Volkswagen Touareg 2003 Service Manual Download Page 3

Page: 3 / 180

Pro

rig

r i

olk

n AG

olk

AG do

ot g

uar

ante

or a

ith

tio

rig

ht b

olk

Contents

Engine list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1

Information on long-life service and time or distance dependent service . . . . . . . . . . . . . .

2.2

Service tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.1

Raising vehicle with lifting platform or trolley jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.2

Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.3

Connecting vehicle diagnosis tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.4

Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.5

Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.6

Countries with elevated sulphur content in diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.7

Engine code and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.8

RME fuel (biodiesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.9

Severe operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.10 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.11 Jacking up mode: Switching self-levelling suspension off and on . . . . . . . . . . . . . . . . . . . . 24
4

Descriptions of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.1

Removable towing bracket: Check and clean if necessary . . . . . . . . . . . . . . . . . . . . . . . . 28

4.2

Turbocharger: Lubricate control motor linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4.3

Swivel joints and axle bearings: Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.4

Additive container: Extract fluid and replenish with new additive . . . . . . . . . . . . . . . . . . . . 32

4.5

Diesel particulate filter: Reading the ash load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4.6

Automatic gearbox: Check ATF level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4.7

Battery cut-off relay: Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4.8

Battery: Check battery terminal clamps for secure seating . . . . . . . . . . . . . . . . . . . . . . . . 40

4.9

Battery: Check using battery tester with printer VAS 5097A or VAS 6161 . . . . . . . . . . . . 47

4.10 Reducing agent (AdBlue®): Replenish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4.11 Reducing agent (AdBlue®): Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

4.12 Checking tyres: Condition, wear pattern, tyre pressure, tread depth and age of tyres . . . . 56

4.13 Storing tyre pressure values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

4.14 Thickness of brake pads/linings and condition of brake discs, front and rear: Check . . . . 59

4.15 Brake system and shock absorbers: Perform visual check for leaks and damage . . . . . . 62

4.16 Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

4.17 Brake fluid level (depending on lining/pad wear): Check . . . . . . . . . . . . . . . . . . . . . . . . . . 66

4.18 Diesel particulate filter: Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

4.19 Window regulators: Check positioning (open and close functions) . . . . . . . . . . . . . . . . . . 68

4.20 Vehicles with reversing camera system: Check number plate . . . . . . . . . . . . . . . . . . . . . . 69

4.21 Vehicle system test: Perform test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

4.22 Front airbag for the front passenger: Check activation / deactivation . . . . . . . . . . . . . . . . 70

4.23 Gearbox, final drive (especially on flanges) and drive shaft bellows: Perform visual check for

leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

4.24 Dust and pollen filter: Clean housing and renew filter element . . . . . . . . . . . . . . . . . . . . . . 71

4.25 Poly V-belt: Check condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

4.26 Diesel fuel filter: Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

4.27 Diesel fuel filter: Renew (Diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

4.28 Interior and exterior body: Performing visual check for corrosion when doors and flaps are

open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

4.29 Compass in roof module: Set compass zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

4.30 Cooling system: Check frost protection and coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . 81

4.31 Air filter: Clean housing and renew filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

4.32 Engine oil level: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

4.33 Engine oil: Drain or extract; renew oil filter and replenish engine oil . . . . . . . . . . . . . . . . . . 99

4.34 Engine cover panel -top-: Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

4.35 Removing and installing engine cover -bottom- (noise insulation) . . . . . . . . . . . . . . . . . . . . 108

Touareg 2003 ➤

Maintenance - Edition 11.2011

Contents

Summary of Contents for Touareg 2003

Page 1: ...r m i t t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t...

Page 2: ...b y V o l k s w a g e n A G Maintenance Heading 1 Engine list 2 Service work 3 General 4 Descriptions of work 5 Exhaust emissions test 6 Glossary Technical information should always be available to t...

Page 3: ...Check using battery tester with printer VAS 5097A or VAS 6161 47 4 10 Reducing agent AdBlue Replenish 47 4 11 Reducing agent AdBlue Change 56 4 12 Checking tyres Condition wear pattern tyre pressure...

Page 4: ...uide rails 124 4 45 Sliding sunroof drains Check not blocked clean if necessary 124 4 46 Window wash wipe system and headlight washer system Checking operation and checking for damage if necessary rep...

Page 5: ...00 300 4000 Bore mm 84 5 84 0 84 0 Stroke mm 93 95 9 95 9 Compression ratio 11 11 25 11 25 Injection ignition Motronic ME 7 1 1 SRE Motronic ME 7 1 1 SRE Motronic ME 7 1 1 SRE RON min 98 unleaded 1 95...

Page 6: ...7 1 1 SRE Motronic ME 7 1 1 SRE Motronic ME 7 1 1 SRE RON min 98 unleaded 1 95 unleaded 95 unleaded Leakage diagnosis system e g USA vehicles no no no Onboard diagnosis OBD no no yes Camshaft drive C...

Page 7: ...Gear train Chain Gear train Engines Diesel engine Diesel engine Diesel engine Diesel engine Capacity I 4 9 2 5 2 5 2 5 Engine code BLE BPD BPE BLK No of cylinders valves per cyl inder 10 2 5 2 5 2 5 2...

Page 8: ...is system e g USA vehicles no no no no Onboard diagnosis yes yes yes yes Camshaft drive Gear train Chain Chain Chain Engines Diesel engine Diesel engine Diesel engine Capacity I 3 0 3 0 4 9 Engine cod...

Page 9: ...dicates LongLife service QG0 or QG2 indicates time or distance dependent service 2 1 2 LongLife service Vehicles with PR number QG1 The LongLife service enables long service intervals depending on ind...

Page 10: ...these vehicles the LongLife service is not factory activated Therefore these vehicles have a non flexible service interval dis play SID page 6 and for maintenance the time or distance dependent interv...

Page 11: ...hicles with time or distance dependent service PR number QG0 QG2 Calculation of service intervals To calculate the service interval for vehicles with time or dis tance dependent service the non flexib...

Page 12: ...reme conditions page 24 the shortest interval for an oil change service is 7 500 km or 1 year However other intervals apply for other countries Your im porter will inform you about this TOUAREG SERVIC...

Page 13: ...every 2 years or 60 000 km NO VW engine oil standards Caution Only engine oils approved by VW may be used for up to date information see ServiceNet Technical information Inspec tions and Servicing Ap...

Page 14: ...ith LongLife service QG1 According to flexible service interval display All remaining vehicles Every 15 000 km or 1 year AIR FILTER page 86 All engines except V6 TDI 2006 Every 120 000 km or 4 years 2...

Page 15: ...Engine type Engine code Model year Change interval Tensioning roller 4 2 l AXQ Since introduction Every 120 000 km 120 000 km Spark plug change intervals Spark plug designation and specified torque P...

Page 16: ...0 000 km page 137 Elastic drive coupling and alternator drive freewheel Renew Only valid for R5 TDI engine codes BAC and BLK Every 150 000 km page 137 Diesel particulate filter Read ash load Only vali...

Page 17: ...chapter only provides information on market specific devia tions This means that all maintenance points that are not shown here are to be found in the normal service tables Indian market Interval Desc...

Page 18: ...l part of the interval service North American market Interval Description of work Sliding sunroof drains Check not blocked clean if necessary Every 60 000 km page 124 Diesel particulate filter Renew O...

Page 19: ...h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Interval Description of work Air filter element Ren...

Page 20: ...page 24 Type plate page 24 Jacking up mode Switching self levelling suspension off and on page 24 3 1 Raising vehicle with lifting platform or trolley jack Note When raising the vehicle the jacking u...

Page 21: ...on vertical stiffener of side member Rear lifting point Position support plate at reinforcement of floor pan near rear axle mounting arrow WARNING Ensure that support plate of raising platform is cen...

Page 22: ...change service or inspection service or legal check such as legislative inspection or gas system check next serv ice due and enter date and mileage Note The new sticker is applied gradually from week...

Page 23: ...ed belt the new change inter val begins at the time the component is changed Therefore it is very important every time a component is changed to document this in the service schedule This also applies...

Page 24: ...r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Vehicle diagnosis and service information system VAS 5052 or subsequent units Diagnosis cable 2 m VAS 5052 3 A N...

Page 25: ...diagnosis tester Switch on vehicle diagnosis tester Switch on ignition Now follow screen display to start desired functions 3 4 Vehicle identification number Location windscreen The vehicle identifica...

Page 26: ...el trim in the footwell on driver side The vehicle data sticker is also found in the service schedule for the customer On the left side of left hand drive vehicles on the right side of right hand driv...

Page 27: ...ius Tajikistan Brazil Cambodia Mongolia Tanzania Brunei Cameroon Myanmar Burma Trinidad and Tobago Dominican Republic Kazakhstan Nigeria Tunisia Ecuador Qatar Pakistan Uruguay Ivory Coast Kenya Paragu...

Page 28: ...jobs will have to be performed before the next service due or at shorter service intervals Severe operating conditions Regular short trips or stop and go operation in urban traffic High percentage of...

Page 29: ...y V o l k s w a g e n A G Switch on ignition Press button LOCK in centre console arrow and hold for 5 seconds The jacking up mode is displayed in the combi instrument a warning lamp flashes in LOCK bu...

Page 30: ...em and shock absorbers Perform visual check for leaks and damage page 62 Changing brake fluid page 63 Brake fluid level dependent upon lining wear Check page 66 Thickness of brake pads linings and con...

Page 31: ...ding radio code using vehicle diagnosis tester page 112 Radio navigation system Activate anti theft coding page 113 Reducing agent AdBlue Replenish page 47 Reducing agent AdBlue Change page 56 Storing...

Page 32: ...s w a g e n A G Spark plugs Renew page 140 Static cornering light cornering light and driving light assist Check function page 151 4 1 Removable towing bracket Check and clean if necessary This chapt...

Page 33: ...it has only to be in agreement with the customer A repair must be charged separately Repair procedure Check contact surfaces arrows of ball head mounting for corrosion If contact surfaces are corroded...

Page 34: ...cating the control motor linkage includes 1 Turbocharger 1 control motor V280 for cylinder bank 1 right engine side 2 Turbocharger 2 control motor V281 for cylinder bank 2 left engine side Remove engi...

Page 35: ...s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Fitting location Front left between steering and housing of front final drive above coolant hoses arrow A Lubricate rotating point of co...

Page 36: ...health and environ ment Protective and hygiene measures Behaviour in case of danger ServiceNet Genuine parts safety data sheets and operating instructions Diesel fuel additive for particulate filter...

Page 37: ...on Collect fluid in a container e g when lines are drained empty etc Route lines of all types e g fuel lines additive lines as well as electrical wires so that the cable guide is in original condition...

Page 38: ...ocated on tank filler neck arrow A Note Always note safety measures when working on additive contain er First pull sealing plug off VENTILATION arrow B page 34 Then pull sealing plug off EXTRACTION FI...

Page 39: ...n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 4 5 Extracting and replenishing with fluid Special tools testers measuring instruments and auxiliary items required Extraction...

Page 40: ...prox 2 3 full see arrow 5 If necessary repeat extraction process Do not reuse extracted used additive fluid Dispose of extracted used additive fluid according to op erating instructions ServiceNet HSO...

Page 41: ...disconnect filling hose using e g hose clamp 3094 Separate filling device VAS 6277 2 and overflow protection VAS 6277 3 from additive container connections arrows A B Connect both sealing plugs onto c...

Page 42: ...dry and well ventilated area 4 5 Diesel particulate filter Reading the ash load Note When checking the diesel particulate filter read the ash load limit Connect vehicle diagnosis tester page 19 Switc...

Page 43: ...Engine does not start transportation device active Procedure The battery cut off relay is located in the footwell in front of driver seat The battery cut off relay is screwed to the earth point of ba...

Page 44: ...and tighten earth cable to 20 Nm Note When battery earth cable has been reconnected Electrical sys tem Rep gr 27 Disconnecting and connecting battery Route connector and relay cable at position shown...

Page 45: ...o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Battery under left front seat checking battery terminal clamps for secure seating Switch off ignition and all electrical c...

Page 46: ...eated securely on positive terminal The following procedure must be followed without exception Disconnecting battery under front left seat WARNING The battery under the front left seat is equipped wit...

Page 47: ...hten securing bolt on battery positive terminal clamp to 6 Nm Only after the positive terminal clamp 2 is secure may the negative terminal clamp 1 be placed on the battery negative terminal Tighten se...

Page 48: ...l tools and workshop equipment required V A G 1331 Torque wrench 5 50 Nm Tighten battery clamp 1 on battery negative terminal to 6 Nm Reinstall engine cover panel Renew securing bolts arrows of seat f...

Page 49: ...battery positive wire 1 and battery negative wire 2 back and forth WARNING If the battery clamp is not seated securely on the positive ter minal first disconnect battery clamp from battery negative te...

Page 50: ...erminal clamp arrow to 6 Nm Only after the positive terminal clamp is secure may the neg ative terminal clamp arrow be placed on the battery negative terminal Tighten securing bolt on battery negative...

Page 51: ...Checking battery 4 10 Reducing agent AdBlue Replenish Note To prevent the descriptions from becoming unclear the NOx re ducing agent AUS 32 AdBlue is merely called reducing agent AdBlue in the followi...

Page 52: ...nd gearbox jack VAG 1383 A Adapter plate VAG 1383A 1 4 10 1 General Properties The reducing agent AdBlue is not a diesel additive and must not be poured into the diesel fuel tank The reducing agent Ad...

Page 53: ...e reducing agent tank is located in the luggage compart ment A refill container approved by Volkswagen must be used for replenishing the reducing agent AdBlue The reducing agent tank has a capacity of...

Page 54: ...ult finding 4 10 2 Health endangerment and cleaning WARNING The reducing agent AdBlue may irritate the skin eyes and respiratory organs Protect your hands In the event of skin contact with this fluid...

Page 55: ...m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 10 4 Work preparation for filling reducing agent tank Note Ensure that vehicle stays on an even ground The reduc...

Page 56: ...pen Lever points in direction of hose cut off tap closed Lever positioned transverse to direction of hose 4 Quick release coupling on breather hose 5 Filling hose 6 Cut off tap for filling hose cut of...

Page 57: ...ose 9 Engine and gearbox jack VAG 1383 A 4 Place filling device VAS 6542 onto reducing agent con tainer ETKA turn union nut COUNTER clockwise until both threads engage with each other Turn then union...

Page 58: ...agent tank au tomatically has the correct fill level After replenishing switch on ignition for at least 20 seconds so that the replenished reducing agent AdBlue can be rec ognised by the system Cauti...

Page 59: ...o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 10 6 Work after filling reducing agent tank Screw in tank cap 1 of...

Page 60: ...through all parts of filling device VAS 6542 under flowing water 4 11 Reducing agent AdBlue Change Procedure Power unit Rep gr 26 SCR system selective catalytic re duction Draining reducing agent tank...

Page 61: ...upping one sided wear porous side walls cuts and punctures Check tyre age We recommend not to use any tyres older than 6 years Inform customer WARNING The customer must be informed of any faults found...

Page 62: ...ures for the relevant model can also be found on a sticker It is attached to the inside of tank flap or to B pillar Adjust the tyre pressure to suit the vehicle load The spare wheel should have the hi...

Page 63: ...n pressure using tyre inflator VAS 5216 cor rect if necessary 4 13 Storing tyre pressure values Correct tyre pressure must be adjusted page 56 Tyres must be cold Switch on ignition Press button 1 to a...

Page 64: ...n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Pliers 3314 Torque wrench 40 200 Nm V A G 1332 Electric hand torch and mirror Note The adapter to loosen and tighten the anti th...

Page 65: ...without backplate Wear limit 2 mm The brake pads have reached their wear limit at a pad thickness of 2 mm without backplate and must be renewed repair meas ure Inform customer Note When replacing bra...

Page 66: ...ssary replacing the brake discs is a repair measure Check brake disc for wear Brake system Rep gr 46 Repairing rear brakes Condition of brake discs Check Check all brake discs for the following damage...

Page 67: ...r this purpose it can be mixed with the previous brake fluid WARNING Brake fluid must under no circumstances come into con tact with fluids containing mineral oils oil petrol cleaning solutions Minera...

Page 68: ...m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Brake filling and bleeding equipment VAS 5234 Brake bleeding wrench VAS 5519 Brake bleeding tool VAS 6564 Observe...

Page 69: ...ning gear brake systems Rep gr 47 Bleeding brake system Bleeding brake system Place brake pedal depressor V A G 1869 2 between driver seat and brake pedal and tension it Screw adapter onto brake fluid...

Page 70: ...on other side of vehicle at front Table Sequence and quantity of brake fluid Sequence Clutch slave cylinder wheel brake cylinder brake calipers Quantity of brake fluid which must flow out Bleeder valv...

Page 71: ...the reservoir MAX marking 1 must not be exceeded Brake fluid level at inspection service The fluid level must always be judged in conjunction with lining pad wear When vehicle is in use fluid level t...

Page 72: ...batteries in luggage compartment and or left front seat have been disconnected and reconnected the one touch win dow operation is disabled Therefore with immediate effect before a new vehicle is de l...

Page 73: ...rms a vehicle system test and reads all control units available for this vehicle type Press button Now all faults are listed Note At this point it is useful to change to operating mode guided function...

Page 74: ...he front passenger Check activation deactivation Note There are vehicles which are fitted with automatic passenger air bag deactivation e g vehicles for the North American market This is performed by...

Page 75: ...e 4 23 1 Protective bellows Visual check Carry out the following procedure Check outer bellows and inner bellows arrows for leaks and damage Note Also check protective bellows on rear axle 4 24 Dust a...

Page 76: ...nks surface cracks Traces of oil and grease Install engine cover Note If faults are found it is absolutely necessary to renew the poly V belt This will avoid possible breakdowns or operating problems...

Page 77: ...lter 5 cylinder diesel engines page 78 4 27 1 Renewing diesel fuel filter 6 cylinder diesel engines Note Please note for engine codes CASA CASB and CATA the fuel system must be bled after changing the...

Page 78: ...r upper part arrows A Pull diesel fuel filter element 4 out of diesel fuel filter lower part on retainer 3 Note Observe disposal regulations Caution If necessary remove dirt and water residues from di...

Page 79: ...bolts to 10 Nm torque Bleeding fuel system for engine codes CASA CASB and CATA Connect vehicle diagnosis tester page 19 Select Guided functions Perform vehicle identification Select respective engine...

Page 80: ...k s w a g e n A G Diesel extractor VAS 5226 Remove engine cover page 106 Removing Remove plug arrow from water drainage connection of diesel fuel filter housing Extract diesel fuel from side water dr...

Page 81: ...n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Pull filter elements 3...

Page 82: ...engine starts immediately after changing the diesel fuel filter bleed the fuel system using vehicle diagnosis tester Connect vehicle diagnosis tester page 19 Switch on ignition Select Guided function...

Page 83: ...ne identification on diesel fuel filter Return line marked blue 2 identified with RT return line to tank Supply line marked black 3 identified with VF supply line to filter Return line 9 identified wi...

Page 84: ...nect vehicle diagnosis tester page 19 Switch on ignition Select Guided functions Perform vehicle identification Select Systems capable of self diagnosis Diesel direct in jection and glow plug system F...

Page 85: ...i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G With ignition switched on press button 3 Select the symbol N using the function buttons 2 in display 1 and confirm with OK To...

Page 86: ...risedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p...

Page 87: ...us protects the complete cooling system against corrosion and reduces the formation of sludge and corrosion G12 Plus Plus is suitable as a filled for life filling for cast iron and all aluminium engin...

Page 88: ...to C Quantity to drain in litres Actual value Specified val ue 5 cylinder engine 5 cylinder en gine1 6 cylinder engine 6 cylinder engine1 0 25 3 5 5 5 4 0 6 0 35 4 0 7 0 4 5 7 5 5 25 3 0 4 5 3 5 5 0...

Page 89: ...l k s w a g e n A G Mixture ratio Caution Only distilled water may be used for mixing Tap or well water does not have the required quality to ensure the functionality of coolant Frost protection to Co...

Page 90: ...oolant if necessary Note Coolant additive G12 Plus Plus prevents frost and corrosion damage scaling and also raises boiling point of coolant For these reasons the cooling system must be filled all yea...

Page 91: ...r i g h t b y V o l k s w a g e n A G 4 31 1 Removing and installing filter element on 10 cylinder engines Remove engine cover page 106 Removing Note The removal and installation of the left air filt...

Page 92: ...r filter housing arrow as follows Press locking ring 1 off flange of line 3 using screwdriver C Press securing sleeve 2 in direction of arrow and pull line A off line B at the same time Pull air filte...

Page 93: ...a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Secure air filter housing with...

Page 94: ...o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Insert securing pins so that marking on pin 1 and marking on air filter housing...

Page 95: ...h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Turn pin until marking 1 aligns with marking on air filter hous ing 3 Pull out securing pin upwards Pull off intake hose Disconnect...

Page 96: ...n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove air filter element A If necessary blow out air filter housing with compressed air and install new air filter element...

Page 97: ...s w a g e n A G Then press locking ring 1 onto flange of line 3 until it can be heard to engage Install intake hose Install intake hose securing pins as follows Insert securing pins so that marking on...

Page 98: ...On the rear line press locking ring 1 off flange of line 3 using screwdriver C Press securing sleeve 2 in direction of arrow and pull line A off line B at the same time On front line press securing r...

Page 99: ...w a g e n A G Secure air filter housing with spring clips 1 Bolt on throttle valve module 2 and tighten to 3 Nm Reconnect connector 3 Push line arrow together again Then press locking ring 1 onto flan...

Page 100: ...t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Disconnect lines to air filter housing arrow as fo...

Page 101: ...m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove air filter element A If necessary blow out air filter housing with compressed air and install new air filter element Installing Install ai...

Page 102: ...6 4 32 Engine oil level Check Please note the following After shutting off engine wait at least 3 minutes so that the oil can flow back into the sump Pull out dipstick and wipe with a clean cloth and...

Page 103: ...l filter must be re newed before changing the engine oil page 100 When removing the filter element a valve is opened the oil in the filter housing automatically flows into crankcase For 8 cylinder and...

Page 104: ...ne page 103 Renewing oil filter on 6 cylinder diesel engine page 105 Renewing oil filter on 8 cylinder petrol engine page 101 Renewing oil filter on 10 cylinder diesel engine page 102 Renewing oil fil...

Page 105: ...O rings before installing Remove oil drain plug 1 of threaded cover and drain oil Loosen threaded cover 2 on hexagon 1 or along perimeter and remove Clean sealing surfaces on threaded cap and oil fil...

Page 106: ...with oil filter element Separate oil filter element 3 from sealing cap 1 Clean sealing surfaces on threaded cap and oil filter housing Installing Renew oil filter element 3 Install sealing cap 1 with...

Page 107: ...25 Nm 4 33 7 Renewing oil filter on 6 cylinder petrol engine Note Observe disposal regulations Oil new O rings before installing Prevent engine oil from dripping onto subframe Carry out the following...

Page 108: ...o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Torque wrench 5 50 Nm V A G 1331 Removing Note Observe disposal regulations Oil new O rings before installing...

Page 109: ...aded cap 3 with new O ring 4 and tighten to 25 Nm Fit oil drain plug 1 with new seal 2 and tighten to 10 Nm The remaining assembly steps are basically a reverse of the dis mantling procedure 4 33 9 Re...

Page 110: ...tling procedure 4 33 10 Replenishing engine oil Oil specifications see page 7 General notes Note Observe disposal regulations After replenishing with oil wait at least 3 minutes and then check oil lev...

Page 111: ...ol engine Unclip engine compartment covers 1 and 2 and remove upwards Caution Do not push with the fist or a tool on the engine cover panel when it is installed or engaged at securing points it could...

Page 112: ...ts observe oil filler neck and oil dipstick Caution Do not push with the fist or a tool on the engine cover when it is installed or engaged at securing points it could be damaged Press engine cover at...

Page 113: ...Front and rear noise insulation Remove bolts A First remove front noise insulation 3 Then remove bolts B Pull rear noise insulation 2 out of spring tabs 1 Tighten bolts to 8 Nm torque 4 36 Engine and...

Page 114: ...bottle has a limited expiry date Therefore the expiry date is indicated on the bottle arrow This example shows that the expiry date 05 2003 has been ex ceeded then the bottle has to be renewed Check t...

Page 115: ...clicks at latest Free travel of operating lever until braking effect be gins 2 3 clicks ABS function Pulsing must be felt at the brake pedal during ABS regulated braking Steering Function steering fre...

Page 116: ...180 Nm 4 40 Reading radio code using vehicle diag nosis tester Authorization prerequisites for vehicle diagnosis tester The vehicle diagnosis tester is connected via the Central Part ner Network CPN w...

Page 117: ...ed from vehicle The anti theft codes are also called radio codes or security codes Security code means that each unit with an anti theft coding is programmed with its own code number This security cod...

Page 118: ...tivate the fixed code as follows Switch radio on The unit automatically displays SAFE and then 1000 For this no buttons are used With the help of station buttons 1 to 4 enter code number ap plied on t...

Page 119: ...removed If the diode flashes the radio navigation system is ready for use and the anti theft coding is activated Activate fixed code on radio navigation system MFD 2 and on radio navigation system MF...

Page 120: ...ox 50 C Do not start engine but bring front wheels to straight ahead position Remove reservoir cap with built in dipstick arrow Wipe off dipstick using a clean cloth Screw cap on hand tight and unscre...

Page 121: ...eflectors and bulbs OK The vehicle must be rolled forward or backward several metres or front and rear springs must be bounced fully several times so that springs settle The vehicle and the headlight...

Page 122: ...driver seat and the vehicle otherwise unloaded unladen weight The unladen weight is the weight of vehicle ready for operation with a full fuel tank at least 90 including weight of all equip ment usua...

Page 123: ...he vertical line Note To simplify finding the breaking point 2 cover and uncover left from driver perspective half of the headlight a few times Then check dipped beam again After correct adjustment of...

Page 124: ...adlight are a mirror image Left headlight from model year 2007 Height adjustment of left headlight Adjust adjustment bolts using a hexagon key 1 Height adjustment for dipped beam main beam Turn vertic...

Page 125: ...adlight B Lateral adjustment for dipped beam main beam and dynamic cornering light Turn lateral adjustment bolt B until correct setting is attained Height adjustment of left headlight Adjust adjustmen...

Page 126: ...nt bolt 1 until correct setting is at tained Note Please check also that both headlights move evenly when head light range control is operated The adjustment bolts for the right headlight are a mirror...

Page 127: ...on the headlight adjustment unit The inclination for fog lights is 2 0 Note Percentage given is based on a projection distance of 10 metres Remove cover 1 from fastenings in direction of arrow Perfor...

Page 128: ...correct setting is attained using hexagon key arrow A lateral adjustment is not possible Other additional lights Additionally retrofitted lights of other systems must be checked and set according to...

Page 129: ...tap water into sliding sunroof drains and check if almost the same quantity of water flows out of the wheel housings If this is the case the test is completed If only a small quantity of water or no w...

Page 130: ...o check pour tap water again through the sliding sunroof drain holes Install in reverse order 4 46 Window wash wipe system and head light washer system Checking opera tion and checking for damage if n...

Page 131: ...e place a drop of water on the glass to improve the readability of the bright dark boundary The bright dark boundary can be clearly recognised on the WATERLINE Check concentration of anti freeze addit...

Page 132: ...nsures that the fan type washer jets remain fully functional at low temperatures Use Genuine Volkswagen Windscreen Clear G 052 164 also in the warmer periods of the year The powerful cleanser re moves...

Page 133: ...e for the left hand headlight right hand mirror image Check jet setting a 100 mm b 75 mm c 230 mm d 50 mm Switch on dipped headlight Operate windscreen washer system The headlights are washed if the w...

Page 134: ...e 12 mm If necessary adjust park position by loosening cone and mov ing wiper arm Wiper arm tightening torque 32 Nm Windscreen of RHD vehicles Check park position The distance A between wiper blade an...

Page 135: ...in service position This can be done by switching the ignition on and off once with bonnet closed Then operate wiper lever and the wipers will stop in service position Take the right hand wiper from...

Page 136: ...the wipers will stop in service position Take the right hand wiper from windscreen and lift Caution To prevent damage ensure that the wiper is only touched at the wiper joint and do not pull on the w...

Page 137: ...same procedure for the left hand wiper Carefully place wiper arm back onto windscreen Switch ignition on and briefly operate the wiper lever to move the wipers back to park position Switch ignition of...

Page 138: ...dicated on display Press the GoTo button on display arrow Indicated on display Press the End button on display arrow Press End button in End menu Switch off ignition and separate diagnosis connections...

Page 139: ...med correctly confirm with button Select one after the other Dash panel insert ARROW Adapting service interval extension Perform adaption according to the information of GUIDED FUNCTIONS Ending adapti...

Page 140: ...A G Check mountings Check that boots arrow are not damaged and are seated correctly 4 51 Transportation mode Switch off Connect vehicle diagnosis tester page 19 Switch on ignition Indicated on displa...

Page 141: ...button in End menu Switch off ignition Note The vehicle diagnosis tester must probably remain connected for further tests 4 52 Door arrester Grease Carry out the following procedure Grease door arrest...

Page 142: ...rument Time The time can be set here and the choice can be made between the 12 and 24 hour display Language The language for the combi instrument can be set here Units The units of measurement for tem...

Page 143: ...arning Time Convenience Language Units Reset Turn knurled wheel 2 until the menu point to be selected is shown Press knurled wheel The selected menu is called up Example setting clock via multifunctio...

Page 144: ...ox and front and rear final drive Checking oil level replenishing if necessary Procedure Power transmission transfer box and final drive Power transmission transfer box and final drive Rep gr 34 Check...

Page 145: ...Gdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g...

Page 146: ...h t b y V o l k s w a g e n A G Spring type clip pliers VAS 6499 4 58 1 Vehicles with 6 cylinder petrol engine Removing Carry out the following procedure Unclip engine covers 1 and 2 and remove upward...

Page 147: ...the flat side of igni tion coil with output stage arrows Slide puller T10095 a from the flat side of the connector in di rection of arrow onto ignition coil with output stage Pull out ignition coil w...

Page 148: ...s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Apply a thin bead of spark plug connector grease G 052 141 A2 on the circumference of the sealing...

Page 149: ...h t b y V o l k s w a g e n A G 4 58 2 Vehicles with 8 cylinder petrol engine Removing Pull out dipstick Remove bracket for left engine cover 1 Unscrew bolts and retaining pin for engine cover arrows...

Page 150: ...ling Screw in new spark plugs using spark plug socket and exten sion 3122 B Note Observe specified torque Current values Power unit Rep gr 28 Ignition system test data When renewing spark plugs grease...

Page 151: ...c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Push on connectors A so that they engage Install left bracket f...

Page 152: ...e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Pull off hose 1 Remove bolts 1 and 2 and carefully pull off in...

Page 153: ...n system test data Observe disposal regulations Carry out the following procedure Installing Screw in new spark plugs using spark plug socket and exten sion 3122 B Note When renewing spark plugs greas...

Page 154: ...c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Reinstall int...

Page 155: ...c cornering light cornering light and driving light assist Check function Static cornering light Switch on ignition and dipped beam Turn steering wheel from centre position one turn to the right and c...

Page 156: ...ls Vehicles with regulated catalytic converter or vehicles with diesel engine 3 years after initial registration and then every 2 years Valid for Germany Vehicles for commercial passenger trans port e...

Page 157: ...and combined with each other according to the instruction manual All work to be performed is displayed by the emissions testing station VAS 6300 Test prerequisites All test conditions and data requir...

Page 158: ...ehicle registration document at posi tions 1 8 1 Vehicle manufacturer e g VOLKSWAGEN VW 2 Vehicle type e g Golf 3 Key number to 1 e g 11 4 Key number to 2 e g 0603 vehicle registration docu ment 4 Key...

Page 159: ...CO content at increased idling speed 6 Lambda at increased idling speed 7 Idling speed 8 Select regulating probe type either step type probe or broad band probe item 1 9 Lambda probe value When all da...

Page 160: ...u m e n t C o p y r i g h t b y V o l k s w a g e n A G Follow instructions on display Switch off ignition Connect diagnosis cable connector to EOBD connection Switch on ignition Perform visual check...

Page 161: ...es are set to zero a regulating probe test is not performed If not all display values are set to zero a regulating probe test will be performed later Confirm condition of MI lamp arrow B Catalytic con...

Page 162: ...utton and the test can be repeated Maintain engine speed in required engine speed range The remaining time to perform measurement is displayed arrow A Measuring idling speed and CO content It is autom...

Page 163: ...ow A They will then be included in the test log When the exhaust emissions test is classed as passed select arrow B EET sticker issued in drop down menu and date Then confirm with Yes see arrow C Afte...

Page 164: ...A G 1798 Or Data reader V A G 1799 Data sheets for exhaust emissions test Note All test conditions and data required for exhaust emissions test Data sheets for exhaust emissions test If possible the...

Page 165: ...tions Note The engine speed adapter VAS 5087 A or the engine speed adapter VAS 6296 can be used instead of the TDC sender for engines where the hole of the TDC sender cannot be reached or cannot be re...

Page 166: ...rt engine and run at idling speed Press F2 button for EET diesel on data reader If the following is indicated on display Please insert vehicle identity card Manual input with button Enter vehicle iden...

Page 167: ...Continue test sequence by pressing the Q button If the following is indicated on display Idling speed Speed ACT xxxx rpm SPEC xxxx rpm Press button Idling speed not within specified range Note The id...

Page 168: ...Speed ACT xxxx rpm SPEC xxx xxxx rpm Release accelerator pedal The data reader accepts the actual figures within 15 seconds If the following is indicated on display Data transfer to diesel tester Dep...

Page 169: ...xx rpm Release accelerator pedal Press button If the following is indicated on display Average opacity figure ACT x xx rpm SPEC x x xx rpm Press button If the following is indicated on display Opacit...

Page 170: ...hicles fitted with On board diagnosis OBD The OBD monitors all components and part systems influenc ing the exhaust emissions quality Special tools and workshop equipment required Emissions testing st...

Page 171: ...h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Manual gearbox Gear lever in neutral Handbrake pulled on Perform exhaust...

Page 172: ...ehicle data input menu is displayed Note For new models the document previously known as the vehicle registration document is now called the vehicle registration certificate part 1 For new models the...

Page 173: ...transmitted via the network to the respective mask Manual specified data input for EET Note All test conditions and data required for exhaust emissions test see Data sheets for exhaust emissions test...

Page 174: ...splay 1 Press button arrow to continue the process Visual check Follow instructions on display Perform visual check If visual check is OK press OK button arrow Note When not OK button is pressed a che...

Page 175: ...ormed Conditioning In the conditioning phase the engine and if necessary the emis sion control systems are brought to operating temperature by throttle bursts and are prepared for the exhaust emission...

Page 176: ...An air quality check is carried out before starting the free accel eration When doing this no emission probe must be in the exhaust tail pipe Otherwise measuring errors or faulty signals could occur...

Page 177: ...t can be assessed by the operator Further throttle bursts Follow instructions on display arrow B Now the next throttle burst follows starting with phase 1 of Free acceleration Many Free accelerations...

Page 178: ...w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Press button Close arrow B to close the menu P...

Page 179: ...Carbon monoxide is produced when fuels containing carbon are not combusted com pletely CN Cetane number measurement unit for ignition quality of diesel fuel DIN Deutsches Institut f r Normung e V Germ...

Page 180: ...to the exhaust system upstream of a special catalytic converter SD Naturally aspirated diesel engine SDI Naturally aspirated diesel engine direct injection TDI Turbo diesel engine direct injection DP...

Search results

Summary of Contents for Touareg 2003

Reviews:

Related manuals for Touareg 2003

Brands by name

Popular brands

Volkswagen Touareg 2003, Service Manual

Search results

Summary of Contents for Touareg 2003

Reviews:

Related manuals for Touareg 2003

Brands by name

Popular brands