Touareg Maintenance

Service
Maintenance
Touareg 2003 ➤
Edition 03.2018 AG. Volkswagen AG d
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Service Department. Technical Information

Service
Maintenance
Heading
1. Engine list
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4. Descriptions of work:
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5. Exhaust emissions test
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6. Glossary
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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 © 2018 Volkswagen AG, Wolfsburg K0058961120

Touareg 2003 ➤
Maintenance - Edition 03.2018
Contents
1 Engine list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Information on long-life service and time or distance dependent service . . . . . . . . . . . . . . 5
2.2 Service tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1 Raising vehicle with lifting platform or trolley jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 Stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3 Connecting vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.4 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.5 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.6 Countries where diesel has a high sulphur content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.7 Engine code and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.8 RME fuel (biodiesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.9 Severe operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.10 Identification 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:Vochecking and cleaning if necessary . . . . . . . . . . . . . . . . . . . . 28
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4.2 Turbocharger: Lubricate ksw agen control motor linkage
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4.3 Swivel joints d b and suspension link mountings: inspecting
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4.4 Additive th ortank: extracting fluid and filling new additive e or . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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4.5 Diesel
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4.6 Automatic gearbox: check ATF level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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

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4.8 Battery: checking battery terminal clamps for secure seating . . . . . . . . . . . . . . . . . . . . . . 40

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4.9 Battery: Checking using battery tester with printer VAS 5097A or VAS 6161 . . . . . . . . . . 47
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4.10 Reducing agent (AdBlue®): replenishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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

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4.12 Tyres: checking condition, wear pattern, tyre pressure and tread depth . . . . . . . . . . . . . . 56
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4.13 Storing tyre pressure values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

4.14 Brakes, front and rear: checking thickness of brake pads and condition of brake discs . . 61
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4.15 Brake system and shock absorbers: inspecting for leaks and damage . . . . . . . . . . . . . . . . 63
4.16 Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
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4.17 Brake fluid level (dependent upon brake pad/lining wear): check. . . . . . . . . . . . . . . . . . . . . 67
4.18 Diesel particulate filter: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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4.19 Electric windows: checking positioning (open and close functions) . . . . . . . . . . . . . . . . . . 69

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4.20 Vehicles with reversing camera system: Check number plate . . . . . . . . . . . . . . . . . . . . . . 70

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4.21 Vehicle system test: Carry out test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

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4.22 Front airbag for the front passenger: Check activation / deactivation . . . . . . . . . . . . . . . . 71
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4.23 Bonnet catch hook: grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

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4.24 Multi-purpose additive for petrol fuel: adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

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4.25 Gearbox, final drive (especially on flanges) and drive shaft bellows: inspect for leaks and
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damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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4.26 Dust and pollen filter: cleaning housing and renewing filter element . . . . . . . . . . . . . . . . . . 73
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4.27 Poly V-belt: checking condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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4.28 Diesel fuel filter: draining water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

4.29 Diesel fuel filter: renewing (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.30 Interior and exterior body: inspecting for corrosion with doors and flaps open . . . . . . . . . . 84
4.31 Compass in roof module: Set compass zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.32 Cooling system: checking frost protection and coolant level . . . . . . . . . . . . . . . . . . . . . . . . 86
4.33 Air filter: cleaning housing and renewing filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.34 Engine oil level: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.35 Engine oil: draining or extracting, renewing oil filter and replenishing engine oil . . . . . . . . 101
Contents i
Touareg 2003 ➤
4.36 Engine cover panel -top-: Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

4.37 Engine cover - bottom (noise insulation): removing and installing . . . . . . . . . . . . . . . . . . . . 110
4.38 Engine and components in engine compartment: inspecting for leaks and damage (from
above and below) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.39 Tyre repair set: checking if bottle is damaged or used; checking shelf life of tyre sealant
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.40 Road test: performing (driving behaviour, noises, air conditioner etc.) . . . . . . . . . . . . . . . . 112
4.41 Wheel securing bolts: tightening to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.42 Radio code: reading using vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4.43 Radio/navigation system: Activating anti-theft coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.44 Power assisted steering: check fluid level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.45 Headlight adjustment: Checking and adjusting as necessary . . . . . . . . . . . . . . . . . . . . . . 119
4.46 Sunroof: checking function, cleaning and greasing guide rails . . . . . . . . . . . . . . . . . . . . . . 127
4.47 Sliding sunroof drains: checking for blockage, cleaning if necessary . . . . . . . . . . . . . . . . 127
4.48 Window wash/wipe system and headlight washer system: Checking operation and checking
for damage, if necessary replenishing fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.49 Wiper blade protection: removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.50 Service interval display: resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.51 Service interval display: recoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4.52 Track rod ends: checking clearance, firm seating and boots . . . . . . . . . . . . . . . . . . . . . . . . 137
4.53 Transportation mode: switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
4.54 Greasing door arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4.55 Elastic drive coupling and freewheel disc: Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4.56 Underbody: inspecting for damage to underbody sealant, underbody panels, routing of lines,
plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.57 Setting time, language and units: On display of dash panel insert . . . . . . . . . . . . . . . . . . . . 140
4.58 Transfer box and front and rear final drive: Checking oil level,gereplenishing n AG. Volkswageifnnecessary
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4.59 Toothed belt for camshaft drive: renewing (8-cylinder ypetrol Vo lks engines) . . . . . . . . . s. n.o.t g.u. . . 142
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4.60 Spark plugs: renewing . . . . . . . . . . . . . . . . . . . r.is.ed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.an.te 142
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4.61 Static cornering light (cornering light) and driving au light assist: check function. . . . . . . . . . . 151
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5 Exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
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5.1 Exhaust emissions test for petrol engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
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5.2 Exhaust emissions test for diesel engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
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5.3 Exhaust emissions test for diesel engines with OBD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
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6 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
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ii Contents
Touareg 2003 ➤
1 Engine list
(VIGG001138; Edition 03.2018)
This chapter provides information on the following subjects:
♦ Petrol engines ⇒ page 1
♦ Diesel engines ⇒ page 3
Note
To ease the search for an engine, the engine codes are listed in
alphabetical order.
Petrol engines
Engines ⇒ Petrol engine Petrol engine Petrol engine
Displacement I 4.2 3.2 3.2
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Engine code lksw
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No. of cylinders/valves per icylinder
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Power au kW at rpm
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228/6200 162/5400or
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Torque Nm at rpm 410/3000 305/3200 300/4000
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Bore ∅ mm 84.5 84.0 84.0
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Stroke mm 93 95.9 95.9
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Compression ratio 11 11.25 11.25
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Injection/ignition Motronic ME 7.1.1 Motronic ME 7.1.1 Motronic ME 7.1.1
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RON min. 98 unleaded 1) 95 unleaded 95 unleaded

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Leakage diagnosis system (e.g. No No Yes
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Onboard diagnosis (OBD) Yes Yes Yes

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Camshaft drive Toothed belt Chain Chain

1) Under exceptional circumstances super unleaded, at least 95 RON, but with
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Engine code BAR BHK BHL
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No. of cylinders/valves per cylinder 8/4 6/4 6/4
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Power kW at rpm 257/6500 cted 206/6200 206/6200
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Torque Nm at rpm 440/3500 360/2800 360/2800
Bore ∅ mm 84.5 89.0 89.0
Stroke mm 92.8 96.35 96.35
Compression ratio 11.5 12.0 12.0
Injection/ignition Motronic MED 9.1.1 Motronic MED 9.1 Bosch Motronic MED
FSI FSI 9.1
FSI
RON min. 98 unleaded 1) 98 unleaded 1) 98 unleaded 1)
Leakage diagnosis system (e.g. USA Yes No Yes
vehicles)
Onboard diagnosis (OBD) Yes Yes Yes
1. Engine list 1
Touareg 2003 ➤
AG. Volkswagen AG d
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Engines d byV ⇒ Petrol engine gu Petrol engine
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Engine code ss BAR BHK
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Displacement I 6,0 3.2 3.2
Engine code BJN BKJ BMV
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Power kW at rpm 331/6200 162/5400 177/6000

Torque Nm at rpm 600/3500 305/3200 300/4000
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Bore ∅ mm 84.0 84.0 84.0
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Stroke mm 90.2 95.9 95.9

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Injection/ignition Motronic ME 7.1.1 Motronic ME 7.1.1 Motronic ME 7.1.1
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RON min. 98 unleaded 1) ht. Cop
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Leakage diagnosis system (e.g. USA No No No
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Onboard diagnosis (OBD) No No Yes
Camshaft drive Chain Chain Chain
reduced output.
Engines ⇒ Petrol engine Petrol engine

Displacement I 3.2 3.2
Engine code BRJ BMX
No. of cylinders/valves per cylinder 6/4 6/4
Power kW at rpm 177/6000 177/6000
Torque Nm at rpm 310/3200 305/3200
Bore ∅ mm 84.0 84.0
Stroke mm 95.9 95.9
Compression ratio 11.25 10.85
Injection/ignition Motronic ME 7.1.1 Motronic ME 7.1.1
manifold inj. manifold inj.
RON min. 95 unleaded 95 unleaded
Leakage diagnosis system (e.g. USA vehicles) No Yes
Onboard diagnosis (OBD) Yes Yes
Camshaft drive Chain Chain
2 1. Engine list
Touareg 2003 ➤
Diesel engines
Engines ⇒ Diesel engine Dieselgeengine
AG. VolkswageDiesel
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Displacement I 4.9 by
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Engine code AYH ho ris BAC BKS tee BKW
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No. of cylinders/valves per cyl‐ 10/2
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Power kW at rpm 230/3750 128/3500 165/4000 230/3750
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Torque Nm at rpm 750/2000 400/2000 to 2300 450/1400 to 3250 750/2000
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Bore ∅ mm 81.0 81.0 83.0 81.0
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Stroke mm 95.5 95.5 91.4 95.5
hole
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Compression ratio 18.5 18.5 17.0 18.5
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Injection/ignition TDI TDI TDI TDI
unit injector unit injector common rail unit injector
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Diesel particulate filter (DPF) No No Yes No
Additive system No No No No
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Leakage diagnosis system No No No No

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Onboard diagnosis (OBD) Yes Yes Yes Yes
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Engines ⇒ Diesel engine Diesel engine Diesel engine Diesel engine
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Displacement I 4,9 2.5
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Engine code BLE BPD BPE BLK
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No. of cylinders/valves per cyl‐ 10/2 cted
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Power kW at rpm 230/3750 120/3500 128/3500 120/3500
Torque Nm at rpm 750/2000 400/2000 400/2000 400/2000 to
2300
Bore ∅ mm 81.0 81.0 81.0 81.0
Stroke mm 95.5 95.5 95.5 95.5
unit injector unit injector unit injector unit injector
Diesel particulate filter (DPF) Yes Yes Yes No
Additive system Yes No No No
(e.g. USA vehicles)
Onboard diagnosis (OBD) Yes Yes Yes Yes
Camshaft drive Gear wheel Gear wheel Gear wheel Gear wheel
Engines ⇒ Diesel engine Diesel engine Diesel engine Diesel engine

Displacement I 4.9 3.0 3.0 3.0
Engine code BWF BUN CASA CASB
No. of cylinders/valves per cyl‐ 10/2 6/4 6/4 6/4
inder
Power kW at rpm 230/3750 155/4000 176/4000 155/3500 to
4750
1. Engine list 3
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Touareg 2003 ➤ olks
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Engines ⇒ss Diesel engine Diesel engine Diesel engine
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Displacement I 4.9 3.0 3.0 3.0
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Engine code BWF BUN CASA CASB
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Torque ot Nm at 750/2000 500/1400 550/2000 to 2250 550/2000 to
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Bore ∅ mm 81.0 83.0 83.0 83.0
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Stroke mm 95.5 91.4 91.4 91.4
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unit injector common rail common rail common rail
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Diesel particulate filter (DPF) Yes Yes yes/no1 Yes

Additive system No No No No
nform
ercia

(e.g. USA vehicles)
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Onboard diagnosis Yes Yes Yes Yes
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Camshaft drive Gear wheel Chain Chain Chain
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Engines ⇒ Diesel engine Diesel engine Diesel engine
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Engine code Prote CASC AG.
CATA CBWA
Power kW at rpm 176/4000 to 4400 165/4500 258/3500
Torque Nm at rpm 500/1500 to 3000 550/2000 850/2000
Bore ∅ mm 83.0 83 81.0
Stroke mm 91.4 91.4 95.5
Injection/ignition TDI TDI TDI
common rail common rail unit injector
with and without Blue‐
TDI
Diesel particulate filter (DPF) Yes Yes Yes
Additive system No No Yes
Leakage diagnosis system (e.g. USA No No No
vehicles)
Onboard diagnosis Yes Yes Yes
Camshaft drive Chain Chain Gear wheel
1Vehicles with diesel particulate filter (fitted at the factory) can be
identified by PR No. 7GG, 7MB, 7MG or 7GA on the vehicle data
sticker.
4 1. Engine list
Touareg 2003 ➤
2 Service work
Information on long-life service and time or distance dependent
service ⇒ page 5
Service tables ⇒ page 7
2.1 Information on long-life service and time

or distance dependent service
Service identification ⇒ page 5
LongLife service ⇒ page 5
Time or distance dependent Aservice ⇒ page 5
G. Volkswagen n AG do
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Service interval display ot g
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– Check vehicle data sticker ⇒ page 22 to determine whether
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the vehicle is equipped with PR number “QG0”, “QG1” or
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⇒ page 7 .
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Vehicle IDs with the following PR number

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“QG1” indicates LongLife service

spec
urposes, in part or in wh
“QG0” or “QG2” indicates time or distance dependent service

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2.1.2 LongLife service

rrectne
Vehicles with PR number “QG1”

The LongLife service enables long service intervals, depending
ss
on individual driving style and the conditions under which the ve‐
o
cial p
hicle is used.
inform
mer
atio
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Note
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For the LongLife service a special LongLife engine oil is required

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⇒ page 7
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Vehicles with PR number “QG1” are fitted at the factory with active
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LongLife service. This means that these vehicles have a flexible
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service interval display and are fitted with the following compo‐
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♦ Flexible service interval display in dash panel insert

♦ Engine oil level sensor
♦ Brake pad wear indicator (if fitted)
For vehicles with LongLife service the service interval is deter‐
mined by the control unit and is indicated on service interval
display (SID) ⇒ page 6 .
Therefore the service intervals for LongLife service are flexible.
These flexible service intervals apply to all types of service in‐
cluding an engine oil change.
2.1.3 Time or distance dependent service

For vehicles with time or distance dependent service with PR
number “QG0/QG2” the non-flexible service intervals are set by
Volkswagen according to predetermined mileage or time values.
2. Service work 5
Touareg 2003 ➤
For normal operating conditions achieving these service intervals

is technically assured.
Therefore the service intervals for time or distance dependent
service are non-flexible.
For vehicles
♦ Which were delivered without extended servicing intervals
(ESI) (PR number “QG0” = without ESI, PR number “QG2” =
ESI cannot be activated)
♦ or for which the extended servicing interval (ESI) was stopped
♦ When no LongLife engine oil was used
the time or distance dependent service applies.
These non-flexible service intervals apply to all types of service
including an engine oil change.
Vehicles are “not” factory-fitted with components for LongLife
service. For maintenance the time or distance dependent inter‐
vals (non-flexible intervals) apply.
For 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 intervals (non-flexible intervals) apply. These vehicles wage
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are fitted with the following components: yV
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♦ Engine oil level sensor ss
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For these vehicles the LongLife service is not factory-activated.
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Therefore, these vehicles have a non-flexible service interval dis‐
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play (SID) ⇒ page 6 and for maintenance the time or distance
spec
dependent intervals (non-flexible intervals) apply. These vehicles
t to the co
are fitted with the following components:
♦ Non-flexible service interval display in dash panel insert
rrectne
2.1.4 Service interval display ss o

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Introduction of extended servicing intervals (ESI) ⇒ page 6

nform
mer
Flexible service interval display (only vehicles with LongLife serv‐

atio
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ice, PR number QG1) ⇒ page 6

o
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Non-flexible service interval display (only vehicles with time or

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distance dependent service, PR number “QG0/QG2)”

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⇒ page 7
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Service interval display: resetting ⇒ page 135
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Introduction of extended servicing intervals (ESI)

Ask your importer if the extended servicing interval (ESI) is avail‐
able for your country.
6 2. Service work
Touareg 2003 ➤
Flexible service interval display (only vehicles with LongLife serv‐

ice, PR number QG1)
Calculation of service intervals:
♦ To calculate the service intervals for vehicles with LongLife
service, input values such as distance driven, fuel consump‐. Volkswage
gen AG
tion, oil temperature and load of diesel particulate kfilter
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For vehicles with long-life service (PR number QG1) but which
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service interval display must be recoded to “non-flexible”
⇒ page 136 .
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Non-flexible service interval display (only vehicles with time or
l purpos
distance dependent service, PR number “QG0/QG2)”

Calculation of service intervals:
nform
ercia
♦ To calculate the service interval for vehicles with time or dis‐

m
at
tance dependent service the non-flexible service intervals are
om
io
set by Volkswagen according to predetermined mileage or
n
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or
time values.
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ate
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♦ For normal operating conditions achieving these service in‐

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2.2 Service tables C py
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The following chapter contains the familiar service tables with the
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service specifications of the Volkswagen brand. Since, in the past,
agen
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individual service specifications were set up in various markets,
mostly through severe operating conditions, these are listed in
service tables with specific deviations.
Service tables ⇒ page 7
Service tables with market-specific deviations ⇒ page 13
Note
♦ For combined kilometre and time display applies: whichever

occurs first.
♦ Depending on conditions under which the vehicle is used
⇒ page 24 and vehicle equipment, extra service work must
be performed in addition to the interval service, inspection
service or interval service inspection.
♦ It is also possible, to perform additional work outside the serv‐
ice intervals with regard to the entries in the service schedule
(or sticker: your next service).
2.2.1 Service tables

Service intervals ⇒ page 8
VW engine oil standards ⇒ page 9
Filter change intervals ⇒ page 10
2. Service work 7
Touareg 2003 ➤
Toothed belt change intervals ⇒ page 11

Spark plug change intervals ⇒ page 11
Other additional work based on time and distance ⇒ page 12
Service intervals
Caution
Applies only to diesel engines

• In some countries, diesel has a higher sulphur content.
• The high sulphur content leads to excessive wear of cyl‐
inders and it considerably reduces the cleanliness of pis‐
tons.
♦ Therefore change engine oil every 7,500 km in countries
where the diesel has a high sulphur content.
♦ Countries where diesel has a high sulphur content.
⇒ page 23
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♦ For extremely uneconomical
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treme conditionsss⇒ page 24 , the shortest interval for an oil
change service is “7,500 km or 1 year”.
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♦ However, other intervals apply for other countries. Your im‐

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porter will inform you about this.

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spec
SERVICE INTERVALS ►2007

es, in part or in w
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from-to Engine/Engine code/ Service/intervals Indicated on

PR No./Remarks service interval display SID
(includes oil change)
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Since intro‐ Diesel in countries where sulphur Oil change service YES
l purpos
duction content in fuel is high every 7,500 km or 1 year

⇒ page 23
Since intro‐ Petrol and diesel with QG0/QG2/ Oil change service YES
nform
ercia
duction QG3 every 15,000 km or 1 year

m
or QG1 vehicles coded to non-

at
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io
flexible interval
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►2004 Petrol and diesel: Oil change service YES

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QG1 vehicles flexible from 15,000 km to

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►2004 Petrol and diesel: Inspection service YES
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or QG1 vehicles coded to non-
flexible interval
2005►2007 Petrol and diesel: Interval service YES
QG1 vehicles flexible from 15,000 km to
max. 30,000 km or 2 years
2005►2007 Petrol and diesel: Interval service inspection YES
all vehicles every 60,000 km or 4 years
8 2. Service work
Touareg 2003 ➤
TOUAREG
SERVICE INTERVALS 2008►
from-to Engine/Engine code/ Service/intervals Indicated on
PR No./Remarks service interval display SID
(includes oil change)
Since in‐ Diesel in countries where sul‐ Oil change service YES
troduc‐ phur content in fuel is high every 7,500 km or 1 year
tion ⇒ page 23
2008► Petrol and diesel: Oil change service YES
QG0/QG2 or QG1 vehicles every 15,000 km or 1 year
coded to non-flexible interval Interval service: YES
every 30,000 km or 2 years
Petrol and diesel: Interval service: YES
QG1 vehicles flexible according to SID from
15,000 km or 1 year up to max.
30,000 km or 2 years
Petrol and diesel: Inspection: NO
all vehicles after 3 years/max. 60,000 km,
then every 2 years/60,000 km
VW engine oil standards
Caution
Only engine oils approved by VW may be used; for up-to-date

information see ⇒ ServiceNet, Technical information, Inspec‐
tion and maintenance, Approved oils , or ask your importer.
G. Volkswagen AG d
TOUAREG lksw
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VW ENGINE
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by STANDARDS ara
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PETROL ENGINES au
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With LongLife service (QG1) Without LongLife service (QG0, QG2, QG3)
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VR6, V8 engines without FSI 504 001 alternative VR6, V8 engines without FSI ►2007 501 01/502
an
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VR6, V8 engines without FSI 2008► 502 00

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VR6 FSI, W12 engines 2008► 502 00

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V8 FSI engine 504 001 alternative V8 FSI engine 502 00

503 01
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DIESEL ENGINES
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V10 engines 506 013 V10 engines 506 013

with and without diesel particu‐ with and without diesel particulate fil‐
late filter ter
nform
ercia
►2006 ►2006
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R5 with engine codes BPD and 507 001 R5 with engine codes BPD and BPE 507 001
com
tion in
BPE with diesel particulate filter

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with diesel particulate filter ►2006

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►2006
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R5 engines without diesel par‐ 506 013 R5 engines without diesel particulate 506 013
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ticulate filter4 filter4

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V10 engines without diesel par‐ 507 001 alternative V10 engines without diesel particulate 507 001 al‐
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506 01
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506 01
2. Service work 9
Touareg 2003 ➤
TOUAREG
VW ENGINE OIL STANDARDS
R5, V10 engines with diesel par‐ 507 001 R5, V10 engines with diesel particu‐ 507 001
ticulate filter4 late filter4
2007► 2007►
V6 with diesel particulate filter 507 001 V6 with diesel particulate filter 507 001
V6 without diesel particulate fil‐ 507 001 V6 without diesel particulate filter 505 01
ter agen
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1) Combination product: 504 00/507 00 d by ara
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2) Combination product: 503 00/506 00 au ra
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3) Combination product: 503 00/506 00/506 01

un
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4) Vehicles with diesel particulate filter (fitted at the factory) can be identified by
erm
ab
PR No. 7GG, 7MB, 7MG or 7GA on the vehicle data sticker.
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Filter change intervals
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TOUAREG
FILTER CHANGE INTERVALS
rrectne
Description of work
ENGINE OIL FILTER: 1) 2) ⇒ page 101
ss o
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Vehicles with LongLife service According to flexible service interval display
inform
“QG1”
mer
atio
All other vehicles Every 15,000 km or 1 year
om
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AIR FILTER: ⇒ page 89
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All engines except V6 TDI ►2006 Every 120,000 km or 4 years
sd
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2007► Every 120,000 km or 6 years
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Only V6 TDI ►2006 Every 90,000 km or 4 years
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2007►
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DIESEL FUEL FILTER: 2) ⇒ page 75
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Diesel conforming to Diesel not conforming Biodiesel (RME) 3)
EN 590 to EN 590
Only R5 TDI ►2009 Every 120,000 km Every 60,000 km Every 30,000 km
Only R5 TDI 2010 ► Every 90,000 km Every 60,000 km Every 30,000 km
Only V10 TDI Every 60,000 km Every 30,000 km Every 30,000 km
Only V6 TDI Every 60,000 km Every 30,000 km Every 30,000 km
All unit injector diesel engines Draining water is deleted.
All common rail diesel engines Drain water every Drain water every
30,000 km 15,000 km
DUST AND POLLEN FILTER: ⇒ page 73
All engine types Every 60,000 km or 2 years
1)A new engine oil filter must be installed at every engine oil
change.
2)Only applies to diesel engines: in some countries, diesel has a
high sulphur content. The high sulphur content leads to excessive
wear of cylinders and it considerably reduces the cleanliness of
pistons. Therefore change engine oil every 7,500 km in countries
where the diesel has a high sulphur content. Countries where
diesel has a high sulphur content. ⇒ page 23
10 2. Service work
Touareg 2003 ➤
1)For vehicles with diesel particulate filter biodiesel must not be

used.
Toothed belt change intervals

• If the engine is fitted with toothed belt or timing chain can be
found in the engine list. . Volkswag n AG en AG
wage does
Volks not
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The camshaft drive with timing chain is maintenance-free!
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TOOTHED BELT CHANGE INTERVALS
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PETROL ENGINES
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spec
Engine type Engine code Model year Change interval Tensioning roller
4.2 l AXQ Since introduction Every 120,000 km 120,000 km
t to the co
rrectne
Spark plug change intervals
• Spark plug designation and specified torque ⇒ Power unit;
ss o
Rep. gr. 28 ; Ignition system; Test data, spark plugs → Ignition
cial p
f in
system; Test data, spark plugs
form
mer
atio
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Note
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For technical reasons it is possible that several cross references

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are not directed to the correct chapter. In this case select the pro‐
r
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cedure manually in the information.

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Spark plug change intervals
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Prote AG.
Engine type Engine code Change intervals Description of

work
W12 BJN EVERY 60,000 km ⇒ page 142
V6 indirect inj. AZZ, BAA, BKJ, BMV, • Mileage more than 60,000 km in 4 years
BRJ, BMX
EVERY 4 years
• Mileage less than 60,000 km in 4 years
V8 AXQ, BAR EVERY 90,000 km

V6 FSI and TFSI BHK, BHL • Mileage more than 90,000 km in 6 years
EVERY 6 years
• Mileage less than 90,000 km in 6 years
2. Service work 11
Touareg 2003 ➤
Other additional work based on time or distance

Additional work based on time and distance Interval Description of
work
– Diesel particulate filter: Read ash loading level At 90,000 km, ⇒ page 38
then every
• Only valid for V10 TDI with diesel particulate filter and additive sys‐ 30,000 km
tem
• When the ash mass limit is reached, renew diesel particulate filter.
– Fuel additive tank: Extract residual fluid and replenish with new ad‐ Every 90,000 km ⇒ page 32
ditive fluid
• Only valid for V10 TDI with diesel particulate filter and additive
agen
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olkswagen AG
does
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• Only valid for vehicles driving more than 90,000
or
ise km in 4 years tee
th or
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– Elastic drive coupling and air ss
conditioner compressor drive free‐ Every 150,000 ⇒ page 139
ce
le
wheel. Renew km
un
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• Only valid for R5 TDI, engine codes BAC and BLK
rm
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– Elastic drive coupling and alternator drive freewheel. Renew Every 150,000 ⇒ page 139
, is n
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spec
• Only valid for R5 TDI, engine codes BAC and BLK
es, in part or in w
t to the co
– Diesel particulate filter: Read ash loading level Every 150,000 ⇒ page 38
km,
• Only valid for R5 TDI with diesel particulate filter without additive then every
rrectness of i
system and 3.0 l TDI 30,000 km
l purpos
• When the ash mass limit is reached, renew diesel particulate filter.
nform
– Elastic drive coupling and air conditioner compressor drive free‐ Every 180,000 ⇒ page 139
ercia
wheel. Renew km
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• Only valid for R5 TDI, engine codes BPD and BPE
n in
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– Elastic drive coupling and alternator drive freewheel. Renew Every 180,000 ⇒ page 139
do
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km
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• Only valid for R5 TDI, engine codes BPD and BPE

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– Diesel particulate filter: read ash load yri
gh Every 180,000
by ⇒ page 38
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Prote AG.
system
– Exhaust emissions test (EET): Perform Every 12 months ⇒ page 153
• For vehicles with commercial passenger transport, e.g. taxis

• Applies only to Germany
– Brake and clutch system: changing brake fluid Every 2 years ⇒ page 64
• Only applies to vehicles ►2007
– Exhaust emissions test (EET): Perform 3 years after ini‐ ⇒ page 153
tial registration,
then every 2
years
– Brake and clutch system: changing brake fluid 3 years after ini‐ ⇒ page 64
tial registration,
• Only applies to vehicles 2008► then every 2
years
12 2. Service work
Touareg 2003 ➤
Additional work based on time and distance Interval Description of

work
– Fuel additive tank: Extract residual fluid and replenish with new ad‐ Every 4 years ⇒ page 32
ditive fluid
• Only valid for V10 TDI with diesel particulate filter and additive sys‐
AG. Volkswagen AG d
tem lkswagen oes
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• Only valid for vehicles driving
ris
edless than 90,000 km in 4 years
b ran
tee
ho
ut or
– Reducing agent tank: schange
sa fluid Every ac
4 years ⇒ page 56
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• Only valid for V6 Blue TDI
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• Only valid when no reducing agent has been replenished for 4 years
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2.2.2 Service tables with market-specific de‐
es, in part or in w
t to the co
viations
rrectness of i
Note
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This chapter only provides information on market-specific devia‐
nform
tions. This means that all maintenance points that are not shown
ercia
here are to be found in the normal service tables.

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Indian market
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Interval Description of
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Interval service (QG0/QG2/QG3)2) Every 15,000 km → Mainte‐
Co
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or 1 year1) nance tables
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Inspection service Every 30,000 km → Mainte‐
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Prote AG.
or 2 years1) nance tables
– Multi-purpose additive for petrol fuel: adding At every service ⇒ page 72
– Dust and pollen filter (cabin filter): renew. Every 15,000 km ⇒ page 73
or 1 year1)
– Air filter element: renew and clean housing. Every 15,000 km ⇒ page 89
or 1 year1)
– Diesel fuel filter: renew. Every 15,000 km ⇒ page 75
– Spark plugs: renewing Every 30,000 km ⇒ page 142
or 2 years1)
or 4 years1)
• Only valid for V6 FSI and TFSI
1) Whichever occurs first.

2) Oil change service has been omitted in the Indian market. The
interval service is carried out as a substitute. Changing the engine
oil is an integral part of the interval service.
2. Service work 13
Touareg 2003 ➤
AG. Volkswagen AG d
agen oes
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Russian market from model yearb2010 yV
o gu
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ed
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ra Interval Description of
ss a c work
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Interval service (QG0/QG2/QG3)2) un Every 15,000 km → Mainte‐
pt
an
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or 1 year1) nance tables
itte
(appears on service interval display)
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(does not appears on service interval display) or 2 years1) nance tables
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or 1 year1)
or 2 years1)
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– Diesel fuel filter: renew. Every 30,000 km ⇒ page 75
s
– Air filter element: check; renew as needed and clean housing. Every 30,000 km ⇒ page 89
s o
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or 2 years1)
inform
mer
atio
om
n
c
2)Oil change service has been omitted in the Russian market.
i
or
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The interval service is carried out as a substitute. Changing the

t
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engine oil is an integral part of the interval service.

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agen
work
Sliding sunroof drains: checking
– for blockage, cleaning if necessary Every 60,000 km ⇒ page 127
Diesel particulate
– filter: Renew Every 120,000 miles ⇒ page 68
• Only valid for V10 TDI with diesel particulate filter without additive
system
China market
Note
In the Chinese market no engine oils to VW standard 504 00/507

00 may be used because of poor fuel quality. ⇒ page 9
work
Oil change service (QG0/QG2/QG3) Once after 5,000 km → Mainte‐
nance tables
Oil change service (QG0/QG2/QG3) Every 10,000 km → Mainte‐
(appears on service interval display) or 1 year1) nance tables
Interval service (QG0/QG2/QG3) Every 20,000 km → Mainte‐
(appears on service interval display) or 2 years1) nance tables
(does not appears on service interval display) or 3 years 1), and nance tables
then every 30,000
km / 2 years
or 1 year1)
14 2. Service work
Touareg 2003 ➤
work
or 2 years1)
• Only applies to 3.6 l V6 FSI and 4.2 l V8 FSI
– Air filter element: renew and clean housing. Every 30,000 km ⇒ page 89
or 2 years1)
or 2 years1)
• Only applies to 6.0 l W12 MPI

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es, in part or in w
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2. Service work 15
Touareg 2003 ➤
3 General information
♦ Raising vehicle with lifting platform or trolley jack
⇒ page 16
♦ Sticker ⇒ page 17
♦ Entries in service schedule ⇒ page 19
♦ Connecting vehicle diagnosis tester ⇒ page 19
♦ Vehicle identification number ⇒ page 21
♦ Vehicle data sticker ⇒ page 22
♦ Countries where diesel has a high sulphur content
⇒ page 23
♦ Engine code and engine number ⇒ page 23
♦ RME fuel (biodiesel) ⇒ page 23
♦ Severe operating conditions ⇒ 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 up mode must be activated,

then the self-levelling suspensionnis
AGswitched
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age does
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Activate jacking-up mode ed
b see ⇒ page 24 . ara
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3.1.1 Safety notes:
t
au ra
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nl
pt
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an
WARNING
itte
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♦ Before driving onto a lifting platform, ensure that there is

wit
sufficient clearance between low-lying vehicle compo‐

, is n
h re
nents and lifting platform.

hole
spec
♦ Before driving a vehicle onto a lifting platform it must be

es, in part or in w
t to the co
ensured that the vehicle weight does not exceed the per‐
missible lifting capacity of the platform.
♦ Vehicle may be lifted only at points indicated in figure to
rrectness of i
avoid damaging vehicle floor pan or tipping vehicle.

l purpos
♦ Never start engine and engage a gear with vehicle lifted

as long as even one driven wheel has contact with the
nf
ercia
floor! Disregarding these warnings risks the danger of an

or
accident!
m
m
atio
om
♦ If work is to be performed under vehicle, it must be sup‐

n in
or c
ported by suitable jack stands.

thi
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16 3. General information
oes Touareg 2003 ➤
AG. Volkswagen AG d
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3.1.2 Lifting points for lifting platform or trolley ss au ra
c
jack:
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pt
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an
itte
Front lifting point:
y li
erm
ab
ility
– Position support plate at reinforcement -arrow- of floor pan.
ot p
wit
, is n
h re
hole
WARNING
spec
es, in part or in w
t to the co
Under no circumstances must vehicle be raised on vertical
stiffener of side member.
rrectness of i
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Rear lifting point:

– Position support plate at reinforcement of floor pan near rear
nf
ercia
axle mounting -arrow-.
orm
m
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om
n in
WARNING
or c
thi
te
sd
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Ensure that support plate of raising platform is centred under

iv
o
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reinforcement.
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3.2 Stickers
In this chapter there are stickers which apply for the German
market. The stickers determined for your country can be obtained
from your importer.
Attaching “Your next service” sticker ⇒ page 17
Attaching “data sticker” in customer service schedule
⇒ page 18
Attaching “LongLife engine oil” sticker ⇒ page 18
3.2.1 Attaching “Your next service” sticker

Sticker up to week 44/2009
– Your “next service dates” sticker: Enter a cross in position for
next oil change service or inspection service (next service due)
and enter date/odometer reading
3. General information 17
Touareg 2003 ➤
Sticker from week 45/2009

– Service sticker “Your next service”: Enter a cross in position
for next oil change service or inspection service or legal check
such as legislative inspection or gas system check (next serv‐
ice due) and enter date and mileage.
Note
The new sticker is applied gradually from week 45/2009.
Service intervals ⇒ page 7
– Attach sticker to driver side door pillar (B-pillar) -arrow-.
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spec
3.2.2 Attaching “data sticker” in customer
t to the co
service schedule:
rrectne
– Attach the lower of the two data stickers -arrow- in the service
schedule.
ss o
cial p
f inform
mer
atio
om
n
c
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n thi
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3.2.3 Attaching “Long-life engine oil” sticker

en
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Cop py
– For vehicles with LongLife service (PR number QG1), the
t. rig
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sticker (article number K69.5121.50.20) as shown below must
p by
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be attached. Prote
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agen
– Attach sticker -arrow- as shown on left side of lock carrier (from

driver perspective).
Touareg 2003 ➤
3.2.4 Entries in service schedule

If a component is changed which has a change interval prescribed
by the manufacturer, e.g. the toothed belt, the new change inter‐
val begins at the time the component is changed.
• Therefore it is very important, every time a component is
changed, to document this in the service schedule.
• This also applies to components which were changed before
the regular change interval.
Note
♦ When using “Genuine parts kits” it must be taken into account

whether it is technically necessary to change all the compo‐
nents included in the genuine parts kits.
♦ If more components are renewed than is technically necessa‐
ry, inform the customer before repair!
3.3 Connecting vehicle diagnostic tester

Special tools and workshop equipment required
♦ Vehicle diagnostic, testing and information system - VAS 5051
B-
AG. Volkswagen AG d
agen oes
olksw not
♦ Diagnostic cable - VAS 5051/6A- d by V gu
ara
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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
nform
mercia
at
om
ion
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or
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ate
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Prote AG.
Touareg 2003 ➤
♦ Vehicle diagnostic and service information system - VAS

5052- or successor
♦ Diagnostic cable, 2 m - VAS 5052/3 A-
Note
AG. Volkswagen AG d
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lksw not
Ensure that the selected vehicle diagnostic
d byV
o
tester is used only gu
ara
with the respective diagnostic cable.
orise nte
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WARNING
un
pt
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♦ During a road test, you must always secure testing and

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measuring equipment on the back seat.

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is n
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♦ Only a passenger may operate these devices while the

ole,
vehicle is in motion.
spec
t to the co
– Carry out the following procedure:

rrectness o
cial p
f inform
mer
atio
om
n
c
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Touareg 2003 ➤
Open cover -1- and connect vehicle diagnostic tester .

– Switch on the vehicle diagnostic tester .
– Switch on ignition.
Now follow information given on screen to start desired functions.
AG. Volkswagen AG d
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3.4 Vehicle identification number
h re
hole
spec
es, in part or in w
Location: windscreen
t to the co
The vehicle identification number -see enlargement- is located
behind the windscreen on driver side.
rrectness of i
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Location: near spare wheel well

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The vehicle identification number is located in rear of vehicle on C py
t. rig
the right near the spare wheel well -arrow A-. gh ht
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3.4.1 Significance of vehicle identification number

WVG ZZZ 7L Z 3 D 000 234
Manufacturer Filler charac‐ Model Filler charac‐ Model year Production lo‐ Serial number
code ters ters 2003 cation
Touareg 2003 ➤
3.5 Vehicle data sticker

Location: dash panel trim
The vehicle data sticker -arrow- is mounted on the dash panel trim
in the footwell on driver side. The vehicle data sticker is also found
in the service schedule for the customer.
On the left side of left-hand drive vehicles, on the right side of
right-hand drive vehicles.
AG. Volkswagen AG d
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Location: near spare wheel well ss c
ce
le
un
pt
The vehicle data sticker is located in rear of vehicle in spare wheel
an
d
itte
well -B-.
y li
erm
ab
ility
Contents of vehicle data sticker
ot p
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is n
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ole,
spec
t to the co
rrectnes
The sticker contains the following data of the vehicle
s o
cial p
f in
1 - Vehicle identification number (chassis number)
form
mer
2 - Vehicle type, engine output, gearbox
atio
om
n
c
3 - Engine and gearbox code letters, paint number, interior equip‐

i
or
n thi
e
ment
t
sd
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pr
4 - Optional equipment, PR numbers

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The sticker in service schedule includes the same data. The leg‐
end can be found below the sticker.
AG. Volkswagen AG d
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d by ara
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h eo
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3.6 Countries where diesel has a high sul‐
pt
du
an
itte
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phur content
erm
ab
ility
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Applies only to diesel engines, as diesel fuel in some countries
wit
, is n
has a high sulphur content The high sulphur content leads to ex‐
h re
hole
cessive wear of cylinders and it considerably reduces the clean‐
spec
liness of pistons. Therefore change engine oil every 7,500 km in
es, in part or in w
t to the co
countries where the diesel has a high sulphur content.
Afghanistan Ghana Cuba Saudi Arabia
rrectness of i
Egypt Guatemala Kuwait Senegal
l purpos
Algeria Honduras Laos Zimbabwe

Angola Indonesia Lebanon Sri Lanka and the Mal‐
dives
nform
ercia
Argentina Iraq Libya Sudan

m
at
om
io
Armenia Iran Madagascar Surinam
n
c
in t
or
Bangladesh Jamaica Mali Syria
his
ate
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Bolivia Jordan Mauritius Tajikistan

p
cum
for
en
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Brazil Cambodia Mongolia Tanzania

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Brunei Cameroon Myanmar (Burma) Trinidad and Tobago
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Dominican Republic Kazakhstan Nigeria Tunisia
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Ecuador Prote
Qatar Pakistan Uruguay
AG.
Ivory Coast Kenya Paraguay Uzbekistan

El Salvador Kyrgyz Republic Peru Venezuela
Gabon Columbia Russian Federation Vietnam
China Republic of Congo Pacific islands, driving on
left
3.7 Engine code and engine number

Engine code and engine number “Power unit” ⇒ Rep. gr. 00
“Technical data/engine number”
3.8 RME fuel (biodiesel)

The RME compatibility for the approved engines is only valid up
to and including model year 2007
Caution
♦ For vehicles with diesel particulate filter RME fuel (biodie‐

sel) must not be used.
♦ When RME fuel is used and your vehicle is not suitable for
this, the fuel system can be damaged.
♦ When filling the tank with biodiesel, only use RME fuel
conforming to EN 14214 (FAME)!
♦ When biodiesel is used which does not conform to the re‐
quired standard, the diesel fuel filter can become blocked.
RME fuel must conform to EN 14214 (FAME).

Characteristics of RME fuel
♦ Performance can slightly be lower when using biodiesel.
♦ Fuel consumption can slightly be higher when using biodiesel.
Touareg 2003 ➤
♦ RME can be used in winter at temperatures to approx. -10 °C

♦ At ambient temperatures below -10 °C we recommend using
winter diesel fuel.
Note
kswage es n
♦ When using biodiesel observe the changed intervalsbyfor Vol ot g
ua
changing the diesel fuel filter ⇒ page 7 o
ir se
d ran
tee
th or
♦ If it is planned not to use the vehicle for approx.
ss
au
two weeks, it ac
is recommended to fill the tank with original diesel beforehand
ce
e
nl
and drive approx. 50 km, to prevent damage to the fuel injec‐
pt
du
an
tion system. itte
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erm
ab
ility
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3.9 Severe operating conditions
wit
, is n
h re
hole
If the vehicle is used under severe operating conditions, some
spec
jobs will have to be performed before the next due service date
es, in part or in w
t to the co
or between the specified service intervals.
Severe operating conditions
rrectness of i
• Regular short trips or stop and go operation in urban traffic
l purpos
• High percentage of cold starts

• Vehicle is used in areas with winter temperatures over a long
nf
ercia
period
orm
m
atio
• Regular long periods of idling (e.g. taxis)
om
n in
or c
• Vehicle is often driven at full throttle with high payload or whilst
thi
te
towing a trailer
sd
iva
o
r
rp
cu
• Using diesel with elevated sulphur content
o
m
f
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ng
t.
yi Co
• Regular operation in areas with high levels of dust t. Cop py
rig
gh ht
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3.10 Identification plate
p by
co Vo
by lksw
cted agen
Prote AG.
The type plate -arrow- is attached to the plenum chamber bulk‐
head on the right (from driver perspective).
Note
Vehicles for certain export countries have no type plate.
3.11 Jacking up mode: switching self-level‐

ling suspension off and on
The self-levelling suspension must be switched off before vehicle
is raised.
The self-levelling suspension is switched off in jacking up mode
to prevent automatic adjustment when lifting platform or trolley
jack is used.
Switch off self-levelling suspension
• The vehicle must be stationary.
Touareg 2003 ➤
– Press button LOCK in centre console -arrow- and hold for 5
seconds.
The “jacking up mode” is displayed in the dash panel insert, a
warning lamp flashes in LOCK button.
After activating, the ignition can be switched off.
Switching on self-levelling suspension lkswage es n
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un
pt
There are two methods to activate the self-levelling suspension
an
d
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again.
rm
ab
pe
ility
– With ignition switched on, press button LOCK in centre console ot
wit
, is n
-arrow- and hold for more than 5 seconds.
h re
hole
spec
or
es, in part or in w
t to the co
– The self-levelling suspension is also activated when driving
faster than 5 km/h.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
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t.
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Cop py
t. rig
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pyri by
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Touareg 2003 ➤
4 Descriptions of work:
♦ Removable towing bracket: checking and cleaning if neces‐
sary ⇒ page 28
♦ Turbocharger: Lubricate control motor linkage
wage⇒ page 30
es ks not
Vol gu
♦ Swivel joints and axle mountings: inspecting
ed
by ⇒ page 31 ara
nte
is
or eo
♦ Additive tank: Extract fluid and au replenish with new additive
th ra
⇒ page 32 ss c
ce
le
un
pt
♦ Automatic gearbox: checking ATF level ⇒ page 38
an
d
itte
y li
rm
♦ Battery cut-off relay: Remove ⇒ page 38
ab
pe
ility
ot
♦ Battery: checking battery terminal clamps for secure seating
wit
, is n
⇒ page 40
h re
hole
spec
♦ Battery: check using battery tester with printer VAS 5097A or
es, in part or in w
VAS 6161 ⇒ page 47
t to the co
♦ Tyres: checking condition, wear pattern, tyre pressure and
tread depth ⇒ page 56
rrectness of i
♦ Brake system and shock absorbers: inspecting for leaks and
l purpos
damage ⇒ page 63
♦ Brake fluid: changing ⇒ page 64
nform
ercia
♦ Brake fluid level (dependent upon lining wear): checking

m
a
⇒ page 67
com
tion in
r
♦ Brakes, front and rear: checking thickness of brake pads and

te o
thi
condition of brake discs ⇒ page 61
s
iva
do
r
rp
cum
♦ Diesel fuel filter: draining ⇒ page 74
fo
en
ng
t.
yi Co
♦ Diesel fuel filter: renewing (diesel engine) ⇒ page 75 t. Cop py
rig
gh ht
yri
♦ Diesel particulate filter: reading ash loading level p by
co Vo
⇒ page 38
by lksw
cted agen
Prote AG.
♦ Diesel particulate filter: Renew ⇒ page 68
♦ Window regulators: checking positioning (open and close
functions) ⇒ page 69
♦ Vehicles with reversing camera system: Check number plate
⇒ page 70
♦ Vehicle system test: Carry out test ⇒ page 70
♦ Front airbag for the front passenger: Check activation / deac‐
tivation ⇒ page 71
♦ Bonnet: greasing catch hook ⇒ page 72
♦ Gearbox, final drive (especially on flanges) and drive shaft
boots: Carry out visual check for leaks and damage
⇒ page 73
♦ Gearbox, transfer box and front and rear final drive: Check oil
level, replenish if necessary ⇒ page 142
♦ Dust and pollen filter: cleaning housing and renewing filter el‐
ement ⇒ page 73
♦ Interior and exterior body: inspecting for corrosion when doors
and flaps are open ⇒ page 84
♦ Poly V-belt: checking condition ⇒ page 73
♦ Compass in roof module: Set compass zones ⇒ page 85
26 4. Descriptions of work:
Touareg 2003 ➤
♦ Cooling system: checking frost protection and coolant level

⇒ page 86
♦ Air filter: cleaning housing and renewing filter element
⇒ page 89
♦ Multi-purpose additive for petrol fuels: adding ⇒ page 72
♦ Oil level: checking ⇒ page 100
♦ Engine oil: draining or extracting; renewing oil filter and re‐
plenishing engine oil ⇒ page 101
♦ Engine cover panel -top-: Removing and installing
⇒ page 109
♦ Engine cover -bottom- (noise insulation): removing and instal‐
ling ⇒ page 110
♦ Engine and components in engine compartment: inspecting
for leaks and damage (from above and below) ⇒ page 111
♦ Checking tyre repair set ⇒ page 112
♦ Road test (performance, handling, noises, air conditioner etc.):
carrying out ⇒ page 112
♦ Wheel securing bolts: tighteningagto specified
en AG. Volkswatorque
gen AG
does
⇒ page 113 Volksw not
g by ua
ed ran
♦ Radio code: readingho
riusing
s vehicle diagnostic tester tee
⇒ page 114 aut or
ac
ss
♦ Radio/navigation system: activating anti-theft coding ce
e
nl
pt
du
⇒ page 115 an
itte
y li
erm
ab
♦ Reducing agent (AdBlue®): replenishing ⇒ page 47 ility
ot p
wit
♦ Reducing agent (AdBlue®): changing ⇒ page 56

, is n
h re
hole
♦ Storing tyre pressure values ⇒ page 60

spec
es, in part or in w
♦ Power assisted steering: checking fluid level ⇒ page 118

t to the co
♦ Headlight adjustment: checking and adjusting as necessary

⇒ page 119
rrectness of i
♦ Sunroof: checking function, cleaning and lubricating guide

l purpos
rails ⇒ page 127

♦ Sliding sunroof drains: checking for blockage, cleaning if nec‐
nform
ercia
essary ⇒ page 127

m
at
om
♦ Window wash/wipe system and headlight washer system:

ion
Check function and for damage, if necessary replenish fluid

c
in t
or
⇒ page 129
his
ate
do
riv
♦ Wiper blade protection: removing ⇒ page 132

p
cum
for
en
ng
♦ Service interval display: resetting ⇒ page 135

t.
yi Co
Cop py
t. rig
♦ Service interval display: recoding ⇒ page 136 opyri
gh by
Vo
ht
c lksw
♦ Track rod ends: checking clearance, security and boots
by
cted agen
Prote
⇒ page 137
AG.
♦ Transportation mode: switching off ⇒ page 138

♦ Door arrester: lubricating ⇒ page 139
♦ Elastic drive coupling and freewheel disc: Renew
⇒ page 139
♦ Underbody: inspecting for damage to underbody sealant, un‐
derbody panels, routing of lines, plugs ⇒ page 140
♦ Setting time, language and units: On dash panel insert display
⇒ page 140
4. Descriptions of work: 27
Touareg 2003 ➤
♦ Camshaft drive toothed belt: renewing (8-cylinder petrol en‐

gines) ⇒ page 142
♦ Spark plugs: renewing ⇒ page 142
♦ Static cornering light (cornering light) and driving light assist:
checking function ⇒ page 151
4.1 Removable towing bracket: checking

and cleaning if necessary
This chapter describes how to check and repair a removable tow‐
ing bracket.
Note
Note that checking towing bracket is included in the respective

service. However, a repair is charged separately and must be re‐
quired by the customer.
Check procedure
– Remove cover (if fitted) -1-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
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a ac
ss
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e
nl
pt
du
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itte
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erm
ab
ility
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wit
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h re
hole
spec
es, in part or in w
t to the co
– Pull off protective cap -1- from ball head mounting -2-.
– Insert ball head into mounting.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
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for
en
ng
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by
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Prote AG.
Touareg 2003 ➤
AG. Volkswagen AG d
agen o
After ball head has been inserted, olks green mark on hand wheel
w es n
ot g
yV
must be aligned with white ed mark on ball head. Hand wheel must
b ua
ran
oris
be entirely in contact. tAfterwards, it must be possible to close the tee
h or
towing bracket lockssby removing the key. If this is not possible,
au ac
the following repair procedure must be performed.
ce
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Note
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If a repair has to be performed, it has only to be in agreement with
h re
the customer. A repair must be charged separately.
hole
spec
es, in part or in w
t to the co
Repair procedure:
– Check contact surfaces -arrows- of ball head mounting for
rrectness of i
corrosion.
l purpos
– If contact surfaces are corroded, eliminate corrosion with a tri‐

angular scraper and clean the treated areas with silicone
remover.
nform
ercia
– Apply a thin coat of lubricating paste G 000 650 or G 000 150

m
at
om
i
on cleaned surfaces.
on
c
in t
or
his
ate
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for
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Cop py
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rig ht
– Check contact surfaces -arrows- of ball head for corrosion.
py by
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cted agen
– If contact surfaces are corroded, eliminate corrosion with a tri‐
Prote AG.
angular scraper and clean the treated areas with silicone

remover.
– Apply a thin coat of lubricating paste G 000 650 or G 000 150
on cleaned surfaces.
– Check again ball head seat in mounting ⇒ page 28 .
– After checking, fit protective cap -1- into ball head mounting
-2-.
Note
If protective cap is damaged or not available, a new protective

cap must be fitted to protect ball head mounting against corrosion
⇒ ETKA
Touareg 2003 ➤
– Insert cover -1-.
lkswage es n
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4.2 Turbocharger: Lubricate control motor
ility
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linkage
wit
is n
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ole,
spec
Lubricating the control motor linkage includes:
t to the co
1. - Turbocharger 1 control motor -V280- for cylinder bank 1 (right
engine side).
2. - Turbocharger 2 control motor -V281- for cylinder bank 2 (left
rrectne
engine side).
– Remove engine cover -bottom- (noise insulation)
ss o
⇒ page 110 .
cial p
f inform
1) Lubricate linkage: Turbocharger control motor -right engine
mer
side-
atio
om
n
c
Fitting location: Front right wheel housing, above steering bel‐
i
or
n thi
e
lows, between front longitudinal member and engine block

t
sd
va
-arrow A-
i
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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Prote AG.
– Lubricate rotating point of control motor shaft and linkage

-arrows A- and -B- by hand.
Only use high-temperature paste - G 052 112 A3- .
2) Lubricate linkage: Turbocharger control motor -left engine side-
Touareg 2003 ➤
Fitting location: Front left, between steering and housing of front

final drive, above coolant hoses -arrow A-.
– Lubricate rotating point of control motor shaft and linkage

-arrows A- and -B- by hand.
Only use high-temperature paste - G 052 112 A3-
AG. Volkswagen AG d
agen oes
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by
4.3 Swivel joints and suspension link
d ara
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or eo
h
mountings: inspecting
ss aut ra
c
ce
le
– Check boot -arrow- of upper swivel joint for leaks and damage.
un
pt
an
d
itte
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rm
ab
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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– Check boot -arrow- of lower swivel joint for leaks and damage.
nform
ercia
– Check axle mounting for damage.

m
a
com
tion in
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Cop py
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Prote AG.
Touareg 2003 ➤
4.4 Additive tank: extracting fluid and filling

new additive
4.4.1 Safety measures and code of conduct

when working on additive tank system
WARNING
Please note the following for all procedures:

♦ The diesel additive fluid is hazardous to health.
♦ Read safety instructions on new additive fluid container!
WARNING

♦ Information concerning “Danger to 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.
♦ Before starting work, place extraction hose of switched on
exhaust extraction system near the connections of addi‐
tive tank, to ensure the released additive emissions are
extracted. . Volkswagen AG
gen AG does
swa
♦ If no exhaust extraction system is available, a radial fany V olk not
gu
3
with a displacement greater than 15 m /h can be used ed b ara
ris nte
providing that motor is not in air flow. ut
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WARNING
erm
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ility
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wit
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♦ For all assembly work on the additive tank system always
hole
spec
wear eye protection and fuel resistant protective gloves
es, in part or in w
(avoid additive contact with skin)!

t to the co
♦ Always perform assembly work on open system in well

ventilated rooms!
rrectness of i
♦ Do not inhale vapours of additive fluid!

l purpos
♦ Keep additive fluid away from heat, sparks and open

flame.
nform
ercia
♦ The fluid vapours in combination with air can create an

m
at
explosive mixture.
om
ion
c
in t
r
♦ Vapours are heavier than air and can spread to igniting

o
his
te
sources near ground level.

a
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priv
cum
for
en
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t.
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Cop py
ht. rig
rig ht
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by lksw
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Prote AG.
Touareg 2003 ➤
WARNING AG. Volkswagen AG d

agen oes
olksw not
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Please note the following for all procedures: ise
d b ara
nte
or eo
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♦ The diesel additive must not drain into sewerage aut
and not ra
c
soak into the soil. If leaks occur, immediately
s bind and
s
ce
e
eliminate.
nl
pt
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itte
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♦ The additive tank is under pressure! Before opening the
erm
ab
system, place a cloth around the connection, and reduce
ility
ot p
pressure by carefully loosening the connection!
wit
, is n
h re
♦ Collect fluid in a container e.g. when lines are drained
hole
spec
empty etc.!
es, in part or in w
t to the co
♦ 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.
rrectness of i
♦ Make sure that there is sufficient clearance to all moving
l purpos
or hot components.
nform
mercia
Caution
at
om
ion
c
in t
r
Information concerning storage and disposal ⇒ ServiceNet →

o
his
te
Environmental protection → Workshop disposal . Ask your im‐

a
do
riv
porter about country-specific information on storage and dis‐

p
cum
or
posal.
f
en
ng
t.
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op
The refill container must be disposed of in accordance with
C py
t. rig
gh
environmental regulations.
ht
pyri by
Vo
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Prote AG.
4.4.2 General information
Note
♦ The additive tank connections are found behind a cover on the

tank cap.
♦ The additive tank has a capacity of approx. 4.5 to 5 litres.
♦ Only use new fluid.
♦ The part number of the 1.0 litre container is -G 052 143 A2-
♦ If the residual capacity in the additive tank is less than 0.3 li‐
tres, this is shown on display in the dash panel insert.
4.4.3 Removing sealing plug

– Open tank flap and remove tank cap.
– Place cap -2- at top of tank flap.
Touareg 2003 ➤
The connections for the additive tank system are found behind
the cover -1-
– Carefully pull cover out of mounting -arrow-.
Note
Now the cover is only secured to the drain hose.
– Turn cover -B- at drain hose connection -C- approx. 90 de‐

grees anti-clockwise so that the connections are visible.
The connections are located on tank filler neck -arrow A-
Note
Always note safety measures when working on additive tank!
– First pull sealing plug off VENTILATION -arrow B-,

⇒ page 35 !
– Then pull sealing plug off EXTRACTION/FILLING -arrow A-
⇒ page 35
– Before opening the system, place a cloth around the connec‐
tion, and reduce pressure by carefully loosening the connec‐
AG. Volkswagen AG d
tion! lkswagen oes
no o t gu
yV
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Pull off sealing plug as follows:

ility
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-Arrow A- round connector side.

wit
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h re
hole
-Arrow B- flat connector side.

spec
es, in part or in w
– Push securing ring in at round side of connector -arrow A- by

t to the co
hand or with suitable tool and pull off connector.

rrectness of i
l purpos
nf
ercia
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Prote AG.
Touareg 2003 ➤
4.4.4 Connections for fuel additive tank

VENTILATION -arrow B- (smaller connection diameter).
EXTRACTION/FILLING -arrow A- (larger connection diameter).
AG. Volkswagen AG d
agen oes
olksw not
V gu
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4.4.5 Extracting and replenishing with fluid aut
hor eo
ra
ss c
Special tools, testers, measuring instruments and auxiliary items
ce
le
un
required
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itte
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ility
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spec
t to the co
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cial p
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mer
atio
om
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or
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Prote AG.
♦ Extraction unit - VAS 6277/1-

♦ Filling device - VAS 6277/2-
♦ Overflow protection - VAS 6277/3-
♦ Hose clamp - 3094-
Extracting fluid:
Note
Observe instruction manual for extraction unit - VAS 6277/1- .
– Push connector -4- of extraction unit - VAS 6277/1- onto con‐

nection for EXTRACTION/FILLING, respective connections
⇒ page 35 .
Touareg 2003 ➤
– Connect compressed air supply -2- to extraction unit - VAS

6277/1- .
– Extract fluid by carefully pulling metering lever -3-.
WARNING
♦ Turn ventilation -1- in direction of the well ventilated room,

do not inhale emitting vapours.
♦ Ensure the extraction container of the extraction unit - VAS
6277/1- is not overfilled during extraction process. A dan‐
ger of overflowing exists.
♦ Finish extraction process when the container is approx. swagen AG. Volkswagen AG does
2/3 full, see -arrow 5-. by
Vol
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♦ If necessary repeat extraction process. tho
ris e or
au ac
♦ Do not reuse extracted (used) additive fluid.ss
ce
le
un
pt
♦ Dispose of extracted (used) additive fluid according to op‐
an
d
itte
erating instructions ⇒ ServiceNet; HSO; Environmental
y li
rm
ab
Handbook 3 .
pe
ility
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hole
– If the total quantity of fluid has been extracted, separate com‐
spec
pressed air supply.
es, in part or in w
t to the co
Replenishing fluid:
rrectness of i
– Bolt container with new additive fluid -1- to filling device - VAS
6277/2- .
l purpos
– Connect filling device - VAS 6277/2- and overflow protection

- VAS 6277/3- with connections -3- and -4- to respective con‐
nform
ercia
nections ⇒ page 35 .
m
a
– Additionally secure hose clamp e.g. hose clamp - VAS 6277/2-
com
tio
on hose end of filling device - 3094-
n in
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The hose clamp prevents that after filling and when pulling off Cop py
ht. rig
hose, fluid is drained from filler hose. rig ht
py by
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The additive tank has a capacity of approx. 4.5 to 5 litres.
Prote AG.
– Open valve -2-, and drain fluid into additive tank.
Note
♦ The system must not be overfilled.

♦ In case of overfilling fluid is visible on hose of overflow pro‐
tection - VAS 6277/3- .
Touareg 2003 ➤
– Seal valve -2-, and clamp off filler hose using e.g. hose clamp
- 3094- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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– Separate filling device - VAS 6277/2- and overflow protection
ce
le
un
pt
- VAS 6277/3- from additive tank connections -arrows A + B-.
an
d
itte
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ab
ility
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ole,
spec
t to the co
rrectness o
– Connect both sealing plugs onto connections.
cial p
f inform
– Reinstall cover -1-.

mer
atio
m
– Seal tank filler neck.

o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
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t.
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Cop py
t. rig
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pyri by
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Prote AG.
4.4.6 Final checks

– Unscrew additive tank from filling device - VAS 6277/2- .
– Drain all fluid from filling device - VAS 6277/2- , so that no
residual fluid will remain in the hose or cut-off valve.
Note
Residual fluid crystallises in combination with oxygen.
Caution
Crystallised fluid may cause malfunctions in the additive sys‐

tem.
Touareg 2003 ➤
WARNING
Remove spilt fluid with absorbing, non-flammable material

(binding agent).
Dispose of materials which are soaked with fluid, e.g. cloths or
binding agents, in a suitable container which can be closed,
observe hazardous material regulations!
– If fluid has been extracted from the additive tank system, fill
used fluid of extraction unit - VAS 6277/1- into empty original
tank of new fluid. Observe hazardous material regulations!
WARNING
. Volkswagen AG
gen AG does
swa
Always store additive fluid in the original container in y V a dry and
o lk not
gu
well ventilated area. rised b ara
nte
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aut ra
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4.5 Diesel particulate filter: reading ash
ce
le
un
pt
an
d
loading level
itte
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pe
ility
ot
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Note
h re
hole
spec
When checking the diesel particulate filter the ash loading limit
es, in part or in w
t to the co
value is read.
– Connect vehicle diagnostic tester . ⇒ page 19
rrectness of i
l purpos
– Select “Guided Function” mode on display.
nform
ercia
– Carry out identification of vehicle.

m
a
– Select vehicle system “Engine”.
com
tion in
– Then, check “ash loading of diesel particulate filter”.

r
te o
thi
s
iva
Follow instructions on display.

do
r
rp
cum
fo
4.6 Automatic gearbox: check ATF level.

en
ng
t.
yi Co
Cop py
– Procedure: “Power transmission” ⇒ Rep. gr. 37 “Checking
ht. rig
rig ht
by
ATF level and topping up-” copy Vo
by lksw
cted agen
Prote
4.7 Battery cut-off relay: Remove
AG.
♦ The battery cut-off relay protects the battery from discharging

by electrical consumers not required during transportation
from manufacturer to dealer.
♦ The battery cut-off relay must be removed at delivery inspec‐
tion. Return delivery is discontinued. Dispose of battery cut-off
relay in compliance with disposal regulations.
Touareg 2003 ➤
Note
♦ Notes on invoicing can be found in “Technical product infor‐

mation” in ELSA:
♦ Technical Service Handbook
♦ Technical solutions
♦ Power unit
♦ Function
♦ Engine problems when starting
♦ Engine does not start / transportation device active
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 battery
negative terminal, in front of driver seat.
Note
The battery below driver seat is equipped with a battery isolator.

Observe safety measures when working on battery isolator “Elec‐
trical system” ⇒ Rep. gr. 27 “Battery isolation switch / Isolation
switch -E74-”.
– Switch off ignition and all electrical consumers and remove

ignition key.
If the trim below driver seat has not been removed:
Volkswa
– To disconnect the battery, remove trim belowswdriver
agen seat “Elec‐ AG does
AG. gen
trical system” ⇒ Rep. gr. 27 “Disconnecting
by
Volk
and connecting not
gu
ara
battery”. ris
ed
nte
tho eo
– Disconnect connector -A- from
ss
arelay
u
cable. ra
c
ce
e
nl
pt
du
an
itte
y li
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
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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cu
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Touareg 2003 ➤
– Pull a padded cover -A- over the relay cable connector.

– Secure the padded cover with adhesive tape.
– Unscrew earth cable -2- from battery switch-off relay -1-.
olkswagen AG
en AG. V
– Unscrew retainer for battery cut-off relay from earth
olks point -B-.
wag does
not
y V gu
b ara
– Connect earth cable to earth point -A-, andorise tighten earth cable
d
nte
to 20 Nm. auth eo
ra
ss c
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e
nl
pt
du
Note an
itte
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erm
ab
When battery earth cable has been reconnected: “Electrical sys‐ ility
ot p
tem” ⇒ Rep. gr. 27 “Disconnecting and connecting battery”.

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Route connector and relay cable at position shown -arrows-.

rrectness of i
– Reinstall trim below driver seat.

l purpos
Observe work steps after connecting battery “Electrical system”

⇒ Rep. gr. 27 “Disconnecting and connecting battery, vehicles
nf
ercia
with two-battery design”.

orm
m
– After that, make a short straight drive to adapt steering angle

atio
m
and then switch ignition off, on, and off again.

o
n in
or c
thi
e
ESP warning lamp goes out and event memory entry is set on
t
sd
iva
"sporadic".
o
r
rp
cu
o
m
f
– Delete event memory entry.

en
ng
t.
yi Co
op py
– Carry out vehicle system test ⇒ page 70 . t. C rig
gh ht
pyri by
Vo
co lksw
by
4.8 Battery: checking battery terminal
cted agen
Prote AG.
clamps for secure seating

Either of two different battery designs may be installed in the ve‐
hicle:
Battery designs “Electrical system” ⇒ Rep. gr. 27 “Battery”.
AG. Volkswagen AG d
agen oes Touareg 2003 ➤
olksw not
yV gu
ed b Maintenance
ara
nte
- Edition 03.2018
ris
ho eo
ut ra
Battery under left front seat: checking
ss a battery terminal clamps for c
secure seating
ce
le
un
pt
an
d
– Switch off ignition and all electrical consumers and remove
itte
y li
ignition key.
rm
ab
pe
ility
ot
After waiting 60 seconds:
wit
, is n
h re
– Remove trim from front and side of left front seat frame.
hole
spec
es, in part or in w
– Remove covers for seat spindles.
t to the co
– Pull caps off seat rails.
– Unscrew securing bolts -arrows-.
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.
– Fold back seat frame together with seat -arrow-.
– Remove bolt -1- and remove air duct -2-.
Touareg 2003 ➤
– Open catches for battery box -arrows- and remove cover.
lkswage es n
o ot g
byV ua
d ran
ir se
– Check whether battery th clamps are secure on battery terminals
o tee
or
by moving batterysearth
s au
cable -1- and battery positive wire ac
-2- back and forth.
ce
le
un
pt
an
d
itte
y li
WARNING
rm
ab
pe
ility
ot
If the battery clamp is not seated securely on the positive ter‐
wit
, is n
h re
minal, first disconnect battery clamp from battery negative
hole
terminal to prevent possible accidents.
spec
es, in part or in w
t to the co
If the battery clamp is not seated securely on positive terminal:
rrectness of i
The following procedure must be followed without exception!
l purpos
Disconnecting battery under front left seat

nform
ercia
WARNING
m
a
com
The battery under the front left seat is equipped with a battery
ion in
isolator to increase crash safety. In the event of an accident,

r
te o
thi
the airbag control unit triggers a charge which interrupts the

s
iva
do
current supply cable to the starter. A pyrotechnic method with

r
rp
cum
a very small amount of explosive is used for isolating the bat‐

fo
en
g
tery. To avoid accidentally triggering the charge when working

n
t.
yi Co
op
on the battery or batteries or the battery isolator, always first C py
t. rig
disconnect the battery earth strap from the battery negative
gh ht
yri by
terminal. cop Vo
by lksw
cted agen
Prote AG.
Note
The battery beneath the front left seat has a battery isolator. Ob‐
serve the safety precautions when working on the battery isolator
»Electrical system« ⇒ Electrical system; Rep. gr. 27 ; Discon‐
necting and connecting battery »Disconnecting and connecting
battery«.
AG. Volkswagen AG d Touareg 2003 ➤
agen
Volksw Maintenance -oeEdition
s no
t gu 03.2018
d by ara
e nte
ris
– Unscrew battery earth cable -1- from battery negative
ut
ho termi‐ eo
nal. ss a ra
c
ce
le
Connecting battery under front left seat
un
pt
an
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
rrectness of i
l purpos
♦ -V.A.G 1331- torque wrench (5-50 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
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
– Tighten securing bolt on battery positive terminal clamp to 6

Nm.
– Only after the positive terminal clamp -2- is secure may the
negative terminal clamp -1- be placed on the battery negative
terminal.
– Tighten securing bolt on battery negative terminal clamp to 6
Nm.
– Reinstall engine cover panel.
– Renew securing bolts -arrows- of seat frame and tighten them

to 45 Nm specified torque.
Note
After the battery has been reconnected: »Electrical system« ⇒

Electrical system; Rep. gr. 27 ; Disconnecting and connecting
battery »Disconnecting and connecting battery«.
If the battery clamp on negative terminal is not seated securely:
Touareg 2003 ➤
Tightening battery clamp on negative pole of battery under front

left seat agen
AG. Volkswagen AG d
o w es n
olks ot g
byV ua
ed ran
ris tee
tho or
au ac
ss
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un
pt
an
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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
rrectness of i
– Tighten battery clamp -1- on battery negative terminal to 6 Nm.
l purpos
– Reinstall engine cover panel.
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
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co Vo
by lksw
– Renew securing bolts -arrows- of seat frame and tighten them Prote
cted AG.
agen
to 45 Nm specified torque.
Note

Checking battery clamps of second battery in luggage compart‐

ment for secure seating
Carry out the following procedure:
Touareg 2003 ➤
– Raise luggage compartment floor cover -2- and secure sup‐

port rod -1-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
– Remove fastenings -arrows- for retaining straps and remove
itte
y li
battery cover with retaining straps.
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
o
– Check whether battery clamps are secure on battery terminals
rm
by moving battery positive wire -1- and battery negative wire
m
atio
m
-2- back and forth.

o
n in
or c
thi
te
sd
a
WARNING
iv
o
r
rp
cu
o
m
f
en
ng
If the battery clamp is not seated securely on the positive ter‐

t.
yi Co
op
minal, first disconnect battery clamp from battery negative C py
ht. rig
terminal to prevent possible accidents. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
♦ The following procedure must be followed without exception!

♦ If the sequence of steps is not followed, the charge of the py‐
rotechnical battery isolator may be triggered and the electrical
equipment of the vehicle damaged.
If the battery clamp is not seated securely on positive terminal:
– Disconnect battery earth strap -arrow- from battery negative

terminal first.
Touareg 2003 ➤
– Then disconnect battery positive cable -arrow- from battery

positive terminal.
Connecting second battery in luggage compartment
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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
– Tighten securing bolt on battery positive terminal clamp
en
ng
t.
yi
-arrow- to 6 Nm.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– 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 terminal clamp
-arrow- to 6 Nm.
Note

If the battery clamp on negative terminal is not seated securely:
Touareg 2003 ➤
– Tighten battery clamp -2- on battery negative terminal to 6 Nm.

– Install battery cover.
– Close luggage compartment floor cover.
Note

4.9 Battery: Checking using battery tester

with printer VAS 5097A or VAS 6161
Note
When a battery cut-off relay is installed, ensure that the battery is

not charged via jump start points. Proceed as described in work‐
shop manual.
Procedure: »Electrical system general information« ⇒ Electrical

system general information; Rep. gr. 27 ; Checking battery
»Checking battery«.
AG. Volkswagen AG d
agen
4.10 Reducing agent (AdBlue®): replenishing
oes
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Vol gu
by ara
ed nte
oris eo
th
au ra
Note ss c
ce
le
un
pt
an
To prevent the descriptions from becoming unclear, the “NOx re‐
d
itte
y li
erm
ducing agent AUS 32” (AdBlue®) is merely called reducing agent
ab
ility
ot p
(AdBlue®) in the following texts.
wit
is n
h re
ole,
spec
Caution
t to the co
On Blue TDI vehicles, only the reducing agent (AdBlue®) can
be filled in. NEVER fill in additive which has been used in the
rrectne
past. It can destroy the reducing agent.
ss o
cial p
f inform
Note
mer
atio
om
♦ The following description applies to diesel vehicles with SCR

n
c
i
or
process (selective catalytic reduction).

thi
te
sd
va
♦ Additional information on the SCR process and reducing agent

i
o
pr
cum
r
(AdBlue ®) can be found in the glossary ⇒ page 165

fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Touareg 2003 ➤
General notes ⇒ page 48

Health/endangerment and cleaning ⇒ page 50
Disposal instructions ⇒ page 51
Work preparation for filling reducing agent tank ⇒ page 51
Filling reducing agent tank ⇒ page 52
Work after filling reducing agent tank ⇒ page 55
Cleaning the filling device - VAS 6542- ⇒ page 56
♦ Filling device - VAS 6542-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
♦ Tank for used reducing agent (AdBlue®) thor eo
au ra
s c
♦ Engine and gearbox jack - VAG 1383 A- s
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
♦ Adapter plate - VAG 1383A-1-
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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Characteristics
♦ The reducing agent (AdBlue®) is not a diesel additive and must
not be poured into the diesel fuel tank.
Touareg 2003 ➤
♦ The reducing agent (AdBlue®) is used for exhaust treatment

to reduce nitrogen oxides in the exhaust gas of diesel powered
vehicles.
♦ The reducing agent (AdBlue®) reduces these nitrogen oxides
to water and nitrogen.
♦ The reducing agent (AdBlue®) is a high-purity 32.5% urea sol‐
ution and is used in systems with exhaust treatment (SCR
catalytic converters ⇒ page 165 ) for diesel engines.
♦ The reducing agent (AdBlue®) is legally prescribed for oper‐
ating vehicles with SCR.
♦ AdBlue® is a registered brand of the VDA (Verband der Auto‐
mobilindustrie – German association of the automotive indus‐
try).
AG. Volkswagen AG d
Application agen oes
olksw not
V gu
by ara
♦ Do not mix the reducing agent ®
(AdBlue ) with additives
orised
and nte
eo
do not dilute it with water. aut
h
ra
ss c
♦ Do not use fluid which has already been used.
ce
e
nl
pt
du
an
♦ Use only reducing agent (AdBlue®) in the intended, original
itte
y li
erm
ab
containers. Also note the expiry date information.
ility
ot p
♦ Additionally note the reducing agent manufacturer's usage
wit
, is n
h re
and storage instructions.
hole
spec
Installation location / specifications
es, in part or in w
t to the co
♦ “NOx reducing agent AUS 32” is the designation according to
ISO 22241-1.
rrectness of i
♦ The reducing agent (AdBlue®) is contained in a separate tank
in the vehicle. It is NOT therefore mixed with diesel fuel.
l purpos
♦ The reducing agent tank is located in the luggage compart‐
nform
ment.
mercia
♦ A refill container approved by Volkswagen must be used for
at
om
io
replenishing the reducing agent (AdBlue®).
n
c
in t
or
his
e
♦ The reducing agent tank has a capacity of approx. 15 litres.

at
do
priv
♦ The part number of the 1.9 litre and 10 litre containers can be cum
for
en
found in ⇒ ETKA .
ng
t.
yi Co
op py
Reducing agent shortage t. C rig
gh ht
pyri by
Vo
If the level of reducing agent is low, one of the following messages
o
by c lksw
cted agen
appears on the dash panel insert: Prote AG.
♦ As of a remaining range of 2400 km, a gong sounds and “Fill

AdBlue! Remaining distance 2400 km” is displayed.
♦ As of a remaining range of 1000 km, a warning buzzer sounds
and “Fill AdBlue! "No engine start in 1000 km" is shown.”
♦ As of a remaining range of 0 km, a three-fold warning buzzer
sounds and “Fill AdBlue! "Engine start no longer possible" is
shown.”
Note
To make a new engine start possible, a minimum of 3 bottles

containing each 1.9 litre of reducing agent (AdBlue®), must be
filled in.
Touareg 2003 ➤
System malfunction or incorrect filling
Caution
When filled with reducing agent (AdBlue®) that does NOT

comply with the standard or when filled with any other fluids,
the vehicle will become damaged.
In case of system malfunction or incorrect filling, one of the fol‐

lowing messages appears on the dash panel insert:
♦ As of a remaining range of 1050 km: “Check AdBlue! Remain‐
ing distance 1050 km”.
♦ As of a remaining range of 1000 km, a warning buzzer sounds
and “Check AdBlue! "No engine start in 1000 km" is shown.”
♦ As of a remaining range of 0 km, a three-fold warning buzzer
sounds and “Check AdBlue! "Engine start no longer possible"
is shown.”
AG. Volkswagen AG d
agen oes
lksw not
WARNING d by Vo gu
ara
rise nte
ho eo
♦ As soon as “Check AdBlue!” appears:“ No engine start s aut ra
c
possible! ” is displayed and the engine is switched soff; the
ce
e
engine cannot be started again.

nl
pt
du
an
itte
y li
♦ Fault recovery ⇒ Guided fault finding
erm
ab
ility
ot p
wit
, is n
4.10.2 Health risk and cleaning
h re
hole
spec
es, in part or in w
t to the co
WARNING
♦ The reducing agent (AdBlue®) may irritate the skin, eyes
rrectness of i
and respiratory organs.
l purpos
♦ Protect your hands.

♦ In the event of skin contact with this fluid, immediately
nf
ercia
o
wash off with plenty of water.
rm
m
atio
m
♦ If necessary, seek advice from a doctor.

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
Caution
o
m
f
en
ng
t.
yi Co
op py
At all times, ensure that no reducing agent (AdBlue®) is spilled
t. C rig
gh ht
yri
on trim or body parts. p by
co Vo
by lksw
cted agen
If this has happened, wash the reducing agent (AdBlue®) out
Prote AG.
again with clear water and a lint-free cotton cloth.

If the reducing agent (AdBlue®) has already crystallised, use
warm water and a sponge.
Reducing agent residues which are not removed crystallise af‐
ter a while and may damage the affected surface.
Touareg 2003 ➤
4.10.3 Disposal instructions
Caution
Information concerning storage and disposal ⇒ ServiceNet →

Environmental protection → Workshop disposal . Ask your im‐
porter about country-specific information on storage and dis‐
posal. gen AG
. Volkswagen AG
d a oes
lksw not
The refill container must be disposed of in accordance
db
yV
o
with gu
ara
environmental regulations. or
ise nte
eo
th
au ra
c
ss
ce
le
4.10.4 Work preparation for filling reducing un
pt
an
d
itte
agent tank
y li
erm
ab
ility
ot p
wit
is n
h re
Note
ole,
spec
Ensure that vehicle stays on an even ground.
t to the co
The reducing agent tank's filler aperture is located under the floor
covering in the luggage compartment.
rrectne
– Raise floor covering -1- and push it back or hook it in.
ss o
– Remove spare wheel -2-, if available, by unscrewing wing nut
cial p
f i
-3-.
nform
mer
– Remove foam part, if fitted.
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.
– Remove tank filler neck sealing plug -1-.
Touareg 2003 ➤
4.10.5 Reducing agent tank: filling

Components of filling device - VAS 6542-
1 - Connection for reducing agent container agen
AG. Volkswagen AG d
oes
olksw not
2 - Union nut for reducing agent container byV gu
ara
ed
ris nte
o
3 - Shut-off tap for breather line (shut-off tap aopen:
ut
h Lever points eo
ra
in direction of line, shut-off tap closed: Lever
s positioned trans‐
s c
verse to direction of line)
ce
le
un
pt
an
d
itte
4 - Quick release coupling on breather line
y li
rm
ab
pe
ility
5 - Filler line
ot
wit
, is n
6 - Shut-off tap for filler line (shut-off tap open: Lever points in
h re
hole
direction of line, shut-off tap closed: Lever positioned transverse
spec
to direction of line)
es, in part or in w
t to the co
7 - Union nut for tank filler neck
8 - Breather line
rrectness of i
l purpos
Caution
Always ensure that all hoses of filling device - VAS 6542- are
nform
ercia
not kinked or blocked. For ease of handling, the breather line

m
can be turned 360°.
a
com
tion in
r
te o
thi
s
iva
Perform procedure and adhere to sequence as follows:
do
r
rp
cum
fo
en
g
♦ 1) Open tank cap in luggage compartment -1-.

n
t.
yi Co
Cop py
.
♦ 2) Clean filler neck of reducing agent tank using a water-
ht rig
rig ht
by
soaked, lint-free cotton cloth. copy Vo
by lksw
cted agen
Prote
3) Close shut-off taps of breather and filler lines of filling device -
AG.
VAS 6542- .
Touareg 2003 ➤
1 - Reducing agent container

2 - Adapter plate - VAG 1383 A-1-
3 - Quick release coupling on breather line
A - Dimension -A- (60-80 cm) for height difference from reducing
agent container to tank filler neck
4 - Breather line
5 - Union nut for tank filler neck
6 - Shut-off tap for filler line (shut-off tap open: Lever points in
direction of line, shut-off tap closed: Lever positioned transverse
to direction of line)
7 - Filler line
8 - Shut-off tap for breather line (shut-off tap open: Lever points
in direction of line, shut-off tap closed: Lever positioned trans‐
verse to direction of line)
9 - Engine and gearbox jack - VAG 1383 A-
lkswage es n
o ot g
byV ua
ed ran
♦ 4) Place filling device - VAS 6542- onto reducing agent
thoris
con‐ tee
or
tainer ⇒ ETKA , turn union nut COUNTER clockwise au until both ac
ss
threads engage with each other. Then turn union nut clockwise
ce
le
to stop.
un
pt
an
d
itte
y li
♦ 5) Position reducing agent container on engine and gearbox
erm
ab
jack - VAG 1383 A- with adapter plate - VAG 1383 A-1- .
ility
ot p
wit
is n
h re
ole,
Note
spec
t to the co
Note that the height difference between the reducing agent con‐
tainer and the reducing agent tank filler neck lies in the range of
60-80 cm, dimension -A-.
rrectnes
♦ 6) Place union nut onto tank filler neck -arrow- and screw on
s o
to stop.
cial p
f inform
♦ 7) Open shut-off tap of breather line -8-.
mer
atio
m
♦ 8) Open shut-off tap of filler line -6-; tank filling begins from this
o
n
c
point on. i
or
n thi
te
sd
iva
o
pr
Caution
um
r
fo
en
ng
t.
yi Co
To prevent overfilling, ensure that filling process (when shut- Cop py
t. rig
off tap of breather line is open) is completed within 10 minutes. gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
The reducing agent tank is filled to maximum when the following
can be recognised:
♦ The container noticeably collapses.
♦ The breather hose is filled with fluid.
If the container is emptied completely during the filling process
and no fluid has escaped from the breather hose as yet, repeat
points 3 to 8 of the procedure.
Touareg 2003 ➤
♦ 9) Close shut-off tap of tank filler line -6-.

♦ 10) Now close shut-off tap of breather line -8- on container.
♦ 11) Separate quick-release coupling on breather line -3-.
♦ 12) Drain excessive fluid into a suitable container -2- for re‐
AG. Volkswagen AG d
ducing agent (AdBlue®). lkswagen oes
no o t gu
yV
edb ara
ris nte
ho eo
Note aut ra
c
ss
ce
e
nl
♦ The procedure is finished when the reducing agent tank au‐

pt
du
an
tomatically has the correct fill level.

itte
y li
erm
ab
♦ After replenishing, switch on ignition for at least 20 seconds,

ility
ot p
so that the replenished reducing agent (AdBlue®) can be rec‐

wit
, is n
ognised by the system.

h re
hole
spec
es, in part or in w
t to the co
Caution
Excessive reducing agent (AdBlue®) must be disposed of and

rrectness of i
must not be reused.

l purpos
Observe the disposal regulations: ⇒ ServiceNet → Environ‐

mental protection → Workshop disposal ! Ask your importer
nf
ercia
about country-specific information on disposal.

orm
m
atio
om
n in
c
♦ 12) When no further fluid flows out of breather line, remove

or
thi
e
filling device - VAS 6542- from tank filler neck.

t
sd
iva
o
r
rp
cu
♦ 13) Clean reducing agent tank filler neck and tank sealing cap
o
m
f
en
using a water-soaked, lint-free cotton cloth.

ng
t.
yi Co
op py
– Remove container from adapter plate and place on the floor. t. C rig
gh ht
pyri by
♦ 14) Open shut-off tap of filler line -6-, and allow remaining fluid
co Vo
by lksw
cted agen
to flow back into container. Prote AG.
♦ 15) Remove filling device - VAS 6542- from container.
Touareg 2003 ➤
4.10.6 Work after filling reducing agent tank

– Screw in tank cap -1- of tank filler neck until it engages.
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
– Carefully insert sealing plug -1-.
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
– Install spare wheel -2- (if available), tightening wing nut -3-
t.
yi Co
op
hand-tight. C py
t. rig
gh ht
yri by
– Insert foam part (if fitted) beneath floor covering. cop Vo
by lksw
cted agen
Prote
– Fold floor covering -1- down and pull forwards.
AG.
Touareg 2003 ➤
4.10.7 Cleaning the filling device - VAS 6542-

– Open both shut-off taps, and clean or flush through all parts of
filling device - VAS 6542- under flowing water.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
4.11 Reducing agent (AdBlue®): changing author eo
ra
ss c
Procedure
ce
e
nl
pt
du
an
⇒ Power unit; Rep. gr. 26 ; SCR system (selective catalytic re‐
itte
y li
duction); Draining reducing agent tank
erm
ab
ility
ot p
4.12 Tyres: checking condition, wear pattern,
wit
, is n
h re
tyre pressure and tread depth
hole
spec
es, in part or in w
t to the co
Checking condition of tyres ⇒ page 57
Checking wear pattern ⇒ page 57
rrectness of i
Checking tread depth of tyres (including spare wheel)
l purpos
⇒ page 57
General notes ⇒ page 58
nform
mercia
Tyre pressure: checking and correcting if necessary at

om
i
⇒ page 59
on
c
in t
or
Storing tyre pressure values ⇒ page 60

his
ate
do
priv

um
for
en
ng
t.
♦ Tyre inflator - VAS 5216-
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Touareg 2003 ➤
4.12.1 Tyres: checking condition

For delivery inspection:
– Check tyre treads and side walls for damage and remove for‐
eign bodies such as, for example, nails or glass splinters.
WARNING agen
AG. Volkswagen AG d
oes
olksw not
byV gu
ara
If damage is determined, always check to see if a new ris tyre
ed
nte
should be fitted. ho eo
aut ra
ss c
ce
e
nl
pt
du
For service:
an
itte
y li
erm
ab
– Check tyre treads and side walls for damage and remove for‐
ility
eign bodies such as, for example, nails or glass splinters. ot p
wit
, is n
h re
– Check tyres for cupping, one-sided wear, porous side walls,
hole
spec
cuts and punctures.
es, in part or in w
t to the co
WARNING
rrectness of i
The customer must be informed of any faults found.
l purpos
4.12.2 Wear pattern: checking
nf
ercia
orm
m
atio
m
Note
o
n in
or c
thi
te
sd
a
The wear pattern on the front tyres will indicate, for example, if
iv
o
r
rp
cu
toe and camber settings should be checked:
o
m
f
en
ng
t.
yi Co
op
Possible causes of fault: C py
ht. rig
rig ht
by
♦ Feathering on tread indicates incorrect toe setting. copy Vo
by lksw
cted agen
Prote
♦ One-sided tread wear is mainly attributed to incorrect camber.
AG.
– When wear of this nature is detected, determine cause by

checking alignment (repair measure).
4.12.3 Tread depth: checking (including spare

wheel)
– Check tyre tread depth.
Minimum tread depth: 1.6 mm
Note
♦ This figure may vary according to legislation in individual coun‐

tries.
♦ The minimum tread depth is reached when the tyres have
worn down level with the 1.6 mm high tread wear indicators
positioned at intervals around the tyre.
♦ If the tread depth is approaching the minimum allowed depth,
inform the customer.
Touareg 2003 ➤
lkswage es n
o ot g
4.12.4 General information ir se
d byV ua
ran
tee
tho
u or
a ac
WARNING ss
ce
e
nl
pt
du
an
itte
♦ For safety reasons, only tyres of same type and tread pat‐
y li
erm
ab
tern should be fitted on a vehicle! Approved wheel and tyre
ility
ot p
combinations, e.g. ⇒ Running gear; Rep. gr. 44 ; Touareg
wit
as of model year 2003
, is n
h re
hole
♦ On vehicles with four-wheel drive, tyres of the same type
spec
and tread pattern must be used. Otherwise the centre dif‐
es, in part or in w
t to the co
ferential may be damaged.
rrectness of i
l purpos
Note
♦ Tyre pressures for the relevant model can also be found on a
nform
ercia
sticker. It is attached to the inside of tank flap or to B-pillar.

m
at
om
♦ Please note that the indicated pressures apply to cold tyres.
ion
c
Do not reduce increased pressures of warm tyres.
in t
or
his
ate
♦ Tyre pressures for the relevant model can also be found on a
do
priv
c
sticker. It is attached to the inside of tank flap or to B-pillar.
um
for
en
ng
t.
♦ Adjust the tyre pressure to suit the vehicle load.
yi Co
Cop py
t. rig
♦ If no inflation pressure is shown for the spare wheel, then in‐
gh ht
yri by
flate the spare wheel to the highest inflation pressure for the
cop Vo
by lksw
cted
vehicle.
agen
Prote AG.
♦ For vehicles with tyre pressure monitoring (TPM), the new tyre
pressures must be adapted ⇒ page 60 .
M+S tyres
Note
♦ Important information on recommended winter tyres can be

found in:
♦ ⇒ Wheel and tyre guide - Standard; Rep. gr. 44 ; Recom‐
mended winter tyres (Running gear → Wheel and tyre guide -
Standard → Rep. Gr. 44 → Recommended winter tyres)
♦ If winter tyres are fitted, a sticker, visible for the customer and
indicating the speed limit, must be applied in the interior of the
vehicle.
♦ For winter tyres, the tyre pressure does not have be increased.
However, this applies only if the winter tyre used corresponds
exactly to the standard summer tyre size and the speed index
is no higher than “H”. If this is not the case, please refer to the
recommendation of the tyre manufacturer.
Note
For technical reasons it is possible that several cross references

lkswage es n
o ot g
byV ua Touareg 2003 ➤
d ran
ir se
tho Maintenance
tee
or - Edition 03.2018
au ac
ss
4.12.5 Tyre pressure: checking and correcting
ce
le
un
pt
an
d
if necessary
itte
y li
erm
ab
ility
ot p
wit
Note is n
h re
ole,
spec
The mandatory tyre pressures for the respective model can be
t to the co
found on a sticker attached to the inside of tank flap or to the B-
pillar.
rrectne
Check tyre pressure using tyre inflator - VAS 5216- , correct if
necessary.
ss
Tyre pressure table for Touareg ⇒ page 59
o
cial p
f inform
Tyre pressure table for Touareg GP ⇒ page 59
mer
atio
Tyre pressure table for Touareg
om
n
c
i
or
n
Half load Full load
thi
te
sd
a
bar/psi bar/psi
iv
o
pr
cum
r
Tyre size Front Rear Front Rear

fo
en
ng
t.
yi Co
235/70 R16 2.4/35
t. Cop
2.5/36 2.4/35
py
rig 2.9/42
gh
235/65 R17 2.5/36 2.6/38 2.6/38 3.0/44
ht
pyri by
Vo
co lksw
by
205/60 R17 2.5/36 Prote
cted 2.6/38
AG.
agen
2.5/36 3.0/44
235/60 R18 2.7/39 2.7/39 2.9/42 3.2/46
255/55 R18 2.6/38 2.9/42 2.8/39 3.1/45
255/50 R19 2.8/39 3.0/44 3.0/44 3.4/49
255/50 R19 M&S 3.0/44 3.0/44 3.1/45 3.4/49
275/45 R19 2.7/39 3.0/44 2.8/39 3.2/46
275/45 R19 M&S 2.8/41 2.8/41 3.0/44 3.2/46
275/40 R20 2.8/39 3.0/44 3.0/44 3.4/49
275/40 R20 3.0/44 3.0/44 3.1/45 3.4/49
295/35 R21 2.7/39 2.9/42 2.8/39 3.4/49
295/35 R21 3.0/44 3.0/44 3.1/45 3.4/49
195/80 171) 3.5/51 3.5/51 3.5/51 3.5/51
195/75 181) 3.5/51 3.5/51 3.5/51 3.5/51
1) Temporary spare wheel (collapsible spare wheel)
Tyre pressure table for Touareg GP
Half load Full load

bar/psi bar/psi
Engine Tyre size Front Rear Front Rear
VR6 FSI 235/65 R17 2.3/33 2.6/38 2.5/36 3.1/45
255/60 R17
255/55 R18
275/45 R19
235/60 R18 2.4/35 2.8/41 2.7/39 3.3/48
255/50 R19
275/40 R20
V8 FSI 235/60 R17 2.5/36 2.7/39 2.7/39 3.2/46
255/60 R17
Touareg 2003 ➤
Half load Full load

bar/psi bar/psi
Engine Tyre size Front Rear Front Rear
255/55 R18
275/45 R19
235/60 R18 2.7/39 2.9/42 2.8/41 3.4/49
255/50 R19
275/40 R20
W12 235/65 R17 2.6/38 2.7/39 2.8/41 3.2/46
255/60 R17 AG. Volkswagen AG d
agen oes
255/55 R18 y Volksw not
gu
d b ara
275/45 R19 orise nte
eo
th
235/60 R18 2.8/41ss au
2.9/42 3.0/44 3.4/49
ra
c
255/50 R19
ce
le
un
pt
an
d
275/40 R20
itte
y li
rm
ab
R5 TDI All types of tyres 2.3/33 2.5/36 2.6/38 3.0/44
pe
ility
ot
wit
V6 TDI 235/65 R17 2.4/35 2.5/36 2.5/36 3.0/44
, is n
h re
255/60 R17
hole
spec
255/55 R18
es, in part or in w
t to the co
275/45 R19
235/60 R18 2.5/36 2.7/39 2.7/39 3.1/45
rrectness of i
255/50 R19
l purpos
275/40 R20
V10 TDI 235/65 R17 2.8/41 2.8/41 3.1/45 3.4/49
nform
ercia
255/60 R17
m
a
255/55 R18
com
tion in
275/45 R19
r
te o
thi
s
iva
235/60 R18 3.0/44 3.0/44 3.1/45 3.4/49

do
r
rp
cum
255/50 R19
fo
en
ng
t.
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275/40 R20
Co
Cop py
t. rig
Vehicles for the North American market
gh ht
pyri by
Vo
co
VR6 FSI 255/60 R17 --- --- 2.7/39 3.2/46
by lksw
cted agen
Prote
V8 FSI
AG.
255/55 R18
275/45 R19
V10 TDI 255/55 R18 --- --- 2.8/41 3.2/46
275/45 R19
Temporary spare wheel (collapsible spare wheel)
For all vehicles 195/80 R17 3.5/51 3.5/51 3.5/51 3.5/51
195/75 R18
1) Temporary spare wheel (collapsible spare wheel)
4.13 Storing tyre pressure values

• Correct tyre pressure must be adjusted ⇒ page 56
• Tyres must be cold
Touareg 2003 ➤
– Press button -1- to activate function of menu selection in dis‐

play of dash panel insert.
– Use knurled wheel -2- to select menu item “Tyre pressure”.
When menu item “Tyre pressure” is marked in display -1-, confirm

selection by pressing knurled wheel.
– In the submenu “tyre pressure monitoring”, turn knurled wheel
until item “Save” is marked in display -1- and save current
pressure by pressing knurled wheel.
– Then drive vehicle without interruption for approx. 8-10 mi‐
nutes.
4.14 Brakes, front and rear: checking thick‐

ness of brake pads and condition of
brake discs
♦ Pliers - 3314- AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
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un
pt
an
d
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ab
pe
ility
ot
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, is n
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hole
spec
es, in part or in w
t to the co
♦ Torque wrench (40-200 Nm) - V.A.G 1332/-

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cum
fo
en
ng
t.
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Cop py
ht. rig
♦ Electric hand torch and mirror rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Touareg 2003 ➤
Note
The adapter to loosen and tighten the anti-theft wheel bolts can
be found in the vehicle tool kit.
Front brake pads:

– For better evaluation of remaining pad thickness, use a test
mirror and, if necessary, remove the wheel on the side where
the brake pad wear indicator is installed.
– If necessary, pull off wheel bolt covers using pliers - 3314- .
– Mark position of wheel relative to brake disc.
– Unbolt wheel bolts and remove wheel.
– Measure thickness of inner and outer pads.
a - Brake pad thickness without backplate
Wear dimension: 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!
AG. Volkswagen AG d
Note lksw
agen oes
not
Vo gu
d by ara
e
♦ When replacinghoris
brake pads, always check brake discs ase well
nte
for wear!s aut or
ac
s
♦ Checking and if necessary replacing the brake discs is a repair
ce
e
nl
pt
du
measure.
an
itte
y li
erm
ab
ility
– Check brake disc for wear ⇒ Brake system ⇒ Rep. gr. 46 ⇒

ot p
wit
Repairing front brakes

, is n
h re
hole
– Install wheel in marked position.

spec
es, in part or in w
– Tighten wheel bolts diagonally and alternately to following

t to the co
specified torque:
Specified torque: 180 Nm
rrectness of i
– Place adapter in vehicle tool kit after completing work.

l purpos
– Fit wheel bolt covers if necessary.

nf
ercia
Rear brake pads:

orm
m
– Illuminate area behind hole in wheel using an electric hand

atio
m
torch.
o
n in
or c
thi
te
sd
iva
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 ➤
– Inspect outer pad to determine thickness.

– Illuminate inner pad with an electric hand torch and mirror.
– Inspect inner pad to determine thickness.
a - Inner and outer pad thickness without backplate
Wear dimension: 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! n AG. Volkswagen A age G do
ksw es n
y Vol ot g
ua
b
ed ran
Note horis tee
t or
au ac
ss
♦ When replacing brake pads, always check brake discs as well
ce
e
nl
for wear!
pt
du
an
itte
y li
♦ Checking and if necessary replacing the brake discs is a repair
erm
ab
measure.
ility
ot p
wit
, is n
h re
– Check brake disc for wear ⇒ Brake system ⇒ Rep. gr. 46 ⇒
hole
spec
Repairing rear brakes
es, in part or in w
t to the co
Brake discs: checking condition
Check all brake discs for the following damage pattern:
rrectness of i
♦ Cracks
l purpos
♦ Scoring
♦ Rust (no surface rust) nf
ercia
or
♦ Degree of wear at the ridge along the circumference

m
m
atio
om
n in
or c
thi
Note
te
sd
iva
o
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rp
cu
Inform customer if brake disc damage is similar to these damage

o
m
f
en
ng
patterns. Renewing the brake discs is a repair measure.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
4.15 Brake system and shock absorbers: in‐
by c lksw
cted agen
Prote AG.
specting for leaks and damage
Check following components for leaks and damage:
♦ Brake master cylinder
♦ Hydraulic unit
♦ Brake pressure regulator and
♦ Brake caliper
♦ Shock absorbers (during inspection only)
♦ Presence of dust caps on brake fluid bleeder valves
– Ensure that brake hoses are not twisted.
– Additionally ensure that brake hoses do not touch any vehicle
components when steering is at full lock.
– Check brake hoses for porosity or brittleness.
– Check brake hoses and lines for chafing.
– Check brake connections and fastenings for correct seating,
leaks and corrosion.
Touareg 2003 ➤
WARNING
Faults found must always be rectified (repair measure).
4.16 Changing brake fluid

Instructions for use and safety ⇒ page 64
Brake fluid specification ⇒ page 64
Changing brake fluid ⇒ page 64
4.16.1 Operation and safety notes

swa
gen AG
. Volkswagen AG
does
k not
Vol gu
d by ara
e nte
WARNING ris
utho eo
ra
a c
ss
♦ Never allow brake fluid to come into contact with fluids that
ce
le
un
pt
contain mineral oils (e.g. oil, petrol, cleaning agents). Min‐
an
d
itte
eral oils damage the seals and boots in the brake system.
y li
rm
ab
pe
ility
♦ Brake fluid is poisonous. In addition, due to its corrosive
ot
nature, it must not come into contact with paint.
wit
, is n
h re
hole
♦ Brake fluid is hygroscopic, which means it absorbs mois‐
spec
ture from the ambient air and should therefore always be
es, in part or in w
t to the co
stored in air-tight containers.
♦ Rinse off spilled brake fluid using plenty of water.
rrectness of i
♦ Do not reuse drained (used) brake fluid.
l purpos
♦ Observe relevant disposal regulations.
nform
ercia
4.16.2 Brake fluid specification

m
a
com
tion in
r
te o
Caution
thi
s
iva
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rp
• For this vehicle only brake fluid VW 501 14 - B 000 750-

um
fo
en
g
must be used.
n
t.
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Cop py
t. rig
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4.16.3 Procedure, changing brake fluid
co lksw
by
cted agen
Prote AG.

♦ Brake filling and bleeding equipment - VAS 5234-
Touareg 2003 ➤
♦ Brake bleeding wrench - VAS 5519-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
le
un
pt
an
d
♦ Brake bleeding tool - VAS 6564-
itte
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erm
ab
ility
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wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
Observe ⇒ operating instructions for -VAS 5234- !
atio
om
– Adjust correct pressure on brake filling and bleeding equip‐
n
c
i
or
n
ment - VAS 5234- »Running gear, brake systems« ⇒ Running
thi
te
sd
a
gear, brake systems; Rep. gr. 47 ; Bleeding brake system

iv
o
r
»Bleeding brake system«.

p
cum
r
fo
en
ng
t.
– Release securing bolts -1- and -2- and remove cover upwards. Cop
yi Co
py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Touareg 2003 ➤ orise nte
h eo
Maintenance - Edition
aut 03.2018 ra
c
ss
ce
le
– Unscrew cap -1- from brake fluid reservoir.
un
pt
an
d
itte
y li
– Extract as much brake fluid as possible using suction hose
rm
ab
from brake filling and bleeding equipment -VAS 5234- with
pe
ility
strainer installed. ot
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
Ensure that no brake fluid runs through the strainer after com‐
pleting extraction (the brake fluid level in the reservoir must be
rrectness of i
even with the lower edge of the strainer).
l purpos
WARNING
nform
ercia
Do not reuse drained (used) brake fluid.

m
a
com
tion in
r
te o
thi
Observe ⇒ operating instructions for -VAS 5234- !
s
iva
do
r
rp
cum
– Adjust correct pressure on brake filling and bleeding equip‐
fo
en
g
ment - VAS 5234- »Running gear, brake systems« ⇒ Running

n
t.
yi Co
op
gear, brake systems; Rep. gr. 47 ; Bleeding brake system C py
t. rig
»Bleeding brake system«.
gh ht
pyri by
Vo
o
by c lksw
– Place brake pedal depressor -V.A.G 1869/2- between driver cted agen
Prote AG.
seat and brake pedal and tension it.
– Screw adapter onto brake fluid reservoir.
Vehicles with manual gearbox
Changing brake fluid in clutch system: ⇒ Power transmission/
Manual gearbox ⇒ Rep. gr. 30 ⇒ Bleeding clutch system
Continuation for all vehicles
– Connect filler hose of -VAS 5234- to adapter.
– Remove caps from bleeder screws of brake calipers.
– Push collector bottle bleeder hose onto rear bleeder screw
1)
, open bleeder screw, and let appropriate quantity of brake
fluid run out. Close bleeder screw, torque: »Running gear,
brake systems« ⇒ Running gear, brake systems; Rep. gr. 47 ;
Repairing rear brake caliper »Repairing rear brake caliper«.
Note
Make sure to use a suitable bleeder hose. It must seat tightly on

bleed screw so that no air can enter the brake system.
1) Start at rear right of left-hand drive vehicles and at rear left of right-hand drive
vehicles.
Repeat procedure on other side of vehicle at rear.
Note
If brake caliper has 2 valves, connect first the outer and then the
inner bleeder valve.
Touareg 2003 ➤
– Push collector bottle bleed hose onto front bleeder screw

2)
, open bleeder screw and let appropriate quantity of brake
fluid run out (see following table). Close bleed screw. Torque:
»Running gear, brake systems« ⇒ Running gear, brake sys‐
tems; Rep. gr. 47 ; Repairing front brake caliper »Repairing
front brake caliper«
2) Start at front right of left-hand drive vehicles and at front left of right-hand drive
vehicles.
Repeat procedure on other side of vehicle at front.

Table: Sequence and quantity of brake fluid
Sequence: Clutch slave cylinder, wheel brake Quantity of brake fluid which must flow out:
cylinder, brake calipers
Bleeder valve clutch slave cylinder 0.15 l
Rear right 0.25 l
Rear left 0.25 l
Front right 0.25 l
Front left 0.25 l
Total quantity: approx. w1.15

agen litres
AG. Volkswagen AG d
oe
ks s no
Vol t gu
– Fit caps on ebleeder
db
y screws of brake calipers. ara
ris nte
o
– Set fill alever
ut
h of brake filling and bleeding equipment - e or a
VAS s5234-
s to position -B- (see operating instructions). c
ce
e
nl
pt
– Take filler hose off adapter.

du
an
itte
y li
– Unscrew adapter from brake fluid reservoir.

erm
ab
ility
ot p
– Check brake fluid level and correct if necessary.

wit
, is n
h re
– Screw on cap -1- of brake fluid reservoir.

hole
spec
es, in part or in w
– Install cover.
t to the co
– Remove brake pedal depressor.

– Check pedal pressure and brake pedal free play. Free play:
rrectness of i
max. 1/3 of pedal travel.

l purpos
nf
ercia
orm
m
atio
om
n in
c
4.17 Brake fluid level (dependent upon brake

or
thi
te
sd
pad/lining wear): check.

iva
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cu
o
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f
Instructions for use and safety ⇒ page 64

en
ng
t.
yi Co
op py
Brake fluid specification ⇒ page 64 t. C rig
gh ht
pyri by
Procedure, brake fluid level (dependent upon lining/pad wear):
o Vo
by c lksw
cted
checking ⇒ page 68
agen
Prote AG.
Touareg 2003 ➤
4.17.1 Procedure, brake fluid level (dependent

upon lining/pad wear): checking
– Release securing bolts -1- and -2- and remove cover upwards.
Please note the following:
Brake fluid level at delivery inspection:

– For the delivery inspection the fluid level must be at MAX.
marking -1-.
Note
Volkswagen AG
In order that brake fluid does not overflow the reservoir, kMAX
swa
gen AG
.
does
marking -1- must not be exceeded. by
Vol not
gu
ara
ed nte
ris
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Brake fluid level at inspection service au
t ra
c
ss
The fluid level must always be judged in conjunction with lining/
ce
le
un
pt
pad wear.
an
d
itte
y li
rm
ab
When vehicle is in use, fluid level tends to drop slightly due to
pe
ility
lining/pad wear and automatic adjustment.
ot
wit
, is n
h re
hole
• Recommended brake fluid level, if brake pads are almost at
spec
wear limit:
es, in part or in w
t to the co
“At MIN. marking or just above” -2-, “REPLENISHING IS NOT
REQUIRED”.
rrectness of i
• Recommended brake fluid level when brake pads are new or
well within wear limit:
l purpos
“Between MIN and MAX marking”.

nform
ercia
WARNING
m
a
com
tion in
If fluid level is below MIN. marking -2-, the brake system should
r
te o
thi
be checked before fluid is topped up “Repair measure”

s
iva
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cum
fo
en
ng
t.
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op
4.18 Diesel particulate filter: renewing
C py
ht. rig
rig ht
py by
Vo
Installation position of diesel particulate filter, see vehicle under‐
co lksw
by
cted agen
side. Prote AG.
– Removing and installing diesel particulate filter ⇒ Diesel en‐

gine ⇒ Rep. gr. 26 ⇒ Removing and installing parts of the
exhaust system.
Touareg 2003 ➤
Note
olkswagen AG
en AG. V
Every time the diesel particulate filter is changed,
ksw
ag the ash mass does
not
Vol
comparison adaption must be set toed»0«,by ⇒ Vehicle diagnostic gu
ara
tester ho
ris nte
eo
t
au ra
c
ss
4.19 Electric windows: checking positioning
ce
e
nl
pt
du
(open and close functions)
an
itte
y li
erm
ab
ility
ot p
WARNING
wit
, is n
h re
hole
spec
After batteries (in luggage compartment and/or left front seat)
es, in part or in w
have been disconnected and reconnected, the roll-back func‐
t to the co
tion of the electric window regulators is disabled. Severe pinch‐
ing injuries could result!
rrectness of i
l purpos
Note
nform
ercia
♦ After batteries (in luggage compartment and/or beneath left

m
front seat) have been disconnected and reconnected, one-
at
om
io
touch window operation is disabled.
n
c
in t
or
his
e
♦ Therefore, with immediate effect, before a new vehicle is de‐

at
do
riv
livered, the window regulators must be reactivated.

p
cum
for
en
g
♦ Once the windows have been repositioned, the batteries must

n
t.
yi Co
not be disconnected again. Cop py
ht. rig
rig ht
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o Vo
Carry out the following procedure to reactivate the automatic by c lksw
cted agen
functions of the window regulators: Prote AG.
Note
The following work description applies to the front left window

regulator. Reactivate the other window automatic functions in the
same manner by operating the respective switch in the driver
door.
– Close all doors and windows completely.

– Open front left side window by pressing and holding switch in
driver door.
– Completely close front left side window by pulling and holding
switch in driver door and release switch.
– Pull switch again for 1 second. The side window must now go
up or down by itself when switch is briefly pulled or pressed.
Touareg 2003 ➤
4.20 Vehicles with reversing camera system:

Check number plate
AG. Volkswagen AG d
agen oes
olksw not
Note ed byV gu
ara
ris nte
ho eo
ut
For vehicles with reversing camera system it is not
s a permitted to ra
c
install an additional number plate bracket or an additional number s
ce
e
nl
plate mounting. Additional information see ⇒ Electrical system ⇒
pt
du
an
Rep. gr. 94 ⇒ Reversing camera system/General notes
itte
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erm
ab
ility
4.21 Vehicle system test: Carry out test ot p
wit
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h re
hole
– Connect vehicle diagnostic tester ⇒ page 19 .
spec
es, in part or in w
t to the co
– Select operating mode “Guided fault finding” on display.
rrectness of i
– Then perform vehicle identification on vehicle diagnostic test‐
er .
l purpos
The programme now automatically performs a vehicle system test

and reads all control units available for this vehicle type.
nform
ercia
– Press > button.

m
at
om
io
Now all faults are listed.
n
c
in t
or
his
ate
do
riv
Note
p
cum
for
en
ng
t.
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♦ At this point it is useful to change to operating mode guided Cop py
functions to carry out further operations with vehicle diagnostic
ht. rig
rig ht
by
tester and to prevent a second vehicle identification on vehicle copy Vo
by lksw
diagnostic tester . cted agen
Prote AG.
♦ To do this, press button operating mode and then guided func‐

tions.
♦ For further procedure see respective work descriptions.
♦ To return to guided fault finding, press button operating mode
and then guided fault finding.
Caution
The vehicle must always be delivered to the customer with

event memory cleared.
Static faults
If one or more static faults are found in the fault memory, we rec‐
ommend in agreement with the customer to rectify these faults
using guided fault finding.
Sporadic faults
If only sporadic faults or notes are stored in the event memory
and the customer has no complaints regarding the electronic ve‐
hicle system, erase event memory.
– Press > button again to reach the test plan.
– Now finish guided fault finding using GoTo button and then
End.
All event memories are read again.
Touareg 2003 ➤
Now it is confirmed on display that all sporadic faults have been

cleared.
Then the diagnostic log is sent “online” or stored on the vehicle
diagnostic tester .
Note
olkswagen AG
en AG. V
♦ If the vehicle diagnosticotester
lksw
ag is not connected to thenonetwork,
does
the diagnostic log eisd bstored and will be sent when the vehicle
yV t gu
ara
diagnostic tester
ho
ri is connected to the network.
s nte
e t or
au
♦ Logs storedssand which are more than 40 days old will be
ac
cleared automatically.
ce
e
nl
pt
du
an
itte
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The vehicle system test is completed.
erm
ab
ility
ot p
4.22 Front airbag for the front passenger:
wit
, is n
h re
Check activation / deactivation
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
There are vehicles which are fitted with automatic passenger air‐
bag deactivation (e.g. vehicles for the North American market).
l purpos
This is performed by a seat occupancy recognition and not man‐

ually by the key switch.
nf
ercia
or
– Check “On / Off function” of key switch as follows:
m
m
atio
om
Front passenger airbag deactivated

n in
or c
thi
e
– Switch off ignition.

t
sd
iva
o
r
rp
cu
– Turn ignition key -1- in key-operated switch in centre console

o
m
f
en
ng
to position “perpendicular to direction of travel”.

t.
yi Co
Cop py
– Check if warning lamp -2- “AIRBAG OFF” in centre console
t. rig
gh ht
yri
lights up continuously with ignition switched on. p by
co Vo
by lksw
cted agen
– Switch off ignition. Prote AG.
Front passenger airbag activated

– Turn ignition key -1- in key-operated switch in centre console

to position “direction of travel”.
– Check if warning lamp -2- “AIRBAG OFF” in centre console
does not light up with ignition switched on.
WARNING
The front passenger airbag must only be deactivated if in ex‐

ceptional cases a child is transported in a rear-facing child seat
on the front passenger seat.
Touareg 2003 ➤
kswage es n
4.23 Bonnet catch hook: grease. ol ot g
byV ua
d ran
ir se tee
o
Special tools and workshop equipmentau required
th or
ac
ss
♦ Universal oil spray G 000 115 A2
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
Vehicle must be at least at room temperature.
h re
hole
spec
es, in part or in w
– Lubricate bonnet arrester with universal oil spray G 000 115
t to the co
A2 at points marked with -arrows-.
– Operate moving parts several times so that universal oil is able
rrectness of i
to penetrate.
l purpos
– Remove any excess lubricant using a lint-free cloth.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
4.24 Multi-purpose additive for petrol fuel:

f
en
ng
t.
yi Co
op
adding
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
Note
AG.
♦ Applies only to Chinese, Russian and Indian markets

♦ Use only additives satisfying the standards VW 507 53 A or
VW 507 53 B.
♦ Observe the dosing instructions on the additive tank.
♦ After adding the additive, always recommend that the custom‐
er fill up the tank completely in order for the additive to be the
most effective.
– Fill multi-purpose additive for petrol fuels into regular fuel tank
during each service.
China Russia India
– Use VW 507 53 B for all petrol – Use VW 507 53 B for all petrol – Use VW 507 53 B for all petrol
engines, including CNG and engines, including CNG and engines, including CNG and
MultiFuel (E85) engines. MultiFuel (E85) engines. MultiFuel (E85) engines.
– Use VW 507 53 A: for all petrol – Use VW 507 53 A: for all petrol
engines, excluding CNG and engines, excluding CNG and
MultiFuel (E85) engines. MultiFuel (E85) engines.
♦ Multi-purpose additive - G 001 ♦ Multi-purpose additive - G 001 ♦ Multi-purpose additive - G 001
780-M3- 780-M3- 780-M3-
♦ Multi-purpose additive - G 001 ♦ Multi-purpose additive - G 001
770-A2- 770-A2-
– Observe dosing instructions on – Observe dosing instructions on – Observe dosing instructions on

additive tank. additive tank. additive tank.
Touareg 2003 ➤
4.25 Gearbox, final drive (especially on flang‐

es) and drive shaft bellows: inspect for
leaks and damage
swage es n
4.25.1 Boots: inspecting
olk ot g
byV ua
d ran
ir se tee
Carry outauthe following procedure:
tho
or
ac
ss
– Check outer bellows and inner bellows -arrows- for leaks and
ce
e
nl
damage.
pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
Also check protective bellows on rear axle.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
4.26 Dust and pollen filter: cleaning housing
nform
ercia
and renewing filter element

m
at
om
i
Procedure
on
c
in t
or
Heating, ventilation, air conditioning system ⇒ Rep. gr. 80 →

his
ate
Repairing heating system → Removing and installing dust and

do
priv
pollen filter
um
for
en
ng
t.
yi Co
Cop py
t. rig
Note
gh ht
pyri by
Vo
co lksw
by
cted agen
For technical reasons it is possible that several cross references Prote AG.
4.27 Poly V-belt: checking condition

– Remove engine cover panel, if necessary.
Touareg 2003 ➤
– Check poly V-belt -1- for:

♦ Sub-surface cracks (cracks, core ruptures, cross sectional
breaks)
♦ Layer separation (top layer, cord strands)
♦ Base break-up
♦ Frayed cord strands
♦ Flank wear (material wear, frayed flanks, flank brittleness -
glassy flanks-, surface cracks)
♦ Traces of oil and grease
– Install engine cover panel.
Note
If faults are found, it is essential for the poly V-belt to be renewed.

This can avoid breakdowns and malfunctions.
n AG. VolkswagenThe replacement
AG do
wage
of a poly V-belt is a repairy Vomeasure.
lks es n
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b ua
ed ran
oris tee
th or
au
4.28 Diesel fuel filter: draining water
ss
ac
ce
le
un
pt
Draining water from diesel fuel filter, 6-cylinder diesel engines
an
d
itte
⇒ page 74
y li
erm
ab
ility
4.28.1 Draining water from diesel fuel filter, 6-

ot p
wit
is n
cylinder diesel engines

h re
ole,
spec

t to the co
♦ Diesel extractor - VAS 5226-

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
op
Remove engine cover ⇒ page 109 .
C py
t. rig
gh ht
yri by
– Remove water extraction plug -arrow A-. cop Vo
by lksw
cted agen
Prote AG.
– Insert hose of diesel extractor - VAS 5226- into water extrac‐
tion hole, using a suitable adapter.
– Extract approx. 100 ml diesel fuel using diesel extractor - VAS
5226- .
– Renew seal of water extraction plug.
– Tighten water extraction plug to 5 Nm.
Touareg 2003 ➤
4.29 Diesel fuel filter: renewing (diesel en‐

gine)
AG. Volkswagen AG d
Replacing diesel fuel filter: 6-cylinder lkdiesel
swa
genengines oes
not
⇒ page 75 db
y Vo gu
ara
rise nte
Renewing diesel fuel filter: u10-cylinder
tho diesel engines (vehicles eo
ra
with engine codes AYH, sBKW)
sa ⇒ page 77 . c
ce
le
Renewing diesel fuel filter: 10-cylinder diesel engines (vehicles
un
pt
an
d
with engine codes BLE and BWF) ⇒ page 80 .

itte
y li
rm
ab
Replacing diesel fuel filter: 5-cylinder diesel engines
pe
ility
ot
⇒ page 82
wit
, is n
h re
4.29.1 Renewing diesel fuel filter: 6-cylinder
hole
spec
diesel engines
es, in part or in w
t to the co
Note
rrectness of i
l purpos
Please note, for engine codes CASA, CASB and CATA, the fuel
system must be bled after changing the diesel fuel filter.
nform
ercia

m
a
com
tio
n 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.

Removing:
Note
♦ Ensure that no diesel fuel contacts coolant hoses.

♦ Clean hoses immediately if soiled.
♦ Please observe disposal instructions!

– Remove water extraction plug -arrow A-.
5226- .
Touareg 2003 ➤
– Remove bolts -arrows B-.

– Remove diesel fuel filter upper part -1- and fuel lines connec‐
ted.
– Remove old seal -2- from diesel fuel filter upper part
-arrows A-.
– Pull diesel fuel filter element -4- out of diesel fuel filter lower
part on retainer -3-.
Note
Please observe disposal instructions!
Caution
Remove any dirt and water residues from diesel fuel filter lower
part.
Installing:
Caution
The seals -2- and -4- and diesel fuel filter element -3- must be
renewed. en AG. V
olkswagen AG
wag does
olks not
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– ris
Insert new diesel fuel filter telement in diesel fuel filter lower
ho eo
part and slightly turn to limit
au stop. ra
c
ss
ce
e
– Insert new seal -4- in diesel fuel filter lower part -5-.
nl
pt
du
an
itte
y li
erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Install new seal -2- on diesel fuel filter upper part -1-
rrectness of i
-arrows-.
l purpos
The seal -2- must be flush on diesel fuel filter upper part -1-
-arrows A-.
nform
ercia
– Place retainer of diesel fuel filter element -3- in direction of

m
retaining lugs -arrows B-.

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 ➤
– Fit diesel fuel filter upper part and seal on diesel fuel filter lower
part and screw in bolts approx. one turn.
Caution
Ensure correct installation position of fuel filter upper part to

fuel filter lower part. -Arrows A- and -arrows B- must align.
AG. Volkswagen AG d
– Tighten bolts -arrows B- alternately and diagonally.olkswagen oes
not
yV gu
– Tighten bolts to 10 Nm torque. db ara
rise nte
tho eo
Bleeding fuel system for engine codes: CASA,
s au CASB and CATA ra
c
s
ce
le

un
pt
an
d
itte
y li
– Select “Guided functions”.
rm
ab
pe
ility
– Perform vehicle identification.
ot
wit
, is n
– Select respective engine in guided functions and then function
h re
hole
“Bleeding fuel system”.
spec
es, in part or in w
– Follow the instructions of vehicle diagnostic tester .
t to the co
Note
rrectness of i
l purpos
If there is still air in the fuel system, the engine can change to
emergency running mode during road test. Switch off engine, and
clear event memory.
nform
mercia
a
com
tio
n in
r
te o
thi
diesel engines (vehicles with engine co‐
s
iva
do
r
des AYH, BKW)

rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
Note
gh ht
pyri by
Vo
co lksw
by
cted agen
♦ There are two different diesel fuel filter systems.
Prote AG.
♦ On system 1 the diesel fuel filter is located on the engine below

the engine cover.
♦ On system 2 the diesel fuel filter is located in engine compart‐
ment, left on suspension turret. Removing and installing diesel
fuel filter ⇒ page 75 .
Touareg 2003 ➤
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
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Removing:
– Remove plug -arrow- from water drainage connection of diesel
rrectne
fuel filter housing.
– Extract diesel fuel from side water drainage connection of die‐
ss
sel fuel filter housing -arrow- using -V.A.G 1390- and -
o
cial p
f i
V.A.G 1390/1- .
nform
mer
– Screw in plug again and tighten to 3 Nm.
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Remove connection for fuel hoses: op Vo
by c lksw
cted agen
Prote
– Remove bolts -arrows- and remove connection with lines from
AG.
filter housing.
Remove diesel fuel filter cover:

– Remove cover bolts -arrows- for diesel fuel filter housing and
remove cover.
Touareg 2003 ➤
– Pull filter elements -3- off cover -1-.

AG. Volkswagen AG d
agen oes
Note olksw not
y V gu
d b ara
rise nte
Please observe autdisposal instructions!
ho eo
ra
ss c
ce
le
Installing:
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
– Insert new filters -3- and renew seal -2-.
t to the co
– Install diesel fuel filter cover -1-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
– Tighten diesel fuel filter cover bolts -arrows- to 8 Nm.

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Touareg 2003 ➤
– Install connection for fuel hoses.
Note
Renew seal between diesel fuel filter cover and connection for
fuel hoses.
– Tighten bolts -arrows- to 8 Nm.

Bleeding fuel system
To ensure the engine starts immediately after changing the diesel
fuel filter, bleed the fuel system using vehicle
swa
gdiagnostic
en AG. V tester . does
olkswagen AG
k not
Vol gu
– Connect vehicle diagnostic tester
ed ⇒ page 19 .
by ara
nte
ris
ho eo
– Switch ignition on. aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Select “Systems capable of self-diagnosis”/“Diesel direct in‐
ility
ot p
jection and glow plug system”/“Functions”/“Bleeding fuel sys‐
wit
, is n
tem”.
h re
hole
spec
es, in part or in w
t to the co
– After bleeding, exit “Guided functions” using GoTo button.
rrectness of i
diesel engines (vehicles with engine co‐
l purpos
des BLE and BWF)

nf
ercia
Special tools and workshop equipment required orm

m
atio
m

o
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.

Removing:
Note
♦ Ensure that no diesel fuel contacts coolant hoses.

♦ Clean hoses immediately if soiled.
Touareg 2003 ➤

– Remove water extraction plug -arrow A-.
5226- .
– Remove bolts -arrows B-.

– Remove diesel fuel filter upper part -1- and fuel lines connec‐
ted.
– Remove old seal -2- from diesel fuel filter upper part
-arrows A-.
– Pull diesel fuel filter element -4- out of diesel fuel filter lower
part on retainer -3-.
Note
Caution
Remove any dirt and water residues from diesel fuel filter lower
part.
AG. Volkswagen AG d
Installing: lksw
agen oes
not
o
byV gu
ara
ed
is nte
Caution ut
hor eo
ra
s a c
s
The seals -2- and -4- and diesel fuel filter element -3- must be
ce
e
nl
pt
du
renewed.
an
itte
y li
erm
ab
ility
ot p
– Insert new diesel fuel filter element in diesel fuel filter lower
wit
, is n
part and slightly turn to limit stop.

h re
hole
spec
– Insert new seal -4- in diesel fuel filter lower part -5-.
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
ht. rig
rig ht
py by
co Vo
by lksw
81
cted agen
Prote AG.
Touareg 2003 ➤
– Install new seal -2- on diesel fuel filter upper part -1-
-arrows-.
The seal -2- must be flush on diesel fuel filter upper part -1-
-arrows A-.
– Place retainer of diesel fuel filter element -3- in direction of
retaining lugs -arrows B-.
– Fit diesel fuel filter upper part and seal on diesel fuel filter lower
part and screw in bolts approx. one turn.
Caution
Ensure correct installation position of fuel filter upper part to

fuel filter lower part. -Arrows A- and -arrows B- must align.
– Tighten bolts -arrows B- alternately and diagonally.

– Tighten bolts to 10 Nm torque.
Bleeding fuel system:
G. Volkswagen nA AG do
wage e
– Select respective Vengine
olks in guided functions and
s no
tthen
gu function
by
“Bleeding fuel
isedsystem”. ara
nt
r ee
tho
– Follow the
au instructions of vehicle diagnostic tester .
or
ac
ss
ce
le
un
pt
an
d
Note
itte
y li
erm
ab
ility
ot p
If there is still air in the fuel system, the engine can change to
wit
is n
emergency running mode during road test. Switch off engine, and
h re
clear event memory.

ole,
spec
t to the co

diesel engines
rrectne

ss 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
82
by lksw
cted agen
Prote
AG.
Touareg 2003 ➤
♦ Spring-type clip pliers - VAS 6499-

Removing:
– The diesel fuel filter -1- is located in the engine compartment,
on the left in front of the bulkhead.
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
– Note fuel line identification on diesel fuel filter.

es, in part or in w
t to the co
♦ Return line (marked blue) -2- identified with “RT” (return line
to tank).
♦ Supply line (marked black) -3- identified with “VF” (supply line
rrectness of i
to filter).
l purpos
♦ Return line -9- identified with “RT” (return line to filter).

♦ Supply line -8- identified with “VM” (supply line to engine).
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 ➤
– To pull off lines, press release button on connecting piece.

Remove diesel fuel filter -5- by loosening securing clip -1- from
bracket -4- using spring-type clip pliers - VAS 6499- and remove
filter upwards.
Note
♦ Note installation position of diesel fuel filter!

Installing:
– Insert new filter -5-.

– Secure diesel fuel filter -5- on bracket A-4-
G. Vwith
olkswclip
agen-1-.
A gen G do
swa es
– Push lines onto diesel fuel bfilter
y V connections and ensure se‐t gua
olk no
cure seating. ris
ed ran
te
tho eo
Bleeding fuel system ss au ra
c
ce
le
To ensure the engine starts immediately after changing the diesel

un
pt
an
fuel filter, bleed the fuel system using vehicle diagnostic tester .
d
itte
y li
rm
ab

pe
ility
ot
wit
– Switch ignition on.

, is n
h re
hole

spec
es, in part or in w

t to the co
– Select “Systems capable of self-diagnosis”/“Diesel direct in‐

jection and glow plug system”/“Functions”/“Bleeding fuel sys‐
rrectness of i
tem”.
l purpos

– After bleeding, exit “Guided functions” using GoTo button.
nform
mercia
4.30 Interior and exterior body: inspecting for

com
tion in
corrosion with doors and flaps open

r
te o
thi
s
iva
do
Test locations
r
rp
cum
fo
en
g
♦ Sliding roof frame

n
t.
yi Co
Cop py
♦ Inner and outer door frame
t. rig
gh ht
pyri by
Vo
o
♦ Area around trim strips
by c lksw
cted agen
Prote AG.
♦ Windscreen roof edge
♦ Outer and inner A-pillar
♦ Bonnet
♦ Wheel arches
♦ Inner and outer tailgate
Touareg 2003 ➤
4.31 Compass in roof module: Set compass

zones
The compass indicates the direction, in which the vehicle drives.
The correct geographic zone must be set for a correct display.
Compass zone: setting
– Your geographic zone can be read off of the zone map.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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
– With ignition switched on press button -3-.

– Select the symbol “N” using the function buttons -2- in display
ss
-1- and confirm with OK .

o
cial p
f in
– To set the compass zone, select with function buttons -2- the
form
mer
selected zone between “1 and 15” and confirm with OK .

atio
om
The selected zone is saved, the compass reading appears in the

c
i
or
display.
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 ➤ agen
AG. Volkswagen AG d
oes
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Maintenance - Edition 03.2018 by Vol
gu
ara
d
rise nte
o eo
4.32 Cooling system: checking frost protec‐
th
au ra
ss c
tion and coolant level
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
h re
♦ The water used for mixing has a major influence on the effec‐
hole
spec
tiveness of the coolant. Because the water quality differs from
es, in part or in w
country to country and even from region to region, the quality
t to the co
of the water to be used in the cooling system has been speci‐
fied by Volkswagen. Distilled water fulfils all requirements.
Therefore, only ever use distilled water when mixing coolant
rrectness of i
for topping up or renewing coolant.
l purpos
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic parts catalogue (ETKA) . Other coolant additives may
reduce corrosion protection substantially. The resulting dam‐
nf
ercia
o
age could lead to loss of coolant and subsequent severe
rm
damage to the motor.
m
atio
om
n in
c
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐

or
thi
rosion damage as well as scaling. Furthermore, the boiling
te
sd
a
point is raised. For these reasons, the cooling system must be

iv
o
r
rp
cu
filled all year round with a coolant additive.
o
m
f
en
ng
t.
yi
♦ Because of its high boiling point, the coolant improves engine
Co
op py
reliability under heavy loads, particularly in countries with trop‐
t. C rig
gh ht
yri
ical climates. p by
co Vo
by lksw
cted agen
♦ Use ONLY refractometer - T10007A- for determining current Prote AG.
anti-freeze value.
♦ Frost protection must be guaranteed down to -25°C as a min‐
imum and, in countries with arctic conditions, down to approx.
-36°C. Increasing the frost protection is permissible only if cli‐
matic conditions require stronger frost protection. It may, how‐
ever, be increased only to a maximum of -48°C. Otherwise,
the cooling effect will be impaired.
♦ Do not reduce the coolant concentration by adding water even
in the warm season or in hot countries. Frost protection must
be guaranteed down to at least -25°C.
♦ Read anti-freeze figures from the respective scale for type of
anti-freeze added.
♦ The temperature read off the refractometer - T10007A- corre‐
sponds the »ice flocculation point«. Flakes of ice may start
forming in the coolant at this temperature.
♦ Never reuse old coolant.
♦ Use only a water/coolant additive mixture as a slip agent for
coolant hoses.
4.32.1 Frost protection: checking, replenishing

coolant additive if necessary
Touareg 2003 ➤
♦ Refractometer - T10007 A-
Note
Read precise value for the following tests at light/dark boundary.

Using a pipette, place a drop of water on the glass to improve the
readability of the light/dark boundary. The bright/dark boundary
can be clearly recognised on the “WATERLINE”.
– Check concentration of coolant additive using refractometer -

T10007 A- (refer to operating instructions).
The scale -1- of the refractometer is calibrated for coolant addi‐
tives G12; G12 Plus, G12 Plus Plus and G11.
The scale -2- is only calibrated for coolant additive G13.
– If frost protection is insufficient, drain coolant and supplement
coolant additive ⇒ page 87 .
. Volkswagen AG
gen AG does
swa
Note by Volk not
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d ara
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or
♦ If athe
ut currently used coolant additive cannot be determined
h eo
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sprecisely, use the scale -2- for coolant additive G13.c
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pt

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– Check coolant additive concentration after road test again.

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4.32.2 Coolant level: checking, replenishing

hole
spec
coolant if necessary
es, in part or in w
t to the co

♦ Cooling system charge unit - VAS 6096-
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Prote AG.
Touareg 2003 ➤
♦ Adapter - V.A.G 1274/8-
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Check coolant level in expansion tank with engine cold.
ole,
spec
t to the co
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cial p
f inform
mer
atio
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– Unscrew cap -1- from expansion tank.
♦ Delivery inspection: Coolant level at max. marking.
♦ Inspection: Coolant level between min. and max. marking.
– If coolant is too low, add required amount according to mixture
ratio.
Note
Small quantities of coolant can be replenished. For larger quan‐

tities use the cooling system charge unit - VAS 6096- .
Note operating instructions for cooling system charge unit - VAS

6096- .
Note
♦ If fluid loss is greater than can be expected through normal

use, determine source and rectify (repair measure).
♦ Coolant level: checking, replenishing coolant if necessary
Touareg 2003 ➤
4.32.3 Mixing ratio:
Caution
Use only distilled water for mixing coolant additives. The use
of distilled water ensures optimum protection against corro‐
sion.
Frost protection to Coolant additive Distilled water

portion
-25 °C approx. 40% approx. 60 %
-36 °C approx. 50 % approx. 50 %
4.33 Air filter: cleaning housing and renewing

filter element
Note
♦ Vehicles with 5- and 6-cylinder engines are equipped with one

air filter.
♦ Vehicles with 8, 10 and 12-cylinder engines have two air filters
in the engine compartment.
Removing and installing air filter element for 10-cylinder diesel

engines ⇒ page 89 . wage
e ks s no
Vol t gu
Removing and installing air filter element for 5-cylindereddiesel
by en‐ ara
gines ⇒ page 92 . thoris nte
eo
au ra
Removing and installing air filter element for 6, s8s and 12-cylinder c
ce
e
petrol engines ⇒ page 95 .

nl
pt
du
an
itte
Removing and installing air filter element for 6-cylinder diesel en‐
y li
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gines ⇒ page 97 .
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4.33.1 Removing and installing filter element
, is n
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hole
on 10-cylinder engines spec

es, in part or in w
t to the co
Removing
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Note
The removal and installation of the left air filter element is descri‐
nform
ercia
bed below. The right air filter element is removed and installed in
m
the same manner.

at
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by
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Prote AG.
Touareg 2003 ➤
– Open spring retainers -1-.

– Remove securing pins for intake hose -2-.
Remove intake hose securing pins:
– Turn pin until marking -1- aligns with marking on air filter hous‐
ing -3-.
– Pull out securing pin upwards.
– Pull off intake hose.
AG. Volkswagen AG d
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– Disconnect lines to air filter housing -arrow- as follows:

wit
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spec
t to the co
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cial p
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mer
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Touareg 2003 ➤
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gen AG does
– Press locking ring -1- off flange of lineV-3-
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– Press securing sleeve -2- in direction
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th of arrow and pull line eo
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-A- off line -B- at the same time.
ss c
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pt
– Pull out upper part of air filter upwards.
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Note installation position of air filter element!
spec
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– Remove air filter element -A-.
rrectness of i
– If necessary, blow out air filter housing with compressed air
l purpos
and install new air filter element.

Installing
nf
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– Install air filter element -A-.
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Note
♦ Ensure that sealing surfaces of air filter housing are properly

seated.
♦ Do not pinch cables or lines.
– Secure air filter housing with spring clips -1-.
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Touareg 2003 ➤ horis tee
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Maintenance - Editions au03.2018 ac
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– Push line -arrow- together again.
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– Then press locking ring -1- onto flange of line -3- until it can
ercia
be heard to engage.
m
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com
tio
– Install intake hose.
n in
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Install intake hose securing pins as follows:
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pyri by
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cted agen
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– Insert securing pins so that marking on pin -1- and marking on

air filter housing -2- align.
4.33.2 Air filter element for 5-cylinder diesel en‐

gines: removing and installing
Touareg 2003 ➤
Removing
– Open clips -1-. AG. Volkswagen AG d
agen oes
olksw not
– Remove securing pins for intake dhoseby
V -2-. gu
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Remove intake hose securing pins:
ut
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– Turn pin until marking -1- aligns with marking on air filter hous‐
m
at
om
i
ing -3-.
on
c
in t
or
– Pull out securing pin upwards.
his
ate
do
riv
– Pull off intake hose.

p
cum
for
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Cop py
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Prote AG.
Touareg 2003 ➤
– Press locking ring -1- off flange of line -3- using screwdriver
-C-.
– Press securing sleeve -2- in direction of arrow and pull line
– Pull out air filter housing part upwards.
Note

Installing
– Install air filter element.
– Fit air filter housing upper part to filter housing
agen lower part. AG do
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Touareg 2003 ➤
be heard to engage.
– Install intake hose.
Install intake hose securing pins as follows:
– Insert securing pins so that marking on pin -1- and marking on

air filter housing -2- align.
– Install engine cover ⇒ page 109
AG. Volkswagen AG d
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4.33.3 Removing and installing air filter ele‐

t to the co
ment for 6, 8 and 12-cylinder petrol en‐

gines
rrectne
Removing
ss o
Remove engine cover if necessary ⇒ page 109 .

cial p
f inform
– Loosen coolant hose from clips.

mer
atio
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n
c
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agen
Prote AG.
Touareg 2003 ➤
– Open clips -1-.

– Pull connector -3- off throttle valve module.
– Remove throttle valve module bolts -2-.
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– On the rear line, press locking ring -1- off flange of line -3-
y li
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using screwdriver -C-.
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– Press securing sleeve -2- in direction of arrow and pull line
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nf
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– On front line, press securing ring -B- together and pull line
rm
m
atio
-A- off air filter housing.
om
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– Pull out air filter housing part upwards.

or
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Prote AG.
Touareg 2003 ➤

Installing
– Install air filter element.
Note

seated.

– Bolt on throttle valve module -2- and tighten to 3 Nm.
– Reconnect connector -3-.
AG. Volkswagen AG d
agen oes
– Push line -arrow-
yV
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lksw again. not
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– Then press horislocking ring -1- onto flange of line -3- until
nte it can
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be heardau to engage.
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– Reconnect line -A- until it engages.

rrectne
– Clip coolant hose into clips.

s

s o
cial p
f inform
mer
atio
om
n
c
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pr
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4.33.4 Air filter element for 6-cylinder diesel en‐
pyri by
Vo
co lksw
by
gines: removing and installing
cted agen
Prote AG.
Removing
Touareg 2003 ➤
– Open clips -1-.

– Pull connector -3- off throttle valve module.
– Remove throttle valve module bolts -2-.
AG. Volkswagen AG d
agen oes
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– Disconnect lines
s au to air filter housing -arrow- as follows: ra
c
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un
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d
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ility
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t to the co
rrectne
– Press locking ring -1- off flange of line -3- using screwdriver
ss
-C-.
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Press upper part of air filter -1- off lower part of air filter -3-.
Touareg 2003 ➤
– Pull air filter housing upper part -1- out upwards of retaining
lug openings -arrows B-.
AG. Volkswagen AG d
agen oes
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Installing
t to the co
rrectness o
cial p
f inform
mer
– Install air filter element -A-.
atio
om
n
c
i
or
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te
sd
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pr
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fo
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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.
– Insert air filter housing upper part with retaining lugs

-arrows A- into holes of air filter housing lower part
-arrows B-.
Touareg 2003 ➤
– Seal air filter element -2- with air filter housing upper part -1-.
Note
wage es n
♦ Ensure that sealing y V surfaces of air filter housing are
olks ot g properly
seated. ir se
d b ua
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♦ Do not pinch
aut
cables or lines. or
ac
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– Bolt on throttle valve module -2- and tighten to 3 Nm.
es, in part or in w
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– Reconnect connector -3-.
rrectness of i
l purpos
nform
mercia
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te o
thi

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be heard to engage.
n
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– Install engine cover ⇒ page 109
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4.34 Engine oil level: checking

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 then push
dipstick in again to limit stop.
– Pull dipstick out again and read oil level.
Note
Note
Oil level must always be in area A for the delivery inspection.

Touareg 2003 ➤
A - Do not fill oil. AG. Volkswagen AG d

agen oes
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B - Oil can be replenished up todareaby
V -A-.
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C - Oil must be replenished.utOil level must then be at least in upper
ho eo
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third of measuring area -B-.
ss a c
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– If oil level is above marking -A-, drain or extract excess oil to
un
pt
an
d
prevent damage to catalytic converter.
itte
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– If oil level is below marking -C-, replenish oil to marking -A-.
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Oil specification ⇒ page 7
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4.35 Engine oil: draining or extracting, renew‐
ing oil filter and replenishing engine oil
rrectne
Engine oil capacities: ⇒ Power unit ⇒ Rep. gr. 17 ⇒ Engine oil
or in ⇒ Maintenance tables
ss o
cial p
f
Draining or extracting engine oil 3) ⇒ page 101
inform
mer
Renew oil filter ⇒ page 102
atio
m
Engine oil: replenishing ⇒ page 108

o
n
c
i
or
n thi
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3) For 8-cylinder and 12-cylinder engines it is not permitted to extract engine oil.
t
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4.35.1 Engine oil: draining or extracting
um
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fo
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ng
t.
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Caution
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pyri by
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by c lksw
♦ For engines with standing oil filter the oil filter must be re‐
cted agen
Prote AG.
newed before changing the engine oil ⇒ page 102 . When
removing the filter element a valve is opened, the oil in the
filter housing automatically flows into crankcase.
♦ For 8-cylinder and 12-cylinder engines it is not permitted
to extract engine oil.
♦ The oil drain plug is fitted with a secure seal, therefore the
oil drain plug must always be renewed.

AG. Volkswagen AG d
agen oes
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Touareg 2003 ➤ d by
V gu
ara
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Maintenance - Edition 03.2018 horis
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aut ra
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– Extract engine oil using used oil collection and extraction unit
ce
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nl
- V.A.G 1782- .
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– Remove oil drain plug.
wit
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– Clean M24 oil drain plug and fit new seal. The M14 oil drain
hole
spec
plug with integrated seal must always be renewed. ⇒ Elec‐
es, in part or in w
tronic Parts Catalogue ETKA
t to the co
– Let engine oil drain.
rrectness of i
Note
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nf
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orm
m
– Screw in oil drain plug together with seal hand-tight and then
atio
m
tighten to specified torque.

o
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or c
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– Replenish engine oil, specification ⇒ page 7 .
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Specified torques:
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t.
♦ Oil drain plug M14: 30 Nm
yi Co
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♦ Oil drain plug M24: 50 Nm
gh ht
pyri by
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by c lksw
cted agen
Prote AG.
WARNING
♦ Torque specifications must not be exceeded.

♦ Excessive torque can cause leaks in the area of the oil
drain plug or even damage.
4.35.2 Oil filter: renewing

Renewing oil filter on 5-cylinder diesel engine ⇒ page 102
Renewing oil filter on 6-cylinder petrol engine ⇒ page 106
4.35.3 Renewing oil filter on 5-cylinder diesel

engine
Removing
Note

♦ Oil new O-rings before installing.
♦ Prevent engine oil from dripping onto components in engine
compartment.

Touareg 2003 ➤
– Loosen threaded cover -1- on hexagonal flats or along perim‐

eter and remove.
– Clean sealing surfaces on threaded cap and oil filter housing.
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– Renew oil filter element -3- and new O-rings -2- and -4-.
rm
ab
pe
ility
Installing
ot
wit
, is n
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– Install threaded cover -1- and tighten to 25 Nm.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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com
tion in
r
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4.35.4 Renewing oil filer on 8-cylinder petrol
t rig
gh ht
pyri by
Vo
o
engine, engine codes AXQ and BHX
c by lksw
cted agen
Prote AG.
Removing
Note

– Remove oil drain plug -1- of threaded cover and drain oil.
– Loosen threaded cover -2- on hexagonal flats -1- or along pe‐
rimeter, and remove.

Touareg 2003 ➤

– Renew filter element -5-.
Installing
– Install threaded cap -3- with new O-ring -4- and tighten to 25
Nm. agen
AG. Volkswagen AG d
o w es n
olks ot g
– Fit oil drain plug -1- with new seal -2-edand
by tighten to 10 Nm.
V ua
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ris tee
ho
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un
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ility
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spec
t to the co
rrectne
4.35.5 Renewing oil filter on 8-cylinder FSI en‐
gine with engine code BAR
ss o
cial p
Remove engine cover ⇒ page 109
f inform
mer
atio
m
♦ Socket insert - SW 32- .

o
n
c
i
or
n thi
e
Removing
t
sd
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ng
Note
t.
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Cop py
t. rig
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♦ Please observe disposal instructions! yri
p by
o Vo
by c lksw
cted
agen
Prote AG.
– Cover area around oil filter sealing cap e.g. with oil spill cloth
- VAS 6204/1- .
– Release sealing cap -arrow- using a 32 mm socket.
– Remove sealing cap together with oil filter element.

Touareg 2003 ➤
– Separate oil filter element -3- from sealing cap -1-.

wage
– Clean sealing surfaces on threaded cap and oil filter o housing.
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Installing ir se tee
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– Renew oil filter element -3-. ss
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– Install sealing cap -1- with new O-rings -2- and -4- and tighten
pt
du
an
itte
to 35 Nm.
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Further assembly is basically the reverse of the removal proce‐
ility
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l purpos
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ercia
4.35.6 Oil filter on 10-cylinder diesel engine: re‐

m
at
om
newing
ion
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or
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do
priv
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Removing
um
for
en
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t.
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Cop py
t. rig
Note gh ht
pyri by
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by
cted agen
♦ Please observe disposal instructions! Prote AG.
– Cover engine with a cloth.

– Remove threaded cap from filter housing using tool -T10192- .

Installing
– Install threaded cap -1- with new O-rings -2- and -4- and tight‐
en to 25 Nm.

Touareg 2003 ➤
4.35.7 Oil filter on 6-cylinder petrol engine: re‐ Volkswa

AG. gen AG
newing Volksw
agen does
not
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Note s au ra
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♦ Prevent engine oil from dripping onto subframe.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove oil drain plug -1- of threaded cover and drain oil.
– Loosen threaded cover -2- on hexagonal flats -1- or along pe‐
rimeter, and remove.
rrectness of i
l purpos
Installing
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
– Renew filter element -4- and seal -3-.

t.
yi Co
Cop py
t. rig
– Install threaded cap -2- with new O-ring and tighten to 25 Nm. opyri
gh by
Vo
ht
c
– Fit oil drain plug -1- with new seal, and tighten it to 10 Nm.
by lksw
cted agen
Prote AG.
4.35.8 Oil filter on 12-cylinder petrol engine: re‐

newing
♦ Torque wrench (5 - 50 Nm) - V.A.G 1331-

Touareg 2003 ➤
Removing
Note

♦ Prevent engine oil from dripping onto components in engine
compartment.
n AG. Volkswagen A
– Remove oil drain
olks
waplug
ge -1- of threaded cover
G do
es n and drain oil.
o
V t gu
by a
– Loosenristhreaded
ed cover -3- on hexagonal flats -2-
ran or along pe‐
tee
rimeter,
ut
ho and remove. or
a ac
ss
ce
le
un
pt
an
Installing
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

com
tion in
r
– Install threaded cap -3- with new O-ring -4- and tighten to 25
te o
thi
Nm.
s
iva
do
r
rp
cum
– Fit oil drain plug -1- with new seal -2- and tighten to 10 Nm.
fo
en
ng
t.
yi Co
Cop py
t. rig
dure. opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.
4.35.9 Oil filter on 6-cylinder diesel engine: re‐

newing
♦ Socket insert - SW 32- .

Touareg 2003 ➤
Removing
Note

– Cover area around oil filter sealing cap e.g. with oil spill cloth
- VAS 6204/1- .
– Release sealing cap -arrow- using a 32 mm socket.
– Remove sealing cap together with oil filter element.
kswage es n
– Separate oil filter belement
yV
ol
-3- from sealing cap -1-. ot g
ua
d ran
ir se
– Clean sealingth surfaces on threaded cap and oil filter housing.
o tee
or
au ac
Installing ss
ce
le
un
pt
– Renew oil filter element -3-.

an
d
itte
y li
rm
ab
– Install sealing cap -1- with new O-rings -2- and -4- and tighten
pe
ility
to 35 Nm.
ot
wit
, is n
h re

hole
dure.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tio
4.35.10 Engine oil: replenishing

n in
r
te o
thi
s
iva
Oil specifications, see ⇒ page 7

do
r
rp
cum
fo
General information
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
Note p by
co Vo
by lksw
cted agen
Prote AG.
– After replenishing with oil, wait at least 3 minutes and then

check oil level.
– Pull out dipstick, wipe with a clean cloth and push dipstick in
again to limit stop.

Touareg 2003 ➤
– Pull dipstick out again and read oil level.

A - Do not fill oil.
B - Oil can be replenished up to area -A-.
C - Oil must be replenished. Oil level must then be at least in upper
third of measuring area -B-.
– If oil level is above marking -A-, drain or extract excess oil to
prevent damage to catalytic converter.
– If oil level is below marking -C-, replenish oil to marking -A-.
Oil specification ⇒ page 7
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
4.36 Engine cover panel -top-: Removing and aut
hor eo
ra
installing ss c
ce
le
un
pt
Side engine cover panel
an
d
itte
y li
erm
ab
Remove right engine cover panel as follows:
ility
ot p
wit
– Lever off cover -2-.
is n
h re
ole,
– Pull engine cover panel out of fastenings -arrows-, and remove
spec
it upwards.
t to the co
Centre engine cover panel for 6-cylinder petrol engine
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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
– Unclip engine compartment covers -1- and -2- and remove Prote AG.
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
be damaged.
Centre engine cover for 10-cylinder diesel engine

Removing:

Touareg 2003 ➤
– Pull out oil dipstick -2-.

– Unclip cover -1- from fastenings -arrows- and pull off upwards.
Installing:
– Fit engine cover -1- at securing points A-arrows-
G. Volkswaand
gen Apress
G do on
until it engages. agen es n
olksw ot
V y gu
db ara
– Do not forget dipstick -2-.
or
ise nte
th eo
s au ra
c
s
Caution
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
be damaged.
wit
is n
h re
ole,
spec
Centre engine compartment cover for 6-cylinder diesel engine
t to the co
(TDI common rail)
Removing:
rrectne
– First pull engine cover off at front with both hands (from driver
perspective) -arrows-, then lift at rear with both hands (in bulk‐
ss
head area).
o
cial p
f inform
mer
Note
atio
om
n
c
i
or
♦ Do not lift engine cover panel abruptly when pulling off. n thi
te
sd
iva
♦ Do not cant engine cover panel when pulling off!

pr
cum
r
fo
en
ng
t.
yi Co
Installing: t. Cop py
rig
gh ht
yri
Place engine cover on securing points, observe oil filler neck and p by
o Vo
by c
oil dipstick.
lksw
cted agen
Prote AG.
Caution
be damaged.
– Press engine cover at front securing points, so that the cover

engages.
– Then press engine cover at rear securing points, so that the
cover engages.
4.37 Engine cover - bottom (noise insulation):

removing and installing
Note
♦ On some vehicles the engine compartment is fitted from below

with an additional skid plate.
♦ Removing and installing skid plate ⇒ General body repairs,
exterior ⇒ Rep. gr. 50 ⇒ Skid plate .

Touareg 2003 ➤
4.37.1 Front side noise insulation
Note
♦ Fastenings for the front left side noise insulation are shown in
the figure. Fastenings for the right side are the mirror image.
♦ To remove or install the front noise insulation, the bolts on the
side must be removed or installed.
– First remove bolts -1- and then -2-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
4.37.2 Front and rear noise insulation
ss aut ra
c ce
le
– Remove bolts -A-.

un
pt
an
d
itte
y li
– First remove front noise insulation -3-.

erm
ab
ility
ot p
– Then remove bolts -B-.

wit
is n
h re
– Pull rear noise insulation -2- out of spring tabs -1-.

ole,
spec
– Tighten bolts to 8 Nm torque.

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
4.38 Engine and components in engine com‐

t.
yi Co
Cop py
partment: inspecting for leaks and dam‐
t. rig
gh ht
pyri by
Vo
age (from above and below)
o
by c lksw
cted agen
Prote AG.
Inspect as follows:
– Check engine and components in engine compartment for
leaks and damage.
– Check lines, hoses and connections of
♦ Fuel system
♦ Cooling and heating system
♦ Lubrication system
♦ Air conditioning system

Touareg 2003 ➤
♦ Intake system
♦ And brake system
For leaks, abrasions, porosity and brittleness.
Caution
Arrange for defects to be rectified as repair measures.

If fluid loss is greater than can be expected through normal use,
determine source and rectify (repair measure).
4.39 Tyre repair set: checking if bottle is dam‐

aged or used; checking shelf life of tyre
sealant
The tyre repair set is located in the spare wheel well -arrow-
The tyre repair set consists of the compressor and a filler bottle
with tyre sealant.
Note
♦ The tyre sealant in the bottle has a limited shelf life.

♦ Therefore the expiry date is indicated
wage
n AG. Von
olksthe
wagbottle
en AG -arrow-.
doe
ks s no
Vol t gu
d by ara
e nte
ris
utho eo
ra
a c
ss
This example shows that the expiry date 05/2003 has been ex‐
ce
le
un
pt
ceeded, then the bottle has to be renewed.

an
d
itte
y li
rm
– Check the expiry date.

ab
pe
ility
ot
– Renew tyre sealant if the expiry date has been reached.

wit
, is n
h re
hole
spec
Caution
es, in part or in w
t to the co
♦ The tyre sealant must not be more than 4 years old.

♦ When the bottle has been opened e.g. at a "flat tyre", it
rrectness of i
has also to be renewed.

l purpos
nform
ercia
Note
m
a
com
tion in
♦ Residual tyre sealant or bottles which are filled and the expiry
r
te o
date has been exceeded, must be disposed of.

thi
s
iva
do
r
♦ Old tyre sealant or residual sealant must not be mixed and

rp
cum
fo
disposed of with other fluids.

en
ng
t.
yi Co
op
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
4.40 Road test: performing (driving behav‐
Prote AG.
iour, noises, air conditioner etc.)

Which of the following can be checked depends on vehicle equip‐
ment and local conditions (urban/country).
Check the following during a road test:

Touareg 2003 ➤
– Engine: output, misfiring, idling speed, acceleration

– Clutch: pulling away, pedal pressure, odours agen
AG. Volkswagen AG d
oes
olksw not
– Gear selection: ease of operation, stick position ed by
V gu
ara
ris nte
– Automatic gearbox: selector lever position, shiftaut lock/ignition
h o eo
ra
key removal lock, shift behaviour, dash panels insert display.
s c
ce
le
un
– Foot brake: Function, free travel and effectiveness, pulling to
pt
an
d
itte
one side, juddering, squealing.
y li
erm
ab
– Parking brake: Sufficient effect for public roads after 5-7 clicks
ility
ot p
at latest. Free travel of operating lever until braking effect be‐
wit
is n
h re
gins, 2-3 clicks.
ole,
spec
– ABS function: Pulsing must be felt at the brake pedal during urposes, in part or in wh
ABS-regulated braking.
t to the co
– Steering: function, steering free clearance, steering wheel
centred when vehicle is travelling straight ahead
rrectne
– Tilting roof: function
ss
– Radio/radio navigation system: function, reception, GALA, in‐
o
cial p
f
terference noise
inform
mer
– Air conditioner: Check function (at low temperatures the func‐
atio
tion of air conditioner must be checked in a workshop)
om
n
c
i
or
n
– Vehicle: pulling to one side when travelling straight-ahead
thi
te
sd
(level road)
iva
o
pr
cum
r
– Imbalance: wheels, drive shafts, propshaft

fo
en
ng
t.
yi Co
– Wheel bearings: noises Cop py
t. rig
gh ht
yri
– Engine: hot starting behaviour p by
o Vo
by c lksw
cted agen
4.41 Wheel securing bolts: tightening to
Prote AG.
specified torque
♦ Torque wrench - V.A.G 1332/-

Touareg 2003 ➤
♦ Adapter set for tamper-proof wheel bolts - T10190-
♦ Adapter set for wheel bolts - T10313-
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
The adapter to loosen and tighten the anti-theft wheel bolts can
ility
ot p
be found in the vehicle tool kit.

wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
Ensure that wheel bolts are tightened diagonally and alternately

to the following torque setting:
rrectness of i
Specified torque: 180 Nm

l purpos
4.42 Radio code: reading using vehicle diag‐

nf
ercia
nostic tester
orm
m
atio
m
Authorization prerequisites for vehicle diagnostic tester

o
n in
or c
• The vehicle diagnostic tester is connected via the Central

thi
te
sd
a
Partner Network (CPN) with the central database (Carport,

iv
o
r
rp
cu
Fazit).
o
m
f
en
ng
t.
• Available access for the user of the system “GeKo” (secrecy
yi Co
op py
and component protection) t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
Note
AG.
♦ The radio codes are also called security codes, they can be
read in the central database and can be displayed on display
of vehicle diagnostic tester .
♦ For radio activation the codes must be entered via radio but‐
tons, as previously.
Procedure

Touareg 2003 ➤
– Touch the field or button on the screen for »GUIDED FUNC‐

TIONS«.
– Confirm with > button.
– Select one after another:
♦ Brand
♦ Model
♦ Model year
♦ Engine code
– Confirm vehicle identification.
♦ “Radio system”
♦ “Reading radio code”
– Read code according to the information of “GUIDED FUNC‐
TIONS”.
– Finish code reading as follows:
– Press the »GoTo« button on display -arrow-.
– Press »End« button on display.
– Press »End« button in End menu.
– Switch off ignition and separate diagnosis connections.
AG. Volkswagen AG d
agen oes
4.43 Radio/navigation system: Activating an‐ d by Volksw not
gu
ara
ti-theft coding thorise nte
eo
au ra
s c
♦ General information ⇒ page 115 s
ce
le
un
pt
♦ Activate anti-theft coding on Volkswagen radio systems
an
d
itte
y li
⇒ page 116
erm
ab
ility
ot p
♦ Activate anti-theft coding on Volkswagen radio/navigation sys‐
wit
tems ⇒ page 117
is n
h re
ole,
spec
t to the co
The anti-theft coding electronically prevents unauthorized per‐
sons from operating the unit after it has been removed from
vehicle.
rrectne
The anti-theft codes are also called radio codes or security codes.
s
Security code means that each unit with an anti-theft coding is
s o
cial p
programmed with its own code number.

f inform
mer
This security code is not active when leaving the factory.

atio
m
The security code is found on the unit card, if fitted.

o
n
c
i
or
n thi
e
Or, the security code can be read using vehicle diagnostic tester
t
sd
va
of a central database, if the unit card is not fitted ⇒ page 114 .

i
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 ➤
Note
♦ If SAFE appears on display when the unit is switched on, the

unit is locked!
♦ The unit must remain switched on for one hour, the lock will
then be released. The code can now be entered again.
♦ If the incorrect security code has been entered twice, the unit
is locked for an hour.
♦ Note: Always two attempts to enter the code, then the unit will
be locked for one hour.
♦ The units are fitted with an electronic convenience anti-theft
system, which is activated in conjunction with the dash panel
AG. Volkswagen AG d
insert. lkswagen oes
n o ot g
yV
♦ After disconnecting the voltage supplyisof
ed the radio or naviga‐
b ua
ran
tion system, it is operational when ureconnecting
tho
r
to voltage tee
or
supply, without entering the security
ss a code again. ac
ce
le
♦ Prerequisite: the electronic anti-theft system has been initially

un
pt
an
d
activated, and the unit is reconnected in same vehicle.

itte
y li
rm
ab
pe
ility
4.43.2 Activating anti-theft coding on Volkswa‐
ot
wit
, is n
gen radio systems
h re
hole
spec
es, in part or in w
Activate fixed code on DELTA radio system as follows:
t to the co
– Switch radio on.
”SAFE” appears on the digital display.
rrectness of i
– Enter radio code using station buttons 1 to 4.
l purpos
– Start with first station button 1 , and press repeatedly, until the
first number in the display matches the first digit of the radio
nform
ercia
code.
m
a
com
– Repeat procedure for digits 2, 3 and 4.

ion in
r
te o
– After entering the four-digit radio code, press one of the search
thi
s
iva
buttons for longer than 2 seconds.

do
r
rp
cum
fo
If the correct radio code has been entered, a radio frequency will
en
ng
t.
yi
appear automatically.
Co
Cop py
t. rig
The unit is now ready to operate.
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
On the “Sound System” radio for vehicles for USA and Canada,
AG.
activate the fixed code as follows:

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 the radio card. Use button 1 to enter the first digit of
the code number, button 2 to enter the 2nd digit and so on.
– Then press and hold arrow button (located above FAD button)
until the anti-theft coding is activated. This is indicated by a
brief sound.
If the code number has been entered correctly into the radio unit,
a radio frequency appears on display.

Touareg 2003 ➤
On the radio system "Premium Sound System" for vehicles for

USA and Canada, activate the fixed code as follows:
The unit automatically displays "SAFE" and then "1000". For this
no buttons are used.
– With the help of station buttonswa1geton A4Genter
. Volkswcode number
agen AG
does ap‐
s
plied on the radio card. Use y V button 1 to enter the first digit
olk not of
g
the code number, button ed b2 to enter the 2nd digit and so on. uara
ris nt ee
tho or
– Then press the station
au button, located below "OK" indicated ac
ss
on display (usually this is the last station button) and hold until
ce
e
nl
the anti-theft coding is activated. This is indicated by a brief
pt
du
an
sound.
itte
y li
erm
ab
If the code number has been entered correctly into the radio unit,
ility
ot p
a radio frequency appears on display.
wit
, is n
h re
hole
spec
4.43.3 Activating anti-theft coding on Volkswa‐
es, in part or in w
t to the co
gen radio/navigation systems
Activate fixed code on “RNS 510” as follows:
rrectness of i
– Switch on radio navigation system using press button -1-.
l purpos
– Enter code by turning rotary/push button -2- until number re‐

quired on number list -3- is highlighted and confirm each
nf
ercia
number by pressing the button briefly.
orm
m
– When the code has been entered fully confirm with “OK” by
atio
m
pressing rotary/push button -2-.

o
n in
or c
thi
e
If the correct code has been entered, the actual radio frequency
t
sd
iva
will appear after a short “learning phase”.

o
r
rp
cu
o
m
f
The LED on the top right of the radio-navigation system must flash
en
ng
t.
yi Co
when the ignition key is removed. t. Cop py
rig
gh ht
If the diode flashes, the radio navigation system is ready-for-use yri
p by
o Vo
and the anti-theft coding is activated.
by c lksw
cted agen
Prote AG.
Activate fixed code on “radio/navigation system MFD 2” and on

“radio/navigation system MFD 2 DVD” as follows:
– Switch on radio navigation system using press button -1-.
– Enter code by turning rotary/push button -2- until number re‐
quired on number list -3- is highlighted and confirm each
number by pressing the button briefly.
– When the code has been entered fully confirm with “OK” by
pressing rotary/push button -2-.
If the correct code has been entered, the actual radio frequency
will appear after a short “learning phase”.
The LED on the top right of the radio-navigation system must flash
when the ignition key is removed.
If the diode flashes, the radio navigation system is ready-for-use
and the anti-theft coding is activated.

Touareg 2003 ➤
4.44 Power assisted steering: check fluid lev‐

el.
Cold fluid:
– 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 filler cap on hand tight and unscrew again.
Caution
G. Volkswagen AG d
The cap must be fully screwed on in order to obtain an accurate
lksw
agen
A
oes
not
fluid level reading. db
yV
o gu
ara
e nte
ris
utho eo
ra
a c
ss
– Check fluid level: The fluid level must be in area of MIN. mark‐
ce
le
un
pt
ing (up to 2 mm above or below marking).
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
hole
♦ If fluid level is above specified range, fluid must be extracted.
spec
es, in part or in w
♦ If fluid level is below above-mentioned area, hydraulic system
t to the co
must be checked for leaks (repair measure). It is not sufficient
just to fill fluid.
rrectness of i
♦ If the hydraulic system is not leaking, fill fluid “G 002 000”.
l purpos
– Screw cap on hand tight.
nform
ercia
Fluid at operating temperature (above approx. 50° C)

m
a
– Do not start engine but bring front wheels to straight-ahead
com
tio
position.
n in
r
te o
thi
s
iva
do
– Remove reservoir cap with built-in dipstick -arrow-.

r
rp
cum
fo
– Wipe off dipstick using a clean cloth.

en
ng
t.
yi Co
op
– Screw filler cap on hand tight and unscrew again.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
Caution
cted agen
Prote AG.
The cap must be fully screwed on in order to obtain an accurate

fluid level reading.

Touareg 2003 ➤
– Check fluid level: The fluid level must be between MIN. and gen AG
. Volkswagen AG
does
swa
MAX. marking. yV
olk not
gu b ara
ed nte
oris e
th or
au
Note ss
ac
ce
le
un
pt
♦ If fluid level is above MAX. marking, fluid must be extracted.
an
d
itte
y li
rm
ab
♦ If fluid level is below MIN. marking, then hydraulic system must
pe
ility
be checked for leaks (repair measure). It is not sufficient just
ot
wit
, is n
to fill fluid. If the hydraulic system is not leaking, fill fluid
h re
“G 002 000”.
hole
spec
es, in part or in w
t to the co
– Screw cap on hand tight.
4.45 Headlight adjustment: Checking and ad‐
rrectness of i
justing as necessary
l purpos
Checking headlight adjustment ⇒ page 119
nform
ercia
Headlights with halogen bulbs: Adjust ⇒ page 124 .

m
a
Headlights with gas discharge bulbs without cornering light sys‐
com
tion in
tem: Adjust ⇒ page 122 .
r
te o
thi
Headlights with gas discharge bulbs with cornering light system:
s
iva
do
r
Adjust ⇒ page 123 .

rp
cum
fo
en
ng
Fog lights and other additional lights: Adjust ⇒ page 125 .

t.
yi Co
Cop py
. rig
4.45.1 Headlight adjustment; checking (using
ht ht
rig by
opy Vo
test screen without 15° setting line)
by c lksw
cted agen
Prote AG.

♦ Headlight adjustment unit - VAS 5046-
♦ or
♦ Headlight adjustment unit - VAS 5047-
♦ Headlight adjustment unit - VAS 5208A-
♦ Headlight adjustment unit - VAS 5209A-
♦ Headlight adjustment unit - VAS 5209B-
♦ Vehicle diagnostic tester
Conditions for testing and adjustment:
♦ Tyre pressures OK.
♦ Lenses must not be damaged or dirty
♦ Reflectors and bulbs OK.

Touareg 2003 ➤
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 adjuster must be on a level sur‐
face → Operating instructions for headlight adjusters VAS
5046, VAS 5047, VAS 5208A, VAS 5209A, wage
nVAS
AG. Vo5209B.
lkswagen AG
doe
ks s no
Vol t gu
♦ Vehicle and headlight adjuster must
ed
by be aligned. ara
ris nte
♦ Inclination must be set. utho eo
ra
a c
ss
♦ Vehicles with air suspension: ensure vehicle is loaded cor‐
ce
e
nl
pt
rectly before entering basic settings.
du
an
itte
y li
♦ Before adjusting headlights on vehicles with gas discharge
erm
ab
ility
headlights, perform basic setting using vehicle diagnostic test‐
ot p
wit
er .
, is n
h re
hole
Inclination information in “%” is stamped into trim above headlight.
spec
Headlights must be adjusted according to this information. Per‐
es, in part or in w
t to the co
centage given is based on a projection distance of 10 metres. For
example: inclination of 1.0 % converts to approx. 10 cm.
For vehicles in the North American market, an inclination of 0.7 %
rrectness of i
is to be set.
l purpos
The inclination for fog lights is 2.0%.
nform
ercia
Note
m
at
om
ion
c
♦ If the vehicle is equipped with separate dipped and main
in t
or
beam, adjust main beam additionally. When adjusting main

his
ate
beam ensure that the adjustment unit is set to 0%. do

priv
cum
for
♦ For NAR vehicles the side adjustment of headlight is not per‐

en
ng
t.
yi
mitted, therefore the adjustment screw is secured against
Co
op py
turning. Adjustment is only allowed once when the headlight
t. C rig
gh ht
yri
is to be exchanged. When the side adjustment screw has been p by
co Vo
adjusted once, it must be secured with a cap ⇒ Electronic
by lksw
cted agen
Prote
parts catalogue ETKA . In this case, push securing cap into
AG.
opening of lateral adjustment until it is correctly seated.
Loading: with one person or 75 kg on the driver seat and the ve‐
hicle 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 usually carried (e.g. spare wheel, tools, jack, fire extinguish‐
er etc.).
If the fuel tank is not at least 90 % full, then load as follows:
– Read level of fuel in fuel tank on fuel gauge. Determine addi‐
tional weight from following table and place weight in luggage
compartment.
Fuel gauge table
Fuel Petrol and diesel engines
gauge Additional weight in kg
To 1/4 60
To 1/2 40
To 3/4 20
Full 0
Example:
When the fuel tank is half full an additional weight of 40 kg must
be placed in the luggage compartment.

Touareg 2003 ➤
Note
♦ For this purpose, a container filled with water or gravel can be

used, for example (a 5-litre fuel canister filled with water
weighs approx. 5 kg).
♦ Write the weight in kg on the container and secure it against
being opened again in order to prevent misuse.
♦ In order to avoid soiling vehicle, place a mat or covering of
some kind in the luggage compartment.
Notes for vehicles with halogen headlights:

Manual headlight range control (if fitted):
♦ The headlight range adjuster thumb wheel must be in basic
setting -0-.
Note
For certain export markets a manually regulated

AG. Volkswagen Aheadlight range
agen G do
control is not offered, thusVthe
olksw-0- position is discontinued.
es n
ot
by gu
ara
ed nte
ris
Headlights: tho eo
au ra
c
ss
Please check the following:
ce
e
nl
pt
du
– Whether, with the dipped beam switched on, the horizontal

an
itte
y li
light-dark border contacts the dividing line -1- of the test area
erm
ab
and
ility
ot p
wit
, is n
– Check, whether the breaking point -2- between the horizontal

h re
part of the light/dark border on the left and the rising part on
hole
spec
the right lies on the vertical line of the central point -3-. The
es, in part or in w
bright core of the light beam must be to the right of the vertical
t to the co
line.
rrectness of i
Note
l purpos
♦ To simplify finding the breaking point -2-, cover and uncover

left (from driver perspective) half of the headlight a few times.
nf
ercia
Then check dipped beam again.

rm
m
atio
m
♦ After correct adjustment of dipped beams, the centre point of

o
n in
c
the main beam must lie on the centre mark -3-.

or
thi
te
sd
iva
o
r
rp
cu
Fog lights:
o
m
f
en
ng
t.
yi Co
– Check whether the upper bright-dark boundary touches the Cop py
setting line and runs horizontally over the entire width of the
t. rig
gh ht
yri by
test screen. cop Vo
by lksw
cted agen
Prote
Other additional lights:
AG.
Additionally retrofitted lights of other systems must be checked

and set according to valid guidelines.

Touareg 2003 ➤
AG. Volkswagen AG d
agen oes
lksw not
4.45.2 Headlights with gas discharge bulb with‐
o
byV gu
ara
ed
is nte
out cornering light system: Adjust aut
hor eo
ra
ss c
Performing basic setting of headlight range control
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
– Select vehicle system “Automatic headlight range control”.
– Mark “Perform basic setting”, and confirm with ►.
rrectne
– Now the number of faults is read, if “0” faults are found, select
“Done”.
ss
– Observe notes displayed and confirm by selecting “Done”.
o
cial p
f in
– Switch on dipped beam and confirm with “Done”.
form
mer
atio
– Adjust headlights as follows:
om
n
c
i
or
n
Left headlight up to model year 2005
thi
te
sd
va
Lateral adjustment of left headlight

i
o
pr
cum
r
fo
1 - Horizontal dipped beam adjustment
en
ng
t.
yi Co
op py
2 - Horizontal main beam adjustment
. C rig
ht ht
rig by
py
– Turn lateral dipped beam adjustment screw -1- and lateral
co Vo
by lksw
cted
main beam adjustment screw -2- until the correct setting is
agen
Prote AG.
achieved.
Height adjustment of left headlight:

1 - Vertical dipped beam and main beam adjustment
– Turn vertical adjustment screw -1- until correct setting is at‐
tained.
The adjustment screws for the right headlight are a mirror image.
Left headlight from model year 2007

Touareg 2003 ➤

– Adjust adjustment screws using a hexagon key.
1 - Height adjustment for dipped beam, main beam
tained.
2 - Lateral adjustment for dipped beam, main beam
– Turn lateral adjustment screw -2- until correct setting is at‐
tained.
– After adjusting, confirm on vehicle diagnostic tester with
“Done”
– Press “GoTo” “End” buttons to exit the “Guided functions”.
4.45.3 Headlights with gas discharge bulb and

cornering light system: Adjust
Performing basic setting of headlight range control
gen AG
. Volkswagen AG
d wa oes
olks not
– Perform vehicle
db
yV identification. gu
ara
e nte
ris
– Select thovehicle system “Automatic headlight range control
eo cor‐
au ra
nering
ss light”. c
ce
le
un
– Mark “Perform basic setting”, and confirm with ►.

pt
an
d
itte
y li
– Now the number of faults is read, if “0” faults are found, select
erm
ab
“Done”.
ility
ot p
wit
is n
– Observe notes displayed and confirm by selecting “Done”.

h re
ole,
spec
– Switch on dipped beam and confirm with “Done”.

t to the co
– Adjust headlights as follows:

Identification characteristic for headlights with cornering light sys‐
tem:
rrectness
Note
o
cial p
f inform
An additional reflector with halogen lamp for the static cornering

mer
light is located between dipped beam and turn signal.

atio
om
n
c
i
or
n thi
The cornering light system headlight has 4 lamps.

te
sd
iva
o
r
1. - The gas discharge bulb (for dipped beam, main beam and
p
cum
r
fo
dynamic cornering light)

en
ng
t.
yi Co
op
2. - The static cornering light lamp
C py
t. rig
gh ht
yri by
3. - The turn signal lamp
cop Vo
by lksw
cted agen
Prote
4. - The side light lamp
AG.

Touareg 2003 ➤
Adjusting left headlight up to model year 2006

B - Lateral adjustment for dipped beam, main beam and dynamic
cornering light
– Turn lateral adjustment screw -B- until correct setting is at‐
tained.
AG. Volkswagen AG d
Height adjustment of left headlight: agen oes
olksw not
V gu
by ara
– Adjust adjustment screws -1- using a hexagon key. rised
nte
ho eo
ut
A - Height adjustment for dipped beam, main beam andss a dynamic ra
c
cornering light
ce
le
un
pt
an
d
– Turn height adjustment screw -A- until correct setting is at‐
itte
y li
tained. erm
ab
ility
ot p
wit
is n
h re
ole,
spec
“Done”
t to the co
Adjusting left headlight from model year 2007
rrectne
ss
– Adjust adjustment screws using a hexagon key.
o
cial p
f in
1 - Height adjustment for dipped beam, main beam and dynamic
form
mer
cornering light
atio
om
n
c
i
or
n
tained.
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
2 - Lateral adjustment for dipped beam, main beam and dynamic

t.
yi Co
op
cornering light C py
t. rig
gh ht
yri
– Turn lateral adjustment screw -2- until correct setting is at‐
p by
o Vo
by c lksw
tained. Prote
cted AG.
agen
“Done”
4.45.4 Adjusting headlights with halogen bulbs

Adjusting left headlight up to model year 2006
2 - Horizontal main beam adjustment
– Turn lateral dipped beam adjustment screw -1- and lateral
main beam adjustment screw -2- until the correct setting is
achieved.

Touareg 2003 ➤

1 - Vertical dipped beam and main beam adjustment
tained. agen
AG. Volkswagen AG d
o
ksw es n
Vol ot g
d by ua
ran
e
ris tee
Note utho or
a ac
ss
Please check also that both headlights move evenly when head‐
ce
e
nl
pt
du
light range control is operated.
an
itte
y li
erm
ab
ility
ot p
wit
, is n
Adjusting right headlight from model year 2007
h re
hole
spec
es, in part or in w
Lateral and height adjustment for right headlight:
t to the co
1 - Height adjustment for dipped beam
rrectness of i
– Turn height adjustment screw -1- and lateral adjustment screw
l purpos
-2- until the correct setting is achieved.
nform
ercia
Note
m
at
om
ion
c
Please check also that both headlights move evenly when head‐
in t
or
light range control is operated.

his
ate
do
priv
cum
or
The adjustment screws for the left headlight are a mirror image.
f
en
ng
t.
yi Co
Cop py
4.45.5 Fog lights and other auxiliary lights: ad‐

t. rig
gh ht
pyri by
Vo
o
justing
c by lksw
cted agen
Prote AG.
There are two fitting location possibilities for fog lights. Firstly, the
fog light can be integrated in the headlight. Secondly, the fog light
can be fitted in the lower part of the bumper.
Fog lights in headlight:
Note
Adjustment of fog lights is performed automatically when adjust‐

ing headlights.
Fog light in bumper up to model year 2006

– Set the appropriate inclination on the headlight adjustment
unit.
• The inclination for fog lights is “2.0 %”.
Note
Percentage given is based on a projection distance of 10 metres.

AG. Volkswagen AG d
agen oes
olksw not
Touareg 2003 ➤ d by
V gu
ara
e nte
Maintenance - Edition 03.2018 horis
eo
aut ra
ss c
– Remove cover -1- from fastenings in direction of arrow.
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
– Carry out adjustment:
nf
ercia
o
1 - Height adjustment
rm
m
atio
m
– Turn height adjustment screw until correct setting is attained,

o
n in
c
using hexagon key -1-.

or
thi
te
sd
a
There is no provision for lateral adjustment.

iv
o
r
rp
cu
o
m
Fog light in bumper up to model year 2007
f
en
ng
t.
yi Co
op
– Set the appropriate inclination on the headlight adjustment C py
t. rig
unit. gh ht
pyri by
Vo
o
by c lksw
• The inclination for fog lights is “2.0%” Prote
cted AG.
agen
Note
Percentage given is based on a projection distance of 10 metres.
– Remove cover cap -arrow- to reach the adjustment screw for

fog light.
– Turn height adjustment screw until correct setting is attained,

using hexagon key -arrow-.
There is no provision for lateral adjustment.
Other additional lights
Additionally retrofitted lights of other systems must be checked
and set according to valid guidelines.

Touareg 2003 ➤
4.46 Sunroof: checking function, cleaning

and greasing guide rails
– Check function of sunroof.
– Clean guide rails arrows and grease with lubricating paste G
060 751 A2.
4.47 Sliding sunroof drains: checking for

blockage, cleaning if necessary
♦ Cleaning and insertion aid - VAS 6620-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
s au ra
c
s
ce
– Open sliding sunroof.

e
nl
pt
du
an
itte
– Check sliding sunroof drain holes -arrows- for dirt and clean if
y li
erm
ab
necessary.
ility
ot p
wit
– Pour tap water into sliding sunroof drains and check if almost
, is n
h re
the same quantity of water flows out of the wheel housings.

hole
spec
If this is the case, the test is completed. If only a small quantity of

es, in part or in w
t to the co
water or no water at all flows out of the wheel housings, perform

the following procedure:
– Removing plenum chamber cover ⇒ General body repairs,
rrectness of i
exterior; Rep. gr. 64 ; Flush bonded windows; Plenum cham‐

ber cover
l purpos
nform
ercia
Note
m
at
om
Removal and installation of plenum chamber is performed as a

on
c
in t
separate charge.
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.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
Touareg 2003 ➤ ut
ho eo
ra
a
Maintenance - Edition 03.2018 ss c
ce
e
nl
pt
du
an
– If fitted, remove cover -1- by loosening fasteners -A and B-.
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
o
– To press out dirt, guide cleaning and fitting tool - VAS 6620-
rm
onto drain valves by pushing and pulling it slowly.
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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Drains -arrows- are located on the left and right side, inside
the plenum chamber.

Touareg 2003 ➤
– Check plenum chamber drains -arrows- for dirt and clean if

necessary.
– To check, pour tap water again through the sliding sunroof
drain holes.
Install in reverse order of removal.
4.48 Window wash/wipe system and head‐

light washer system: Checking opera‐
tion and checking for damage, if neces‐
sary replenishing fluid
Check anti-freeze protection of fluid, replenish fluid
⇒ page 129 .
Window wiper and washer system: Check spray jet settings and
adjust jets if necessary ⇒ page 131
Headlight washer system: checking spray jet settings
⇒ page 131
Washer jet adjustment for rearagwindow
en AG. V wash
olkswagesystem
n AG d
oes
⇒ page 132 Vo lksw not
g y ua
db r
Windscreen wiperoblades:
ris
e
Check park position ⇒ page 132 antee
th or
au ac
4.48.1 Anti-freeze
ss protection of fluid: checking
ce
le
and topping up fluid

un
pt
an
d
itte
y li
rm
Checking anti-freeze concentration:

ab
pe
ility
ot

wit
, is n
h re
♦ Refractometer - T10007 A-
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
Read precise value for the following tests at light/dark boundary.

rp
cum
fo
Using a pipette, place a drop of water on the glass to improve the

en
ng
t.
yi
readability of the light/dark boundary. The bright/dark boundary
Co
op py
can be clearly recognised on the “WATERLINE”. t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
– Check concentration of anti-freeze additive using refractome‐

ter - T10007 A- .
The scale -4- of the refractometer is calibrated for Windscreen
Clear - G 052 164- .
Mixing ratio:
Frost protection to Windscreen Clear Water

G 052 164
-17/-18°C 1 part 3 parts
-22/-23°C 1 part 2 parts
-37/-38°C 1 part 1 part
Replenishing fluid: AG. Volkswagen AG d

agen oes
lksw not
The fluid reservoir of the window washer system must d bybe
V filled
o gu
ara
completely. orise nte
h eo
ut ra
Starting immediately, use only “Genuine Volkswagen
ss a Wind‐ c
screen Clear” all-year-round when replenishing window wash/
ce
le
un
pt
wipe system.
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
hole
♦ Genuine Volkswagen Windscreen Clear “G 052 164” protects
spec
the washer jets, fluid reservoir and hoses from freezing.
es, in part or in w
t to the co
♦ For all vehicles having fan-type spray jets, the reservoir must
be filled with “Genuine Volkswagen Windscreen Clear
G 052 164”, as this fluid has a low viscosity at temperatures
rrectness of i
below freezing. Otherwise the complicated spray jet system

can become blocked by the crystallised washer fluid, which
l purpos
affects the spray pattern of the spray jet. “Genuine Volkswa‐

gen window cleaner” ensures that the fan -type washer jets
nform
ercia
remain fully functional at low temperatures.

m
♦ Use Genuine Volkswagen Windscreen Clear “G 052 164” also

a
com
tio
in the warmer periods of the year. The powerful cleanser re‐

n in
r
moves wax and oil residue from the glass.

te o
thi
s
iva
do
♦ Frost protection in the washer system must be guaranteed to

r
rp
cum
approx. -25 °C (approx. -35 °C in countries with an arctic cli‐

fo
en
ng
mate).
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
4.48.2 Window wiper and washer system:

Checking spray jet settings and adjust‐
ing jets if necessary
Note AG. Volkswagen AG d

agen oes
olksw not
y V gu
♦ If the spray field is uneven ise due to soiling in the spray jet, re‐
d b ara
nte
move spray jet ⇒ Electrical
thor
system ⇒ Rep. gr. 92 ⇒ Removing eo
and installing sprayss a jets for windscreen wash/wipe system and
u ra
c
rinse with water opposite to direction of spray.
ce
e
nl
pt
du
an
♦ Subsequent blowing through with compressed air against the
itte
y li
spraying direction is permitted.
erm
ab
ility
ot p
♦ Never use solid objects to clean the washer jets!
wit
, is n
h re
hole
Spray jet adjustment for window wash/wipe system:
spec
es, in part or in w
t to the co
The spray jets are preset. However, small differences in height
may be corrected.
– If both spray fields are not at same height, adjust spray direc‐
rrectness of i
tion upwards or downwards as follows:
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
g
– Adjust spray jet at adjuster -1- by hand upwards or down‐

n
t.
yi Co
op
wards. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4.48.3 Headlight washer system: checking

spray jet settings
Caution
Only control function of spray jets but do not adjust them.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
Touareg oris 2003 ➤ nte
eo
th
Maintenance
s au - Edition 03.2018 ra
c
s
ce
le
un
pt
The following jet setting figures are for the left-hand headlight
an
d
itte
(right-hand mirror image):
y li
erm
ab
ility
– Check jet setting.
ot p
wit
is n
a - 100 mm
h re
ole,
spec
b - 75 mm
t to the co
c - 230 mm
d - 50 mm
rrectne
– Switch on dipped headlight.
s
– Operate windscreen washer system.
s o
cial p
f
The headlights are washed if the windscreen wiper lever is held
inform
in “Wipe position” for at least 1.5 seconds.
mer
atio
m
The spray jet should spray on the headlight lens, as shown in

o
n
c
illustration.
i
or
n thi
te
sd
a
If spray pattern deviates from specifications, carry out repair

iv
o
pr
c
measures.
um
r
fo
en
ng
t.
yi Co
op
4.48.4 Washer jet adjustment for rear window
C py
ht. rig
rig ht
wash system:
py by
co Vo
by lksw
cted agen
Prote AG.
Note
♦ The spray jet of the rear window wash system is part of the
additional brake light and cannot be adjusted.
♦ If stream of water is uneven or does not hit the wiped area,
renew additional brake light with spray jet.
Removing and installing additional light ⇒ Electrical system ⇒

Rep. gr. 94 ⇒ Lights, bulbs, switches - exterior
4.48.5 Windscreen wiper blades: Checking

park position
Procedure
⇒ Electrical system; Rep. gr. 92 ; Windscreen wiper system;
Adjusting wiper blade park position
Note
♦ Adjusting the wiper blades is a repair measure.

♦ The repair measure is carried out subject to a separate charge.
4.49 Wiper blade protection: removing

Currently there are three versions to separate the wiper blade
protection from the wiper blade or to exchange a transport wiper
arm.

AG. Volkswagen AG d Touareg 2003 ➤
agen
olksw Maintenance
oes
not - Edition 03.2018
yV gu
edb ara
ris nte
Version 1 ut
ho eo
a ra
s c
On this wiper arm, the blade protector
s is secured to the wiper arm
ce
e
with two securing clips -arrows-.
nl
pt
du
an
itte
y li
Perform the following procedure:
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
– Set wipers in service position. This can be done by switching

the ignition on and off once with bonnet closed. Then operate
nform
ercia
wiper lever and the wipers will stop in service position.

m
at
om
– Take the right-hand wiper from windscreen and lift.
ion
c
in t
or
his
ate
Caution
do
priv
cum
for
en
g
To prevent damage, ensure that the wiper is only touched at

n
t.
yi Co
the wiper joint and do not pull on the wiper blade. Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Now remove upper securing clip upwards and lower securing

clip downwards -arrows-.
– Pull blade protector off wiper blade from bottom to top.

– Carefully place wiper arm back onto windscreen.
Carry out the same procedure for the left-hand wiper.
– Switch ignition on and briefly operate the wiper lever to move
the wipers back to park position. Switch ignition off again.
Version 2

Touareg 2003 ➤
This transport wiper arm is fitted without wind deflector.

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
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
wiper lever and the wipers will stop in service position.
es, in part or in w
t to the co
– Take the right-hand wiper from windscreen and lift.
rrectness of i
Caution
l purpos

the wiper joint and do not pull on the wiper blade.
nf
ercia
orm
m
atio
om
n in
or c
thi
e
– Depending on version, turn the wiper arm with lip upwards and
t
sd
iva
pull off, or release wiper arm at joint -3- by pushing locking
o
r
rp
cu
device -1- into mounting -2- and pull wiper arm out.
o
m
f
en
ng
t.
yi Co
– Slide the new wiper arm into mounting and ensure that it au‐ Cop py
t. rig
dibly engages. opyri
gh by
Vo
ht
c lksw
by
cted agen
Prote AG.
Version 3
On this wiper arm the blade protector -arrow- is slid on the wiper
blade.

Touareg 2003 ➤

wiper lever and the wipers will stop in service position. wagen AG. Volkswagen AG doe
ks s no
Vol t gu
– Take the right-hand wiper from windscreen andedlift.
by ara
ris nte
utho eo
ra
a
Caution ss c
ce
le
un
pt
an
d
itte
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the wiper joint and do not pull on the wiper blade.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
– Pull blade protector off wiper blade upwards.
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
4.50 Service interval display: resetting
en
ng
t.
yi Co
Cop py
.
The service interval display must be reset (adapted) during
t rig
gh ht
pyri by
Vo
co
♦ delivery inspection
by lksw
cted agen
Prote AG.
♦ Every service
.
Note
It is also possible to reset the service interval display manually. If

the SID is reset manually, it must be taken into account that the
vehicle is coded to non-flexible intervals, i.e. every 15,000 km or
12 months. This also modifies the adaptation channel for oil qual‐
ity.

– Touch the field or button on the screen for »GUIDED FUNC‐
TIONS«.
If the display is not as shown in the procedure ⇒ Operating in‐
structions for vehicle diagnostic tester
– Confirm with > button.
♦ Brand
♦ Model
♦ Model year
♦ Engine code
– Confirm vehicle identification.

Touareg 2003 ➤
– Select one after another: AG. Volkswagen AG d

agen oes
lksw not
♦ “Dash panel insert” -ARROW- d byV
o gu
ara
ise nte
r
♦ “Resetting service interval display” ut
ho eo
ra
s a c
s
ce
e
nl
pt
du
an
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
– Carry out adaption according to the information of “GUIDED
rrectness of i
FUNCTIONS”.
l purpos
Ending adaption
Indicated on display:
nform
ercia

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
by
Indicated on display: copy Vo
by lksw
cted agen
Prote
– Press the »End« button on display -arrow-.
AG.

After the ignition is switched on, the type of service is no longer
displayed in the distance display in the dash panel insert.
4.51 Service interval display: recoding

– Touch the field or button on the screen for “GUIDED FUNC‐
TIONS”.
Note
If the display is not as shown in the procedure ⇒ Operating in‐

structions for vehicle diagnostic tester

♦ Brand
♦ Model
♦ Model year
♦ Engine code

Touareg 2003 ➤
AG. Volkswagen AGMaintenance - Edition 03.2018
agen does
olksw not
– Confirm vehicle identification. yV gu
db ara
rise nte
o eo
If the vehicle identification has beenaperformed
ut
h
correctly, confirm ra
with > button. ss c
ce
le
un
pt
an
d
itte
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erm
ab
♦ “Dash panel insert” -ARROW-
ility
ot p
♦ “Adapting service interval extension”.
wit
is n
h re
ole,
– Carry out adaption according to the information of “GUIDED
spec
FUNCTIONS”.
t to the co
Ending adaption
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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
4.52 Track rod ends: checking clearance,

firm seating and boots
– With vehicle raised (wheels hanging free), check play by mov‐
ing track rods and wheels. Clearance: zero clearance

Touareg 2003 ➤
– Check attachment.
– Check that boots -arrow- are not damaged and are seated
correctly.
4.53 Transportation mode: switching off

Selecting operating mode
– Press button for »Vehicle self-diagnosis« on display.
Note n AG. Volkswagen AG do

lkswage es n
o ot g
yV ua
If the display is not as shown in the procedure: ⇒ Operatingir se in‐
d b ran
tee
structions for diagnostic tester utho
or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
– Press the button on display for “Collection services”.
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
com
tion in
r
– Press the button on display for “Switch off transportation

te o
thi
s
mode”.
iva
do
r
rp
cum
End output
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
horis
eo Touareg 2003 ➤
ut
ss a Maintenance
ra
c - Edition 03.2018
ce
le
un
pt
an
d
itte
y li
rm
– Press »GoTo« button on display -arrow-.
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
ercia
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Note Cop py
t. rig
gh ht
pyri by
The vehicle diagnostic tester must probably remain connected for
o Vo
by c lksw
cted
further tests.
agen
Prote AG.
4.54 Greasing door arrester

– Grease door arrester at points shown -arrows-.
Use lubricating paste - G 000 150- .
4.55 Elastic drive coupling and freewheel

disc: Renew
Note
Always renew elastic drive coupling and freewheel disc together.
For alternator drive (5-cylinder unit injector TDI engines)

– ⇒ Electrical system ⇒ Rep. gr. 27 ⇒ Alternator, Removing
and installing freewheel disc .
For air conditioning compressor drive (5-cylinder unit injector TDI
engines)
– ⇒ Electrical system ⇒ Rep. gr. 87 ⇒ Air conditioner com‐
pressor, Removing and installing mounting with freewheel

Touareg 2003 ➤
AG. Volkswagen AG d
agen oes
lksw not
4.56 Underbody: inspecting for damage to Vo gu
d by ara
ise nte
underbody sealant, underbody panels, or eo
h
aut ra
routing of lines, plugs ss c
ce
e
nl
pt
du
an
During inspection, also check floor pan, wheel housings and sills. itte
y li
erm
ab
Always ensure that all lines are secured in their mountings, all
ility
ot p
plugs are available and that there is no visible damage on the
wit
, is n
underbody.
h re
hole
spec
es, in part or in w
Note
t to the co
Faults found must always be rectified (repair measure). This in‐
rrectness of i
hibits corrosion and rusting through.
l purpos
4.57 Setting time, language and units: On

display of dash panel insert
nform
mercia
♦ Time: The time can be set here and the choice can be made
at
om
io
between the 12 and 24 hour display.
n
c
in t
or
his
e
♦ Language: The language for the dash panel insert can be set
at
do
riv
here.
p
cum
for
en
g
♦ Units: The units of measurement for temperature, consump‐

n
t.
yi Co
tion and pressure figures can be set here. t. Cop py
rig
gh ht
yri
4.57.1 Dash panel insert Highline (one-colour
p by
o Vo
by c lksw
cted
display):
agen
Prote AG.
Operating the menus is done either with the control elements in

the windscreen wiper lever, or with the control elements of the
multi-function steering wheel.
1) Operation via wiper lever:
– Press rocker switch -B- for longer than 2 seconds, until the
main menu is displayed.
– Press the rocker switch up or down until the menu point “CON‐
VENIENCE SET-UP” is shown marked in the display.
The main menu “CONVENIENCE SET-UP” has the following
functions, e.g.: “Lights”, “Speed warning”, “Time”, “Convenience”,
“Language”, “Units”, “Reset”.
– Press button -A- several times until the corresponding menu
is called up.
Use the button and the rocker switch to operate all other menus
in the dash panel insert.
2) Operation via multifunction steering wheel:

Touareg 2003 ➤
– Operate (press) button -1- or button -3- to change the menus,

and to select (turn) knurled wheel -2-.
– Press button -1- or button -3- until the menu point “CONVEN‐
IENCE SET-UP” is shown marked.
“Language”, “Units”, “Reset”. Volkswa AG. gen AG
agen does
Turn knurled wheel -2- until the menu point
olks to be selected is
w not
yV gu
shown. se
d b ara
nte
ri
ho eo
– Press knurled wheel. The selected
au
t menu is called up. ra
c
ss
Example setting clock, via multifunction steering wheel:
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
– Press button -1- to activate function in menu selection in dis‐
wit
is n
play of dash panel insert.
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
– Use knurled wheel -2- to select menu item “Time”.
i
or
n thi
te
sd
a
When menu item “Time” is marked in display -1-, confirm selection

iv
o
pr
by pressing knurled wheel. cum

r
fo
en
ng
t.
– Using knurled wheel, set time as well as 12 or 24-hour display.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c
Note
lksw
cted agen
Prote AG.
If the clock is located in the rev. counter, the clock can be set via
a setting knob below the rev. counter.
4.57.2 Dash panel insert Premium (colour dis‐

play)
Note
Ambient temperature, time and odometer are displayed continu‐

ously in the colour display.
Operation with multi-function steering wheel:

Touareg 2003 ➤
– Operate (press) button -1- or button -3- to change the menus,

and to select (turn) knurled wheel -2-.
– Press button -1- or button -3- until the menu point “CONVEN‐
IENCE SET-UP” is shown marked.
“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.
4.58 Transfer box 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 ;
Checking gear oil in transfer box »Checking gear oil in transfer
box«
Procedure: »Power transmission, transfer box and final drive« ⇒
Power transmission, transfer box and final drive; Rep. gr. 39 ;
Checking gear oil in front/rear final drive »Checking gear oil in
front/rear final drive«
4.59 Toothed belt for camshaft drive: renew‐

AG. Volkswagen AG d
agen
ing (8-cylinder petrol engines)
yV
olksw oes
not
gu b ara
ed
– Carry out procedure ⇒ 8-cylinderthinjection
or
is engine ⇒ Rep. gr. nte
e or
15 ⇒ Cylinder head s au ac
s
ce
le
4.60 Spark plugs: renewing

un
pt
an
d
itte
y li
Spark plugs: renewing on 6-cylinder engine ⇒ page 144

rm
ab
pe
ility

ot
wit
, is n
h re

hole
spec
es, in part or in w
t to the co
Note
♦ Spark plug designation and torque setting ⇒ Power unit ⇒

rrectness of i
Rep. gr. 28 ⇒ Ignition system, test data

l purpos

nform
ercia

m
a
com
♦ Spark plug socket - 3122B-

ion 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.

Touareg 2003 ➤
♦ Torque wrench - V.A.G 1331/-
♦ Assembly tool - T10118- for 6-cylinder engine
♦ Puller - T10095 A- for 6-cylinder engine

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
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Puller - T40039- for 8-cylinder engine

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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
♦ Spring-type clip pliers - VAS 6499-
4.60.1 Vehicles with 6-cylinder petrol engine

Removing: AG. Volkswagen AG d
agen oes
olksw not
Carry out the following procedure: d byV gu
ara
ise nte
r
– Unclip engine cover panels ut
h -1- and -2- and remove upwards.
o eo
ra
s a c
Release connection locking device:
s
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
– Apply tool T10118 to connection locking device -arrow- and

l purpos
carefully pull upwards until connection locking device relea‐

ses.
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
– Pull off connectors -1...6- for ignition coils with output stage
AG.
upwards.
Note
Before pulling off, note positions of ignition coils with output

stages relative to connectors.

Touareg 2003 ➤
The flat side of the connector must align with the flat side of igni‐
tion coil with output stage -arrows-.
– Slide puller T10095/a from the flat side of the connector in di‐
rection of arrow onto ignition coil with output stage.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
– Pull out ignition coil with output ustage
tho
upwards vertically. eo
ra
s a c
s
– Unscrew spark plugs using spark plug socket - 3122B- .
ce
le
un
pt
an
Installing:
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Screw in new spark plugs using spark plug socket and exten‐
s
sion 3122 B.
s o
cial p
f inform
mer
Note
atio
om
n
c
Observe specified torque!

i
or
n 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 ➤
– Carefully set ignition coils with output stages onto spark plugs
by hand so that the flat sides of connectors align -arrows-.
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
– Reconnect connectors -1...6-.
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
– Install engine cover panels -1- and -2-.

en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Removing:
– Pull out dipstick.
– Remove bracket for left engine cover -1-.
– Unscrew bolts and retaining pin for engine cover -arrows-.

Touareg 2003 ➤
Press connection locking device -arrows- in direction of arrow and

pull connectors -A- off ignition coils with output stage.
Note
Before pulling off connectors, note positions of ignition coils with

output stages relative to connectors and mark if necessary.
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
– Pull out ignition coils with output stages in direction of arrow
wit
, is n
using puller - T40039- .
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
– Unscrew spark plugs using spark plug socket - 3122B- .
or c
thi
te
Installing:
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
sion 3122 B.
Note
Observe specified torque! Current values ⇒ Power unit ⇒ Rep.

gr. 28 ⇒ Ignition system, test data
– Push on ignition coils with output stages turning slightly. They

must be felt to engage.

Touareg 2003 ➤
Maintenance - Edition 03.2018 agen
AG. Volkswagen AG d
oes
olksw not
y V gu
b ara
– Push on connectors -A- so that they engage. rise
d
nte
tho eo
u
– Install left bracket for engine cover -1-
ss aand tighten to 10 Nm. ra
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
c
Removing:
um
r
fo
en
ng
t.
yi
– Remove engine cover panels.
Co
Cop py
t. rig
gh
– Loosen clips -1- and -2- using spring-type clip pliers - VAS
ht
pyri by
Vo
6499- and pull off intake hose.
co lksw
by
cted agen
Prote AG.
– Pull off connector -1-.

Touareg 2003 ➤
– Pull off hose -1-.
– Remove bolts -1- and -2- and carefully pull off intake manifold
side part.
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
– Remove bonded rubber seal -3-.
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
– Disconnect connectors -1- at ignition coils with output stages

rm
m
-2-.
atio
om
n in
c
– Note installation position of ignition coils with final output

or
thi
e
stages.
t
sd
iva
o
r
rp
cu
– Carefully pull out ignition coils -2-.

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

Touareg 2003 ➤
wage es n
– Unscrew spark plugs using spark plug sockety V- o3122
lks B- . ot g
ua
b
ed ran
oris tee
th or
Note au ac
ss
ce
e
nl
pt
du
♦ Spark plug designation and torque setting ⇒ Power unit ⇒
an
itte
y li
Rep. gr. 28 ⇒ Ignition system, test data
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
Installing:
t to the co
rrectness of i
sion - 3122 B- .
l purpos
– Push on ignition coils with output stage turning slightly, they

must be felt to engage.
nform
ercia
Note location.
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
– Push on connectors -1- so that they engage. yri
p by
o Vo
by c lksw
cted agen
Prote AG.
– Reinstall intake manifold side part -2-.
Note
Renew seal -3-.
– When installing ensure that the seal -3- lies in the guide pins
-1-.

Touareg 2003 ➤
– Tighten bolts -1- and -2- to 8 Nm.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
– Push on connector -1-.
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
– Connect hose -1-.
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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Secure intake hose with clips -1- and -2- using spring-type clip
pliers - VAS 6499- .
– Install engine cover panels.
4.61 Static 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 check if cornering light bulb lights up in the right headlight.

Touareg 2003 ➤
– Repeat this procedure for the left side.

Driving light assist
• Prerequisite: The test can only be carried out in daylight.
– Turn light switch to position for driving light assist.
During daylight, the headlights should not light up.
– Cover rain/light sensor, behind windscreen near interior rear
view mirror, from outside by hand or with a suitable object.
This measures the light incidence and both headlights are switch‐
ed on.
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
Prote AG.

Touareg 2003 ➤
5 Exhaust emissions test
Note
♦ Please observe the country specific legal regulations.

♦ The following exhaust emissions test description is applicable
only in countries where no specific exhaust emission regula‐
tions have to be adhered
agen
AG.to.
Volkswagen AG
do
ksw es n
Vol ot g
by ua
Exhaust emissions
ris
ed test for petrol engines ⇒ page 153 ran
tee
tho o
Exhaust
ss
auemissions test for diesel engines ⇒ page 155 r ac
ce
e
Exhaust emissions test for diesel engines with OBD

nl
pt
du
an
⇒ page 162
itte
y li
erm
ab
5.1 Exhaust emissions test for petrol en‐
ility
ot p
wit
gines
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Exhaust gas testing station L - VAS 7320 A-
rrectness of i
Note
l purpos
♦ The following description refers to vehicles fitted with “On‐

board diagnosis” OBD.
nf
ercia
♦ The OBD monitors all components and part systems influenc‐

rm
m
ing the exhaust emissions quality.

atio
om
n in
c
♦ It is possible to carry out an exhaust emissions test only when

or
thi
e
all units of the emissions testing station are connected prop‐

t
sd
iva
erly and joined to each other according to the operating in‐

o
r
rp
cu
structions.
o
m
f
en
ng
t.
yi Co
♦ All work to be performed is displayed by the emissions testing
Cop py
station .
t. rig
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Conditions for testing Prote AG.
• All test conditions and data required for exhaust emissions test
are found on EET data sheet for the respective engine.
• For bar code reading the EET data sheet must be printed out.
• Automatic gearbox: selector lever in position “P” or “N”.
• Manual gearbox: gear lever in neutral
• Parking brake applied
• 12V battery fully charged (if battery charge is too low, raise
idling speed if necessary).
– Perform exhaust emissions test according to instructions on
display.
Vehicle data input
– Enter the following data:
♦ Registration number
♦ Key numbers
♦ Vehicle identification number
♦ Fuel type
5. Exhaust emissions test 153

Touareg 2003 ➤
♦ Mileage
The following vehicle data can be found in the vehicle registration
certificate part 1:
♦ Registration number: “e.g. WOB-HH 1234”
♦ Emission key number “Field 14.1 (code for field 14)”
♦ Vehicle manufacturer: “Field 2”, “Field 2.1 (code for field 2)”
♦ Vehicle identification number “field E”
♦ Type and version “Field D2 (type only)”, “Field 2.2 (code for
field D.2)”
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Specified data input for EET agen oes
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There are different ways to enter the specified data: rise
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♦ 1. By manual input ss a ra
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♦ 2. By bar code input from EET data sheet un
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♦ 3. Through ELSA web service
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Note
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♦ To use the ELSA web service, the exhaust gas testing station
es, in part or in w
t to the co
L which is used for the exhaust emissions test must be inte‐
grated in the workshop network.
♦ The ELSA web service automatically transmits the data for the
rrectness of i
specific vehicle via the network to the respective mask.
l purpos
Manual specified data input for EET:
nform
mercia
a
Note
com
tion in
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te o
thi
All test conditions and data required for exhaust emissions test
s
iva
can be found in the ⇒ Data sheets for exhaust emissions test for
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respective engine.
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– Perform manual data input according to instructions on dis‐
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cted
– Enter displayed values on EET data sheet in column “Test
agen
Prote AG.
values for exhaust emissions test” on display as follows:
1- Test speed (idling speed)
2- Warm-up phase for catalytic converter
3- Engine temperature
4- Increased idling speed
5- 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”.
9- Lambda probe value
Specified data input for EET as bar code:
– If specified data for EET are available as bar code, read bar
code of EET data sheet with bar code reader.
154 5. Exhaust emissions test

Touareg 2003 ➤
All data required are shown on display.

Inspection
– Inspect all exhaust emissions relevant components.
– Check if exhaust system is fitted and complete and check for
leaks and damage.
Procedure
olkswagen AG
en AG. V
– Follow instructions from exhaust gasoltesting
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ag station . does
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5.2 Exhaust emissions
tho
ris
e
test for diesel en‐ nte
eo
gines au ra
ss c
ce
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nl
The test sequence is designed for the test with test unit combi‐
pt
du
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nation for the emissions test.
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ility
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♦ Diesel tester - V.A.G 1743-
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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♦ Engine speed adapter - VAS 5087 A-

sd
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Prote AG.
♦ or
♦ Engine speed adapter - VAS 6296-
♦ Data reader - V.A.G 1798-

Touareg 2003 ➤
♦ 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 test should be completed outdoors following a
road test. If this is not possible for various reasons (weather,
excessive noise in residential areas), then the test can be car‐
ried out in a workshop.
♦ To reduce noise levels, the bonnet should be closed on first
catch during tests.
Carrying out visual check of components influencing emissions

– Performing visual check for:
♦ Installation
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♦ Completeness lksw
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♦ Leakage rised ara
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♦ Damage aut ra
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Faults found are to be rectified.
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Test prerequisites
spec
es, in part or in w
• Engine temperature at least 80 °C
t to the co
• No fault stored in event memory
Connecting test units rrectness of i
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Connect diesel tester - V.A.G 1743- according to operating in‐

structions.
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Description, measuring process, function, setting up and opera‐

tion see ⇒ V.A.G 1743 operating instructions
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tion in
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Note
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iva
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♦ The engine speed adapter - VAS 5087 A- or the engine speed

fo
en
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adapter - VAS 6296- can be used instead of the TDC sender,

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for engines where the hole of the TDC sender cannot be C py
ht. rig
reached or cannot be reached easily or is large. rig ht
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♦ It is not possible to use the diesel tester pick-up clamp (for cted agen
Prote AG.
cylinder 1).

Touareg 2003 ➤
– Connect engine speed adapter - VAS 5087 A- with ignition

switched off as follows: gen AG
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♦ Follow operating instructions for engine speed adapter - VAS
ce
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nl
pt
5087 A- !
du
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erm
♦ Strictly follow the safety precautions in the operating instruc‐
ab
ility
tions!
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– Connect adapter cable - VAS 1587/3- from output connector
hole
spec
of engine speed adapter - VAS 5087 A- to pick-up clamp input
es, in part or in w
of diesel tester - V.A.G 1743- .
t to the co
– Turn switch for number of cylinders to respective number of
cylinders.
rrectness of i
– Connect a cable from adapter - VAS 5087/1- to engine speed
l purpos
adapter - VAS 5087 A- (socket VAS 5087/1).
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Prote AG.

Touareg 2003 ➤
– Using the other wires from adapter - VAS 5087/1- make a

connection to the vehicle battery, by connecting:
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♦ Red clamp on positive agen oes
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♦ Black clamp on negative. rised
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Note
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♦ When using the engine speed adapter - VAS 5087 A- press
erm
ab
button “Start”. The red signal lamp must flash for approx. 10
ility
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seconds. Then the green signal lamp must light up.
wit
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♦ The engine speed must now be displayed on ignition tester -
hole
spec
V.A.G 1767- . es, in part or in w
t to the co
♦ If the engine speed is displayed incorrectly or not at all ⇒ Op‐
erating instructions for VAS 5087
rrectness of i
Test sequence
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– Start engine and run it at idling speed.

– Press F2 for “EET diesel” on data reader.
nform
mercia
If this message appears on the display:
at
om
ion
c
in t
or
Please insert vehicle identity card!!
his
e
Manual input with -> button

at
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c
– Enter vehicle identification data as follows, using data reader
um
for
en
keyboard:
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t.
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♦ Registration number t. C rig
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♦ Vehicle manufacturer = “NO. 2”
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♦ Key number = “to NO. 2”
♦ Vehicle type = “NO. 3”
♦ Key number = “to NO. 3” (the first 3 digits)
♦ For vehicle identification number = “NO. 4”
♦ Engine code
♦ Mileage
– Confirm entry of vehicle identification data by pressing Q but‐
ton.
Check input with -> button
Continue with Q button
– Confirm entry of vehicle identification data with Q button.

Read bar code
Manual input with the -> button
– Enter specifications using bar code reader of data reader, to

do this slide bar code reader over respective bar code of data
sheet in “Exhaust emissions test” binder.
or
– Carry out entry by hand following instructions on data reader
display by pressing the → button.
Check input with the -> button
Continue with the Q button

Touareg 2003 ➤
agen
AG. Volkswagen AG d
oes Maintenance - Edition 03.2018
olksw not
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– Confirm vehicle data enteredrior
se read using Q button. nte
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If this message appears onssthe
a display: c
ce
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nl
pt
du
Visual check OK = y Not OK = n
an
itte
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erm
– Enter result of visual check.
ab
ility
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hole
spec
F1 Temperature measurement with sensor
F2 Enter temp. measurement manually
es, in part or in w
t to the co
– Press F1 button for “Temperature measurement with sensor”.
– If engine oil temperature has reached 80 °C, pull out measur‐
rrectness of i
ing sensor and push dipstick in until stop.
l purpos
– Continue test sequence by pressing the Q button.

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Idling speed ->
m
Speed ACT. xxxx rpm SPEC. xxxx rpm

o
n in
or c
– Press → button.
thi
te
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Idling speed not within specified range:

rp
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f
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t.
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Cop py
Note
t. rig
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pyri by
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by
The idling speed and maximum speed can be checked but not cted agen
Prote AG.
adjusted.
– If the values are not within specified range, a repair must be

made.
Rev limit 5 sec.
Speed ACT. xxxx rpm SPEC. xxxx..xxxx rpm
– Depress accelerator pedal fully and hold for specified time.
WARNING
If the rev limit is exceeded, lift off accelerator pedal immediately

and perform repair measures.

Rev limit ->
Speed ACT. xxxx rpm SPEC. xxxx..xxxx rpm
– Release accelerator pedal.

– Check actual figure, to do this switch further the actual display
using → button.
Rev limit not within specified range:
– If the values are not within specified range, a repair must be
made.

Touareg 2003 ➤

Idling speed 1st measurement 15 sec
Speed ACT. xxxx rpm SPEC. xxx...xxxx rpm
– The data reader accepts the actual figures within 15 seconds.

Data transfer to diesel tester
Depress accelerator quickly
– Depress accelerator pedal fully and hold.

Neutral accel. running
– Continue to depress and hold accelerator pedal.

Idling speed 2nd measurement 15 sec

The data reader accepts the actual figures within 15 seconds.
– Depress accelerator pedal fully and hold. AG. Volkswagen AG d

agen oes
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If this message appears on the display: by Vol not
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rise nte
Data transfer to diesel tester tho eo
Neutral accel. running au ra
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nl
pt
du
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itte
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ab
ility
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Idling speed 3rd measurement 15 sec
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i

l purpos
– Depress accelerator pedal fully and hold.

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n in

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thi
te
sd
a

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Idling speed 4th measurement 15 sec t. rig
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Speed ACT. xxxx rpm SPEC. xxx...xxxx rpm pyri by
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agen
Prote AG.

Touareg 2003 ➤
AG. Volkswagen AG d
If this message appears on the display: ksw
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– Depress accelerator pedal fully and hold. s
ce
le
un
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ab
ility
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is n
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ole,
spec
t to the co
Highest opacity figure ->
ACT. x.xx rpm SPEC. x...x.xx rpm
rrectne
s
s o
cial p
f i
nform
mer
atio
Average opacity figure ->
om
ACT. x.xx rpm SPEC. x...x.xx rpm
n
c
i
or
n thi
e
t
sd
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pr
c
If the following is indicated on display:
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ng
t.
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Opacity band width -> Cop py
ACT. x.xx rpm SPEC. x...x.xx rpm t. rig
gh ht
pyri by
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cted agen
Prote AG.
If the following is indicated on display:
Test OK Continue with Q button
Repeat test with F1 button
– Press Q button.
Note
♦ If this message appears on the display:

♦ Press F1 button and repeat test or carry out repair measures.
Test n.OK Continue with Q button
Repeat test with F1 button

Enter remarks with -> button
Continue with the Q button
– Enter remarks if necessary after pressing the → button.

– Press Q button.
Select tester / manual input F3
F1 XXXXX F2 XXXXX
– Select tester or enter name using F1 to F3 buttons.

– Press Q button, wait for log print-out.
– End test by pressing the F2 button.

Touareg 2003 ➤
5.3 Exhaust emissions test for diesel en‐

gines with OBD
♦ Exhaust gas testing station L - VAS 7320 A-
Note
♦ The following description refers to vehicles fitted with “On‐

board diagnosis” OBD.
♦ The OBD monitors all components and part systems influenc‐
ing the exhaust emissions quality.
♦ It is possible to carry out an exhaust emissions test only when
all units of the emissions testing station are connected prop‐
erly and joined to each other according to the operating in‐
structions.
♦ All work to be performed is displayed by the emissions testing
station . AG. Volkswagen AG d
agen oes
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Conditions for testing rised ara
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tho eo
• All test conditions and data required for exhaust
s auemissions test ra
c
are found on EET data sheet for the respective engine.
s
ce
le
un
pt
• For bar code reading of specified data for EET, the EET data
an
d
itte
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sheet must be printed out.
rm
ab
pe
ility
• Automatic gearbox: selector lever in position “P” or “N”.
ot
wit
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• Manual gearbox: gear lever in neutral
hole
spec
• Parking brake applied
es, in part or in w
t to the co
• 12V battery fully charged (if battery charge is too low, raise
idling speed if necessary).
rrectness of i
– Perform exhaust emissions test according to instructions on
display.
l purpos
Vehicle data input

nform
ercia
– Enter the following data:

m
♦ Registration number
com
tion in
r
♦ Key numbers
te o
thi
s
iva
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♦ Vehicle identification number

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rp
cum
fo
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♦ Fuel type
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♦ Mileage
t. C rig
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pyri by
Vo
The following vehicle data can be found in the vehicle registration
o
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cted agen
certificate part 1: Prote AG.
♦ Registration number: “e.g. WOB-HH 1234”

♦ Emission key No. “field 14.1 (code for field 14)”
♦ Vehicle manufacturer: “Field 2”, “Field 2.1 (code for field 2)”
♦ Vehicle identification number “field E”
♦ Type and version “Field D2 (type only)”, “Field 2.2 (code for
field D.2)”
♦ Nominal speed “field P4”

Touareg 2003 ➤
Specified data input for EET agen

AG. Volkswagen AG d
oes
olksw not
There are different ways to enter the specified
d by V
data: gu
ara
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♦ 1. By manual input autho eo
ra
ss c
♦ 2. By bar code input from EET data sheet
ce
e
nl
pt
du
an
♦ 3. Through ELSA web service
itte
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erm
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ility
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wit
Note
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hole
spec
♦ If there is no ESP to deactivate the engine speed limiter, the
es, in part or in w
rev limit can be measured using the engine speed limited by
t to the co
the control unit. To do this, all the EET specifications must be
entered manually.
rrectness of i
♦ To use the ELSA web service, the exhaust gas testing station
L which is used for the exhaust emissions test must be inte‐
l purpos
grated in the workshop network.

♦ The ELSA web service automatically transmits the data for the
nform
ercia
specific vehicle via the network to the respective mask (ex‐

ception: nominal speed can only be entered manually).
m
at
om
ion
c
in t
or
Manual specified data input for EET:
his
ate
do
priv
cum
for
en
Note
ng
t.
yi Co
Cop py
t. rig
♦ See ⇒ Data sheets for exhaust emissions test of the respective
gh ht
yri by
engine for the requisite test conditions and data for the emis‐
cop Vo
by lksw
sions test.
cted agen
Prote AG.
♦ The nominal speed is located in field P4 of the registration

certificate part 1 or field 7 of the vehicle document and must
always be entered manually.
♦ If the engine speed limiter cannot be deactivated, enter the
value 2500 ± 200 rpm in the box for rev limit and 2500 in the
box for engine speed for conditioning.
– Perform manual data input according to instructions on dis‐

play.
– Enter displayed values on EET data sheet in column “Test
values for exhaust emissions test” on display as follows:
1- Speed for conditioning
2- Number of throttle bursts for conditioning
3- Engine oil temperature (min. value)
4- Select engine oil temperature measurement procedure
5- Idling speed
6- Governed speed
7- Nominal speed (registration certification part 1, vehicle
document)
8- Governed speed measuring period (1 second)
9- Type plate value ⇒ page 164
10 - Select probe type (No. of probe)
11 - Select measuring mode
12 - Measured period portion

Touareg 2003 ➤
Note
♦ When performing the exhaust emissions test, the respective

engineer must always use the vehicle-specific exhaust emis‐
sions limit value indicated on the type plate.
♦ If no value is indicated on the type plate, the opacity figure
specified by the manufacturer and indicated in ELSA must be
used.
♦ If no value is indicated on the type plate and no opacity figure
has been specified by the manufacturer, the statutory opacity
figures (2.5 m -1 or 1.5 m -1, depending on date of initial reg‐
istration) must be used.
♦ For all Euro-6-vehicles an opacity figure of max. 0.5 m -1 ap‐
plies.
Specified data input for EET as bar code:

– If specified data for EET are available as bar code, read bar
code of EET data sheet with bar code reader.
The nominal speed can only be entered manually.
If the opacity figure on the EET data sheet is different from the swa
gen AG
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does
value indicated on the type plate, enter the type plate valueby V man‐
olk not
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ually. ris
ed ara
nt ee
tho or
Inspection s au ac
s
ce
e
– Inspect all exhaust emissions relevant components.

nl
pt
du
an
itte
– Check if exhaust system is fitted and complete and check for
y li
erm
ab
leaks and damage.
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wit
Procedure
, is n
h re
hole
– Follow instructions from exhaust gas testing station .
spec
es, in part or in w
Evaluation
t to the co
Note
rrectness of i
l purpos
If the exhaust emissions test was performed at governed speed,

the log note “governed speed <90 % of the nominal speed (idle
speed control)” is entered in the log.
nf
ercia
orm
m
atio
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n in
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thi
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Prote AG.

Touareg 2003 ➤
6 Glossary
wage
e
ks s no
Vol t
These explanations
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are not necessarily generally valid! nte
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au ac
Term ss Explanation
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nl
pt
du
ABS Anti-lock brake system: the ABS is a regulating system in the brake system, that pre‐
an
itte
vents locking when braking. This helps to maintain directional stability and steerability.
y li
erm
ab
ility
AUS 32 Abbreviation for “aqueous urea solution” with an urea concentration of 32.5 %, see also
ot p
(AdBlue®) ⇒ page 165
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AdBlue® Is an invented name.
hole
spec
This fluid is also called “NOx reducing agent AUS 32”, “AUS 32” or “Diesel Exhaust Fluid”
es, in part or in w
in the USA
t to the co
AdBlue® is a clear aqueous urea solution which is used for exhaust treatment to reduce
nitrogen oxides emissions and particulates.
AdBlue® is a registered trademark of the VDA (Verband der Automobilindustrie - Ger‐
rrectness of i
man Association of the Automotive Industry) in the USA, Germany, the European Union
and other countries.
l purpos
The AdBlue urea solution is not mixed with diesel fuel, but is carried in a separate tank
in the vehicle.
nform
ercia
ATF Automatic transmission fluid: gear oil for automatic gearboxes.

m
at
ATF level Filling level of ATF in gearbox
om
ion
c
in t
CO Carbon monoxide is produced when fuels containing carbon are not combusted com‐
or
his
e
pletely.
at
do
priv
CN Cetane number: measurement unit for ignition quality of diesel fuel

um
for
en
ng
DIN Deutsches Institut für Normung e.V (German Institute for Standardization)
t.
yi Co
Cop py
Part no. Abbreviation for part number
t. rig
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EN European standard
co Vo
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cted agen
Prote
EOBD European On-Board Diagnosis
AG.
FAME Fatty acid methyl ester

FSI Fuel stratified injection: fuel stratified and homogeneous fuel injection
TFSI Turbo fuel stratified injection
TSI From model year 2008 the designation TFSI is replaced by TSI. Therefore the desig‐
nation TSI is given to TSI turbocharger and TSI twincharger.
TSI turbocharger: charging only with turbocharger
TSI twincharger: charging with turbocharger and compressor
MIL Malfunction indicator light: American designation for exhaust emissions warning lamp
K83
OBD Onboard diagnosis: the OBD monitors all components influencing the exhaust emis‐
sions quality.
OBD-II American onboard diagnosis
Unit injector Unit injector for diesel engines
PR No. Abbreviation for production control number. Identifies among other things optional
equipment and country-specific deviations
PM Particulate matter: soot particulate value for diesel engine emissions
QG0 Vehicles are “not” factory-fitted with components for LongLife service. For maintenance,
the intervals based on time and distance (non-flexible intervals) apply.
QG1 Vehicles are factory-fitted with active LongLife service. This means vehicles have a
flexible service interval display and are fitted with the following components:
♦ Flexible service interval display in dash panel insert
♦ Brake lining wear indicator
6. Glossary 165
Touareg 2003 ➤
Term Explanation
QG2 The LongLife service is not factory-activated. This means vehicles have a non-flexible
service interval display (time and distance dependent service intervals) and are fitted
with the following components:
AG. Volkswagen AG d
♦ Brake lining wear indicator agen oes
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QG3 rise
The LongLife service is not factory-activated. This means vehicles have aenon-flexible
nte
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service interval display (timeau and distance dependent service intervals) andor
aare
c fitted
ss
with the following components:
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e
nl
pt
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♦ Brake lining wear indicator
erm
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ility
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Readiness code 8-digit binary code which indicates if all exhaust relevant diagnoses have been per‐
wit
, is n
formed by the engine management.
h re
hole
spec
RON Research octane number: measurement unit of the knock resistance of petrol
es, in part or in w
t to the co
SAE Society of automotive engineers: association which creates proposals and guidelines
for implementing legal requirements (e.g. standards)
SCR With the SCR process (selective catalytic reduction) the noxious nitrogen oxides emis‐
rrectness of i
sions are reduced to a great extent and are converted to steam and nitrogen by the urea
solution.
l purpos
A special urea solution (AdBlue®) is injected into the exhaust system upstream of a
special catalytic converter.
nf
ercia
SD Naturally aspirated diesel engine
orm
m
atio
SDI Naturally aspirated diesel engine - direct injection
om
n in
c
TDI Turbo diesel engine - direct injection

or
thi
te
sd
a
DP Distributor injection pump

iv
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r
rp
cu
ULEV Ultra low emission vehicle
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f
en
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ESI Extended service interval
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Cop py
t. rig
Common rail Refers to a common high-pressure injection line (rail), which supplies all cylinders of the gh ht
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relevant cylinder bank with fuel. cop Vo
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LongLife service The LongLife service enables extremely long inspection or oil change intervals, de‐
AG.
pending on individual driving style and conditions under which the vehicle is used. For
the LongLife service a special engine oil is required.
Step-type probe Also called finger probe (LPH lambda probe heating), (FLP flat lambda probe) or planar
lambda probe. The voltage of the output signal of the lambda probe jumps rapidly. The
lambda probe value is determined by a change in voltage. The probe is used as after
catalytic converter probe.
Broad-band probe Also called ULP probe (universal lambda probe). The voltage of the output of the lambda
probe nearly increases linear. The lambda probe value is determined by a change in
voltage. This enables to measure the lambda probe value via a larger measuring range
(broad band). The probe is used as before catalytic converter probe.
TPMS, TPLI Tyre pressure monitoring, tyre monitor display
Additive This fluid enables to attain the ignition temperature required to burn soot particles in
diesel particulate filters, which are installed at some distance from the engine.
Ash mass Is the mass which remains in the filter as waste product, when soot particles are burnt
or by regeneration of the diesel particulate filter. The permissible ash mass must be read
with diagnostic tester and is the criteria for changing the DPF.
166 6. Glossary

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Service

Service Department. Technical Information

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Copyright © 2018 Volkswagen AG, Wolfsburg K0058961120

4.6 Automatic gearbox: check ATF level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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

4.8 Battery: checking battery terminal clamps for secure seating . . . . . . . . . . . . . . . . . . . . . . 40

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

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

4.13 Storing tyre pressure values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

4.19 Electric windows: checking positioning (open and close functions) . . . . . . . . . . . . . . . . . . 69

4.20 Vehicles with reversing camera system: Check number plate . . . . . . . . . . . . . . . . . . . . . . 70

4.21 Vehicle system test: Carry out test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

4.23 Bonnet catch hook: grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

4.24 Multi-purpose additive for petrol fuel: adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

4.28 Diesel fuel filter: draining water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

4.36 Engine cover panel -top-: Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

5.1 Exhaust emissions test for petrol engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Bore ∅ mm 84.5 84.0 84.0

Stroke mm 93 95.9 95.9

Compression ratio 11 11.25 11.25

RON min. 98 unleaded 1) 95 unleaded 95 unleaded

Onboard diagnosis (OBD) Yes Yes Yes

Camshaft drive Toothed belt Chain Chain

Engines ⇒ Petrol engine Petrol engine Petrol engine

Displacement I 4.2 3.6 3.6

Engines ⇒ Petrol engine Petrol engine Petrol engine

Power kW at rpm 331/6200 162/5400 177/6000

Stroke mm 90.2 95.9 95.9

Engines ⇒ Petrol engine Petrol engine

Leakage diagnosis system No No No No

Camshaft drive Gear wheel Gear wheel Chain Gear wheel

Engines ⇒ Diesel engine Diesel engine Diesel engine Diesel engine

Bore ∅ mm 81.0 83.0 83.0 83.0

Stroke mm 95.5 91.4 91.4 91.4

Diesel particulate filter (DPF) Yes Yes yes/no1 Yes

Leakage diagnosis system No No No No

2.1 Information on long-life service and time

the vehicle is equipped with PR number “QG0”, “QG1” or

“QG2”. The PR number is decisive for the service intervals

Vehicle IDs with the following PR number

“QG1” indicates LongLife service

“QG0” or “QG2” indicates time or distance dependent service

2.1.2 LongLife service

Vehicles with PR number “QG1”

For the LongLife service a special LongLife engine oil is required

♦ Flexible service interval display in dash panel insert

2.1.3 Time or distance dependent service

For normal operating conditions achieving these service intervals

For 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 intervals (non-flexible intervals) apply. These vehicles

2.1.4 Service interval display ss o

Introduction of extended servicing intervals (ESI) ⇒ page 6

Flexible service interval display (only vehicles with LongLife serv‐

ice, PR number QG1) ⇒ page 6

Non-flexible service interval display (only vehicles with time or

distance dependent service, PR number “QG0/QG2)”

Introduction of extended servicing intervals (ESI)

Flexible service interval display (only vehicles with LongLife serv‐

are serviced according to time or distance dependent service, the

distance dependent service, PR number “QG0/QG2)”

♦ To calculate the service interval for vehicles with time or dis‐