ab
ility
ot p
11 - Cap
wit
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❑ For filter housing

h re
hole
spec
12 - Locating pin
es, in part or in w
t to the co
rrectness of i
l purpos
1.3 Renewing fuel filter

nform
ercia
Note
m
at
om
ion
c
in t
The fuel filter is located in the left opening of fuel tank, as seen
or
his
e
from direction of travel.

at
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
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

. Volkswagen AG
gen AG does
– Cut open carpet on left side from point -A- to -B- in the pre-cut
Vol
ksw
a
not
area -arrows-. ed by gu
ara
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove nuts -1- from cover. If necessary, unscrew backrest
rrectness of i
mounting -2- or support mounting ⇒ General body repairs,
interior; Rep. gr. 72 ; Rear seats .
l purpos
– Unscrew locking ring from left flange using wrench -T10202- .
nform
ercia
– Completely remove flange on left side of tank.

m
– Empty fuel filter housing.

at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
– Mark installation position of filter cover -2- using coloured felt
gh ht
pyri by
tip marker pen.
o Vo
by c lksw
cted agen
Prote AG.
– Pull off earth wire -1- and unscrew filter cover -arrows- from
housing.
If filter element is changed, ensure that earth connection contacts
are not bent and have sufficient preloading.

Touareg 2003 ➤
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)
5 - Connection to left and right fuel delivery units (no pressure)
6 - Gravity valve
1.4 Schematic diagram of fuel lines and

components in fuel tank
-A- left side of fuel tank
-Arrow- points in direction of travel
-B- Right side of tank
1 - Gravity valve
❑ Left side.
2 - Flange
❑ Left side.
3 - Fuel filter
4 - Gravity valve
❑ Right side.
5 - Supply line
❑ To fuel rail. AG. Volkswagen AG d
agen oes
olksw not
6 - Supply line for auxiliary d byV gu
ara
heater orise nte
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h
ut ra
7 - Flange ss a c
ce
le
❑ Right side.
un
pt
an
d
itte
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8 - Fuel pressure regulator

rm
ab
pe
ility
9 - Return line
ot
wit
, is n
❑ From fuel pressure reg‐

h re
hole
ulator
spec
es, in part or in w
❑ To fuel delivery unit on

t to the co
left and right sides

10 - Supply line for suction-jet
pumps
rrectness of i
11 - Fuel delivery unit

l purpos
❑ Right side.
nform
ercia
m
❑ Right side.
a
com
tion in
13 - Delivery line
r
te o
thi
❑ Black
s
iva
do
r
rp
❑ To fuel delivery unit on

um
fo
en
left side.
ng
t.
yi Co
op py
14 - Delivery line
. C rig
ht ht
rig by
py
❑ Black co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
❑ To fuel delivery unit on right side
AG. Volkswagen AG d
❑ Left side. ksw
agen oes
not
Vol
y gu
16 - Fuel delivery
ise
d unit
b ara
nte
or
❑ Left side.
auth eo
ra
ss c
ce
le
un
pt
an
d
itte
Installation position of fuel delivery unit flange
y li
erm
ab
Insert left or right flange with marking -arrow- in direction of travel.
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
1.5 Safety precautions when working on
atio
m
fuel supply system

o
n
c
i
or
n thi
te
sd
va
Caution
i
o
pr
cum
r
fo
en
ng
t.
yi
Co
op py
t. C rig
gh ht
tions: pyri by
Vo
co lksw
by
cted
agen
Prote AG.
sitions.
♦ 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.
♦ Fuse nos. 13 and 14 are located in the E-box fuse holder in
the left plenum chamber.
When removing and installing fuel gauge sender or fuel pump
(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
♦ Even before work commences, the extraction hose of an ac‐
tivated fume extraction system has to be placed in the vicinity
of the assembly opening of the fuel tank to trap any escaping
fumes. If no exhaust gas extraction system is available, a ra‐
dial fan with a displacement greater than 15 m3/h can be used
providing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
1.6 Rules for cleanliness

When working on the fuel supply and injection system, pay careful
attention to the following „5 rules“ for cleanliness:

Touareg 2003 ➤
♦ 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.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
♦ When system is open: do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely nec‐
essary.
1.7 Emptying fuel tank

♦ Fuel extractor -VAS 5190- wage
es n
olks ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Special wrench -T10202-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
WARNING
c by lksw
cted agen
Prote AG.
Procedure
– Note safety precautions before beginning work ⇒ page 99 .
– Open fuel tank filler flap.

Touareg 2003 ➤
– 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. The tank may be
removed while containing remaining fuel. If work must be per‐
formed on fuel pumps or fuel tank senders, proceed as follows:
– Cut carpet open from point -A- to point -B- in the pre-cut area
-arrows-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
– Remove nuts -1- from cover. If necessary, unscrew
ut
ho backrest eo
ra
mounting -2- or support mounting ⇒ Generalss a body repairs, c
ce
e
nl
pt
du
an
– Hold a cloth on connections for fuel supply line and auxiliary
itte
y li
erm
heater and pull off hose couplings.
ab
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
Release connection by pressing button on hose coupling.
t to the co
– Disconnect connector for fuel pump and fuel tank sender.
rrectness of i
– Now remove locking ring from flange using fuel tank sender
l purpos
unit tool -T10202- .

– Carefully lever out flange and raise it slightly.
nform
ercia
– Insert suction hose of fuel extractor -VAS 5190- as deeply as

m
at
om
possible into right and then left side of fuel tank and extract
ion
c
fuel.
in t
or
his
ate
– For work on left side of fuel tank, proceed as described above.

do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
– 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‐
moved.
If fuel tank needed only to be emptied, install flanges again.
– First check that flange seals are properly seated.
Note
Always renew seals if the fuel has caused them to swell.
– Insert flange with locating tab facing forwards -arrow-.

– Tighten locking rings on left and right to specified torque using
wrench -T10202- .
AG. Volkswagen AG d
agen oes
olksw not
yV gu
1.8 Removing and installing fuel delivery
d b ara
ise nte
or eo
unit, fuel gauge sender and suction-jet
h
aut ra
ss c
pumps
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne

ss o
Test prerequisites
cial p
f inform
mer
• Fuel tank must be empty ⇒ page 100 .

atio
m
o
n
c
ets.
or
n thi
te
sd
va
• Connectors and wires for left and right flanges have been re‐
i
o
pr
cum
moved.
r
fo
en
ng
t.
yi
• Locking rings for left and right flanges have been unscrewed.
Co
Cop py
ht. rig
ht
Procedure
rig by
copy Vo
by lksw
cted
agen
Prote AG.

Touareg 2003 ➤
– 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.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
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– Detach fuel supply line to suction-jet pumps from fuel delivery
ce
le
un
pt
unit -arrow- on left and right sides of fuel tank.
an
d
itte
y li
– Unscrew fuel delivery unit in bottom of fuel tank by turning
rm
ab
pe
ility
about 90° to left.
ot
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
The fuel delivery unit housing is filled with fuel. Fuel may run out
if housing is tipped or canted.
rrectness of i
– Now unclip fuel gauge senders on each side of fuel tank and
l purpos
pull them out.

– Now unclip suction-jet pumps from bottom on each side and
nform
ercia
remove with a slight turn.

m
– Pull out hose ends through left and right sender openings.
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
1.9 Removing and installing fuel tank with attached components

equipment required
♦ Fuel extractor -VAS 5190-
1331-
1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
Prerequisites
wit
is n
h re
• Fuel tank must be empty ⇒ page 100 .

ole,
spec
t to the co
ets.
Removing
rrectne

ss
WARNING
o
cial p
f inform
mer
atio

om

n
c
i
or

thi
te
sd
iva
o
pr
cum
r
fo
en
ng
First, reduce the fuel pressure as follows:

t.
yi Co
op py
– Wrap a cloth around the joint to catch fuel which flows out.
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen
Volksw
oes
not Touareg 2003 ➤
by gu
ised 8-cylinder
ara
nte injection engine - Edition 11.2011
or eo
h
ut ra
– Disconnect
ss a
fuel supply line -arrow- in engine compartment. c
ce
e
nl
Once the fuel pressure has been reduced:
pt
du
an
itte
y li
– Remove silencers and mountings .
erm
ab
ility
ot p
– Remove rear propshaft tube ⇒ Transfer box and final drive;
wit
, is n
Rep. gr. 39 ; Removing and installing propshaft .
h re
hole
spec
– Remove rear axle ⇒ Running gear, axles, steering; Rep. gr.
es, in part or in w
42 ; Repairing rear axle; Removing and installing rear axle .
t to the co
– Open fuel flap and remove fuel tank cap.
– Pull rubber gasket off filler neck.
rrectness of i
l purpos
– Remove securing bolts -1- on filler neck and pull off earth wire
-2-.
nform
ercia
– Remove rear right wheel housing liner: ⇒ General body re‐

m
pairs, exterior; Rep. gr. 66 ; Removing and installing wheel
at
om
io
housing liner .
n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Unbolt cover plate -arrows-.
– Fuel tank breather lines are attached to longitudinal member.

Unclip them at securing clip.

Touareg 2003 ➤
– Remove securing bolts for filler neck -1- and activated char‐
coal filter -2- in wheel housing.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
tho eo
– Now bend filler neck
s au slightly downwards and pull off breather ra
c
line connections to activated charcoal filter. s
ce
le
un
pt
an
d
itte
y li
rm
Note
ab
pe
ility
ot
wit
, is n
Release connection by pressing button on hose coupling.
h re
hole
spec
– Pull off earth wire clipped to activated charcoal filter and re‐
es, in part or in w
t to the co
move activated charcoal filter.
rrectness of i
l purpos
– Disconnect connector to fuel pumps on left next to fuel tank.

– Now remove securing straps to left and right with cover below nform
ercia
fuel tank.
m
– Support fuel tank using engine and gearbox jack -V.A.G 1383
com
tion in
A- and remove securing strap at middle of fuel tank.

r
te o
thi
– Carefully lower fuel tank about 30 cm.

s
iva
do
r
rp
cum
fo
en
g
WARNING
n
t.
yi Co
Cop py
ht. rig
rig ht
py by
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gloves to avoid injuries and skin contact. Before loosening by c lksw
cted agen
hose connections, wrap a cloth around the connection. Then Prote AG.
– Reach through between fuel tank and vehicle floor and hold a
cloth above fuel supply hose. Now disconnect fuel supply line
and breather line from flange.
Note
This step saves cutting carpet in vehicle interior in vicinity of

flange cover.
– Lower fuel tank.

Installing
note the following:

Touareg 2003 ➤
♦ Connections for breather and fuel elines

n AG. must
Volkswengage
agen AG audibly
when joined. olkswag does
no
V t gu
by ara
♦ Install breather and fuel
ris hoses free of kinks.
ed nte
ho eo
ut
♦ Secure fuel hoses
ss with spring-type clips.
a ra
c
ce
♦ Ensure that fuel hose connections are tight. le
un
pt
an
d
itte
y li
♦ Ensure earth cable -2- is secured tight to body.
erm
ab
ility
ot p
wit
is n
Note
h re
ole,
spec
Before bolting on fuel tank, check that supply and breather lines
t to the co
are still clipped onto fuel tank.
rrectne
1.10 Checking fuel pumps
s
Checking delivery rate of pumps ⇒ page 108
s o
cial p
f i
Checking current draw of pumps ⇒ page 109 .
nform
mer
Checking non-return valve of right pump ⇒ page 111
atio
om
n
c
Checking non-return valve of left pump ⇒ page 113
i
or
n thi
te
sd
iva
o
pr
c
um
r
fo
equipment required
en
ng
t.
yi Co
op py
♦ Diesel extractor -VAS t. C rig
gh ht
5226- yri
p by
co Vo
by lksw
cted
♦ Pressure gauge -V.A.G
agen
Prote AG.
1318-
♦ Remote control for V.A.G
1348 -V.A.G 1348/3 A-
♦ Multimeter -V.A.G 1715- or
hand-held multimeter -
V.A.G 1526D- with pickup
clamp -V.A.G 1526B/2-
5024 A-
♦ Current flow diagram
♦ Measuring container

Touareg 2003 ➤
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
olkswagen AG
en AG. V
• Fuses -13- and -14- -arrow- must be removed
olks from their sock‐
wag does
not
ets. d byV gu
ara
e nte
ris
• Battery voltage at least 11.5 V autho eo
ra
ss c
• Fuel pump relays -1- for right fuel delivery unit and -2- for left
ce
le
un
fuel delivery unit must be removed from their sockets.
pt
an
d
itte
y li
Test procedure
rm
ab
pe
ility
ot
wit
, is n
h re
– Remove filler cap from fuel tank filler neck.
hole
spec
es, in part or in w
– First, reduce the fuel pressure as follows:
t to the co
WARNING rrectness of i
l purpos

nform
mercia
a
com
tion in
r
– Wrap a cloth around the joint to catch fuel which flows out and
te o
thi
disconnect fuel supply line -arrow-.

s
iva
do
r
rp
cum
Once the fuel pressure has been reduced:

fo
en
ng
t.
yi
– Retighten threaded connection.
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
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.
– Connect positive terminal of remote control to positive pole in
engine compartment.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Disconnect fuel supply hose -1- from fuel rail.
wit
, is n
h re
– Hold hose in measuring container -2- with minimum capacity
hole
spec
of 1000 cm3.
es, in part or in w
t to the co
– Empty measuring container before making measurement.
– Operate remote control for 15 seconds. At least 800 cm3 fuel
rrectness of i
per 15 seconds must be delivered.
l purpos
nform
mercia
at
om
ion
c
1.11.2 Checking delivery quantity of left pump

in t
or
his
ate
do
riv
– Connect remote control -V.A.G 1348/3 A- with adapter cable

p
cum
- Phaeton -V.A.G 1348/3-3- to connection -arrow- of fuel pump

for
en
g
relay for left fuel delivery unit.

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
– Operate remote control 15 seconds again. At least 800 cm3 by c lksw
cted agen
Prote
fuel per 15 seconds must be delivered.
AG.
– In addition, check both fuel delivery units.

– To do so, connect adapter cable - Phaeton -V.A.G 1348/3-3-
to connections of relays for left and right fuel delivery units.
– Operate remote control 10 seconds. At least 800 cm3 fuel per
10 seconds must be delivered.
If the minimum delivery rate is not attained during one of the tests:
– Check fuel lines for possible restrictions (kinks) or blockages.
If fuel lines are ok:
– Renew fuel filter.
If delivery rate has been attained, but nevertheless you suspect
a fuel supply system fault (e.g. intermittent failure of fuel supply
system):
– Check current draw of fuel pumps ⇒ page 109 .
1.11.3 Checking current draw of pumps

– Check current draw of each fuel pump separately as follows:
– Reconnect all disconnected fuel lines.

Touareg 2003 ➤
– 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,
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
– 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.
– Start engine and run at idling speed.

– Measure current draw of fuel pump. Specification: max. 11
amps.
If current draw is exceeded:
– Right fuel pump is defective. Renew fuel delivery unit
⇒ page 102 .
– Repeat test on left fuel delivery unit.
If current draw is exceeded:
WARNING
– Left fuel pump is defective. Renew fuel delivery unit.
Note
If the fuel system malfunction is intermittent, you can perform the

check during a road test, but a 2nd person is necessary.en AG. Volkswagen AG
ag does
ksw not
y Vol gu
b ara
ed
1.12 Checking non-return valve of right pump ris nte
tho eo
au ra
c
ss
Test prerequisites
ce
le
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• Fuel pump relays -1- for right fuel delivery unit and -2- for left
d
itte
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fuel delivery unit must be removed from their sockets.

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ility
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Prote AG. 1. Parts of fuel supply system
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Touareg 2003 ➤ Volksw not
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8-cylinder injection engine - Edition 11.2011 rise
d b ara
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– Now unscrew locking ring from flange (fuel filter) using
ss wrench c
-T10202- .
ce
le
un
pt
an
d
itte
– Carefully lever flange and raise it slightly.
y li
erm
ab
– Disconnect connectors next to fuel filter.
ility
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wit
is n
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ole,
spec
t to the co
rrectnes
– Then detach fuel supply hose -2- leading from right fuel deliv‐
s o
ery unit from fuel filter -1-.
cial p
f inform
– Allow fuel from connection -1- to flow back into fuel tank.
mer
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om
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– Close pressure gauge shut-off tap (lever at right angles to di‐

rection 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 1318/17- as shown.
Note
Ensure that fuel supply line connection engages audibly when

joined.

Touareg 2003 ➤
– 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. 4 bar has built up.
– Watch pressure drop on pressure gauge. After 10 minutes,
pressure must not drop below 3.0 bar.
If pressure drops:
– Right fuel pump is defective. Renew right fuel delivery unit
⇒ page 102 .
To convert the pressure tester for the left fuel pump:
– Open lever of pressure tester and let fuel flow back to fuel tank
through hose -V.A.G 1318/13- . en AG. V
olkswagen AG
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1.13 Checking non-return valve of left pump
Test prerequisites
rrectness of i
• Remote control -V.A.G 1348/3 A- is still connected.
l purpos
Note
nform
mercia
At the same time, this test checks for leaks in the fuel supply line
at
om
io
connections from the fuel delivery units to the point at which the
n
c
in t
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pressure tester -V.A.G 1318- is connected.

o
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ate
do
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– Then detach fuel supply hose -2- leading from left fuel delivery
um
for
en
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unit from fuel filter -1-.

n
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Prote AG.

AG. Volkswagen AG d
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Touareg 2003 ➤ horis
eo
ut
ss a - Edition 11.2011 ra
c
ce
le
un
pt
– Close pressure gauge shut-off tap -arrow- (lever at right an‐
an
d
itte
gles to direction of flow).
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f in
– Connect pressure tester -V.A.G 1318- with adapter -
form
mer
V.A.G 1318/7- , adapter -V.A.G 1318/13- and adapter -
atio
V.A.G 1318/24- as shown.
om
n
c
i
or
n thi
te
sd
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Note
iv
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pr
cum
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fo
en
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Ensure that fuel supply line connection engages audibly when

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joined. C py
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cted agen
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– Connect remote control -V.A.G 1348/3 A- with adapter -

V.A.G 1348/3-3- to connection -arrow- of fuel pump relay for
left fuel delivery unit.
– Operate remote control at short intervals until a pressure of
approx. 4 bar has built up.
– Watch pressure drop on pressure gauge. After 10 minutes,
pressure must not drop below 3.0 bar.
If pressure drops:
– Left fuel pump is defective. Renew left fuel delivery unit
⇒ page 102 .
– Open lever of pressure tester and let fuel flow back to fuel tank
through hose -V.A.G 1318/13- .
– Remove pressure tester -V.A.G 1318- with adapters.

n AG. Volkswagen AG do Touareg 2003 ➤
wage es n
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olks ot g 8-cylinder injection engine - Edition 11.2011
d b ua
ran
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2 ss
a
Electronic power control (EPC) ac
ce
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un
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an
d
itte
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1 - Bearing bracket
rm
ab
pe
ility
❑ Removing and instal‐
ot
wit
ling: ⇒ Brake systems;
, is n
h re
Rep. gr. 46 ; Assembly
hole
overview - brake pedal
spec
es, in part or in w
(LHD) .
t to the co
2 - Connector
❑ Black, 6-pin.
rrectness of i
3 - 10 Nm
l purpos
4 - Accelerator position sender

-G79- and accelerator position
nform
ercia
sender 2 -G185-
m
❑ Not adjustable.
a
com
tion in
❑ Remove footwell cover
r
te o
to remove sender.
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Function of EPC system

The position of the accelerator is transmitted to the engine control
unit by two accelerator position senders (variable resistors to‐
gether in one housing) connected to the accelerator.
The position of the accelerator (driver's requirement) is a main
input value for the engine control unit.
The throttle valve is operated over the complete engine speed
and load range by an electric motor (throttle valve positioner) in
the throttle valve module.
The throttle valve is operated by the throttle valve positioner which
is controlled by the engine control unit.
When the engine is not running and the ignition is switched on,
the engine control unit moves the throttle valve exactly as pre‐
scribed by the accelerator position sender. That is, when the
accelerator is depressed halfway, the throttle valve positioner
opens the throttle valve by the same amount. The throttle is then
approximately half open.
2. Electronic power control (EPC) 115

AG. Volkswagen AG d
agen oes
olksw not
Touareg 2003 ➤ d byV gu
ara
e
8-cylinder injection engine - Edition 11.2011 horis nte
eo
aut ra
ss c
When the engine is running (under load), the engine control unit
ce
le
un
can open or close the throttle valve independently of the accel‐
pt
an
d
erator position sender.
itte
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rm
ab
pe
This means that the throttle valve can already be completely open
ility
ot
even though the accelerator is only depressed half way. This has
wit
, is n
the advantage of preventing throttling losses at the throttle valve.
h re
hole
spec
This also results in significantly improved consumption and ex‐
es, in part or in w
haust emission values under certain load conditions.
t to the co
The torque required by the engine can be produced by the engine
control unit by optimising the combination of throttle valve cross-
rrectness of i
section and charge pressure.
l purpos
After evaluating the torque requirements of various components
(e.g. air conditioning system, automatic gearbox, ABS/ESP and
so on), the engine control unit calculates the optimal throttle valve
nform
ercia
opening angle for the respective situation. m
a
com
t
Observe safety precautions.
ion in
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Observe rules for cleanliness.
thi
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rig ht
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by lksw
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Prote AG.

Touareg 2003 ➤
3 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.
Fuel vapours pass from the highest point in the tank (on filler neck)
through the expansion tank and into the activated charcoal filter.
The activated charcoal stores these vapours like a sponge.
When the car is being driven and the Lambda control is active
(engine warm), the activated charcoal filter solenoid valve 1 -N80-
is activated (pulsed) by the engine control unit depending upon
load and engine speed. The opening period depends on the input
signals.
During the purging procedure (regeneration of activated char‐
coal), the intake manifold vacuum draws fresh air through the vent
of the activated charcoal filter. The fuel vapours stored in the ac‐
tivated charcoal and fresh air are fed to combustion in metered
quantities.
The activated charcoal filter solenoid valve 1 -N80- is closed when
it is not supplied with current (e.g. open circuit). The activated
charcoal filter will not be purged.
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gen AG does
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♦ Hose connections aut are secured with either spring-type or
h eo
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ss c
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nl
pt
♦ Spring-type clip pliers -VAS 6340- or spring-type clip pliers -

du
an
itte
VAS 5024 A- are recommended for installation of spring-type

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clips.
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es, in part or in w
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Assembly overview - activated charcoal filter system

⇒ page 118 .
rrectness of i
Function of pressure retention valve ⇒ page 118

l purpos
Checking fuel system for leaks ⇒ page 118 .

nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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Prote AG.
3. Activated charcoal filter system 117

Touareg 2003 ➤ lkswage es n
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8-cylinder injection engine - Edition 11.2011 byV ua
d ran
ir se tee
tho
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3.1 Assembly overview - activated charcoal filter system ss
a ac
ce
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nl
pt
du
an
itte
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1 - Expansion tank
erm
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ility
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2 - Gravity valve
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3 - To gravity valve
hole
spec
4 - Pressure retention valve
es, in part or in w
t to the co
❑ Function ⇒ page 118 .
5 - 9 Nm
rrectness of i
6 - Connecting hose l purpos
7 - Air filter
❑ Clean if soiled.
nform
ercia
8 - Connector
m
at
om
i
❑ For breather line.
on
c
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9 - Activated charcoal filter
his
ate
do
riv
10 - 9 Nm
p
cum
for
en
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11 - Connector
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13 - Rubber bracket
AG.
14 - To connection
❑ On intake manifold
15 - Breather line
Function of pressure retention valve

From gravity valve (on expansion tank) the pressure retention
valve is open in both directions of flow. -Arrow 1- is the side to
expansion tank.
On the other side it is only open for flow in one direction.
-Arrow 2- is the side to activated charcoal filter.
3.2 Checking fuel system for leaks


Touareg 2003 ➤
♦ Hose clips up to 25 mm Ø -3094-
♦ Tester -V.A.G 1371-
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Procedure: s aut ra
c
s
– Remove rear right wheel and wheel housing liner.
ce
e
nl
pt
du
an
itte
– Clamp off hose -arrow- between activated charcoal filter and
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erm
ab
air filter using a hose clamp -3094- .
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
or
– Disconnect breather line -arrow- to solenoid valve in engine
m
m
atio
compartment.
om
n in
or c
thi
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Prote AG.

Touareg 2003 ➤
– 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.
If no pressure builds up or the pressure is not held for at least 5
minutes, localise leak as follows:
– Perform visual check on all components and hoses of the fuel
system.
Note
Also check fuel tank cap for leaks.
Only if still no fault has been detected:
– Check breather line and activated charcoal filter for leaks. To

do this, disconnect breather line -A- from activated charcoal
filter and seal connection with a plug -B-.
– Repeat pressure test.
If pressure still drops, the leakage can be
agen
AGfound
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agethe
n AGactivated
does
charcoal filter or breather line: Volksw not
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ility
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– When valve is open -A-, check the following lines and compo‐
wit
is n
nents for leaks by hearing, touching, with commercially avail‐

h re
ole,
able leak detector spray or using ultrasonic tester -V.A.G

spec
1842- .
t to the co
♦ Line from engine compartment to activated charcoal filter.

♦ Activated charcoal filter
rrectne
If the pressure does not drop again, the leakage can be found on
fuel tank:
ss o
cial p
f inform
mer
atio
om
n
c
– To do this, reconnect breather line -A- to activated charcoal

i
or
n thi
filter.
te
sd
iva
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pr
cum
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fo
en
ng
t.
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Cop py
t. rig
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by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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aut
h
ra Touareg 2003 ➤
s c
s 8-cylinder injection engine - Edition 11.2011
ce
e
nl
pt
du
an
– With valve -A- is open, check fuel tank for leaks by hearing,
itte
y li
erm
touching, with commercially available leak detector spray or
ab
ility
ultrasonic tester -V.A.G 1842- .
ot p
wit
, is n
h re
hole
Caution
spec
es, in part or in w
t to the co
After completing work check tyre pressure!
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
4 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;
the quantity depends upon the air pressure and ambient temper‐
ature.
The activated charcoal filter system prevents these HC emissions
escaping to the atmosphere.
Fuel vapours pass from the highest point in the tank (on filler neck)
through the expansion tank and into the activated charcoal filter.
The activated charcoal stores these vapours like a sponge.
When the vehicle is being operated and the Lambda control is
active (engine warm), the activated charcoal filter system sole‐
noid valve 1 -N80- is activated (pulsed) by the engine control unit
-J623- depending on load and engine speed. The opening period
depends on the input signals.
During the purging procedure (regeneration of activated char‐
coal), the intake manifold vacuum draws fresh air through the vent
of the activated charcoal filter. The fuel vapours stored in the ac‐
tivated charcoal and fresh air are fed to combustion in metered
quantities.
The activated charcoal filter solenoid wagvalve
en AG. 1 -N80- is closed
Volkswagen AG
does when
s
it is not supplied with currenty(e.g.
Volk open circuit). The activatednot
gu
charcoal filter will not beripurged.
se
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tho or
Description of leakage
s a diagnosis
u ac
s
ce
e
The activated charcoal filter system, including fuel tank, is equip‐

nl
pt
du
ped with leakage diagnosis which can detect if there is a leak in

an
itte
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the system.
erm
ab
ility
ot p
The diagnosis is based on a pressure method and indicates leaks

wit
, is n
with a diameter greater than 0.5 mm.

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hole
spec
During the diagnosis, the fuel system diagnostic pump -V144-

es, in part or in w
builds up pressure in the activated charcoal system. For this, the

t to the co
activated charcoal filter solenoid valve 2 -N115- is closed. Once

the pressure is attained, the pump switches off. If the pressure
drops below a certain value, the pump switches on again. Self-
rrectness of i
diagnosis monitors the intervals at which the pump is switched on

or off and if the intervals are too short, writes a fault to the fault
l purpos
memory.
nf
ercia
orm
m
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om
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Touareg 2003 ➤
AG. Volkswagen AG d
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Note orise nte
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h
aut ra
s c
♦ Hose connections are secured with either spring-type or s
ce
le
clamp-type clips.
un
pt
an
d
itte
y li
♦ Use spring-type clip pliers -VAS 6340- for installation of spring-
erm
ab
type clips
ility
ot p
wit
is n
♦ or space-saving hose clip pliers -VAS 6362- .
h re
ole,
spec
t to the co
rrectne
4.1 Assembly overview - activated charcoal filter system
ss o
1 - Expansion tank
cial p
f inform
❑ Right side.
mer
atio
2 - Gravity valve
om
n
c
i
or
n
3 - Fuel filler neck
thi
te
sd
va
4 - 5 Nm
i
o
pr
cum
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fo
en
ng
5 - Bracket
t.
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op py
6 - Vacuum line
t. C rig
gh ht
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❑ For vacuum supply of
op Vo
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fuel system diagnostic
cted agen
Prote AG.
pump -V144-
❑ To vacuum connection
on intake manifold
ing.
7 - Fuel system diagnostic
pump -V144-
❑ Checking fuel system
for leaks ⇒ page 124 .
❑ Black connector, 3-pin
8 - Connecting hose
❑ Between air filter, fuel
system diagnostic pump
-V144- and activated
charcoal filter solenoid
valve 2 -N115-
ing.
9 - 5 Nm
10 - Air filter
❑ Clean if soiled.
11 - Rubber bush
12 - Activated charcoal filter solenoid valve 2 -N115-
❑ Black connector, 2-pin
❑ Location: in rear right wheel housing.
4. Activated charcoal filter system (vehicles for USA and Canada) 123
Touareg 2003 ➤
14 - Securing bolts
❑ Qty. 3
❑ 9 Nm
15 - Breather line
❑ To vacuum connection on intake manifold
16 - Connector
❑ Black, 2-pin.
17 - Activated charcoal filter solenoid valve 1 -N80-
18 - Rubber bracket
19 - Breather line
❑ Function ⇒ page 124 .
Function of pressure retention valve

From gravity valve (on expansion tank) the pressure retention
valve is open in both directions of flow. -Arrow 1- is the side to
expansion tank.
On the other side it is only open for flow in one direction. ksw
age es n
-Arrow 2- is the side to activated charcoal filter. y Vol ot g
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4.2 Checking fuel system for leaks

h re
ole,
spec

t to the co
♦ Fuel system tester (so-called smoke tester) -KLI 9210-

♦ Adapter hose -KLI 9210/55-2-
rrectne
♦ Vehicle diagnosis tester -VAS 5051B- , -VAS 5052- or -VAS

5053-
ss o
♦ Hose clamps up to 25 mm -3094-

cial p
f inform
Test prerequisite:
mer
atio
m
• A leak has been detected by the fuel system diagnostic pump

o
n
c
-V144- .
i
or
n thi
te
sd
a
• Guided fault finding has been performed with the vehicle di‐
iv
o
pr
agnosis tester .
um
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fo
en
ng
t.
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Preparation of fuel system tester -KLI 9210- :
Co
Cop py
t. rig
gh ht
pyri by
Vo
co
Note
by lksw
cted agen
Prote AG.
The fuel system tester -KLI 9210- may differ in appearance de‐
pending on the version.

Touareg 2003 ➤
– 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-.
AG. Volkswagen AG d
– Set valve -D- to „Test“. agen oes
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– Regulate pressure to 25 mbar oris (10 in. H2O) with pressure re‐
e nte
ducer -J-. aut
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– Set valve -D- to „Hold“.
ce
le
un
pt
an
d
– Now pressure must be maintained for at least 2 minutes.

itte
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Check tester if pressure is not maintained.
rm
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ility
ot
Checking fuel system for leaks:
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Pull off rear engine cover -arrows-.
nform
mercia
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com
tion in
r
te o
thi
s
iva
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cum
fo
en
ng
t.
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– In engine compartment, disconnect breather line -arrow- to
activated charcoal filter solenoid valve 1 -N80- .
– Connect adapter hose -KLI 9210/55-2- between activated

charcoal filter solenoid valve 1 -N80- and breather line -A- as
shown in illustration.
– Connect measuring hose -G- from fuel system tester -KLI
9210- to adapter hose -KLI 9210/55-2- .
– Connect fuel system tester -KLI 9210- to vehicle battery.
4. Activated charcoal filter system (vehicles for USA and Canada) 125
Touareg 2003 ➤
– Connect vehicle system tester to vehicle.

– On vehicle system tester, select operating mode OBD .
– Now select diagnostic mode 8 „Tank leak test“.
– Select entry „Tank leak test“ and press right arrow button ► to
initiate test.
Note
♦ Once the diagnostic mode 8 „Tank leak test“ has been acti‐
vated, the leak diagnostic pump and the activated charcoal
filter solenoid valve 2 -N115- are closed for max. 1,000 sec‐ G. Volkswagen AG d
onds. The activated charcoal filter solenoid valve 1 -N80- lkisswagen A oes
not
not activated. Now the entire system is closed. by Vo gu
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ise
♦ If the engine control unit cancels the test, it is possible
ut
ho
r
to ini‐ tee
or
tiate it again by switching off and restarting the
ss engine.
a ac
ce
e
nl
pt
du
an
itte
– Set valve -D- to „Test“. The fuel system will now be filled with
y li
erm
ab
nitrogen.
ility
ot p
wit
– Observe pressure gauge -C- and flow meter -E-. When the
, is n
h re
throughput quantity decreases and the pressure increases to
hole
25 mbar (10 in. H2O), the fuel system is filled.
spec
es, in part or in w
t to the co
Note
rrectness of i
Depending on the filling level of the fuel tank, this process can
take up to 3 minutes.
l purpos
– Once pressure has stabilised, set valve -D- to „Hold“.
nf
ercia
orm
• After 5 minutes the pressure must not drop below 20 mbar
m
atio
m
(8 in. H2O).
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If pressure does not drop, exit from diagnostic mode 8 and check
thi
te
sd
a
if fuel system diagnostic pump -V144- can build up pressure

iv
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⇒ page 129 .
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If no pressure builds up or the pressure is not held for at least 5
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minutes, localise leak as follows: t. C rig
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Leave engine running at idling speed for at least 8 minutes with
co Vo
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activated diagnostic mode 8.
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– First check activated charcoal filter solenoid valve 1 -N80- for

leaks. To do this, clamp off hose to activated charcoal filter
solenoid valve 1 -N80- using a hose clip -arrow-. Also refer to
⇒ Item A (page 128) .

Touareg 2003 ➤
– 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. H2O), the fuel system is filled.
– Once pressure has stabilised, set valve -D- to „Hold“.
– If the pressure does not drop again, renew activated charcoal
filter solenoid valve 1 -N80- .
If pressure still drops:
– Set valve -D- again to „Test“.
– While fuel system is being filled, press button -I- for smoke
generator for approx. one minute.
The fuel system is now pressurised and filled with smoke.
– Check whether smoke escapes from any visible fuel system
line or hose. Also check fuel tank cap.
Note
♦ Light up the components and hoses with a strong floodlight. In

the floodlight, smoke is more visible.
♦ For leak detection in accessible areas, also use ultrasonic de‐
tector or commercially available leak detecting spray.
♦ Depending on how long the fault finding takes, it may be nec‐
essary to press the smoke generator button from time to time.
This ensures that sufficient smoke is present in the fuel sys‐
tem.
If no fault is found:
– Remove rear right wheel housing liner.
If smoke escapes from air filter ⇒AItem
G. Vol7
ks(page
wagen 128) :
n AG do
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– Clamp off hose between d by
activated charcoal filter solenoid
ua
ran
ir se
valve 2 -N115- tho and air filter -arrow-. Also refer to tee
or
⇒ Item B (page
au 128) . ac
ss
ce
le
– Observe air filter. If smoke no longer escapes, activated char‐

un
pt
coal filter solenoid valve 2 -N115- is leaking. Renew activated

an
d
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charcoal filter system solenoid valve 2 -N115- .

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127
cted agen
Prote AG.
4. Activated charcoal filter system (vehicles for USA and Canada)
Touareg 2003 ➤
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. Renew fuel
system diagnostic pump -V144- .
If no smoke escapes from air filter ⇒ Item 7 (page 128) :
– Check whether smoke escapes from any fuel system compo‐
nent or hose.
To inspect flanges for fuel pump and fuel filter, open assembly
openings in vehicle interior.
– Renew leaking hoses or components.
After completing work, perform guided function „checking fuel
tank breather system for leaks“ using ⇒ Vehicle diagnostic tester.
4.2.1 Overview of activated charcoal filter system

2 - Location of adapter hose -
KLI 9210/55-2-
❑ For leak detection in fuel
system
3 - Activated charcoal filter sol‐
enoid valve 1 -N80-
4 - Breather line
❑ To intake manifold.
5 - Solenoid valve n AG. Volkswagen AG do
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❑ For fuel system diag‐ byV ua
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nostic pump -V144- ir se tee
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6 - Vacuum line ss
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❑ To intake manifold.
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7 - Air filter
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❑ For fuel system diag‐

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nostic pump -V144-

is n
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8 - Fuel system diagnostic

spec
pump -V144-
t to the co
9 - Fuel tank
10 - Cap
rrectne

solenoid valve 2 -N115-
ss o
cial p

inform
mer
A - Clamp off in this area

atio
m
❑ For leak detection in fuel

o
n
c
system
i
or
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❑ For checking activated

iva
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charcoal filter solenoid

p
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fo
valve 1 -N80- .
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B - Clamp off in this area
C py
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❑ For leak detection in fuel system p by
co Vo
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cted
❑ For checking activated charcoal filter solenoid valve 2 -N115- .
agen
Prote AG.

Touareg 2003 ➤
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:
• Fuel system tester -KLI 9210- is connected to vehicle via
adapter hose -KLI 9210/55-2- .
• Valve -D- is set to „Hold“.
• Diagnostic mode 8 is completed and engine is running at idling
speed.
Fuel system must not be under pressure for test. Proceed as fol‐
lows to reduce residual pressure:
– Briefly open quick-release coupling -arrow- for adapter hose -

KLI 9210/55-2- to release pressure in fuel system. Pressure
gauge -D- must drop to 0 in. H2O.
– On vehicle system tester, select operating mode Guided
AG. Volkswagen AG d
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– Select guided function „Checking otank
ris ventilation system for
e nte
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leaks“. au
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– Initiate test.
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– Observe pressure gauge while test is running.

itte
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– Fuel system diagnostic pump -V144- must pump up pressure

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in fuel system at least to 18 mbar (7 in. H2O).

wit
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– If pressure is not reached, check vacuum supply of fuel system

hole
spec
diagnostic pump -V144- ⇒ page 129 .

es, in part or in w
t to the co
– If fuel system is free of leaks and vacuum supply of fuel system

diagnostic pump -V144- is OK, renew fuel system diagnostic
pump -V144- .
rrectness of i
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4.2.3 Checking vacuum supply of fuel system

diagnostic pump -V144-
nf
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or

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129
agen
Prote AG.
4. Activated charcoal filter system (vehicles for USA and Canada)
Touareg 2003 ➤
♦ Turbocharger tester -V.A.G 1397A-
♦ T piece -251 201 346-

♦ Hose ∅ 6 mm
AG. Volkswagen AG d
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Fitting location of fuel system diagnosis pump -V144- : in rear right
orise nte
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wheel housing under wheel housing liner. s aut
h
ra
c
s
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nl
– Remove rear right wheel and wheel housing liner.
pt
du
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itte
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– Remove securing bolts ⇒ Item 14 (page 123) of activated
erm
ab
charcoal filter and lower filter to have better access to vacuum
ility
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line.
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hole
spec
Caution
es, in part or in w
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Support activated charcoal filter to prevent its hanging down
from hoses and lines. This prevents damages.
rrectness of i
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– Disconnect vacuum line -1- from fuel system diagnostic pump

-V144- .
nf
ercia
o
– Connect turbocharger tester -V.A.G 1397A- with T-piece and
rm
hose ∅ 6mm, between vacuum line -1- and fuel system diag‐
m
atio
m
nostic pump -V144- -2-.

o
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thi
– Switch on measuring range I (absolute pressure measure‐
te
sd
iva
ment).
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– Connect vehicle diagnosis tester and start engine.

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t.
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– On vehicle diagnosis tester, select operating mode Guided
. C rig
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functions . py by
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– Select guided function „Checking tank ventilation system for Prote AG.
leaks“.
– Observe display on turbocharger tester -V.A.G 1397A- while
test is running.
• Pressure must pulsate and must not exceed 0.700 bar during
test.
– If pressure exceeds 0.7 bar during test, vacuum supply is too
low. Check vacuum line to intake manifold for possible kinks
or blockages.

AG. Volkswagen AG d
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olksw not
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horis nte
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aut 8-cylinder
ra injection engine - Edition 11.2011
ss c
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nl
pt
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24 – itte
Mixture preparation - injection
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ility
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1 Repairing injection system
h re
hole
spec
General notes on injection
es, in part or in w
t to the co
♦ Fuel hoses in engine compartment must be secured only with
spring-type clips. The use of clamp or screw-type clips is not
permissible.
rrectness of i
♦ For trouble-free operation of electrical components, a voltage
l purpos
of at least 11.5 V is necessary.

Safety precautions ⇒ page 137 .
nform
ercia
Rules for cleanliness ⇒ page 137 .

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io
Technical data ⇒ page 137 .
n
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Assembly overview - intake manifold ⇒ page 132 .

at
do
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Assembly overview - fuel rail ⇒ page 133
for
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Assembly overview - air filter ⇒ page 133 . . Cop py
rig
ht ht
rig
Assembly overview - vacuum hose assembly on intake manifold py by
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⇒ page 136 .
by c lksw
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Prote AG.
1. Repairing injection system 131

Touareg 2003 ➤
1.1 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.
7 - Throttle valve module -
J338-
❑ Gold-plated connector
contacts
❑ If renewed, adapt en‐
gine control unit to throt‐
tle valve module ⇒ Ve‐
hicle diagnostic tester; ;
„Guided functions“ .
8 - 10 Nm
9 - Crankcase breather valve
10 - Connecting hose
11 - Connecting pipe
12 - 10 Nm
AG. Volkswagen AG d
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13 - 10 Nm olksw not
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14 - Clip horis nte
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15 - Connection ss c
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nl
pt
du
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tion.
itte
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ab
16 - Dowel cone
ility
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❑ Fit gasket before instal‐
, is n
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lation.
hole
17 - Dowel pin, 3 Nm spec

es, in part or in w
t to the co
18 - 10 Nm
❑ To secure intake manifold.
rrectness of i
❑ 7 securing bolts on each side

l purpos
nf
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orm
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Cop py
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rig ht
py by
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by lksw
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Prote AG.
132 Rep. gr.24 - Mixture preparation - injection

Touareg 2003 ➤
lkswage es n
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1.2 Assembly overview - fuel rail ir se
d byV ua
ran
tee
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ss
1 - Threaded connection, 22
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nl
Nm
pt
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itte
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❑ Counterhold when tight‐
erm
ab
ening.
ility
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wit
❑ For fuel supply.
, is n
h re
hole
2 - Fuel supply hose
spec
es, in part or in w
t to the co
ing.
❑ Secure with spring-type
clip.
rrectness of i
3 - 10 Nm
l purpos
4 - Ball stud, 3 Nm
nform
ercia
❑ For engine cover

m
5 - Fuel rail
at
om
ion
❑ With retaining tabs for
c
in t
or
knock sensor connec‐
his
ate
tors.
do
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cum
or
6 - Seal
f
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ng
t.
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❑ Renew. Cop py
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❑ Before installing, mois‐
ht
pyri by
Vo
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ten lightly with clean en‐
c by lksw
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gine oil. Prote AG.
7 - Valve 2 for variable intake

manifold changeover. -N261-
8 - Vacuum actuator
❑ For intake manifold
change-over.
❑ Black side of valve faces
intake manifold connec‐
tion
10 - Variable intake manifold changeover valve -N156-
11 - Injector (N30...N33, N83...N86)
13 - Retaining clip
1.3 Assembly overview - air filter

Separating connecting line to air suspension compressor
⇒ page 135 .

Touareg 2003 ➤
1 - Intake hose
3 - Intake hose
4 - 6 Nm
5 - Air mass meter -G70- with
intake air temperature sender -
G42-
6 - Seal
7 - Air filter upper part
❑ On the right side with
connection to secon‐
dary air pump motor -
V101- .
8 - Filter element
9 - To secondary air pump mo‐
tor -V101-
10 - Air duct
❑ Secured to lock carrier.
11 - Rubber bush
❑ Clipped to longitudinal
member.
12 - Air filter lower part
❑ To remove lower part of
air filter on right, right
engine cover retainer n AG. Volkswagen AG do
must be removed olkswage es n
ot g
⇒ page 134 . d byV ua
ran
ir se tee
13 - 10 Nm utho
or
a ac
ss
14 - Connection from air sus‐
ce
le
un
pension compressor
pt
an
d
itte
y li
❑ Removing ⇒ page 135

rm
ab
pe
ility
ot
wit
, is n
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Removing bracket for right engine cover

hole
spec
– Press in lug -1- from below and pull bracket out in

es, in part or in w
t to the co
-direction of arrow-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
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s
iva
do
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fo
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
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.
Then press clamping ring -2- in direction of -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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aut ra
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nl
pt
du
an
itte
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erm
ab
ility
– Now pull loosened line -B- off connection -A- on air filter.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
AG. Volkswagen AG d
agen
1.4 Assembly
by
Vooverview
lksw - vacuumoehose
s no
t gu assembly on intake manifold
ara
ed nte
oris e
th or
1 - Combination au
ss valve
ac
❑ For injection of secon‐
ce
e
nl
pt
du
dary air
an
itte
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erm
ab
2 - To secondary air pump mo‐
ility
ot p
tor -V101-
wit
, is n
h re
3 - Connecting hose
hole
spec
❑ Route without tension.
es, in part or in w
t to the co
4 - Vacuum connection
❑ For combination valve.
rrectness of i
5 - Secondary air inlet valve -
N112-
l purpos
❑ Secured to fuel rail.
nform
ercia
6 - Bracket
❑ Secured to fuel rail.
m
at
om
ion
c
in t
or
his
te
8 - To vacuum reservoir
a
do
priv
c
❑ ⇒ Item 10 (page 156)
um
for
en
ng
t.
yi
9 - Valve 2 for variable intake
Co
Cop py
manifold changeover. -N261-
t. rig
gh ht
pyri by
Vo
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10 - Non-return valve by c lksw
cted agen
Prote AG.
❑ Black side of valve faces
intake manifold connec‐
tion
11 - Vacuum actuator
❑ For intake manifold
change-over.
changeover valve -N156-
13 - Vacuum actuator
❑ For intake manifold change-over.
14 - To cylinder block.
❑ ⇒ Item 3 (page 17)
15 - Crankcase breather valve

Touareg 2003 ➤
1.5 Safety precautions

♦ For safety reasons, fuse nos. -13-waand gen A-14-
G. Vo-arrows- must
lkswagen AG
does be
removed from the fuse holder olks
before opening the fuel system.
not
y V gu
Otherwise, the fuel pump risecould be activated by the driver's
d b ara
nte
door contact switch. utho eo
r
sa ac
♦ Fuse nos. 13 and 14
s
are located in the E-box fuse holder in
ce
e
nl
the left plenum chamber.
pt
du
an
itte
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erm
ab
WARNING
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
To prevent injuries to persons and/or damage to the injection and
ignition system, the following must be observed:
l purpos
♦ Do not touch or disconnect ignition cables when the engine is

running or being turned at starter speed.
nf
ercia
orm
♦ Switch off ignition before connecting or disconnecting injection
m
atio
m
and ignition system wiring as well as test instrument cables.

o
n in
or c
Note the following if testers and measuring instruments have to
thi
te
sd
a
be used during a road test:

iv
o
r
rp
cu
o
m
♦ Test and measuring instruments must always be secured to
f
en
ng
t.
rear seat and operated by a second person from this location.
yi Co
Cop py
t. rig
If test and measuring instruments are operated from front pas‐
gh ht
pyri by
senger seat and the vehicle is involved in an accident, there is a
co Vo
by lksw
cted
possibility that the person sitting in this seat may receive serious
agen
Prote AG.
injuries when the airbag is triggered.
♦ If the engine is to be turned at starter speed without starting:
– Pull connectors off ignition coils with output stage (cylinders
1…8).
1.6 Rules for cleanliness

When working on the fuel supply and injection system, pay careful
attention to the following „5 rules“ for cleanliness:
♦ 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.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
♦ When system is open: do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely nec‐
essary.
1.7 Technical data

Engine codes AXQ BHX
Idling check
Idling speed3) rpm 670...730 670...730

Touareg 2003 ➤
Engine codes AXQ BHX

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 rpm from approx. 6500 from approx. 6500
3) Not adjustable.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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aut ra
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nl
pt
du
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erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
2 Checking components
Checking injectors ⇒ page 139 .
Checking fuel pressure regulator and holding pressure
⇒ page 142 .
2.1 Checking injectors

Checking injectors for leaks and quantity injected ⇒ page 139

equipment required
♦ Remote control for V.A.G
1348 -V.A.G 1348/3A- with
adapter cable - Phaeton -
V.A.G 1348/3-3- .
♦ Injection rate tester -V.A.G
1602-
♦ Adapter cable -V.A.G
1348/3-2-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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2.1.1 Checking injectors for leaks and quanti‐

ty injected
nform
ercia
• The fuel pressure must be in order, checking ⇒ page 142 .

m
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
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Cop py
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rig ht
py by
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by lksw
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Prote AG.
2. Checking components 139

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
Touareg 2003 ➤ aut ra
c
s
8-cylinder injection engine - Edition 11.2011 s
ce
le
un
pt
an
d
itte
Checking for leaks
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rm
ab
pe
ility
ot
WARNING
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove complete fuel rail (fuel supply line remains connec‐
l purpos
ted) ⇒ page 133 .
– Remove fuse holder cover.
nform
ercia
– Pull fuel pump relays -1- and -2- from their sockets.
m
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
– Connect remote control -V.A.G 1348/3- with adapter line -

V.A.G 1348/3-3- -arrow- to connection of fuel pump relay for
right fuel delivery unit.
– Now connect second connection of adapter cable -

V.A.G 1348/3-3- to connector connection -arrow- for fuel pump
relay for left fuel delivery unit.

Touareg 2003 ➤
– 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 moregethan 1oto
AG. V 2agen AG d
lksw
a n
drops per minute must escape from each valve Volksw when fuel
oes
not
gu
pump is running. ed
by ara
n ris tee
ho
If the fuel loss is greater: aut or
ac
ss
– Renew defective injector.
ce
e
nl
pt
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Pay attention to the following when installing the injectors:
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♦ Renew O-rings on all injectors and lightly moisten with clean
ility
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engine oil.
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♦ Insert injectors vertically and in the correct position into the fuel
hole
spec
rail and secure with retaining clips.
es, in part or in w
t to the co
♦ Fit fuel rail with secured injectors onto intake manifold and
press in evenly.
rrectness of i
Checking quantity injected
l purpos
• Fuel pump relays and fuses 13 and 14 are fitted in their sock‐
ets.
nform
ercia
– Connect test box -V.A.G 1598/31- to engine control unit.

m
at
om
i
– Bridge test box sockets 1 and 65 using adapter cable from
on
c
auxiliary measuring set -V.A.G 1594- .
in t
or
his
ate
– Insert the injector to be checked into injection rate tester meas‐
do
priv
c
uring glass -V.A.G 1602- .
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– Connect a contact of injector to be tested to engine earth using

auxiliary cables from auxiliary measuring set -V.A.G 1594- .
– Connect second injector contact to remote control -
V.A.G 1348/3- using adapter cable -V.A.G 1348/3-2- .

Touareg 2003 ➤
– 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.
– Switch off ignition.
– After all injectors have been activated, place measuring beak‐
ers on a level surface and compare the quantity injected.
Specification: 95..0.115 ml per injector
If the measured values of one or more injectors are above or be‐
low the prescribed specifications:
– Renew defective injector.
Install injectors in reverse order. In the process, note the follow‐
ing:
♦ Renew O-rings on all injectors and lightly moisten with clean
engine oil.
♦ Insert injectors vertically and in the correct position into the fuel
rail and secure with retaining clips.
♦ Fit fuel rail with secured injectors onto intake manifold and
press in evenly.
2.2 Checking fuel pressure regulator and

holding pressure
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♦ Pressure gauge -V.A.G 1318- ir se
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♦ Adapter set -V.A.G 1318/7- s au ra
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♦ Adapter set -V.A.G 1318/10-

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♦ Adapter set -V.A.G 1318/13-

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♦ Spring-type clip pliers -VAS 6340-

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Touareg 2003 ➤
Test procedure
The fuel pressure regulator maintains the fuel pressure at a con‐
stant 4.0 bar.
• Fuel pump delivery is OK.
WARNING
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– Wrap a cloth around the threaded connection -arrow- d by and
V re‐ gu
ara
lease fuel pressure by quickly opening and closingorisconnection.
e nte
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– Loosen spring-type clip and disconnect fuelsshose
a
from con‐ c
nection on fuel rail ⇒ Item 14 (page 133) .
ce
le
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– Now connect pressure tester -V.A.G 1318- using adapters -

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V.A.G 1318/7- , -V.A.G 1318/10- and -V.A.G 1318/13- as
ab
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shown in the illustration.
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– The lever on pressure tester -V.A.G 1318- -1- points in direc‐
h re
hole
tion of flow.
spec
es, in part or in w
t to the co
– Always secure both hose ends with clips -2-.
rrectness of i
l purpos
– Measure fuel pressure. Specification: approx. 4.0 bar.
nform
ercia
If the specification is not attained:

m
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– Check delivery rate of fuel pumps ⇒ page 107 .
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tion in
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– Renew fuel pressure regulator -2-, if necessary. cop Vo
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If specification is attained:
AG.

– Now check for leaks and holding pressure. Do this by observ‐
ing pressure drop on gauge. After 10 minutes, there must be
a residual pressure of at least 3.0 bar.
If the holding pressure drops below 3 bar:
– Check pressure tester for leaks.
– Check non-return valves of left and right fuel pumps
⇒ page 111 and ⇒ page 113 .
When the pressure tester is removed after the test has been
completed:

Touareg 2003 ➤
– 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 ⇒ Item 14 (page 133) .
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Touareg 2003 ➤
3 Engine control unit

Removing and installing engine control unit ⇒ page 145 .
Reading and clearing engine control unit fault memory
⇒ page 145 .
3.1 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“.
Removing
– Remove windscreen wiper motor on right side: ⇒ Electrical
system; Rep. gr. 92 ; Removing and installing windscreen
wiper system .
– Release both connectors from control unit and pull off.
– Control unit can now be removed.
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– Place control unit into retaining
orise frame. nte
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– Fit connector and lock inss aposition. c
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– Install windscreen wiper motor on right side: ⇒ Electrical sys‐
pt
du
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tem; Rep. gr. 92 ; Windscreen wiper system .
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– Install plenum chamber cover.
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– Adapt new engine control unit: ⇒ Vehicle diagnostic tester;

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„Guided functions“ .
hole
spec
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3.2 Reading and erasing engine control unit t to the co
fault memory
rrectness of i

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♦ Vehicle diagnosis, testing and information system -VAS 5051-

♦ Diagnosis cable -VAS 5051/1- or -VAS 5051/3-
nform
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ate
do
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Procedure
– Connect vehicle diagnosis, testing and information system -
VAS 5051- as follows:
3. Engine control unit 145

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Touareg 2003 ➤ wage
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– Connect connector of diagnosis cable -VAS
sa
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t
or - ra
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VAS 5051/3- to diagnostic connection. s
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Only when engine does not start:
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– Switch on ignition.
is n
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Selecting operating mode:
spec
– Press button on display for „Vehicle self-diagnosis“.
t to the co
Selecting vehicle system:
rrectne
– Press „01 - Engine electronics“ button on display.
The control unit identification with code as well as chassis number
s
and immobilizer identification number will be indicated on the dis‐
s o
cial p
play.
f inform
mer
atio
m
Note
o
n
c
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A print-out can be made if required. Tghen press the Print but‐

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– Press → button. ht. Cop py
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Select diagnostic function:
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– Press „02 - Read fault memory“ button on display.
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– If no fault is stored in engine control unit „0 fault detected“ is

displayed.
– If faults are stored in the engine control unit, these are shown
one below the other on the display.
– Press ← button.
– Press „05 - Clear fault memory“ button on display.
– Select „06-End output“ function.

Touareg 2003 ➤
26 – Exhaust system
1 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 153
Note
After working on the exhaust system, ensure that the system has
sufficient clearance to the bodywork. If necessary, loosen flange
on catalytic converter and realign silencers and exhaust pipes
⇒ page 154 .

♦ Lambda probe open ring spanner set -3337-
lkswage es n
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♦ Torque wrench -V.A.G 1332-

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es, in part or in w
t to the co
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1. Removing and installing parts of exhaust system 147

Touareg 2003 ➤
1.1 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.
4 - M8 25 Nm, M10 40 Nm
5 - Lambda probe -G39- 50 Nm
❑ Bank 1, probe 1.
❑ Installed in exhaust gas
stream of cylinders 1, 2,
3 and 4.
⇒ page 149
6 - Starter catalytic converter
❑ Installed in exhaust gas lkswage es n
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stream of cylinder bank d byV ua
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1. ir se tee
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7 - Lambda probe after catalyt‐ ss
ic converter -G130- 50 Nm
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❑ Bank 1, probe 2.
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⇒ page 149
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8 - Catalytic converter
hole
spec
9 - Mounting
es, in part or in w
❑ Installation position t to the co

⇒ page 154 .
rrectness of i
10 - 25 Nm
l purpos
11 - To centre silencer
12 - Mounting
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13 - To centre silencer
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14 - Gasket
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❑ Renew.
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15 - M8 25 Nm, M10 40 Nm
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16 - Bracket
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❑ For supporting gearbox on right.
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17 - Lambda probe 2 after catalytic converter -G131- , 50 Nm cop Vo
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❑ Bank 2, probe 2. Prote AG.

18 - Lambda probe 2 -G108- 50 Nm
❑ Bank 2, probe 1
❑ Installed in exhaust gas stream of cylinders 5, 6, 7 and 8.
148 Rep. gr.26 - Exhaust system

Touareg 2003 ➤
19 - Catalytic converter lkswage es n
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yV ua
20 - Starter catalytic converter ir se
d b ran
tee
o
❑ Installed in exhaust gas stream of cylinder bankau2.
th or
ac
ss
21 - 25 Nm
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22 - Bracket
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❑ For supporting gearbox on left.
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23 - 25 Nm
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hole
24 - Exhaust manifold
spec
es, in part or in w
t to the co
❑ Removal only possible with engine removed.
❑ Removing ⇒ page 149
rrectness of i
25 - Gasket l purpos
❑ Renew.
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Removing and installing exhaust manifold
n in
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– Oil dipstick guide tube retainer -1- must be removed to enable

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removal of cylinder bank 2 exhaust manifold.
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– Then disconnect refrigerant line -2- and seal connections with

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a clean cloth. C py
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– Now unscrew securing nuts -arrows-.
1.2 Removing and installing Lambda

probes

Touareg 2003 ➤
♦ Open ring spanner with 3/8" drive (flared spanner)
♦ Lambda probe open ring spanner set -3337-
Removing:
– Remove cover for engine and intake
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– Remove intake hoses by
Vo -1- and -2-. Loosen hose clip
ot g
for
ua crank‐
case breatherorisvalve
ed -3- and pull crankcase breather valve
ran
tee off
hose connection.
auth or
a
ss c
– Remove intake air duct to throttle valve module -J338- .
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nl
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spec
es, in part or in w
t to the co
– Disconnect connector for respective Lambda probe and lay

rrectness of i
cable to Lambda probe aside.

l purpos
1 - Lambda probe after catalytic converter -G130-

2 - Lambda probe -G39-
nf
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3 - Lambda probe 2 after catalytic converter -G131-

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4 - Lambda probe 2 -G108-

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Connector for cylinder bank 1 = black, connector for cylinder bank C py
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2 = brown
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Touareg 2003 ➤
Lambda probe 2 -G108- (bank 2, probe 1):

– Unscrew Lambda probe 2 -G108- -item 1-.
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Lambda probe -G39- (bank 1, probe 1):
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ility
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– Unscrew Lambda probe -G39- -item 2-.
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t to the co
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mer
atio
Lambda probe 2 after catalytic converter -G131- (bank 2, probe
om
2) and Lambda probe after catalytic converter -G130- (bank 1,
n
c
i
or
n
probe 2):
thi
te
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– Unscrew bolts and remove rear noise insulation tray -2-.

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Lambda probe 2 after catalytic converter -G131- (bank 2, probe

2):
– Unscrew Lambda probe 2 after catalytic converter -G131-
-item 2-.

Touareg 2003 ➤
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‐
ature paste -G 052 112 A3- . Paste may not come into contact
with slots on probe body.
– Restore wiring to original position.
Further installation is carried out in the reverse order.
Note
♦ Threads of new Lambda probes are already coated with as‐

sembly paste; the paste must not get into the slots on the probe
body.
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♦ When installing, the Lambda probe electrical wiringVmust
olks al‐
wa not
ways be reattached at the same locations to prevent
ed by the gu
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Lambda probe wiring from coming into contactthoris with the ex‐ nte
eo
haust pipe. au ra
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♦ Fit all cable ties in the original position when installing.
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Specified torques
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ility
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Component Nm
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Lambda probe in exhaust pipe 50

spec
es, in part or in w
Heat shield to final drive 9

t to the co
Air pipe to bracket 9

rrectness of i
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AG. Volkswagen AG d
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Vol not
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d ara
orise 8-cylinder injection ntengine
ee - Edition 11.2011
h
aut or
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1.3 Assembly overview - silencers with mountings
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1 - Exhaust tailpipe
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2 - Rear silencer
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❑ Centre and rear silenc‐ hole
spec
ers are installed as a
es, in part or in w
single component dur‐
t to the co
ing production. In case
of repair, the centre and
rear silencers are sup‐
rrectness of i
plied separately, with a
double repair clamp for
l purpos
connecting.
❑ In case of repair, align
nform
ercia
rear silencer free of

stress.
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tion in
3 - Mounting
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❑ Installation position
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⇒ page 154 .
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4 - 25 Nm
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5 - Exhaust tailpipe
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6 - Separating point
❑ For repair cases
❑ Marked by impressions
on exhaust pipe.
❑ 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‐
plied separately, with a
double repair clamp for
connecting.
❑ Cut through connecting
pipe at right angles at
separating point using e.g. pneumatic sabre saw -V.A.G 1523A- .
❑ The notches to the left and right of the separating points must be visible following the installation of the
double clamp.
7 - Mounting
❑ Installation position ⇒ page 154 .
8 - 25 Nm
9 - Mounting
10 - Double clamp
❑ Must be slid to its mid-point on forward exhaust pipe.
❑ Note installation position: Securing bolt ends must not project beyond lower edge of clamp.
11 - Mounting
12 - Double clamp, 40 Nm
❑ Must be slid to its mid-point on forward exhaust pipe.

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Touareg 2003 ➤ oris e nte
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8-cylinder injectionaut engine - Edition 11.2011 ra
c
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13 - To exhaust manifold
pt
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14 - Centre silencer
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❑ Centre and rear silencers are installed as a single component during production. In case of repair, the
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centre and rear silencers are supplied separately, with a double repair clamp for connecting.
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15 - Double clamp
spec
es, in part or in w
❑ For repair cases
t to the co
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Installation position, double repair clamp in direction of travel
l purpos
– The end of bolt -1- must not project beyond lower edge of
double clamp.
nf
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– The angle -2- must be 10° + 5°.
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Aligning exhaust system
AG.
• Exhaust system cold

– Push exhaust system in direction of travel -1- and tighten dou‐
ble clamps until dimension -a- is attained at the mountings.
Centre silencer: dimension a = 10 mm; Rear silencer: dimen‐
sion a = 15 mm

Touareg 2003 ➤
2 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 . Volkswagen AG
gen AG
temperature). This produces an oxygen rich exhaust olkgas,
swa causing does
not
afterburning and reducing the heat-up phase eof d bthe catalytic con‐
y V gu
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verter. The engine control unit activates the horissystem via the sec‐ nte
eo
ondary air pump relay -J299- to the secondary
aut air inlet valve - ra
c
N112- and combination valve. Additionally,
ss
after each
ce
le
subsequent engine start (up to max. 80 C engine temperature),
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pt
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the secondary air system will, after a 20 second delay, switch in
d
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for 5 seconds during idling and will be checked by the self-diag‐
rm
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Assembly overview - removing and installing parts of secondary
h re
air system ⇒ page 155
hole
spec
es, in part or in w
2.1 Assembly overview - removing and in‐
t to the co
stalling parts of secondary air system
rrectness of i
Note
l purpos
Secondary air pump relay -J299- ⇒ page 156
nform
mercia
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tion in
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2. Secondary air system 155

Touareg 2003 ➤
2 - 10 Nm
3 - To secondary air inlet valve
-N112-
5 - Gasket
6 - Connecting hose
❑ From cylinder bank 1 to
cylinder bank 2.
7 - Secondary air inlet valve - AG. Volkswagen AG d
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8 - 10 Nm rise
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9 - Bracket ss au ra
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10 - Vacuum reservoir
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11 - Hose coupling
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❑ Press together at front
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to release.
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12 - Pressure hose
spec
es, in part or in w
t to the co
ing.
❑ Press together at front
to release.
rrectness of i
13 - Secondary air pump motor
l purpos
-V101-
14 - From air filter.
nform
ercia
15 - Pressure pipe
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❑ Bolted to cylinder head
n
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in t
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cover.
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16 - 8 Nm
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17 - 10 Nm
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18 - To secondary air inlet valve -N112- t. C rig
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Secondary air pump relay -J299-
Note
♦ The secondary air pump relay -1- is in socket A4.

♦ If tools are necessary to pull relays or control units out of the
relay plate, first disconnect battery earth strap ⇒ Electrical
system; Rep. gr. 27 ; Disconnecting and reconnecting batter‐
ies.

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General notes on ignition system ole,
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♦ For trouble-free operation of electrical components, a voltage
t to the co
of at least 11.5 V is necessary.
♦ Certain tests may lead to a fault being detected by the control
unit and stored. Therefore after completing all checks and re‐
rrectne
pairs the fault memory must be read and if necessary cleared.
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Assembly overview - parts of ignition system ⇒ page 157
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Safety precautions ⇒ page 158 .
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Spark plug test data ⇒ page 159 .
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Removing and installing ignition coils with output stage
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⇒ page 158 .
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1.1 Assembly overview - parts of ignition system
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1 - Connector for knock sensor
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❑ Secured to fuel rail with
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2 - Knock sensor 1 -G61-

❑ Gold-plated contacts on
sensor and connector.
❑ Line to knock sensor se‐
cured to coolant pipe.
3 - 20 Nm
❑ The specified torque in‐
fluences the function of
the knock sensor.
4 - Hall sender 2 -G163-
❑ For inlet camshaft bank
2.
❑ Gold-plated contacts on
sensor and connector.
5 - 10 Nm
6 - 25 Nm
7 - Washer
❑ Conical.
tion.
8 - Screen
❑ For Hall sender.
❑ When installing note fix‐
ing arrangement.
9 - Ignition coil with output
stage -(N70, N127, N291,
N292, N323, N324, N325,
N326)-
❑ Remove and install only with puller -T40039- .
1. Repairing ignition system 157

Touareg 2003 ➤
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
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11 - Knock sensor 2 -G66- lkswagen AG do
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12 - Bracket utho or
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13 - 10 Nm
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14 - Hall sender -G40-

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❑ For inlet camshaft bank 1.
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❑ Gold-plated contacts on sensor and connector.
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1.2 Safety precautions
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To prevent injuries to persons and/or damage to the injection and
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♦ Switch off ignition before connecting or disconnecting injection
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and ignition system wiring as well as test instrument cables.

♦ If the engine is to be turned at starter speed without starting:
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– Pull connectors off ignition coils with output stage (cylinders

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Note the following if testers and measuring instruments have to

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♦ Test and measuring instruments must always be secured to

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rear seat and operated by a second person from this location.
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If test and measuring instruments are operated from front pas‐
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injuries when the airbag is triggered.
1.3 Removing and installing ignition coils

with output stage
♦ Puller -T40039-
158 Rep. gr.28 - Ignition system

Touareg 2003 ➤
– Press in catch of respective connector -A- to be removed in

-direction of arrow- and disconnect connector.
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– Before disconnecting by V connectors of cylinders 5 to 8t gremove
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bracket -1- by riunscrewing
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– Fit puller -T40039- onto ignition coil with output stage and pull
rrectness of i
off ignition coil with output stage in -direction of arrow-.

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– To install, insert ignition coil with output stage in correct posi‐

tion into respective spark plug recess and push ignition coil
with output stage by hand onto spark plug to stop.
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1.4 Test data, spark plugs
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Engine code AXQ / BHX
Firing order 1-5-4-8-6-3-7-2
Spark plugs
VW/Audi 101,905,615 A
Manufacturer's designation FGR 7 KQE 0
Electrode gap max. 1.1 mm
Specified torque 4). 30 Nm
4) Remove and install spark plugs with spark plug socket and extension 3122 B.
1. Repairing ignition system 159

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Service

Service Department. Technical Information

All rights reserved.

Copyright © 2011 Volkswagen AG, Wolfsburg K0058961520

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.2 Renewing camshaft oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

2.3 Renewing Hall sender seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2.5 Removing and installing roller rocker finger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

2.6 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

2.7 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

2.8 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

1 Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

1.1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

1.3 Dismantling and assembling oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

1.4 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

1.5 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

1.5 Assembly overview - parts of cooling system, engine side, rear . . . . . . . . . . . . . . . . . . . . 81

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

1.11 Checking delivery rate of pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

1 Repairing injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

1.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

1.2 Assembly overview - fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

1.7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Engine data ⇒ page 1

gine code“ and „serial number“.

Engine code AXQ BHX

1) In exceptional circumstances min. 95 RON, however with reduced perform‐

10 – Removing and installing engine

Special tools and workshop

♦ Left support -VAS 6131/6-1-

2 Rep. gr.10 - Removing and installing engine

♦ Stepladder -VAS 5085-

1.1 Removing engine

♦ To enable the propshaft to rotate freely, move selector lever

to the „N“ position.

♦ Leave key in ignition to prevent steering wheel lock from en‐

engine removal. The vehicle can then be lowered on hoist until

♦ To prevent damage to removed components, place them in

the container for removed parts -V.A.G 1698- .

removed must be replaced in the same position when engine

1. Removing and installing engine 3

– Disconnect fuel supply line -arrow-. agen

– Open fuse box cover in plenum chamber on left and separate

4 Rep. gr.10 - Removing and installing engine

– Disconnect starter wire -1- and and lay it on engine.

– Remove intake hose on right leading to throttle valve module.

– Pull intake hose leading to secondary air pump motor -V101-

– Remove air filter element.

– Then pull connecting line -arrow- to air suspension compres‐

sor off right air filter housing downwards ⇒ page 135 .

on right and remove it.

1. Removing and installing engine 5

– Separate connectors -A- on gearbox as well as transfer box

– Remove gearbox transverse support -A-.

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 and close expansion tank cap to release pressure in