K0058962920-10-Cylinder Diesel Engine Volkswagen R GMBH

Service
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
Workshop Manual
aut ra
ss c
ce
le
un
pt
Touareg 2003 ➤
an
d
itte
y li
rm
ab
pe
10-cylinder diesel engine Volkswagen R GmbH
ility
ot
wit
, is n
CBW
h re
hole
Engine ID
A
spec
es, in part or in w
t to the co
Edition 09.2012
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.
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
21 - Turbocharging/supercharging
23 - Mixture preparation - injection
26 - Exhaust system
28 - Glow plug system
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
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
Technical information should always be available to the foremen and mechanics, because their
his
ate
do
riv
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
p
cum
or
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
f
en
ng
matter of course, be observed.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
All rights reserved.
by lksw
cted agen
Prote
No reproduction without prior agreement from publisher.
AG.
Copyright © 2015 Volkswagen AG, Wolfsburg K0058962920

Touareg 2003 ➤
10-cylinder diesel engine aVolkswagen
gen AG R
. VolkswageGmbH
n AG do Edition 09.2012
-
w es n
olks ot g
yV ua
Contents
b
ed ran
ris tee
tho or
au ac
ss
ce
e
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
nl
pt
du
an
itte
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
y li
erm
ab
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ility
ot p
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
wit
, is n
h re
hole
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
spec
es, in part or in w
1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
t to the co
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Removing engine from scissor-type assembly platform VAS 6131 . . . . . . . . . . . . . . . . . . 12
rrectness of i
1.3 Securing engine on engine and gearbox support VAS 6095 . . . . . . . . . . . . . . . . . . . . . . 13
l purpos
1.4 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
nform
ercia
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

m
at
om
1.1 Assembly overview - components in the V space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ion
c
in t
1.2 Assembly overview - gear train assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
or
his
te
1.3 Removing and installing gear train assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

a
do
priv
c
1.4 Removing and installing engine mounting and engine support (left and right) . . . . . . . . . . 22
um
for
en
g
1.5 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

n
t.
yi Co
op py
2 Balancer shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
. C rig
ht ht
rig
2.1 Assembly overview - balancer shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
py by
co Vo
by lksw
cted agen
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prote AG.
26
3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2 Removing and installing bearing saddle for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4 Sealing flange, seals and vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.1 Assembly overview - front sealing flange and vibration damper . . . . . . . . . . . . . . . . . . . . 30
4.2 Renewing crankshaft oil seal, vibration damper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.3 Renewing crankshaft oil seal - engine timing end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.4 Renewing alternator shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5 Timing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1 Assembly overview - timing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.2 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.4 Piston rings, cylinder bore and piston installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 41
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.2 Removing and installing camshaft compensating gear and drive gear wheel . . . . . . . . . . 45
1.3 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.4 Adjusting valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.5 Removing and installing cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.6 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.2 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.3 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.4 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.5 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Contents i
Touareg 2003 ➤
10-cylinder diesel engine Volkswagen R GmbH - Edition 09.2012
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1 Engine oil . .w.a.ge. n.A.G.. .V.ol.ks.w.a.g.en. A. G. d. o.e.s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
ks n
1.1 Oil capacitiesVol . . . . . . . . . . . . . . . . . . . .ot. g.ua. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
d by ra
e
1.2 Checking
ho
ris engine oil level . . . . . . . . . . . . . . .nt.ee. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
t or
2 au
ssOil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
a
2.1 Assembly overview - sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
ce
le
un
pt
an
2.2 Applying sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
d
itte
y li
rm
ab
3 Oil pump, oil filter housing and oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
pe
ility
3.1 Assembly overview - oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
ot
wit
, is n
3.2 Assembly overview - oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
h re
hole
spec
3.3 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
es, in part or in w
3.4 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
t to the co
3.5 Checking oil pressure at front of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
rrectness of i
1 Parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
l purpos
1.1 Assembly overview - radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

1.2 Assembly overview - fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
nform
ercia
1.3 Parts of cooling system - body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

m
a
1.4 Parts of cooling system - engine side and at top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
com
1.5 Parts of alternator and fuel cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . tion in 84

r
te o
thi
1.6 Fitting location of continued coolant circulation pump and fuel cooling pump . . . . . . . . . . 85
s
iva
do
r
1.7 Assembly overview - thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

rp
cum
fo
1.8 Assembly overview - coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

en
ng
t.
yi Co
1.9 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Cop py
t. rig
1.10 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
gh ht
pyri by
Vo
o
1.11 Removing and installing fan support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
by c lksw
cted agen
Prote AG.
1.12 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.13 Removing and installing coolant connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.14 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

1 Parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.3 Assembly overview - fuel tank with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.4 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.5 Schematic diagram of fuel lines and components in fuel tank . . . . . . . . . . . . . . . . . . . . . . 103
1.6 Schematic diagram of fuel hoses in engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.7 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.8 Removing and installing fuel delivery unit, fuel gauge sender and suction-jet pumps . . . . 107
1.9 Removing and installing fuel tank with attached components . . . . . . . . . . . . . . . . . . . . . . 109
1.10 Checking fuel pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.11 Checking tandem pump and fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
1.12 Removing and installing tandem pump and fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.13 Assembly overview - accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2 Additive tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.1 Safety precautions when working on additive tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.2 Assembly overview - additive tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.3 Removing and installing additive tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
ii Contents
Touareg 2003 ➤
1.3 Installing hose connections with connector couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

1.4 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.5 Assembly overview - parts of charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.6 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

1 Repairing diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
1.3 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
1.4 Assembly overview - intake connecting pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.5 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.6 Assembly overview - unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
1.7 Removing and installing unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.8 Checking and adjusting position of pump plungers in unit injectors . . . . . . . . . . . . . . . . . . 141
1.9 Renewing O-rings for unit injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
2 Engine control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
2.1 Reading and clearing. Vfault memory of engine control units . . . . . . . . . . . . . . . . . . . . . . . . 145
n AG olkswagen AG do
2.2 Adapting functions
lkswage and components es.n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ot g 146
Vo
2.3 Removing
ed
by and installing engine control units ua
ran . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
ris tee
tho o
26 - Exhaust
ss
a system
u
. . . . . . . . . . . . . . . . . . . . . . .r a.c . . . . . . . . . . . . . . . . . . . . . . . . . . 148
ce
le
1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

un
pt
an
d
1.1 Assembly overview - exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

itte
y li
erm
ab
1.2 Assembly overview - front exhaust pipe with catalytic converter, particulate filter and
ility
ot p
attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
wit
is n
1.3 Assembly overview - silencers with mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

h re
ole,
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

spec
urposes, in part or in wh

t to the co

2.3 Assembly overview - exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
rrectne
2.4 Assembly overview - bypass flap with exhaust gas recirculation cooler . . . . . . . . . . . . . . 156
2.5 Removing and installing bypass flap with exhaust gas recirculation cooler . . . . . . . . . . . . 158
s
2.6 Vacuum hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

s o
cial p
f in
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

form
mer
atio
1 Glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

om
1.1 Removing, installing and checking glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

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.
Contents iii
Touareg 2003 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
iv Contents
Touareg 2003 ➤
00 – Technical data
1 Technical data
(VRL005181; Edition 09.2012) AG. Volkswagen AG d
agen oes
Engine number ⇒ page 1 olksw not
V gu
d by ara
e nte
Engine data ⇒ page 1 horis
eo
aut ra
1.1 Engine number ss c
ce
le
un
pt
an
d
The engine number (“engine code” and “serial number”) is located
itte
y li
on the cylinder block below the cylinder head of cylinder bank 2.
erm
ab
ility
ot p
The engine number consists of up to nine characters (alphanu‐
wit
is n
meric). The first part (maximum 3 characters) makes up the
h re
ole,
“engine code”, and the second part (6 characters), the “serial
spec
number”. If more than 999,999 engines with the same engine

code are produced, the first of the six characters is replaced with
t to the co
a letter.
Additionally there is a sticker on the acoustic cover of the cylinder
rrectne
head of cylinder bank 1 with “engine code” and “serial number”.
The engine code is also included on the vehicle data sticker.
ss o
cial p
f inform
Cylinders are numbered beginning with the right side -A- (cylinder
mer
bank 1) from the driver's perspective, not from the power output
atio
m
end -C-. Cylinders are numbered sequentially on each side.

o
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.
1.2 Engine data

Engine codes CBWA
Manufactured 08.07 ►
Emissions fulfil EU4 standard/Tier 21)
Capacity l 4.9
Output kW at rpm 258/3500
Torque Nm at rpm 850/2000
Bore ∅ mm 81.0
Stroke mm 95.5
Compression ratio 18.5
Fuel according to DIN EN 590
Firing order 1-6-5-10-2-7-3-8-4-9
Catalytic converter yes
Particulate filter yes
Exhaust gas recirculation yes
Turbocharging/supercharging yes
Charge air cooler yes
1. Technical data 1
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
Touareg 2003 ➤ ir se
d ran
tee
o
10-cylinder diesel engine Volkswagen aR
u GmbH - Edition 09.2012
th or
ac
ss
ce
le
un
pt
an
d
itte
y li
1) Only for USA and Canada.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2 Rep. gr.00 - Technical data

Touareg 2003 ➤
10 – Removing and installing engine

1 Removing and installing engine
Removing engine ⇒ page 3 .
Removing engine from scissor-type assembly platform -VAS
6131- ⇒ page 12 .
Securing engine on engine and gearbox support -VAS 6095-
⇒ page 13 .
Notes on installing ⇒ page 14 .
1.1 Removing engine
Special tools and workshop

equipment required
♦ Scissor-type assembly
platform -VAS 6131-
♦ Drip tray -V.A.G 1306-
♦ Rack -T10191-
♦ Spring-type clip pliers -VAS
5024 A-
♦ Torque wrench (40…200
Nm) -V.A.G 1332-
♦ Spring tensioner -VW 552-
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
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
Not illustrated:
r
rp
cum
fo
en
♦ Basic kit for Touareg -VAS 6131/6-

ng
t.
yi Co
op py
♦ Support for V10,V8- and V6 engines, Touareg -VAS 6131/8- t. C rig
gh ht
pyri by
Vo
♦ Container for removed parts -V.A.G 1698-
co lksw
by
cted agen
Prote AG.
♦ Engine bung set -VAS 6122-
1. Removing and installing engine 3

Touareg 2003 ➤
♦ Cable ties
The engine is removed downwards with gearbox.
– Before removing, read fault memory of all control units: ⇒ Ve‐
hicle diagnostic tester; or VAS 5052 “Guided functions” .
Note
♦ To enable the propshaft to rotate freely, move selector lever

to the “N” position.
♦ Leave key in ignition to prevent steering lock from engaging.
♦ It is advisable to remove the front wheels before beginning
removal. The vehicle can then be lowered on hoist until the
brake disc splash plates are just above the floor. This provides
the most ergonomic working position regarding accessibility of
engine compartment components.
♦ Some components cannot be removed, or removed only with
difficulty, with the engine installed. Therefore, you should de‐
termine all defective components before removing engine and
renew them while engine is removed.
♦ To prevent damage to removed components, place them in
the container for removed parts -V.A.G 1698- .
♦ All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
Caution
The procedure for disconnecting batteries must be strictly fol‐

lowed!
AG. Volkswagen AG d
agen oes
– Switch off ignition and all electrical consumers.
Vol
ksw not
gu
by ara
ed
– First disconnect battery under driverhoseat
ris nte
eo
t
au ra
– Then disconnect second battery inss spare wheel well in luggage c
compartment ⇒ Electrical system; Rep. gr. 27 ; Disconnecting
ce
le
un
pt
and connecting battery .

an
d
itte
y li
rm
ab
– Remove left and right wiper arms ⇒ Electrical system; Rep.

pe
ility
gr. 92 ; Wiper system .

ot
wit
, is n
h re
– Pull engine compartment seal off bulkhead.

hole
spec
– Remove covers -A-, -B- and -C- from engine compartment, if

es, in part or in w
fitted, and -D- for plenum chamber.

t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
4
Prote AG.
Rep. gr.10 - Removing and installing engine
Touareg 2003 ➤
– Disconnect the smaller connectors -A- from engine control

units and disconnect earth connection -arrow- of wiring har‐
ness.
– Open fuse box cover in plenum chamber on left and separate

connectors -A-, -B- and -C-.
– Remove wiring harness from plenum chamber and lay it on
engine.
– Remove intake line between air filter and intake connecting
pipe on both sides.
Note
Always observe installation instructions when removing and in‐

stalling connector couplings ⇒ page 126 .
– Disconnect vacuum lines -1- for vacuum unit of bypass flap

(mark lines prior to disconnecting them) and of brake servo
-2-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
– Disconnect following electrical connectors and move wiring

an
d
itte
clear:
y li
rm
ab
pe
ility
1 - Black 6-pin connector: for lambda probe -G39-

ot
wit
, is n
2 - Brown 6-pin connector: for lambda probe 2 -G108-

h re
hole
spec
3 - Black 2-pin connector: for exhaust gas temperature sender 1

es, in part or in w
-G235-
t to the co
4 - Brown 2-pin connector: for exhaust gas temperature sender 1

for bank 2 -G236-
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
5
co Vo
by lksw
cted
1. Removing and installing engine
agen
Prote AG.
Touareg 2003 ➤
– Disconnect connectors -arrows- for glow plugs of cylinder

bank 1 and cylinder bank 2.
– Secure suspension strut, as shown, with spring tensioner -VW

552.- .
– Remove upper bolts of suspension strut ⇒ Running gear,
axles, steering; Rep. gr. 40 ; II - Assembly overview - front
suspension .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation .
– Extract air conditioning refrigerant ⇒ Heating, air conditioning;
Rep. gr. 87
– Drain coolant ⇒ page 89 . AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e
– Disconnect line -arrow- on lower right
horis of gearbox oil cooler. nte
eo
Collect escaping oil. s aut ra
c
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
rrectne
– Disconnect line -A- from power-assisted steering oil cooler on

bottom left. Collect escaping oil.
ss o
cial p
– Remove charge air connecting pipe -B- for cylinder bank 1 and
f in
cylinder bank 2.
form
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.
6 Rep. gr.10 - Removing and installing engine

Touareg 2003 ➤
– Loosen clamp -arrow- from connecting pipes to air filters for

cylinder bank 1 and cylinder bank 2 and pull off hoses.
– Pull off coolant hoses -arrows- and lay them so that they can‐
not be pinched when engine is removed or installed.
– Disconnect starter wire -A- and alternator wire -B- and lay
. Volkswagen AG
them on engine. swa
gen AG does
olk not
yV gu
edb ara
ris nte
tho eo
au ra
c
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
– Unclip gearbox breather line -arrows-.

rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
7
Prote AG.
1. Removing and installing engine
Touareg 2003 ➤
– Pull connector off intake manifold temperature sender -G42-

-A- and from air mass meter -G70- -B- for cylinder bank 1.
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
– Pull connector off air mass meter 2 -G246- -A- and from intake
es, in part or in w
manifold temperature sender 2 -G299- -B- for cylinder bank 2.
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
– Disconnect the connecting line -arrow- of the air suspension

rp
cu
o
m
compressor at the air filter housing ⇒ page 138 .
f
en
ng
t.
yi Co
op
– Remove both upper parts of air filter upwards. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Open clamp and pull off power-assisted steering line -A-.

Catch escaping oil. Unbolt air conditioning lines -B- from air
conditioning system compressor.

Touareg 2003 ➤
– Pull fuel lines -arrows- off fuel filter.

– Separate the particulate filter and exhaust pipe from one an‐
other and remove exhaust system ⇒ page 152 .
– Remove heat shield on steering box and separate universal
joint ⇒ Running gear, axles, steering; Rep. gr. 48 ; Steering
column .
– Separate connectors on gearbox as well as transfer box and
separate selector lever cable ⇒ Automatic gearbox 09D; Rep.
gr. 37 ; Repairing selector mechanism .
– Remove rear propshaft ⇒ Transfer box and final drive; Rep.
gr. 39 ; Removing and installing propshaft .
– Remove gearbox transverse support -A-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
– Disconnect brake line at point shown -arrow-. Collect brake
ot
wit
, is n
fluid which runs out.
h re
hole
spec
– Separate all connectors between body and front axle in wheel
es, in part or in w
housings.
t to the co
Preparing scissor-type assembly platform -VAS 6131- for further
procedure:
rrectness of i
l purpos
Note
nform
The basic set for Touareg -VAS 6131/6- consists of the supports
ercia
-VAS 6131/6-1- to -VAS 6131/6-7- . To make the following pro‐

m
a
cedure easier to understand, we designate them here as support
com
tio
1 (for VAS 6131/6-1) to support 7 (for VAS 6131/6-7).
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.

Touareg 2003 ➤
– Assemble support -1- left and support -2- right (arrows point
forwards) on scissor-type assembly platform -VAS 6131- and
secure bolts at following positions:
♦ Left support -1-: A5, B4 and B5
♦ Right support -2-: G4, H4 and H5
– Bolt support 3 and support 4 to scissor-type assembly platform
at following positions:
♦ Left support -3-: A6 and C6
♦ Right support -4-: F6 and H6
– Screw turntables of supports -3- and -4- downwards.
– Place supports -5- for subframe and support -6- for gearbox
in appropriate positions on assembly platform.
If engine and gearbox are to be separated following removal
– Remove soundproofing mat under lower part of sump.
– Loosen clips of starter cable.
– Loosen and remove gearbox bolts -A-

– Unscrew the six torque converter bolts working through the
hole in the upper part of sump -arrows-. Turn engine on vibra‐
tion damper using counter-hold tool -T10172- and correspond‐
ing pin -T10172/2- .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
– Install supports -7- for gearbox support at the respective po‐
ce
le
un
sitions on scissor-type assembly platform and screw turnta‐

pt
an
d
itte
bles to lowest position.

y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
– Immediately before raising the scissor-type assembly plat‐

form , attach the support for V10, V8- and V6 engines, Touareg
-VAS 6131/8- (must be screwed to lowest position) to the hole
in the gearbox flange -arrow- as shown in illustration.
Continued:
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
itte
y li
erm
ab
ility
– Position horizontal scissor-type assembly platform under en‐
ot p
wit
gine/gearbox assembly. The supports -1- and -2- must be
, is n
h re
guided into corresponding mountings on left and right
hole
spec
-arrow-.
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
Vo
– At the same time, guide the supports -6- for the left and right
co lksw
by
cted agen
sides of the gearbox transverse into corresponding holes Prote AG.
-arrows-.
When all four supports are in the receptacle holes without pres‐
sure:
– If incorrect, correct support height of support for V10, V8 and
V6 engine, Touareg -VAS 6131/8- at the knurled nut and
mount support in position D7 on the scissors-type assembly
platform .
– Screw the two turntables of supports 3 and 4 under wishbones
(with slight pretension), until the spring tensioner -VW 552-
can be removed.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
Touareg 2003 ➤ rise
d b ara
nte
10-cylinder diesel engineautVolkswagen R GmbH - Edition 09.2012
ho eo
ra
ss c
ce
le
– Guide supports -5- into their respective receptacles in sub‐
un
pt
frame, correcting support height as necessary with knurled
an
d
itte
y li
nuts.
erm
ab
ility
ot p
– Secure subframe to body ⇒ Running gear, axles, steering;
wit
is n
Rep. gr. 40 ; l - Assembly overview - subframe, lower sus‐
h re
ole,
pension links, anti-roll bar .
spec
t to the co
rrectness o
cial p
– Loosen subframe bolts -2- and -3- as well as gearbox trans‐
f in
verse support -4-.
form
mer
atio
If the subframe was not located/secured:
om
n
c
i
or
n
– Loosen subframe bolts -1-.
thi
te
sd
iva
o
pr
cum
r
fo
Note
en
ng
t.
yi Co
Cop py
Perform wheel alignment if the subframe was not located/secured
t. rig
gh ht
yri
⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheel alignment .
p by
co Vo
by lksw
cted agen
Prote AG.
– Now slowly lower assembly, constantly observing the clear‐
ance.
1.2 Removing engine from scissor-type as‐

sembly platform -VAS 6131-
Special tools and workshop equipment required
♦ Workshop hoist -VAS 6100-
♦ Transportation plate -T10126-
♦ Transportation plate -T10126/1-
♦ Rack -T10191-
♦ Lifting tackle -3033-
Procedure
– Unbolt gearbox from engine ⇒ Automatic gearbox 09D; Rep.
gr. 37 ; Removing and installing gearbox .
– Loosen threaded connection -A- of engine mounting on both
sides of engine.
– Loosen support for V10, V8 and V6 engine, Touareg -VAS
6131/8- from scissor-type assembly platform and remove sup‐
port.

Touareg 2003 ➤
– Fit transport bracket -T10126- and transport bracket -

T10126/1- as shown-arrows- on cylinder heads.
– Attach lifting tackle -3033- to workshop hoist -VAS 6100- and
transport brackets .
– Lift engine off scissor-type assembly platform .
– Place the engine in the frame -T10191- .
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
itte
y li
1.3 Securing engine on engine and gearbox
erm
ab
ility
ot p
support -VAS 6095-
wit
, is n
h re
hole
spec
es, in part or in w
♦ Engine and gearbox support -VAS 6095-
t to the co
♦ Universal mounting -VAS 6095/1-
♦ Bracket for V10 TDI engine, Touareg/Phaeton -VAS 6095/1-2-
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
♦ To carry out assembly work and to mount V10 engine, engine

and gearbox support -VAS 6095- must be converted using
universal mounting -VAS 6095/1- .
♦ Universal mounting -VAS 6095/1-

Touareg 2003 ➤
– Attach bracket for V10 TDI engine, Touareg/Phaeton -VAS

6095/1-2- on cylinder block on the correct side (see sticker on
bracket).
– Bolt the engine with brackets which is hanging on the work‐
shop hoist -VAS 6100- to engine and gearbox support -VAS
6095- using all securing bolts and tighten bolts by hand.
– Tighten securing bolts of bracket for V10 TDI engine, Touareg/
Phaeton -VAS 6095/1-2- on cylinder block to 50 Nm.
– Tighten bolts on universal mounting -VAS 6095/1- and bracket
for V10 TDI engine, Touareg/Phaeton -VAS 6095/1-2- to 50
Nm.
– Only if these steps have been completed lower engine on
workshop hoist -VAS 6100- .
1.4 Notes on installing
Caution
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, addi‐
tive, coolant, refrigerant, brake fluid and vacuum) and
electrical wiring in their original positions. wage
e ks s no
Vol t gu
♦ To avoid damage to lines, ensure sufficient
ed
by clearance to ara
all moving or hot components. thoris nte
eo
au ra
c
ss
ce
e
nl
Install in reverse order. In the process, note the following:

pt
du
an
itte
y li
– Check whether dowel sleeves for centring engine/gearbox
erm
have been fitted in cylinder block, insert if necessary. ab

ility
ot p
wit
, is n
– Reconnect all lines, hoses and connectors which were sepa‐ h re

hole
rated during removal.

spec
es, in part or in w
– Electrical connections and routing ⇒ Current flow diagrams,

t to the co
Electrical fault finding and Fitting locations.

– Reconnect air conditioning system lines ⇒ Heating, air con‐
rrectness of i
ditioning system; Rep. gr. 87 .

l purpos
– Replenish oil for power-assisted steering ⇒ Maintenance ;

Booklet 17.1 .
nform
ercia
– Replenish coolant ⇒ page 89 .

m
at
– Check headlight adjustment and correct if necessary ⇒ Main‐

om
io
tenance ; Booklet 17.1.

n
c
in t
or
his
e
– Carry out road test and read all fault memories ⇒ Vehicle di‐
at
do
riv
agnostic tester; or VAS 5052 “Guided functions” .

p
cum
for
en
g
Specified torques
n
t.
yi Co
Cop py
.
Threaded connection Specified torque
ht rig
rig ht
py by
co Vo
Engine to gearbox M10 45 Nm
by lksw
cted agen
Prote AG.
(except for starter) M12 80 Nm
Engine support to cylinder block 50 Nm
Engine support to engine mounting 75 Nm
Engine mounting to engine carrier 60 Nm
Engine carrier to body 100 Nm + 1/2 turn
(180°).

Touareg 2003 ➤

AG. Volkswagen AG d
agen
Gearbox transverse support VolkswNm + 1/4 turn (90°)
50
oes
not
by gu
ara
ed
Subframe to body ⇒ Running hgear,oris axles, steering; Rep. gr. nte
eo
40 ; l - Assembly overview - subframe,
ut lower suspension links, ra
sa c
anti-roll bar s
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
13 – Crankshaft group olksw

agen
AG. Volkswagen AG d
oes
not
V gu
d by ara
e
1 Dismantling and assembling engine ris nte
ho eo
aut ra
ss c
ce
le
un
Caution
pt
an
d
itte
y li
rm
ab
♦ The top part of the bearing saddle is bolted to the cylinder
pe
ility
block by two multi-point socket bolts M8, which are located
ot
wit
, is n
in the V space between the cylinder heads. These bolts
h re
must not be loosened under any circumstances, for this
hole
spec
will lead to warping of the cylinder block which cannot be
es, in part or in w
repaired.
t to the co
♦ Crankshaft, piston and conrods must not be replaced.
These components may only be removed and reinstalled.
rrectness of i
l purpos
Note
nform
mercia
♦ If large quantities of swarf or metal particles (caused, for ex‐
a
com
tio
ample, by partial seizure of the crankshaft or conrod bearings)
n in
r
are found in the engine oil when performing repairs, clean the
te o
thi
oil passages thoroughly and renew the oil cooler in order to
s
iva
do
r
prevent subsequent damage.

rp
cum
fo
en
ng
♦ Engine must not be set down on oil sump, as this will damage
t.
yi Co
op
the liquid gasket between the upper and lower sump. To set C py
t. rig
down engine, use frame -T10191- .
gh ht
pyri by
Vo
o
by c lksw
♦ Secure engine on engine and gearbox support -VAS 6095- to cted agen
Prote AG.
carry out repairs.
Assembly overview - components in the V space ⇒ page 16

Assembly overview - gear train assembly ⇒ page 18
Removing and installing gear train assembly ⇒ page 19
Removing and installing engine mounting and engine support (left
and right) ⇒ page 22
Removing and installing drive plate ⇒ page 23 .
1.1 Assembly overview - components in the V space
16 Rep. gr.13 - Crankshaft group

Touareg 2003 ➤
1 - Drive hub
2 - 8 Nm
3 - Coupling
❑ Gradual introduction of
elastic drive coupling ⇒
Electrical system; Rep.
gr. 27 ; Alternator .
4 - 50 Nm + 1/4 turn (90°) fur‐
ther
AG. Volkswagen AG d
agen
❑ Renew. olksw
oes
not
byV gu
ara
d
5 - 20 Nm orise nte
eo
h
ut ra
6 - Alternator ss a c
ce
le
❑ Removing and instal‐

un
pt
ling: ⇒ Electrical sys‐
an
d
itte
y li
tem; Rep. gr. 27 ; Alter‐
erm
ab
nator .
ility
ot p
wit
is n
7 - Oil filter housing upper part
h re
ole,
spec
8 - Coolant connection
❑ With coolant tempera‐
t to the co
ture display sender -
G62- .
rrectne
❑ Removing and installing
⇒ page 93 .
ss
9 - Gasket
o
cial p
f i
❑ Renew.
nform
mer
10 - Seal
atio
om
❑ Renew.
n
c
i
or
n thi
e
11 - 20 Nm + 1/4 turn (90°) fur‐

t
sd
iva
o
pr
c
ther
um
r
fo
en
ng
❑ Renew.
t.
yi Co
Cop py
12 - Oil filter housing lower part ht. rig
rig ht
py by
❑ Assembly overview - oil filter housing ⇒ page 74 .
co Vo
by lksw
cted agen
Prote
❑ With thermostat housing; Assembly overview ⇒ page 85 .
AG.
13 - Cover
14 - Noise insulation
❑ Not necessarily installed
15 - Bypass flap with exhaust gas recirculation cooler
❑ Assembly overview ⇒ page 156 .
16 - Dowel sleeve
❑ Before installing, locate with commercially available grease if necessary
1. Dismantling and assembling engine 17

Touareg 2003 ➤
1.2 Assembly overview - gear train assembly
1 - Sleeve
❑ For link plate mounting
❑ Renew if there are any
noticeable protrusions
of the compensating link AG. Volkswagen AG d
plate. agen oes
olksw not
V gu
by ara
2 - Compensating link plate rised
nte
ho eo
ut
3 - Camshaft pulley ss a ra
c
❑ Cylinder bank 1: with
ce
le
un
pt
camshaft position send‐
an
d
itte
y li
er wheel
erm
ab
ility
ot p
wit
⇒ page 45 .
is n
h re
ole,
4 - Compensating gear
spec
t to the co
⇒ page 45 .
5 - 150 Nm + 1/4 turn (90°) fur‐
rrectne
ther
6 - Shaft
ss o
cial p
f
7 - Compensating piston
inform
❑ Renew.
mer
atio
m
8 - 20 Nm
o
n
c
i
or
n
❑ Observe tightening se‐
thi
te
quence ⇒ page 38 .
sd
iva
o
pr
cum
r
9 - Seal
fo
en
ng
t.
yi
❑ Do not additionally oil or
Co
op py
grease the oil seal seal‐
t. C rig
gh ht
yri
ing lip. p by
o Vo
by c lksw
❑ Before installing, re‐
cted agen
Prote AG.
move oil residue from
crankshaft journal using
a clean cloth.
❑ Renew. ⇒ page 32 .
10 - Timing housing
11 - Cheese-head screw
❑ First tighten to 60 Nm, then to 150 Nm + 1/4 turn (90°) further.
12 - Sump, upper part

13 - Hexagon bolt
❑ First tighten to 60 Nm, then to 150 Nm + 1/4 turn (90°) further.
14 - Gear train assembly

❑ Removing and installing ⇒ page 19 .

Touareg 2003 ➤
1.3 Removing and installing gear train assembly

equipment required
wage
♦ Engine and gearbox sup‐ Vo lks es n
ot g
y
port -VAS 6095- d b ua
ran
ir se tee
ho
♦ Guide pins -T10200-aut or
ac
ss
♦ Assembly tool -T10208/3-
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Not illustrated:
♦ Torque wrench (40…200 Nm) -V.A.G 1332-
Prerequisites:
• Engine and gearbox removed
• Engine secured on engine and gearbox support -VAS 6095-
⇒ page 13 .
1.3.1 Removing
– Drain engine oil ⇒ Maintenance ; Booklet 17.1
– Turn crankshaft to TDC No. 1 cylinder ⇒ page 49 , Checking
timing.
– Remove cylinder heads ⇒ page 43 .
– Unbolt gearbox from engine ⇒ Automatic gearbox 09D; Rep.
gr. 37 ; Removing and installing gearbox .
– Remove all necessary hoses, lines and pipes from the from
gear train side.

Touareg 2003 ➤
– Remove sump lower part and upper part ⇒ page 68 .

olkswagen AG
en AG. V
– Loosen threaded connection ofolgear
ksw train assembly.
ag does
not
yV gu
db ara
rise nte
Caution au
tho eo
ra
ss c
ce
e
Make sure that the drive shafts for oil and coolant pump do not
nl
pt
du
fall out of the cylinder block.
an
itte
y li
erm
ab
ility
ot p
– Pull the gear train assembly carefully out of the helical teeth.
wit
, is n
h re
hole
1.3.2 Installing
spec
es, in part or in w
t to the co
– Screw the guide pins -T10200- into the threaded holes of the
bearing saddle's upper section as shown.
– Place the gear train assembly onto the guide pins.
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
cted agen
Prote AG.
Note
Observe the following adjustment markings or prerequisites, tak‐

ing into account that the helical teeth cause the gears to turn
slightly as they are pushed on.

Touareg 2003 ➤
– The holes in the splines of the crankshaft sprocket and driving

gear for the oil pump must be opposite each other as shown.
– The drive shaft fits in only one position. Turn the shaft so that
the wide notch in the hole is opposite the wide tooth on the
journal
.
– The hole in the compensating gear of cylinder bank 1 must

align over the cast lug on the inside of the gear train assembly
as shown.
– Carefully push the gear train assembly on the guide pins into
its seat, while keeping an eye on the designated adjustment
markings. en AG. V
olkswagen AG
ag does
ksw not
y Vol gu
b ara
ed nte
oris eo
th
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
– Centre the gear train assembly by placing the thrust piece of

ot p
wit
the assembly device -T10208/3- on the alternator shaft journal

, is n
h re
-A-. The press piece must be positioned in the recess without

hole
spec
force.
es, in part or in w
t to the co
– Replace the guide pins individually with the bolts and tighten
the bolts to 60 Nm.
– Now, tighten bolts to 150 Nm +1/4 turn (90°).
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 ➤
1.4 Removing and installing engine mount‐

ing and engine support (left and right)
♦ Engine and gearbox jack -V.A.G 1383 A-
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
itte
y li
erm
ab
ility
ot p
♦ Subframe -T10296-
wit
, is n
Removing h re
hole
spec
– Remove front noise insulation tray ⇒ General body repairs,
es, in part or in w
t to the co
exterior; Rep. gr. 50 ; Noise insulation .
– Remove front wheel housing liners ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liners
rrectness of i
– Remove lower part of air filter for cylinder banks 1 and 2

l purpos
⇒ page 136 , Assembly overview - air filter.

– Unscrew securing nut -2- of engine mounting on left and right
nf
ercia
engine supports.
rm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
– Align mounting pin of assembly carrier -T10296- with mount‐

ing of cylinder block -arrows- centrally to assembly carrier .
Tighten mounting pin.
– Insert assembly carrier -T10296- into engine and gearbox jack
-V.A.G 1383 A- and support engine and gearbox assembly on
cylinder block mountings -arrows- (tensioned slightly).
wage es n
– Now removeyleft Vo and right securing bolts -1- oof
lks
t guengine mount‐
ing. ir se
d b ara
nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Carefully lift engine and gearbox assembly with assembly car‐
rrectness of i
rier -T10296- and remove engine mounting.

l purpos
Caution
nform
ercia
Note the available space between cylinder heads and bulk‐

m
head.
com
tion in
r
te o
thi
s
iva
– If necessary, unbolt engine support from cylinder block and

do
r
rp
remove engine mounting together with engine support.

um
fo
en
ng
t.
yi
Installing
Co
Cop py
t. rig
– Ensure dowel pin of engine mounting is correctly seated in
gh ht
pyri by
engine carrier.
co Vo
by lksw
cted agen
Prote AG.
– Start all securing bolts and nuts by hand and tighten them to
respective specified torque.
Specified torques
Engine support to cylinder block 50 Nm
Engine mounting to engine carrier 60 Nm
-1-
Engine support to engine mounting 75 Nm
-2-
Further assembly is basically the reverse of the dismantling se‐
quence.
1.5 Removing and installing drive plate


AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Touareg 2003 ➤ orise nte
h eo
10-cylinder diesel engine Volkswagenaut R GmbH - Edition 09.2012 ra
c
ss
ce
e
nl
♦ Clutch counterhold -VW 558-
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
ercia

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Not illustrated:
♦ Vernier gauge
♦ M8×50 hexagon bolt and three M12 hexagon nuts
Loosening and tightening drive plate
– Fasten clutch counterhold -VW 558- to drive plate with M8×50
hexagon bolt. Insert three M12 hexagon nuts between coun‐
terhold and drive plate. Installation position of counterhold:
-A- when loosening; -B- when tightening
Installing drive plate
– Position drive plate with shim ⇒ Item 8 (page 37) .
– Fit new bolts and tighten to 30 Nm.
– Use the vernier gauge to check the distance between the drive
plate and cylinder block. Specification dimension -a-: 19.0 …
20.6 mm.
If specification is not attained:
– Remove drive plate again and place spacer between crank‐
shaft and drive plate. Tighten bolts to 30 Nm again.
– Tighten securing bolts to 50 Nm and then turn 90° 1/4 turn
further (turning further can be done in several stages).

Touareg 2003 ➤
2 Balancer shaft
Note lkswage es n
o ot g
byV ua
d ran
ir se tee
Secure engine on engine and gearbox support -VAS 6095-
utho to or
carry out repairs. ss
a ac
ce
le
un
pt
Assembly overview - balancer shaft ⇒ page 25 .
an
d
itte
y li
erm
ab
2.1 Assembly overview - balancer shaft
ility
ot p
wit
is n
h re
ole,
Note
spec
t to the co
It is only possible to remove the balancer shaft if the gear train
assembly has been removed beforehand ⇒ page 19 .
rrectne
1 - Thrust washer
ss o
cial p
f
2 - Main bearing bolt
inform
mer
quence and torque
atio
om
⇒ page 28 , Tightening
n
c
i
or
n
main bearing bolts
thi
te
sd
va
3 - Bearing cap bolt

i
o
pr
cum
r
fo
❑ For balancer shaft bear‐
en
ng
t.
yi
ing
Co
Cop py
t. rig
❑ Observe tightening se‐ gh ht
yri by
quence and torque cop Vo
by lksw
cted agen
Prote AG.
main bearing bolts
4 - Bearing cap
❑ With eye facing oil-
pump fastening
5 - Bearing shell
6 - Balancer shaft
❑ Positioning ⇒ page 21
7 - Bearing shell
8 - Thrust washer
9 - Bearing cap
❑ Bearing cap with re‐
cesses for thrust wash‐
ers
2. Balancer shaft 25
Touareg 2003 ➤
3 Crankshaft
Caution
♦ The top part of the bearing saddle is bolted to the cylinder

block by two multi-point socket bolts M8, which are located
in the V space between the cylinder heads. These bolts
must not be loosened under any circumstances, for this
will lead to warping of the cylinder block which cannot be
repaired.
♦ Crankshaft, piston and conrods must not be replaced.
These components may only be removed and reinstalled.
Note
G. Volkswagen
Secure engine on engine and gearbox
lksw support -VAS 6095-esto
agen
A AG do
not
carry out repairs. db
yV
o gu
a
e ran
ris tee
tho or
Assembly overview - scrankshaft
au ⇒ page 26 . ac
s
ce
le
Removing and installing bearing saddle for crankshaft

un
pt
⇒ page 27
an
d
itte
y li
erm
ab
Crankshaft dimensions ⇒ page 29 .
ility
ot p
3.1 Assembly overview - crankshaft wit

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

Touareg 2003 ➤
1 - Bearing saddle
❑ Is installed preten‐
sioned
⇒ page 27 . . Volkswagen AG
gen AG does
swa
2 - Thrust washer y Volk not
gu
db ara
❑ For lower part of bearing orise nte
eo
saddle aut
h
ra
ss c
3 - Main bearing bolt
ce
e
nl
pt
du
an
itte
y li
quence and torque
erm
ab
ility
ot p
main bearing bolts
wit
, is n
h re
4 - Bearing shell
hole
spec
es, in part or in w
5 - Crankshaft
t to the co
❑ Axial clearance new:
0.07…0.17 mm; wear
limit: 0.37 mm.
rrectness of i
❑ Check radial clearance
l purpos
with Plastigage, new:

0.03…0.08 mm, wear
limit: 0.17 mm
nform
ercia
❑ Do not rotate crankshaft

m
at
when checking radial
om
ion
clearance.
c
in t
or
his
e
❑ Crankshaft dimensions
at
do
riv
⇒ page 29 .
p
cum
for
en
g
6 - 8 Nm
n
t.
yi Co
Cop py
7 - Oil spray jet
t. rig
gh ht
yri by
❑ For piston cooling.
op Vo
by c lksw
cted agen
Prote AG.
8 - Bearing shell
9 - Cylinder block
❑ With upper part of bearing saddle
❑ Checking cylinder bores ⇒ page 42 .
❑ Piston and cylinder dimensions ⇒ page 40 .
10 - Engine speed sender -G28-
❑ Remove engine mounting and right engine support in order to remove and install ⇒ page 22 .
11 - 10 Nm
12 - Thrust washer
❑ For upper part of bearing saddle
3.2 Removing and installing bearing saddle

for crankshaft
Caution
The top part of the bearing saddle is bolted to the cylinder block
by two multi-point socket bolts M8, which are located in the V
space between the cylinder heads. These bolts must not be
loosened under any circumstances, for this will lead to warping
of the cylinder block which cannot be repaired.
3. Crankshaft 27
Touareg 2003 ➤
Note
Secure engine on engine and gearbox support -VAS 6095- to

carry out repairs.

♦ Tensioning element -T10201-

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
es, in part or in w
t to the co
Not illustrated:
♦ Torque wrench (40…200 Nm) -V.A.G 1332- rrectness of i
Removing
l purpos
– Remove bolts of lower part of bearing saddle.

nform
ercia
– Place the tensioning element -T10201- onto the lower part of

bearing saddle as shown.
m
at
om
ion
– Tighten bolts of tensioning element -T10201- to 20 Nm.

c
in t
or
his
te
– Remove lower part of bearing saddle.

a
do
priv
cum
or
Installing
f
en
ng
t.
yi Co
– Place tensioning element -T10201- on the lower part of bear‐ Cop py
t. rig
ing saddle and tighten bolts to 20 Nm. opyri
gh by
Vo
ht
by c
– Check that all bearing shells are properly seated in their
lksw
cted agen
Prote
mounting brackets ⇒ Item 4 (page 27) . Pay attention to the
AG.
thrust washers ⇒ Item 2 (page 27) .

– Carefully place the lower part of bearing saddle into the cylin‐
der block.
Tightening main bearing bolts ⇒ page 28 .
Tightening main bearing bolts

lkswage es n
o ot g
byV ua
d ran
ho
ir se Touareg
tee 2003 ➤
t or
10-cylinder
au diesel engine Volkswagen R GmbH - Edition
ac 09.2012
ss
ce
e
nl
– Tighten main bearing bolts in three stages in sequence as
pt
du
an
itte
shown as follows (-arrow- points forwards).
y li
erm
ab
1- Tighten initially with torque wrench:
ility
ot p
wit
, is n
Stage I = 35 Nm
h re
hole
spec
Stage II = 65 Nm
es, in part or in w
t to the co
2- Turn further with rigid spanner:
Stage III = 1/2 turn (180°)
rrectness of i
l purpos
nform
3.3 Crankshaft dimensions
mercia
at
(Dimensions in mm)
om
ion
c
in t
or
Honing Crankshaft bearing Conrod
his
ate
dimension in mm journal ∅ journal ∅
do
priv
cum
or
Basic dimension -0.032 -0.022

f
en
ng
t.
yi
65.00 58.00
Co
Cop py
t. rig
-0.047 -0.042
gh ht
pyri by
Vo
co
Stage I -0.032 -0.022
by lksw
cted agen
Prote AG.
64.75 57.75
-0.047 -0.042
Stage II -0.032 -0.022
64.50 57.50
-0.047 -0.042
3. Crankshaft 29
Touareg 2003 ➤ agen
AG. Volkswagen AG d
oes
ksw
10-cylinder diesel
by
V engine Volkswagen R GmbH
ol not
-guEdition 09.2012
ara
ed nte
oris e
th or
au
4 Sealing flange, seals and vibration
ac
ss
ce
le
damper
un
pt
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
hole
spec
carry out repairs.
es, in part or in w
t to the co
Assembly overview - front sealing flange and vibration damper
⇒ page 30
rrectness of i
Renewing crankshaft oil seal, vibration damper end
l purpos
⇒ page 31
Renewing crankshaft oil seal - engine timing end ⇒ page 32
nform
ercia
Renewing alternator shaft oil seal ⇒ page 34

m
a
com
tio
4.1 Assembly overview - front sealing flange and vibration damper
n in
r
te o
thi
s
iva
do
r
rp
cum
1 - Front sealing flange
fo
en
ng
t.
❑ Must seat on dowel
yi Co
op
sleeves.
C py
t. rig
gh ht
yri by
2 - 8 Nm
op Vo
by c lksw
cted agen
Prote AG.
3 - Coolant pump cover
4 - Vibration damper
5 - 50 Nm + 1/4 turn (90°) fur‐
ther
❑ Renew.
6 - Washer
7 - Seal
ing lip.
a clean cloth.
8 - 13 Nm

Touareg 2003 ➤
Tightening sequence for securing bolts for front sealing flange

and coolant pump cover
– Tighten securing bolts to 8 Nm in sequence as shown.
4.2 Renewing crankshaft oil seal, vibration

damper end
♦ Counterhold -T10172-
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
itte
y li
erm
ab
♦ Puller hooks -T20143/2-
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
io
Not illustrated:
n
c
in t
or
his
e
♦ Assembly tool -T10196-

at
do
priv
Procedure
um
for
en
ng
t.
yi
– Bring lock carrier into service position ⇒ General body repairs,
Co
op py
exterior; Rep. gr. 50 ; Lock carrier .
. C rig
ht ht
rig by
opy Vo
– Remove vibration damper ⇒ Item 4 (page 30) . by c lksw
cted agen
Prote AG.
Note
Ensure that sealing surface is not damaged when removing seal.
4. Sealing flange, seals and vibration damper 31

Touareg 2003 ➤
– Pull old oil seal carefully out of seat using puller hook -
T20143/2- .
– Remove oil residue from crankshaft journal using clean cloth.
Note
Do not remove support ring from seal until immediately before

installation.
– Assemble fitting tool sleeve -T10196/1- and fitting tool sleeve

-T10196/2- . Push seal -A- onto fitting tool sleeve -T10196/2-
to stop.
– Separate the two fitting sleeves.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b a
– Fit assembly sleeve
rise
d -T10196/2- together with oil seal onrancrank‐
tee
shaft flangeut and tighten knurled bolts -A- hand-tight.
ho
or
a ac
ss
– Press oil seal in to stop using thrust piece -T1096/3- .
ce
le
un
pt
an
d

itte
y li
quence.
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
4.3 Renewing crankshaft oil seal - engine

thi
te
sd
va
timing end
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 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
Not illustrated:
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
Prerequisite:
ot p
wit
, is n
• Engine removed
h re
hole
spec
• Gearbox detached from engine
es, in part or in w
t to the co
Procedure
rrectness of i
Note
l purpos
nform
ercia
m
T20143/2- .
at
om
ion
c
– Remove oil residue from crankshaft journal using clean cloth.

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.
– Assemble fitting tool sleeve -T10207/1- and fitting tool sleeve

-T10207/2- . Push seal -A- onto fitting tool sleeve -T10207/2-
to stop.
– Separate the two fitting sleeves.

AG. Volkswagen AG d
agen oes
olksw not
Touareg 2003 ➤ d by
V gu
ara
e nte
horis
- Edition 09.2012 eo
aut ra
ss c
– Fit assembly sleeve -T10207/2- together with oil seal on crank‐
ce
e
nl
shaft flange and tighten knurled bolts -A- hand-tight.
pt
du
an
itte
y li
– Press oil seal in to stop using thrust piece -T1207/3- .
erm
ab
ility
ot p
wit
, is n
quence.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
4.4 Renewing alternator shaft oil seal
f
en
ng
t.
yi Co
op py
Special tools and workshop equipment required t. C rig
gh ht
pyri by
o Vo
by c lksw
cted agen
Prote AG.
Not illustrated:
Procedure
– Remove bypass flap together with exhaust gas recirculation
cooler ⇒ page 156 .
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
nator .
Note

Touareg 2003 ➤
T20143/1- .
– Remove oil residue from alternator drive shaft using a clean
cloth.
– Press the inner part of the oil ring outwards as shown.
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
rm
ab
pe
ility
– Screw guide sleeve -T10208/1- hand tight onto alternator drive
ot
wit
, is n
shaft and carefully push seal -A- onto stop.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

. Volkswage
Touareg 2003 ➤ wage
n AG n AG d
oes
olks not
10-cylinder diesel
d byengine Volkswagen R GmbH - Edition
V gu
ar 09.2012
e an
ris tee
ho
– First, put thrusts apiece
ut
-T10208/2- on and then press inner part or ac
of oil seal in as
s far as stop.
ce
le
un
pt
– Now, put thrust piece -T10208/3- on and then press outer part
an
d
itte
y li
of oil seal in as far as stop.
erm
ab
ility
ot p
wit
is n
quence.
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
5 Timing housing
Note

carry out repairs.
Assembly overview - timing housing ⇒ page 37
5.1 Assembly overview - timing housing
1 - Gear train assembly

⇒ page 19 .
2 - Timing housing
❑ Install with silicone seal‐ lkswage es n
Vo ot g
ant -D 176 501 A1- ed
by ua
ran
⇒ page 38 . thoris tee
u or
a ac
3 - 20 Nm ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
4 - 20 Nm
ility
ot p
wit
, is n
5 - Seal
h re
hole
spec
es, in part or in w
t to the co
ing lip.
rrectness of i
a clean cloth.
l purpos
nform
ercia
6 - Drive plate
m
at
om
⇒ page 23 .
on
c
in t
or
7 - 50 Nm + 1/4 turn (90°) fur‐

his
ate
do
riv
ther
p
cum
for
❑ Renew.
en
ng
t.
yi Co
op
8 - Washer
C py
t. rig
gh ht
yri by
9 - 13 Nm cop Vo
by lksw
cted agen
Prote AG.
5. Timing housing 37
Touareg 2003 ➤
Sealant bead on gear train housing

– Apply the bead of sealant onto the clean sealing surface of the
control housing as shown.
Tightening sequence for control housing securing bolts.

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
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
6 Pistons and conrods
Caution
Crankshaft, piston and conrods must not be replaced. These

components may only be removed and reinstalled.
Note

carry out repairs.
Assembly overview - pistons and conrods ⇒ page 39 .

Checking piston projection at TDC ⇒ page 40 .
Piston and cylinder dimensions ⇒ page 40 .
Piston rings, cylinder bore and piston installation position
⇒ page 41
6.1 Assembly overview - pistons and conrods
1 - Conrod bolt, 30 Nm + 1/4

turn (90°) further
❑ Renew.
❑ Oil threads and contact
surface.
❑ Use old bolt for measur‐
ing radial clearance. n AG. Volkswagen AG do
lkswage es n
o ot g
2 - Conrod bearing cap d byV ua
ran
ir se tee
❑ Note installation uposi‐
tho
or
tion. ss
a ac
ce
le
3 - Bearing shell
un
pt
an
d
itte
❑ Note installation posi‐

y li
erm
ab
tion.
ility
ot p
❑ Note version: Upper

wit
is n
bearing shell (towards

h re
ole,
piston) is made of a
spec
more wear resistant ma‐

t to the co
terial. Identification:
Black line on bearing
surface in area of joint.
rrectne
❑ Do not interchange
used bearing shells.
s
❑ Insert bearing shells

s o
cial p
centrally.
inform
❑ Check for secure seat‐

mer
ing.
atio
om
❑ Axial clearance, wear

c
i
or
limit: 0.37 mm
thi
te
sd
va
❑ Check radial clearance

i
o
pr
cum
r
with Plastigage: Wear

fo
en
ng
limit: 0.08 mm, do not ro‐

t.
yi Co
op
tate crankshaft when C py
t. rig
checking radial clear‐
gh ht
pyri by
ance.
co Vo
by lksw
cted agen
Prote AG.
6. Pistons and conrods 39

Touareg 2003 ➤
olkswAG. V agen AG
agen does
lksw not
4 - Conrod db
y Vo gu
ara
e nte
❑ Mark with cylinder number th-arrow
oris
A-. eo
u ra
❑ Installation position: markings
ss a
-arrows B- face towards vibration damper endc
ce
e
nl
5 - Circlip
pt
du
an
itte
y li
6 - Piston
erm
ab
ility
ot p
❑ With combustion chamber.
wit
, is n
❑ Mark installation position and cylinder number.
h re
hole
❑ Installation position and allocation of piston to cylinder ⇒ page 42 .
spec
es, in part or in w
❑ Arrow on piston crown points to intake side
t to the co
❑ Install using piston ring clamp.
❑ Checking piston projection at TDC ⇒ page 40 .
rrectness of i
❑ Piston and cylinder dimensions ⇒ page 40 .
l purpos
❑ Checking cylinder bores ⇒ page 42 .

7 - Piston pin
nf
ercia
o
❑ If difficult to remove, heat piston to 60 °C.
rm
m
atio
m
❑ Remove and install using drift -VW 222 A- .

o
n in
or c
8 - Piston rings
thi
te
sd
iva
❑ Offset gaps by 120°.
o
r
rp
cu
o
m
❑ Use piston ring pliers to remove and install.
f
en
ng
t.
yi Co
❑ “TOP” faces towards piston crown. t. Cop py
rig
gh
❑ Checking ring gap ⇒ page 41 .
ht
pyri by
Vo
o
by c lksw
❑ Checking ring-to-groove clearance ⇒ page 41 . Prote
cted AG.
agen
6.2 Checking piston projection at TDC

The piston projection cannot be measured with normal workshop
equipment. Due to the tension-rod principle for the threaded con‐
nection of the cylinder head, combined with the aluminium cylin‐
der block, the cylinder block shrinks, whereby such shrinking
cannot be reproduced with the cylinder head removed. For this
reason, a new cylinder head gasket with the same index code
( ⇒ page 45 ) must always be installed when the cylinder head
gasket is replaced.
6.3 Piston and cylinder dimensions
Note
No repair sizes are provided!
Honing dimension Piston ∅ Cylinder bore ∅

Basic dimen‐ mm 80.97 81.01
sion

Touareg 2003 ➤
6.4 Piston rings, cylinder bore and piston in‐

stallation position
Checking piston ring gap

♦ Feeler gauges
Test procedure
– Push piston ring squarely from above down to approx. 15 mm
from bottom end of cylinder.
Piston ring New Wear limit
dimensions in mm
1st compression ring 0.20...0.40 1.0
2nd compression ring 0.30...0.50 1.0
Oil scraper ring 0.25...0.50 1.0
Checking ring-to-groove clearance wage
es n
olks ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co

♦ Feeler gauges
rrectness of i
Test procedure
l purpos
– Clean ring groove before checking.

nf
ercia
Piston ring New Wear limit

rm
m
atio
dimensions in mm
om
n in
c
1st compression ring 0.08...0.10 0.25

or
thi
te
sd
a
2nd compression ring 0.03...0.05 0.25

iv
o
r
rp
cu
Oil scraper ring 0.02...0.05 0.15

o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6. Pistons and conrods 41

Touareg 2003 ➤
Checking cylinder bores

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
nf
ercia
o
rm
m
atio
m
♦ Internal dial test indicator 50…100 mm

o
n in
or c
thi
Test procedure
te
sd
iva
o
r
rp
– Take measurements at 3 positions in both transverse -A- and
cu
o
m
f
longitudinal -B- directions, as illustrated.
en
ng
t.
yi Co
op
Deviation from nominal dimension max. 0.05 mm.
C py
t. rig
gh ht
yri by
Pistons: installation position and allocation of piston to cylinder cop Vo
by lksw
cted agen
Prote AG.
Pistons are marked on the piston crown point
♦ Pistons 1 to 5: cylinder bank 1
♦ Pistons 6 to 10: cylinder bank 2
Positioning:
♦ Arrow on piston crown points to intake side

Touareg 2003 ➤
olkswagen AG
15 – Cylinder head, dvalve ksw gear
ag en AG. V does
not
y Vol gu
b ara
e nte
ris
tho eo
1 Cylinder head ss
au ra
c
ce
le
un
pt
an
d
Caution
itte
y li
rm
ab
pe
ility
Due to the bolted connection of the cylinder head through the ot
wit
, is n
aluminium cylinder block into the bearing saddle (tie bolt), it is
h re
absolutely necessary always to reinstall both cylinder heads.
hole
spec
If only one cylinder head is removed and installed, the cylinder
es, in part or in w
block will warp.
t to the co
rrectness of i
Note
l purpos
♦ Secure engine on engine and gearbox support -VAS 6095- to
nform
ercia
carry out repairs.

m
♦ When installing an exchange cylinder head with fitted cam‐
a
com
tio
shaft, the contact surfaces between the bucket tappets and
n in
r
the cam must be oiled before installing the cylinder head cov‐
te o
thi
er.
s
iva
do
r
rp
cum
♦ The plastic protectors fitted to protect the open valves must be
fo
en
g
removed only immediately before the cylinder head is fitted.

n
t.
yi Co
Cop py
♦ If the cylinder heads are replaced, the entire coolant must also
t. rig
gh ht
yri by
be renewed. cop Vo
by lksw
cted agen
Prote AG.
Assembly overview - cylinder head ⇒ page 43 .
Removing camshaft drive gear ⇒ page 45
Checking valve timing ⇒ page 49 .
Adjusting valve timing ⇒ page 51 .
Removing and installing cylinder heads ⇒ page 53
Checking compression ⇒ page 55 .
1.1 Assembly overview - cylinder head
Note
The components shown here correspond to cylinder bank 1. They

are mirror images of the components of cylinder bank 2.
1. Cylinder head 43
Touareg 2003 ➤
1 - Connecting hose
❑ To crankcase breather
valve
ing.
2 - Seal
❑ Renew if damaged.
ing.
3 - Retainer
❑ For intake line between
air filter and intake mani‐
fold flap.
4 - Acoustic cover
. Volkswagen AG
wa gen AG does
5 - Cylinder head cover olks not
byV gu
ara
❑ Before fitting, thorough‐rised nte
ly clean sealing surface
ut
ho eo
ra
of cylinder head cover
ss
a c
with a clean cloth
ce
e
nl
pt
du
an
❑ Only renew gasket to‐
itte
y li
gether with cylinder
erm
ab
head cover if damaged
ility
ot p
or leaking
wit
, is n
h re
❑ Note tightening se‐
hole
spec
quence for securing
es, in part or in w
bolts ⇒ page 44
t to the co
6 - 20 Nm
❑ Between control hous‐ rrectness of i
ing and cylinder head
l purpos
7 - Cylinder head gasket

❑ Renew.
nform
ercia
❑ Installing new gasket

m
with same thickness

at
om
⇒ page 45
on
c
in t
or
❑ Replacement part number label -A- must be readable (not upside down etc.)
his
ate
do
riv
❑ After renewing, renew entire coolant.

p
cum
for
8 - Cylinder head
en
ng
t.
yi Co
op
❑ Removing and installing ⇒ page 53 . C py
t. rig
gh ht
yri by
9 - Cylinder head bolt cop Vo
by lksw
cted agen
❑ Renew. Prote AG.
❑ Note sequence when loosening and tightening ⇒ page 53 , Removing and installing cylinder head.
Tightening sequence for securing bolts of cylinder head cover.

44 Rep. gr.15 - Cylinder head, valve gear

Touareg 2003 ➤
Cylinder head gasket identification

1- Number of holes (indicates thickness of gasket) 1)
2- Control code (can be ignored)
3- Part number
1) The cylinder head gasket is available in three different thick‐
nesses, whereby the number of holes indicates the respective
thickness ⇒ Electronic parts catalogue (ETKA) . When replacing
gasket, a new gasket of the same thickness must always be in‐
stalled.
1.2 Removing and installing camshaft com‐

pensating gear. Vand drive gear wheel
olkswag
AG en AG
agen does
olksw not
V gu
by ara
Note orised nte
th eo
au ra
c
Every times the gear train is detached,
the position of the pump
s
ce
e
plungers in the unit injectors must be checked after assembly and,

nl
pt
du
if necessary, adjusted ⇒ page 141

an
itte
y li
erm
ab
ility
ot p
wit
, is n

equipment required h re
hole
spec
es, in part or in w
♦ Torque wrench (5…50 Nm)

t to the co
-V.A.G 1331-
rrectness of i
Nm) -V.A.G 1332-

l purpos
♦ Puller -T10055-
♦ Bit XZN 16 -T10198-
nf
ercia
♦ Clamp -T10199-
rm
m
atio
m
♦ Wrench -T10211-
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.
1. Cylinder head 45
Touareg 2003 ➤
Note
The procedure described here and the components in the illus‐

trations correspond to cylinder bank 1. The difference to cylinder
bank 2 is only slight and, for this reason, is not described sepa‐
rately.
Removing
– Remove engine and gearbox ⇒ page 3 .
– Remove the intake manifold flap and the crankshaft ventilation
line of the respective cylinder.
– Remove acoustic cover and cylinder head cover of respective
cylinder head.
– Check contact surfaces of rocker arm shaft for wear or seizure.
– Remove the coolant pipe under the tandem pump and fuel
pump.
– Remove vibration damper ⇒ Item 4 (page 30) . Use counter‐
hold -T10172- with screw pins -T10172/1- .
– Bolt crankshaft clamp -T10195- onto crankshaft stump. Note
dowel pin when doing this.
– Now carefully turn crankshaft until pin of crankshaft clamp -
T10195- slips into fitting hole.
– Remove respective pump ⇒ page 116 , Removing and instal‐
ling tandem pump and fuel pump.
♦ Cylinder bank 1: tandem pump
♦ Cylinder bank 2: fuel pump
– Remove oil supply line to turbocharger.
AG. Volkswagen AG d
agen oes
– Fit wrench -T10211- as shown and loosen adapter oring
lksw of cen‐ not
yV gu
tral connector for unit injectors. se
d b ara
nte
ri
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove Hall sender -G40- -C- (only for cylinder bank 1).
rrectness of i
– Remove outer bearing cap -A-, set clamp -T10199- on cam‐

l purpos
shaft gear and tighten its bolts to 40 Nm.

– Loosen securing bolt -B- of camshaft gear using socket -
nf
ercia
T10198- and remove it along with drive for tandem pump.

orm
m
atio
– Loosen bolts of clamp -T10199- and remove.

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
46
cted agen
Prote
Rep. gr.15 - Cylinder head, valve gear
AG.
Touareg 2003 ➤
– Undo and remove compensating piston -B- for shaft of com‐

pensating link plate.
– Unscrew puller head for unit injectors from puller -T10055- .
– Screw puller -T10055- intogeshaft

n AG. Vas
olksshown
wagen Aand
G do pull shaft out
of its seat with careful
Volkstrokes
swa in -direction of arrow-.
es n
ot
by gu
ara
ed nte
oris eo
th
au ra
c
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
– Remove outer compensating link plate on gearbox side, in‐
cluding bush. Loosen by light taps - with a plastic hammer if rrectness of i
necessary.
l purpos
– Remove camshaft gear.

– Now, remove compensating gear and the inner compensating
nform
ercia
link plate on the engine side.

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op
– Remove diamond washer from the camshaft stump.
C py
ht. rig
rig ht
py by
Installing co Vo
by lksw
cted agen
Prote AG.
– Clean contact surfaces of bearing cap to remove any sealant
residue.
– Oil the guide surface of sleeve for compensating link plate.
Note
If there are any noticeable cavities or protrusions on the guide

surface of the sleeves for the compensating link plates, they must
be replaced.
1. Cylinder head 47
Touareg 2003 ➤
– First, attach the inner, compensating link plate -A- at the bot‐
tom on the engine side (if necessary, use
n AG. Vola finger
ksw agen Ato
G dguide it
through the hole of the compensating
lkswage piston) and thenoepush
s no it
Vo t gu
onto the top of the sleeve.
ed by ara
n is tee
or
– Place a new diamond
au
th washer on the camshaft stump. or
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
– Bring the lower compensating link plate on the gearbox side
into position ⇒ page 49 and insert the compensating gear
with phase -arrow- in the direction of the gearbox.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
– When inserting the camshaft gear, turn it so that the marking
yi Co
op py
-arrow- on the sender wheel aligns with the upper edge of the t. C rig
gh ht
sealing surface. yri
p by
co Vo
by lksw
cted
– Secure the construction by carefully pushing in the shaft by
agen
Prote AG.
hand, applying force as uniformly as possible.
Caution
There is a risk that a link plate from the gear wheel casing will
swing out to the side and will not be secured by the shaft or will
tilt when the shaft is inserted.
– Insert the guide sleeve into the compensating link plate on the
gearbox side.
– Carefully pull the shaft out again. Make sure that the compen‐
sating link plates that have already been positioned stay in
their correct position.
– Install the compensating link plate on the gearbox side with
the writing facing in the direction of the gearbox. If necessary,
you can make this easier with light taps of a plastic hammer
on the guide sleeve.
– Check that the compensating link plates are correctly seated
by pushing your finger through the hole of the compensating
piston.
– The compensating gear must be positioned in such as way
that the holes in the four plates and the gear are aligned with
each other in a row ⇒ page 49 .

Touareg 2003 ➤
Position of the compensating link plates
lks wage es n
o ot g
byV ua
d ran
– Oil the shaft, then ocarefully
rise push it in by hand, applying force tee
as uniformly asapossible.
uth
If there is a clear gap in relation to or
ac
the cylinder head bore -arrow-, the shaft is correctly seated.
ss
ce
le
un
pt
– Fit the drive of the tandem pump and fuel pump.
an
d
itte
y li
erm
– Position the bearing cap flush with the edge of the cylinder
ab
ility
head with sealant -AMV 176 501- and tighten the cap firmly.
ot p
wit
Specified torque ⇒ page 49 .
is n
h re
ole,
– Install new compensating piston. Specified torque
spec
⇒ page 49 .
t to the co
– Fit clamp -T10199- and tighten bolt of camshaft gear to level
II ⇒ page 49 .
rrectne
– Check position of pump plungers in unit injectors and adjust
as necessary ⇒ page 141 .
ss
– If not already done, tighten bolt of camshaft gear to level III
o
cial p
⇒ page 49 . f inform
mer
Specified torques
atio
om
n
c

i
or
n thi
te
sd
a
Bolts, nuts M6 10 Nm
iv
o
pr
cum
r
M8 20 Nm
fo
en
ng
t.
yi
M10 45 Nm
Co
Cop py
t. rig
gh
M12 60 Nm
ht
pyri by
Vo
co
Except for the following:
by lksw
cted agen
Prote AG.
Compensating piston 110 Nm
Camshaft gear bolt Stage I 60 Nm
Stage II 150 Nm
Stage III 1/
4 turn (90°)
Bearing cap bolt 8 Nm + 1/4 turn (90°)
1.3 Checking valve timing
1. Cylinder head 49
Touareg 2003 ➤

equipment required
♦ Camshaft clamp -T10193-
for cylinder bank 1
for cylinder bank 2 AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
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
o
by c lksw
cted agen
Prote AG.
Procedure
– Remove noise insulation ( ⇒ Item 14 (page 17) ) and covers
( ⇒ Item 13 (page 17) ) from cylinder heads.
– Using counterhold -T10172- , slowly turn crankshaft in direc‐
tion of engine rotation until you can insert camshaft clamp -
T10193- for cylinder bank 1 and camshaft clamp -T10194- for
cylinder bank 2 into fitting holes as shown.
– Raise the vehicle on the lifting platform.

Touareg 2003 ➤
– Check that marking -arrow A- on vibration damper aligns with

dowel pin -arrow B-.
If the markings are not aligned:
– Adjust valve timing ⇒ page 51 .
1.4 Adjusting valve timing

equipment required
for cylinder bank 1
for cylinder bank 2
♦ Crankshaft clamp -T10195-
♦ Bit XZN 16 -T10198-
♦ Clamp -T10199-
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
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tio
Procedure
n in
r
te o
thi

s
iva
do
r
rp
– Remove fuel and tandem pumps from cylinder heads

um
fo
en
g
⇒ page 116 .
n
t.
yi Co
op py
– Remove noise insulation ( ⇒ Item 14 (page 17) ) and covers
t. C rig
gh ht
yri
( ⇒ Item 13 (page 17) ) from cylinder heads.
p by
co Vo
by lksw
cted agen
Prote AG.
1. Cylinder head 51
Touareg 2003 ➤
– Remove acoustic covers and cylinder head covers .

– Turn engine using counterhold -T10172- until at least one
camshaft clamp can be inserted.
– Fit clamp -T10199- on gear of clamped camshaft and loosen
bolt of camshaft gear. The gear can now be turned freely on
the camshaft.
If it was only possible to fit one camshaft clamp:
– Turn engine with counterhold -T10172- until camshaft clamp
Volkswagen AG
for other cylinder bank can be inserted. swagen AG. does
k not
Vol gu
– Fit clamp -T10199- onto camshaft by
dgear wheel and loosen its ara
ise nte
bolt. This gear can now be turned
tho
r freely on the camshaft. eo
au ra
c
– Remove vibration damper s⇒s
Item 4 (page 30) . Use counter‐
ce
e
hold -T10172- with screw pins -T10172/1- .

nl
pt
du
an
itte
y li
erm
ab
– Bolt crankshaft clamp -T10195- onto crankshaft stump. Note
ility
ot p
dowel pin when doing this.
wit
, is n
h re
– Now carefully turn crankshaft until pin of crankshaft clamp -
hole
T10195- slips into fitting hole.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
– Fit clamp -T10199/1- as shown and tighten its clamping bolt
om
to 70 Nm. ion
c
in t
or
his
e
– Fit torque wrench (40 to 200 Nm) -V.A.G 1332- into the square
at
do
riv
drive of the clamping tool and exert a force of 80 Nm (opposite

p
cum
or
to engine direction of rotation) to remove the play from the gear

f
en
ng
train.
t.
yi Co
Cop py
t. rig
♦ Cylinder bank 1: -in direction of arrow- opyri
gh by
Vo
ht
by c lksw
♦ Cylinder bank 2: -in opposite direction to arrow- Prote
cted AG.
agen
– Maintain this force and tighten camshaft gear wheel securing

bolts to 50 Nm using socket -T10198- .
– Remove clamp -T10199/1- .
– Fit clamp -T10199- onto camshaft gear wheel.
Note
Ensure the clamp -T10199- lies flush with the cylinder head.
– Tighten bolts for clamp -T10199- to 40 Nm.

– Then secure camshaft gear wheel with clamp -T10198- .
Specified torque: 150 Nm + 1/4 turn (90°).
– Remove clamp -T10199- .
– Remove locking devices from camshafts and crankshaft.
– Turn crankshaft two rotations in engine direction of rotation
until crankshaft is set to TDC No. 1 cylinder again.

Touareg 2003 ➤
. Volkswage G
10-cylinder diesel engine Volkswagen
swagen AG R GmbHn A - Edition
does 09.2012
k not
Vol gu
d by ara
– Check that the camshaft clamp as well as the crankshaft ris clamp
e nte
can be inserted at the same time. utho eo
ra
a c
ss
– Check position of pump plungers in unit injectors
ce
le
un
pt
⇒ page 141 .
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
1.5 Removing and installing cylinder heads
l purpos
Caution
nform
mercia
Due to the bolted connection of the cylinder head through the
a
com
tio
aluminium cylinder block into the bearing saddle (tie bolt), it is
n in
r
absolutely necessary always to reinstall both cylinder heads.

te o
thi
If only one cylinder head is removed and installed, the cylinder
s
iva
do
block will warp.
r
rp
cum
fo
en
ng
t.
yi Co
op py
t. C rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
Not illustrated:
♦ Container for removed parts -V.A.G 1698-
♦ Engine bung set -VAS 6122-
♦ Cable ties
1. Cylinder head 53
Touareg 2003 ➤
Removing
– Remove acoustic covers and cylinder head covers from cyl‐ agen
AG. Volkswagen AG d
oes
inder heads. olksw not
byV gu
ara
ed
– Remove fuel and tandem pumps from cylinder heads horis nte
eo
⇒ page 116 . aut ra
c
ss
ce
e
nl
pt
du
timing.
an
itte
y li
erm
ab
– Remove camshaft gear wheels ⇒ page 45 .
ility
ot p
– Undo and remove bolts / ⇒ Item 8 (page 44) ) between valve
wit
, is n
h re
timing housing and cylinder head of cylinder banks 1 and 2.
hole
spec
– Loosen cylinder head bolts in sequence given and then re‐ es, in part or in w
move completely (-arrow- points forwards).
t to the co
– Carefully remove cylinder heads with the assistance of a 2nd
mechanic.
rrectness of i
l purpos
Note
nform
ercia
The cylinder heads must be guided carefully to prevent damage.

m
at
om
io
– Place clean cloths in cylinders so that no dirt or emery cloth
n
c
in t
or
particles can get in between cylinder wall and piston.
his
ate
do
riv
– Also prevent dirt and emery cloth particles from getting into
p
cum
or
coolant.
f
en
ng
t.
yi Co
– Now carefully clean sealing surfaces of cylinder head and cyl‐ Cop py
ht. rig
inder block. Ensure thereby that surfaces are not scored or py
rig by
ht
scratched (if abrasive paper is used, grade must not be less co Vo
by lksw
than 100).
cted agen
Prote AG.
Installing
Note
♦ Always renew cylinder head bolts.

♦ Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
♦ Install cylinder head gasket with same “thickness” index as
that of removed gasket.
♦ Handle gasket very carefully. Damage to the silicone coating
or the indented area will lead to leaks.
– Turn crankshaft to TDC marking for cylinder 1 before fitting

cylinder heads.
– Turn crankshaft against engine direction of rotation until all
pistons are about the same distance below TDC.
– Position cylinder head gasket.

Touareg 2003 ➤
– Fit cylinder head, observing position of compensating link

plate -arrow-, screw in cylinder head bolts with corresponding
washers and tighten bolts by hand.
Caution
All cylinder head bolts except for those with tightening se‐
quence numbers -1-, -2-, -17- and -19- must have grooved
washers ⇒ ETKA (Electronic Parts Catalogue)
– Tighten cylinder heads in four stages in sequence shown as

follows (-arrow- points forwards).
1- Tighten initially with torque wrench:
Stage I = 30 Nm
Stage II = 60 Nm
2- Turn further with rigid spanner:
AG. Volkswagen AG d
agen
Stage III = 1/2 turn (180°)
oes
ksw not
Vol y gu
db ara
1/ turn ise nte
Stage IV = 2 utho (180°)
r eo
a ra
ss c
– Install camshaft gear wheels ⇒ page 45 .
ce
e
nl
pt
du
– Adjust valve timing ⇒ page 51 .

an
itte
y li
erm
ab
ility
1.6 Checking compression

ot p
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
The static compression test on this engine involves considerable

labour. We therefore recommend checking the idling speed
rrectness of i
smooth running control before removing ⇒ Vehicle diagnostic

tester; or VAS 5052 “Guided fault finding; Repair group 15; Sub‐
l purpos
systems, Marginal conditions” . The compression test is warran‐

ted only if one or more cylinders are conspicuous in this idling
speed check.
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.
1. Cylinder head 55
Touareg 2003 ➤

equipment required
-V.A.G 1331-
♦ Adapter -V.A.G 1381/12-
♦ Compression tester -V.A.G
1763-
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
riv
Test prerequisites
p
cum
for
• Engine oil temperature min. 30 °C.

en
ng
t.
yi Co
op py
• Ignition switched off t. C rig
gh ht
pyri by
Test procedure
co Vo
by lksw
cted agen
Prote AG.
– Drain coolant ⇒ page 89 .
– Seal connecting cover of fuel filter unit with sealing tool -
T10247- .

Touareg 2003 ➤
– Connect fuel supply line -A - to fuel return line -B- using con‐
necting hose -VAS 6278- .
– Remove upper part of oil filter housing ⇒ page 74 , Assembly
overview - oil filter housing.
– Remove glow plugs ⇒ page 162 .
– Remove right plenum chamber cover -D-.

– Pull the small connectors off the engine control units.
Note
♦ Pulling the small connectors off the engine control units stops
the engine from starting in spite of the turning starter. Faults
may be stored to the fault memory during starting, necessitat‐
ing reading and possibly erasing of the fault memory.
♦ Read "checking compression" in fault memory ⇒ page 145 ,
Reading and erasing fault memory of engine control unit .
– Screw in adapter -V.A.G 1381/12- instead of glow plug on the

cylinder to be tested. n AG. Volkswagen AG do
ks wage es n
– Reinstall upper part of housing of oil filter housing byV
ol ot g
ua
⇒ page 74 , Dismantling and assembling oil filter housing.ir se
d ran
tee
tho
or
– Check compression using compression tester -V.A.G ss
au
1763- . ac
ce
le
un
pt
an
d
itte
Note
y li
rm
ab
pe
ility
Using compression tester ⇒ operating instructions .
ot
wit
, is n
h re
hole
– Operate starter until tester shows no further pressure in‐
spec
crease.
es, in part or in w
t to the co
Compression pressures:
♦ New: 25…31 bar
rrectness of i
♦ Wear limit: 19 bar.

l purpos
♦ Maximum permissible difference between all cylinders: 5 bar

nform
ercia
– Install glow plugs ⇒ page 162 .

m

com
tion in
– After you have checked all cylinders and assembled the en‐
r
te o
thi
gine again, read out the fault memory and delete it if necessary
s
iva
do
⇒ page 145 , Reading and clearing fault memory of engine

r
rp
cum
fo
control units .
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Cylinder head 57
Touareg 2003 ➤
2 Valve gear
Note

carry out repairs. agen
AG. Volkswagen AG d
oes
lksw not
Cylinder heads with cracks y Vbetween the valve seats may be
o
♦ d b gu
ara
used without reducing orisengine life, provided the cracks are
e nte
eo
small and not more aut than 0.5 mm wide.
h
ra
ss c
ce
e
nl
Assembly overview - valve gear ⇒ page 58 .
pt
du
an
itte
y li
Reworking valve seats ⇒ page 61 .
erm
ab
ility
ot p
Checking valve guides ⇒ page 62 .
wit
, is n
h re
Renewing valve stem seals ⇒ page 63 .
hole
spec
Removing and installing camshaft ⇒ page 65 .
es, in part or in w
t to the co
2.1 Assembly overview - valve gear
rrectness of i
1 - 20 Nm + 1/4 turn (90°) fur‐
l purpos
ther
❑ Renew.
nform
ercia
❑ Note sequence when

m
loosening and tighten‐ at

om
io
ing ⇒ page 65 , Re‐
n
c
in t
or
moving and installing

his
ate
camshaft.
do
priv
cum
or
2 - Rocker arm shaft

f
en
ng
t.
yi
❑ Do not interchange.
Co
Cop py
ht. rig
ht
3 - Bearing cap
rig by
copy Vo
by lksw
❑ When installing, seal cted agen
Prote AG.
parting surfaces of outer
bearing caps with seal‐
ant -AMV 176 501-
⇒ page 60 .
4 - Bucket tappet
❑ Do not interchange.
❑ With hydraulic valve
clearance compensa‐
tion.
❑ Set down with contact
surface facing down‐
wards.
❑ Before installing, check
camshaft axial clear‐
ance ⇒ page 60 .
❑ Oil contact surface.
❑ Before removing, re‐
move camshaft bearing
caps
5 - Cotters
6 - Valve spring plate
7 - Outer valve spring
❑ Removing and installing ⇒ page 63 , Renewing valve stem seals.

AG. Volkswagen AG d
Touareg 2003 ➤
10-cylinder dieselsw agen Volkswagen
engine R oGmbH
es n - Edition 09.2012
olk o t gu
yV
db ara
8 - Inner valve spring ir se nte
ho eo
ut ra
❑ Removing and installing ⇒ page s63
s , Renewing
a
valve stem seals. c
ce
le
un
9 - Valve stem seal
pt
an
d
itte
y li
erm
ab
ility
ot p
10 - Diamond-coated washer
wit
is n
❑ Renew.
h re
ole,
spec
11 - Sleeve
t to the co
❑ For link plate mounting
12 - Cylinder head
rrectne
❑ See “Note” ⇒ page 58
❑ Reworking valve seats ⇒ page 61 .
ss
13 - Valves
o
cial p
f in
❑ Valve dimensions ⇒ page 61
form
mer
14 - Unit injector
atio
om
n
c
i
or
n thi
te
sd
15 - Washer
iva
o
pr
c
❑ For cylinder head bolts.
um
r
fo
en
ng
t.
❑ Insert in cylinder head before installing bearing caps
yi Co
Cop py
❑ Note “"Caution" text” ⇒ page 55 .
t. rig
gh ht
pyri by
Vo
o
16 - Bearing shell
c by lksw
cted agen
Prote AG.
❑ Do not interchange used bearing shells (mark).
❑ Ensure that retaining lugs are correctly seated in bearing caps and cylinder head
17 - Camshaft
❑ Checking axial clearance ⇒ page 60 .
❑ Identification and valve timing ⇒ page 61 .
❑ Check radial clearance with Plastigage, wear limit: 0.11 mm.
❑ Runout: max. 0.01 mm.
18 - Bearing shell
❑ Do not interchange used bearing shells (mark).
❑ Ensure that retaining lugs are correctly seated in bearing caps and cylinder head
19 - Cylinder head bolt
❑ Renew.
❑ Observe sequence when loosening and tightening ⇒ page 53 , Removing and installing cylinder heads.
❑ Before installing, insert washers ⇒ Item 15 (page 59) in cylinder head.
20 - 8 Nm + 1/4 turn (90°) further
❑ Renew.
2. Valve gear 59
Touareg 2003 ➤
Checking camshaft axial clearance

♦ Universal dial gauge bracket -VW 387-
♦ Dial gauge
Test procedure
Check with bucket tappets removed and bearing caps fitted:
Cylinder bank 1
• Bearing caps 2, 4 and 6 installed
Cylinder bank 2
• Bearing caps 9, 11 and 13 installed
Wear limit: max. 0.15 mm
Sealing parting surfaces of outer bearing caps
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
♦ Sealant -AMV 176 501-

ility
ot p
wit
Procedure
, is n
h re
hole
– Apply sealant -AMV 176 501- thinly and evenly on the surfaces
spec
-1-.
es, in part or in w
t to the co
Cylinder bank 1
♦ Seal bearing caps 1 and 7 with sealant -AMV 176 501-
rrectness of i
Cylinder bank 2
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
60
agen
Prote AG.
Rep. gr.15 - Cylinder head, valve gear
Touareg 2003 ➤
♦ Seal bearing caps 8 and 14 with sealant -AMV 176 501-

Valve dimensions
Note
lkswage es n
ot g
Valves must not be reworked. Only y Vlapping-in is permitted.
o
d b ua
ran
ir se tee
tho
u or
Dimension ss Inlet valve
a Exhaust valve ac
ce
le
∅a mm 35.950 31.450
un
pt
an
d
itte
∅b mm 6.980 6.956
y li
rm
ab
pe
ility
c mm 89.950 89.950
ot
wit
, is n
α ∠° 45 45
h re
hole
spec
es, in part or in w
Camshaft identification, valve timing
t to the co
Identification
♦ Cam base diameter: a = 52.8 mm ∅.
rrectness of i
♦ Identification by stamped numbers and letters on drive-end
l purpos
face of camshaft.
Drive end -arrow-
nform
ercia
Cylinder bank 1. 07Z G

m
a
com
tio
Cylinder bank 2. 07Z H
n in
r
te o
thi
Valve timing at 1 mm valve lift
s
iva
do
r
rp
Inlet opens ATDC 12.0° cum

fo
en
ng
t.
yi
Inlet closes ABDC 21.5°
Co
Cop py
t. rig
Exhaust opens BBDC 30.0°
gh ht
pyri by
Vo
co
Exhaust closes BTDC 20.5°
by lksw
cted agen
Prote AG.
2.2 Reworking valve seats

♦ Depth gauge
♦ Valve seat refacing tool
Note
♦ When repairing engines with leaking valves, it is not sufficient

to rework or renew valve seats and valves. There is also a
requirement to check the valve guides for wear. This is par‐
ticularly important on high mileage engines.
♦ Valve seats are only to be reworked to the extent required to
yield a proper surface appearance. Before beginning to rework
valve seats, calculate the maximum permissible reworking di‐
mensions. If the reworking dimension is exceeded, the hy‐
draulic valve clearance compensation can no longer be
guaranteed and the cylinder head must be renewed.
The max. permissible reworking dimension is calculated as fol‐

lows:
– Insert valve and press firmly against seat.
2. Valve gear 61
Touareg 2003 ➤
olks
wage es n
o
yV t gu
db ara
rise nte
tho eo
Note s au ra
c
s
ce
le
un
pt
If the valve is to be renewed as part of a repair, use a new valve
an
d
itte
y li
for the calculation.
erm
ab
ility
ot p
wit
– Measure distance -a- between end of valve stem and upper
is n
h re
edge of cylinder head.
ole,
spec
– Calculate maximum permissible reworking dimension from
t to the co
measured distance -a- and minimum dimension.
Minimum dimension:
rrectne
♦ Inlet valve 43.4 mm
♦ Exhaust valve 43.2 mm
ss o
cial p
Measured distance minus minimum dimension = max. permissi‐
f in
ble reworking dimension.
form
mer
atio
Example:
om
n
c
i
or
n
Measured distance 44.1 mm
thi
te
sd
va
– Minimum dimension 43.4 mm

i
o
pr
cum
r
fo
Max. permissible reworking dimension 0.7 mm
en
ng
t.
yi Co
Cop py
t. rig
Reworking inlet valve seat gh ht
pyri by
Vo
co lksw
by
a - ∅ 35.7 mm Prote
cted AG.
agen
b - 1.6 mm
45° - Valve seat angle
Note
The 30° lower valve seat chamfer is necessary to ensure that the
inlet channel flow characteristics are maintained.
Reworking exhaust valve seat

a - ∅ 31.4 mm
b - 2.7 mm
45° - Valve seat angle
2.3 Checking valve guides


Touareg 2003 ➤
♦ Universal dial gauge bracket -VW 387-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
Not illustrated: ot
wit
, is n
♦ Dial gauge
h re
hole
spec
Test procedure
es, in part or in w
t to the co
– Insert new valve into guide. The end of the valve stem must
be flush with the guide. On account of differing stem diame‐
ters, only use inlet valve in inlet guide and exhaust valve in
rrectness of i
exhaust guide.
l purpos
– Determine rock. Wear limit: max. 1.3 mm

– Cylinder head must be renewed if rock exceeds wear limit.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
2.4 Renewing valve stem seals
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Valve gear 63
Touareg 2003 ➤

equipment required
♦ Valve assembly device
-2036-
♦ Puller -3047 A-
♦ Fitting tool -3129-
♦ Valve lever -VW 541/1 A-
♦ Thrust piece -VW 541/5-
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
Removing
en
ng
t.
yi Co
op
(With cylinder head installed) C py
t. rig
gh ht
yri by
– Remove camshaft ⇒ page 65 . cop Vo
by lksw
cted agen
Prote
– Remove bucket tappets and place them with the contact sur‐
AG.
face downwards. When doing this, ensure that the tappets are
not interchanged.
– Set piston of respective cylinder to top dead centre (TDC).
– Fit valve assembly tool -2036- and adjust mountings to height
of studs.
– Remove valve springs using valve lever -VW 541/1 A- and
press tool -VW 541/5- .
Note
The valves are supported by the piston crown.

Touareg 2003 ➤
– Pull off valve stem seals using puller -3047 A- .

Installing
– Place the plastic sleeve -A- suppliedwon agenthe respective Avalve

AG. Volkswagen G d
oe
stem. This will prevent the newyvalve
Volks
stem seal -B- being s not gu
damaged. ise
d b ara
nt r ee
tho
– Place new valve stem sseal
au in fitting tool -3129- . or
ac
s
ce
– Oil valve stem seal sealing lip and press carefully onto the
le
un
pt
valve guide.
an
d
itte
y li
rm
ab
– Install camshaft ⇒ page 65 .
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
2.5 Removing and installing camshaft
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Sealant -AMV 176 501-

Removing
– Remove camshaft gear wheel ⇒ page 45 .
– Remove rocker arm shafts ⇒ Item 2 (page 58) .
– Loosen bearing caps from outer to inner, loosen bolts of last
two bearing caps alternately and diagonally.
2. Valve gear 65
Touareg 2003 ➤
Installing
Note
♦ Ensure that no valve is pressed against a piston during instal‐

lation of the camshaft. Position pistons as uniformly as possi‐
ble below TDC.
♦ Do not interchange used bearing shells (mark).
♦ When installing the camshaft, ensure proper seating of retain‐
ing lugs in bearing caps and cylinder head.
♦ Before installing bearing caps, ensure that cylinder head bolt
washers are inserted in the cylinder head.
– Oil running surfaces of shell bearings.

– Tighten two bearing caps alternately and diagonally to 8 Nm
+ 1/4 turn (90°) further (renew).
– Install remaining bearing caps and tighten also to 8 Nm + 1/4
turn (90°) further (renew).
Note
When installing, seal parting surfaces of outer bearing caps with

sealant -AMV 176 501- ⇒ page 60 .
– Install rocker arm shafts and tighten securing bolts, first the
inner and then the outer, diagonally and evenly. Specified tor‐
que: 20 Nm + 1/4 turn (90°) further (renew).
– Install camshaft drive gear wheel ⇒ page 45 . AG. Volkswagen AG d
agen oes
lksw not
– Adjust valve timing ⇒ page 51 . d by
Vo gu
ara
ise nte
r
– Install acoustic cover and cylinder head cover of respective
ut
ho eo
ra
cylinder head. ss a c
ce
le
– Install engine and gearbox ⇒ page 3 .

un
pt
an
d
itte
y li
erm
ab
Note ility
ot p
wit
is n
h re
When new bucket tappets have been installed the engine must
ole,
spec
not be started for about 30 minutes. Hydraulic compensation el‐
ements must settle (otherwise valves will strike pistons).

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
17 – Lubrication
1 Engine oil
Caution
The oil level must not be above the max. mark - danger of
damage to catalytic converter! Markings on oil dipstick
⇒ page 67
Draining engine oil ⇒ Maintenance ; Booklet 17.1

Engine oil specification ⇒ Maintenance ; Booklet 17.1
Oil capacities ⇒ page 67
Checking engine oil level ⇒ page 67
1.1 Oil capacities

Without oil filter 11.2 l
With oil filter 11.5 l
1.2 Checking engine oil level

Markings on oil dipstick
AG. Volkswagen AG d
agen oes
1 - Max. mark olksw not
byV gu
ara
d
2 - Min. mark horise nte
eo
aut ra
a - Area above hatched field
s up to max. mark: Do not top up with
s c
engine oil!
ce
e
nl
pt
du
an
itte
b - Oil level within hatched field: can be topped up with engine oil.
y li
erm
ab
c - Area from min. mark up to hatched field: Must be topped up,

ility
ot p
max. 0.5 l of engine oil!

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Engine oil 67
Touareg 2003 ➤
2 Oil sump
Caution
⇒ page 67
Note

the liquid gasket between the upper and lower sump. To set
carry out repairs. n AG. Volkswagen AG do
lkswage es n
o ot g
yV
Assembly overview - sump ⇒ page 68 ir se
d b ua
ran
o tee
h
Applying sealant ⇒ page 71 aut or
ac
ss
ce
2.1 Assembly overview - sump
e
nl
pt
du
an
itte
y li
Assembly overview - lower part of sump ⇒ page 68
erm
ab
ility
ot p
Assembly overview - upper part of sump ⇒ page 70
wit
, is n
h re
2.1.1 Assembly overview - lower part of sump
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.
68 Rep. gr.17 - Lubrication

Touareg 2003 ➤
1 - 8 Nm
2 - 8 Nm
n AG . Volkswagen AG
3 - Oil level and oil temperature wage does
sender -G266- Volks not
gu
by ara
ed
❑ Checking ⇒ Current flow horis nte
eo
diagrams, Electricalsa
ut ra
c
fault finding and Fitting
s
ce
e
locations.
nl
pt
du
an
itte
y li
4 - Seal
erm
ab
ility
❑ Renew.
ot p
wit
, is n
5 - Oil drain plug, 30 Nm
h re
hole
spec
❑ If seal is leaking, nip
es, in part or in w
open and renew.
t to the co
6 - Sump, lower part
❑ Clean sealing surface
rrectness of i
before fitting.
l purpos
❑ Install with sealant -

AMV 176 501-
⇒ page 71
nform
ercia
7 - Oil pipe
m
at
om
io
8 - 8 Nm
n
c
in t
or
his
e
9 - O-ring
at
do
riv
❑ Renew.
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Oil sump 69
Touareg 2003 ➤
2.1.2 Assembly overview - upper part of sump
1 - 8 Nm
2 - 8 Nm
3 - Oil pipe
4 - Sump, upper part
❑ Clean sealing surface
before fitting.
❑ Install with sealant -
AG. Volkswagen AG d
AMV 176 501- ksw
agen oes
not
l
⇒ page 71 by
Vo gu
ara
ed
❑ Pay attention to oil pipes horis nte
eo
on the inside s aut ra
c
⇒ page 70 s
ce
le
un
pt
5 - 10 Nm
an
d
itte
y li
erm
ab
6 - Baffle plate
ility
ot p
wit
7 - Cylinder block
is n
h re
ole,
❑ Dismantling and assem‐
spec
bling engine ⇒ page 16
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Oil pipes in upper part of sump
– Insert the oil pipes -A- as shown in the illustration and tighten
the bolts -B- to 8 Nm.

Touareg 2003 ➤
2.2 Applying sealant . Volkswagen AG

gen AG does
swa
Special tools and workshop equipment required yV
olk not
gu
d b ara
e nte
♦ Sealant -AMV 176 501- horis
eo
aut ra
Procedure ss c
ce
le
un
pt
– Remove sealant residue on sump using a rotating brush, e.g.
an
d
itte
an electric drill with a plastic brush attachment (wear safety
y li
rm
ab
goggles).
pe
ility
ot
wit
– Clean sealing surfaces. They must be free of oil and grease.
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
♦ Note the expiry date of the sealant .
rrectness of i
♦ Install sump within 5 minutes of applying sealant .
l purpos
nform
ercia
– Cut off tube nozzle at forward marking (∅ of nozzle approx. 3

mm).
m
a
com
tio
– Apply sealant , as shown, to clean sump sealing surface.
n in
r
Sealant bead must be:

te o
thi
s
iva
do
♦ 2…3 mm thick.
r
rp
cum
fo
♦ Run bead along inner side of bolt holes -arrows-.
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Sealant contour for lower part of sump

– Apply sealant to clean sealing surface of lower part of sump
as shown.
Sealant contour for upper part of sump

– Apply sealant to clean sealing surface of upper part of sump
as shown.
2. Oil sump 71
Touareg 2003 ➤
AG. Volkswagen AG d
agen oes
lksw not
3 Oil pump, oil filter housing and oil Vo gu
d by ara
ise nte
pressure or eo
h
aut ra
ss c
ce
le
un
pt
Caution
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
⇒ page 67
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos
nform
ercia

m
a
com
tion in
the liquid gasket between the upper and lower sump. To set
r
te o
thi
s
iva
do
r
rp
cum
fo
carry out repairs.
en
ng
t.
yi Co
Cop py
t.
Assembly overview - oil pump ⇒ page 72
rig
gh ht
pyri by
Vo
o
by c
Assembly overview - oil filter housing ⇒ page 74
lksw
cted agen
Prote AG.
Removing and installing oil filter housing ⇒ page 75 .
Checking oil pressure and oil pressure switch ⇒ page 75 .
Checking oil pressure at front of engine ⇒ page 77 .
3.1 Assembly overview - oil pump

Touareg 2003 ➤
1 - 8 Nm + 1/4 turn (90°) further AG. Volkswagen AG d

agen oes
lksw not
2 - Oil pressure line byV
o gu
ara
ed
ris nte
3 - Gasket ut
ho eo
ra
a
❑ Renew if damaged. ss c
ce
e
nl
pt
4 - Oil pump
du
an
itte
y li
❑ Loosen return flow con‐
erm
ab
nections ⇒ page 73
ility
ot p
wit
❑ To remove, after remov‐
, is n
h re
ing all fasteners, push
hole
spec
slightly in direction of
es, in part or in w
gear train side and re‐
t to the co
move
5 - 10 Nm
rrectness of i
6 - Baffle plate
l purpos
7 - Slider
8 - Baffle plate
nf
ercia
orm
9 - 20 Nm + 1/4 turn (90°) fur‐
m
atio
m
ther
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.
Disconnecting oil return connections on oil pump

– Pull locking clips -A- out in the direction of arrow and push
connecting pieces in direction of arrow -B-.
3. Oil pump, oil filter housing and oil pressure 73

Touareg 2003 ➤
3.2 Assembly overview - oil filter housing

AG. Volkswagen AG d
agen oes
olksw not
1 - Oil filter cover, 25 Nm ed by
V gu
ara
is nte
❑ With bypass valve for oil ut
hor eo
filter ss a ra
c
❑ Loosen and tighten with
ce
le
un
pt
oil filter tool -T10192-
an
d
itte
y li
⇒ page 74
erm
ab
ility
ot p
2 - Oil filter
wit
is n
h re
3 - Cap
ole,
spec
❑ Renew seal if damaged.
t to the co
4 - Upper part of housing
5 - 8 Nm
rrectne
6 - 10 Nm
s
7 - Gasket
s o
cial p
f
inform
mer
8 - Filler neck
atio
m
9 - Oil cooler
o
n
c
i
or
n thi
e
10 - Lower part of housing

t
sd
iva
o
r

p
cum
r
fo
⇒ page 75 .
en
ng
t.
yi Co
op
11 - 20 Nm + 1/4 turn (90°) fur‐
C py
t. rig
gh ht
yri
ther p by
o Vo
by c lksw
❑ Renew.
cted agen
Prote AG.
12 - 20 Nm + 1/4 turn (90°) fur‐

ther
❑ Renew.
Loosening and tightening oil filter cover

♦ Oil filter tool -T10192-
Procedure
– Loosen and tighten oil filter cover with oil filter tool -T10192- .
♦ Specified torque: 25 Nm.

Touareg 2003 ➤
3.3 Removing and installing oil filter housing
Note
The oil filter housing is located in the V space beneath the fuel
rails and the intake manifolds.
Removing
– Remove engine cover.
– Separate all necessary connectors of engine wiring harness
above engine.
– Remove charge air pipes to intake connecting pipes.
– Remove coolant connection ⇒ page 93 .
– Remove connection from thermostat housing ⇒ page 85 .
olkswagen AG
en AG. V
– Remove intake olkconnecting
swa
g
pipes together
does
with
not intake manifold
flap motor ed and
by V exhaust gas recirculation valve gu from intake
ara
manifold
horis ⇒ page 134 . nte
e
t or
au a
– Remove
ss vacuum lines to bypass flap for exhaust gas recircu‐
c
lation ⇒ Item 2 (page 157) .
ce
e
nl
pt
du
an
itte

y li
erm
ab

ility
ot p
– Remove fuel rails and then intake manifolds ⇒ page 133 .

wit
, is n
h re
hole
– Remove upper part of oil filter housing ⇒ page 74 .

spec
es, in part or in w
– Remove securing bolts for upper part of oil filter housing

t to the co
-arrows- and remove upper part upwards.

Installing
rrectness of i
Installation is performed in the reverse sequence. In the process,

l purpos
note the following:

– Renew all seals and O-rings.
nf
ercia
– Reconnect all lines, hoses and connectors which were sepa‐

rm
m
atio

om
n in
c
– Filling with coolant ⇒ page 89

or
thi
te
sd
iva
o
r
rp
cu
o
m
f
3.4 Checking oil pressure and oil pressure switch

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

Touareg 2003 ➤

equipment required
♦ Oil pressure tester -V.A.G
1342-
♦ Voltage tester -V.A.G 1527
B-
♦ Auxiliary measuring set -
V.A.G 1594 C-
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
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Note Prote AG.
Functional check and repair of the optical and acoustic oil pres‐
sure indicators ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations and ⇒ Vehicle diagnostic tester; or VAS 5052
“Guided fault finding”
Test procedure
Note
When unscrewing oil pressure switch, counterhold by the banjo

bolt so that there are no leaks in the area of the oil line.

Touareg 2003 ➤
– Remove oil pressure switch -F1- and screw it into oil pressure
tester -V.A.G 1342- . Volkswa AG. gen AG
agen do
– Screw oil pressure olktester
sw into banjo bolt in place
es n
otof
guoil pressure
yV
switch . sed b ara
n
ri te
ho e
– Connectut brown wire of oil pressure tester to earth (-). or a
sa s c
– Connect diode test lamp of voltage tester -V.A.G 1527 B- to
ce
le
un
pt
battery positive (+) and oil pressure switch using cables from
an
d
itte
y li
auxiliary test set -V.A.G 1594 C- . LED must not light up.
erm
ab
ility
ot p
– Install bypass flap together with exhaust gas recirculation
wit
is n
h re
ole,
– Start engine and increase speed slowly.
spec
– At 0.55…0.85 bar the LED must light up, otherwise renew oil
t to the co
pressure switch -F1- .
– Increase engine speed further. At 2,000 rpm and an oil tem‐
rrectne
perature of 80°C the oil pressure should be at least 2.0 bar.
At higher engine speed, oil pressure must not exceed 7.0 bar.
ss o
cial p
f in
3.5 Checking oil pressure at front of engine
form
mer
atio
m

o
n
c
i
or
n
♦ Oil pressure tester -V.A.G 1342-
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.

Test procedure
– Remove covers in engine compartment.
– Remove noise insulation ( ⇒ Item 14 (page 17) ) from cylinder
heads.

Touareg 2003 ➤
– Unscrew the oil channel plug -A- on the cylinder bank to be

checked.
Caution
The thread depth in the hole of the oil channel is very small.
The adapter -V.A.G 1342/19- must not be overtightened (max.
14 Nm), otherwise the thread could be damaged.
– Connect oil pressure tester -V.A.G 1342- to oil channel hole

using adapter -V.A.G 1342/19- .
– Seal test hole for oil pressure switch on oil pressure tester -
V.A.G 1342- with plug for engine.
– Start engine.
At 1000 rpm and an oil temperature of 80°C, the oil pressure must
not be below 1.4 bar.
– After checking, install plug -A - with new seal.
♦ Specified torque: 14 Nm. AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
19 – Cooling
1 Parts of cooling system
Caution

tions:
electrical wiring in their original positions.
♦ To avoid damage to lines, ensure sufficient clearance to
all moving or hot components.
Note
♦ When the engine is warm, the cooling system is under pres‐

sure. If necessary, release pressure before beginning repair
work.
♦ Hoses are secured with spring-type clips. In case of repair,
only use spring-type clips.
♦ Spring-type clip pliers -VAS 5024 A- are recommended for in‐
stallation of spring-type clips.
♦ When installing coolant hoses, route stress-free so that
wage
nthey
AG. Volkswagen AG d
oe
do not come into contact with other components yV
o(observe
lks s no
t gu
markings on coolant connection and hose).ised b ara
nte
r
ho eo
♦ Test for leaks in cooling system usingscooling
au
t
system tester - ra
c
V.A.G 1274- , adapter for cooling system
s tester -V.A.G 1274/8- ce
e
and adapter for cooling system tester -V.A.G 1274/9- .

nl
pt
du
an
itte
y li
erm
ab
Assembly overview - radiator ⇒ page 80 .
ility
ot p
Assembly overview - fans ⇒ page 81 .

wit
, is n
h re
hole
Parts of cooling system - body side ⇒ page 82 .

spec
es, in part or in w
Parts of cooling system - engine side and at top ⇒ page 83

t to the co
Parts of alternator and fuel cooling ⇒ page 84

rrectness of i
Installation position of continued coolant circulation pump and fuel

cooling pump ⇒ page 85
l purpos
Assembly overview - thermostat housing ⇒ page 85

nform
ercia
Assembly overview - coolant pump ⇒ page 87

m
Coolant hose schematic diagram ⇒ page 88 .

at
om
ion
c
Draining and filling with coolant ⇒ page 89 .

in t
or
his
ate
Coolant mixture ratios ⇒ page 89 , draining and filling with cool‐

do
priv
ant
um
for
en
ng
t.
yi
Removing and installing fan support ⇒ page 92 .
Co
Cop py
t. rig
Removing and installing radiator ⇒ page 92 .
gh ht
pyri by
Vo
co lksw
by
Removing and installing coolant connection ⇒ page 93 cted agen
Prote AG.
Removing and installing coolant pump ⇒ page 94 .
1. Parts of cooling system 79

Touareg 2003 ➤
1.1 Assembly overview - radiator
1 - Upper coolant hose

❑ Secured to radiator with
retaining clip. n AG. Volkswagen AG do
wage es n
❑ Check for secure seat‐ y Volks ot g
ua
ing. rised b ran
t ee
tho or
2 - Radiator/cooler s au ac
s
ce
le
un
pt
⇒ page 92 .
an
d
itte
y li
❑ After renewing, renew
erm
ab
entire coolant.
ility
ot p
wit
is n
3 - Condenser
h re
ole,
❑ For air conditioning sys‐
spec
tem
t to the co
4 - ATF cooler
❑ For gear oil
rrectne
5 - Oil cooler
❑ For power-assisted
ss o
steering fluid.
cial p
f inform
6 - Lock carrier
mer
atio
m
7 - Bolts, 10 Nm
o
n
c
i
or
n
8 - Radiator/cooler
thi
te
sd
va
❑ For fuel cooling

i
o
pr
cum
r
fo
9 - Bolts, 10 Nm
en
ng
t.
yi Co
op py
10 - Rubber bush t. C rig
gh ht
pyri by
11 - Retaining clip
co Vo
by lksw
cted agen
Prote
AG.
ing.
12 - Rubber bush
13 - Radiator outlet coolant
temperature sender -G83-
❑ Before removing, release pressure in cooling system if necessary.
14 - Lower coolant hose
❑ Secured to radiator with retaining clip.
❑ Check for secure seating.
15 - Junction
❑ For coolant hose from expansion tank
80 Rep. gr.19 - Cooling

Touareg 2003 ➤
1.2 Assembly overview - fans

AG. Volkswagen AG d
agen oes
1 - Radiator fan -V7- Volksw not
gu
by ara
ed
2 - Mounting forhofan
ris nte
eo
ut
❑ Removing
ss a and installing ra
c
⇒ page 92 .
ce
e
nl
pt
du
an
3 - Bolts, 10 Nm
itte
y li
erm
ab
4 - Bolts, 10 Nm
ility
ot p
wit
, is n
5 - Radiator fan 2 -V177-
h re
hole
6 - Radiator fan control unit -
spec
es, in part or in w
J293-
t to the co
7 - Bolts, 10 Nm
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
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
1.3 Parts of cooling system - body side
1 - Cap
❑ Check using cooling
system tester -V.A.G
1274- and adapter for
cooling system tester -
V.A.G 1274/9- .
❑ Test pressure: 1.4…1.6
bar.
2 - Expansion tank
❑ Test cooling system for
leaks using cooling sys‐
tem tester -V.A.G 1274-
and adapter for cooling
1274/8- .
❑ Depending on equip‐
ment, connection may
be sealed with a blank‐
ing plug
3 - Y-piece
tion.
4 - Coolant hose agen
AG. Volkswagen AG d
oes
olksw not
❑ Secured to lock carrier. d by
V gu
ara
ise nte
r
5 - Retainer ut
ho eo
ra
s a c
s
6 - Radiator/cooler
ce
le
un
pt

an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
1.4 Parts of cooling system - engine side and at top
1 - Cap
V.A.G 1274/9- .
bar.
2 - Expansion tank
1274/8- .
ing plug
3 - Coolant pipe AG. Volkswagen AG d
agen oes
❑ To thermostat housing olksw not
byV gu
ara
ed
4 - Coolant pipe horis nte
eo
ut
❑ To exhaust gasss recircu‐
a ra
c
lation cooler.
ce
le
un
pt
an
d
5 - Coolant hose
itte
y li
rm
ab
❑ To auxiliary coolant
pe
ility
heater
ot
wit
, is n
h re
6 - Coolant hose
hole
spec
❑ From heat exchanger

es, in part or in w
t to the co
7 - Upper coolant hose

❑ Secured to radiator with
retaining clip.
rrectness of i

l purpos
ing.
8 - Lower coolant hose
nform
ercia
❑ Secured to radiator with retaining clip.

m

com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
1.5 Parts of alternator and fuel cooling system
1 - Expansion tank
1274/8- .
ing plug
2 - Cap
V.A.G 1274/9- .
bar.
3 - Coolant pipe
❑ To fuel cooling pump -
V166- agen
AG. Volkswagen AG d
oes
olksw not
4 - Coolant pipe ed byV gu
ara
is nte
❑ To fuel cooler ut
hor eo
⇒ Item 6 (page 84) ss a ra
c
ce
e
5 - Coolant hose
nl
pt
du
an
itte
❑ From fuel cooler

y li
erm
⇒ Item 6 (page 84) ab

ility
ot p
6 - Radiator/cooler wit
, is n
h re
hole
spec
es, in part or in w
7 - Coolant hose
t to the co
❑ From fuel cooling pump

-V166- to cooler
⇒ Item 6 (page 84)
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
1.6 Fitting location of continued coolant circulation pump and fuel cooling pump
1 - Continued coolant circula‐

tion pump -V51-
❑ Bolted on right of engine
AG. Volkswagen AG d
2 - Fuel cooling pump -V166- agen oes
olksw not
V gu
❑ Bolted on right of engine d by ara
ise nte
or eo
h
3 - To fuel cooling pump - aut ra
c
V166- ss
ce
le
un
pt
4 - From fuel cooling pump -
an
d
itte
y li
V166- .
erm
ab
ility
ot p
5 - Non-return valve
wit
is n
h re
ole,
tion.
spec
6 - From continued coolant cir‐
t to the co
culation pump -V51- .
7 - To continued coolant circu‐
rrectne
lation pump -V51- .
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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1.7 Assembly overview - thermostat hous‐

ing
Note
♦ The thermostat housing is located in lower part of oil filter

housing.
♦ Routing of coolant hoses on thermostat housing ⇒ page 83 ,
Parts of cooling system engine side and top.

Touareg 2003 ➤
1 - Oil filter housing lower part

❑ With thermostat hous‐
ing
❑ Assembly overview - oil
filter housing ⇒ page 74
2 - 20 Nm + 1/4 turn (90°) fur‐
ther
❑ Renew.
3 - Hexagon bolt, 10 Nm
4 - Bracket
5 - Hexagon socket head bolt,
10 Nm
6 - Map-controlled engine cool‐
ing thermostat -F265-
7 - Connection
8 - Gasket
❑ Renew.
9 - Thermostat
tion.
❑ Checking: heat thermo‐
stat in water.
❑ Opening begins at ap‐
prox. 80 °C.
❑ Ends at approx. 105 °C.
❑ Opening lift at least 7
mm.
10 - 20 Nm + 1/4 turn (90°) fur‐ n AG. Volkswagen AG do
wage es n
ther yV
olks ot g
ua
d b
❑ Renew. o
ir se
ran
tee
th or
au 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
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
1.8 Assembly overview - coolant pump
1 - Seal
❑ Renew.
2 - Coolant drain plug, 40 Nm
AG. Volkswagen AG d
agen
3 - Coolant pump Volksw
oes
not
gu
by ara
❑ Removing and installing rised
nte
⇒ page 94 . ut
ho eo
ra
s a c
s
4 - 20 Nm + 1/4 turn (90°) fur‐
ce
le
un
pt
ther
an
d
itte
y li
erm
5 - Coolant pump cover
ab
ility
ot p
6 - 8 Nm
wit
is n
h re
ole,
spec
quence ⇒ page 94 ,
Removing and installing
t to the co
coolant pump.
7 - Seal
rrectne
❑ Renew.
8 - O-ring
ss o
cial p
❑ Renew.
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.

Touareg 2003 ➤ gen AG
. Volkswagen AG
does
swa
y V - Edition 09.2012
olk not
gu b ara
ed nte
oris
1.9 Coolant hose schematic diagram th e or
s au ac
s
ce
e
nl
pt
du
an
1 - Heat exchangers
itte
y li
erm
ab
❑ For heater unit
ility
ot p
wit
2 - Cylinder head/cylinder
, is n
h re
block
hole
spec
3 - Fuel cooler
es, in part or in w
t to the co
4 - Radiator/cooler
❑ For exhaust gas recircu‐
rrectness of i
lation.
l purpos
5 - Thermostat housing
6 - Valve body
nform
ercia
7 - Fuel cooling pump -V166-

m
at
om
8 - Radiator/cooler
ion
c
in t
or
9 - Radiator/cooler
his
ate
do
riv

p
cum
for
en
g
10 - Continued coolant circula‐

n
t.
yi Co
tion pump -V51- ht. Cop py
rig
rig ht
11 - Non-return valve py by
co Vo
by lksw
cted agen
Prote AG.
tion.
12 - Expansion tank

Touareg 2003 ➤
1.10 Draining and filling coolant

equipment required
♦ Refractometer -T10007 A-
♦ Spring-type clip pliers -
VAS 5024 A-
♦ Cooling system charge unit
-VAS 6096-
♦ Torque wrench -
V.A.G 1331-
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
1.10.1 Draining
rrectness of i
l purpos
WARNING
Steam may escape when expansion tank is opened. Wear eye

nf
ercia
protection and protective clothing to avoid eye injuries and

rm
m
scalding. Cover cap with cloth and open carefully.

atio
om
n in
or c
thi
te
sd
a
– Open cap on coolant expansion tank.

iv
o
r
rp
cu
o
– Remove noise insulation ⇒ General body repairs, exterior;

f
en
ng
t.
Rep. gr. 50 ; Noise insulation .
yi Co
Cop py
t. rig
– Remove cross member ⇒ General body repairs, exterior; Rep.
gh ht
yri by
gr. 63 ; Front bumper; Removing and installing bumper cover:
cop Vo
by lksw
cted
Assembly overview - cross member .
agen
Prote AG.

Touareg 2003 ➤
– Unscrew plug -arrow- from radiator.
Note
Follow disposal regulations for coolant!
– To drain coolant from engine, also detach coolant hoses from

thermostat housing -arrows-.
1.10.2 Filling
Caution
Only distilled water may be used for mixing with coolant addi‐
tives. The use of distilled water ensures optimum protection gen AG. Volkswagen AG d
against corrosion. Vol
ksw
a oes
not
y gu
db ara
rise nte
tho eo
s au ra
c
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
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
Note
♦ The amount of water used in the coolant mixture has a great

influence on its effectiveness. Because the water quality dif‐
fers from country to country and even region to region, Volks‐
wagen has decided to define the quality of the water to be used
in the coolant system. Distilled water fulfils all requirements. It
is therefore recommended that distilled water be mixed with
the coolant whenever an older model's coolant is replenished
or replaced.
♦ Use only coolant additives in accordance with the ⇒ Electronic
parts catalogue (ETKA) . Other coolant additives may reduce
corrosion protection substantially. The resulting damage could
lead to loss of coolant and subsequent severe damage to the
engine.
♦ The correct coolant solution ratio helps prevent damage from
freezing and corrosion as well as scaling. Moreover, the boil‐
ing temperature is raised. Therefore, the cooling system must
be filled all year round with coolant additive.
♦ Because of its higher boiling point,enthe coolant
AG. Volkswageimproves
n AG en‐
gine reliability under heavy loads,
olks
wag particularly in countries
does
nowith
tropical climates. ed byV t gu
ara
ris nte
♦ Frost protection must
au
tho be guaranteed down to about -25 °C (in eo
ra
countries with Arctic
ss climates: down to about -36 °C). c
ce
e
nl
♦ The coolant concentration must not be reduced by adding wa‐

pt
du
ter even in warmer seasons and in warmer countries. The an

itte
y li
erm
coolant additive concentration must be at least 40%. ab

ility
ot p
♦ If a stronger anti-freeze mixture is necessary due to harsher wit

, is n
weather conditions, the coolant additive content can be in‐

h re
hole
creased. But only to 60 % otherwise, the antifreeze protection

spec
will be reduced again and the cooling effect will be impaired.

es, in part or in w
t to the co
♦ ONLY refractometer -T10007A- may be used for determining

current anti-freeze density.
rrectness of i
♦ Read off anti-freeze figures for respective replenished anti-

freeze.
l purpos
♦ The temperature read off the refractometer -T10007A- equa‐

tes to the »ice flocculation point«. Ice flocculation can start
nf
ercia
forming in the coolant below this temperature.

rm
m
atio
m
♦ Do not reuse old coolant.

o
n in
or c
thi
♦ Use only a water/anti-freeze mixture as a slip agent for coolant

te
sd
a
hoses.
iv
o
r
rp
cu
o
m
f
en
ng
Coolant mixture ratio

t.
yi Co
Cop py
t. rig
• Coolant additive (40 %) and water (60 %) for frost protection yri
gh by
ht
to -25 °C cop Vo
by lksw
cted agen
Prote
• Coolant additive (50 %) and water (50 %) for frost protection
AG.
to -36 °C
• Coolant additive ⇒ Electronic parts catalogue
Procedure
– Install coolant hoses and secure.
– Screw adapter for cooling system tester -V.A.G 1274/8- onto
expansion tank.

Touareg 2003 ➤
– Fill coolant circuit using cooling system charge unit -VAS

6096- ⇒ operating instructions for cooling system charge unit
-VAS 6096- .
1.11 Removing andwaginstalling

en AG. V
olkswafan
gen Asupport
G do
eks s no
Vol t gu
ed
by equipment required ara
is nte
or
♦ Torque wrenchaut(5…50
h Nm) -V.A.G 1331- eo
ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing
nform
ercia
– Pull out retaining clamp for upper coolant hose and remove
m
at
bolt -1-.
om
ion
c
in t
r
– Pull upper coolant hoses off radiator.

o
his
ate
do
riv
– Remove front bumper ⇒ General body repairs, exterior; Rep.

p
cum
or
gr. 63 ; Front bumper .

f
en
ng
t.
yi Co
– Bring lock carrier into service position ⇒ General body repairs, Cop py
t. rig
exterior; Rep. gr. 50 ; Lock carrier . opyri
gh by
Vo
ht
c
– Detach radiator fan connectors.
by lksw
cted agen
Prote AG.
– Undo fastening elements -arrows- and remove fan support
upwards.
Installing
Installation is carried out in the reverse order. When installing,
note the following:
– Fan support must engage in its intended fastenings.
1.12 Removing and installing radiator


Touareg 2003 ➤
Removing
– Remove fan support ⇒ page 92 .
– Remove retaining clips on bumper carrier ⇒ General body
repairs, exterior; Rep. gr. 63 ; Front bumper; Removing and
installing bumper cover: Assembly overview - bumper carrier .
– Release securing clamps for air conditioning system condens‐
er and ATF cooler -arrow-.
– Remove upper securing bolts for radiator and remove radiator
upwards.
Installing
Installation is carried out in the reverse worder. When
gen AG installing,
. Volkswagen AG
does
s a
note the following: yV
olk not
gu b ara
ed
– Replenish coolant ⇒ page
tho
89
ris . nte
e or
au ac
– Electrical connectionsssand routing ⇒ Current flow diagrams,
ce
e
Electrical fault finding and Fitting locations

nl
pt
du
an
itte
– Install front bumper ⇒ General body repairs, exterior; Rep. gr.

y li
erm
ab
63 ; Front bumper .
ility
ot p
wit
– Check headlight adjustment and correct if necessary ⇒ Main‐

, is n
h re
tenance ; Booklet 17.1

hole
spec
es, in part or in w
1.13 Removing and installing coolant con‐

t to the co
nection
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
cted agen
Prote AG.

Touareg 2003 ➤
Removing
– Pull coolant hoses off coolant connections.
– Pull connector off coolant temperature sender -G62- .
– Unscrew securing bolts for coolant connections.
– Push cylinder connections in -direction of arrow- into coolant
connections -1-.
Installing
note the following:
AG. Volkswagen AG d
– Always renew seals and gaskets
lksw -2-.
agen oes
not
o
yV gu
– Tighten coolant connection ed b -1- securing bolts to 8 Nm. ara
ris nte
tho eo
– Replenish coolant au⇒ page 89 . ra
c
ss
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
1.14 Removing and installing coolant pump

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
94
Prote AG.
Rep. gr.19 - Cooling
Touareg 2003 ➤
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
itte
y li
erm
ab
Removing ility
ot p
wit
, is n
– Remove front bumper ⇒ General body repairs, exterior; Rep.

h re
hole
gr. 63 ; Front bumper .

spec
es, in part or in w
– Bring lock carrier into service position ⇒ General body repairs,

t to the co
exterior; Rep. gr. 50 ; Lock carrier .

rrectness of i
timing.
l purpos
– Remove vibration damper ⇒ Item 4 (page 30) .

nf
ercia
or
– Pull coolant hose -3- off coolant pipe. Undo and remove
m
m
atio
bolts /-1- and -2- and push coolant pipe towards the front.
om
n in
or c
– Remove coolant drain plugs ⇒ Item 2 (page 87) .

thi
te
sd
iva
– Remove coolant pump cover ⇒ Item 5 (page 87) .

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

Touareg 2003 ➤
– Undo and remove bolts securing the coolant pump -arrows-

AG. Volkswagen AG d
and remove coolant pump. agen oes
olksw not
V gu
by ara
ed nte
oris eo
th
Note au ra
c
ss
ce
le
un
pt
If the coolant pump bolts are not accessible, fit the vibration
an
d
itte
damper in position and turn the crankshaft with counter-hold tool
y li
rm
ab
-T10172- and screw pins -T10172/1- until the bolts are accessi‐
pe
ility
ble.
ot
wit
, is n
h re
hole
Installing
spec
es, in part or in w
t to the co
note the following:
– Wet new O-ring with coolant, do not use any other lubricants.
rrectness of i
– Fit coolant pump.
l purpos
– Tighten coolant pump securing bolts -arrows- to 20 Nm +1/4
nform
ercia
turn (90°).
m
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.
– Tighten coolant pump cover securing bolts to 8 Nm in se‐

quence as shown.

Touareg 2003 ➤
20 – Fuel supply system

1 Parts of fuel supply system
Note
♦ Hose connections are secured with couplings or spring-type

or clamp-type clips.
♦ Always renew clamp-type clips with spring-type clips.
♦ Fuel hoses on engine must be secured with spring-type clips
only. The use of clamp or screw-type clips is not permissible.
♦ Spring-type clip pliers -VAS 5024A- are recommended for in‐
Observe safety precautions when working on the fuel supply sys‐

tem ⇒ page 98 .
Observe rules for cleanliness ⇒ page 98 .
Assembly overview - fuel tank with attachments ⇒ page 99 .
Assembly overview - fuel filter ⇒ page 101
Schematic diagram of fuel lines and components in fuel tank
⇒ page 103
Schematic diagram of fuel hoses in engine compartment
⇒ page 104
Emptying fuel tank ⇒ page 105 .
Removing and installing fuel delivery unit, fuel gauge sender and
suction-jet pumps ⇒ page 107 AG. Volkswagen gen AG do
swa es n
Removing and installing fuelbytank
Vol with attachments
k ot g
ua
⇒ page 109 . ris
ed ran
tee
tho or
Checking fuel pumps
s a ⇒ page 113
u ac
s
ce
le
Checking tandem pump and fuel pump ⇒ page 114

un
pt
an
d
itte
Removing and installing tandem pump and fuel pump

y li
erm
ab
⇒ page 116
ility
ot p
wit
Assembly overview - accelerator mechanism ⇒ page 118 .

is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Parts of fuel supply system 97

Touareg 2003 ➤
1.1 Safety precautions when working on

fuel supply system
WARNING

tions:
♦ Ensure that there is sufficient clearance to all moving or
hot components.
♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
♦ The fuel system is also under pressure! olks
Before
wage opening es n
ot g
the system, place cloths around the d b connections.
yV Then ua
ran
carefully loosen connection tohorelease
ris
e
the pressure! tee
ut or
♦ Wear eye and hand protection
ss
a
when performing any type ac
of repair work on the fuel system!
ce
le
un
pt
an
d
itte
y li
rm
ab
When removing and installing fuel gauge sender or fuel delivery
pe
ility
ot
unit from a full or partly full fuel tank, observe the following:
wit
, is n
h re
When removing and installing the fuel gauge sender from a full or
hole
spec
partly full fuel tank, the following must be observed:
es, in part or in w
t to the co
♦ Before beginning work, place an extraction hose close to
sender opening in fuel tank to extract escaping fuel fumes and
switch on exhaust extraction system. If no exhaust gas ex‐
rrectness of i
traction system is available, a radial fan with a displacement
greater than 15 m3/h can be used providing that motor is not
l purpos
in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
nform
ercia
1.2 Rules for cleanliness

m
a
com
tion in
When working on the fuel supply and injection system, observe

r
te o
thi
the following “7 rules” for cleanliness:

s
iva
do
r
rp
cum
♦ Thoroughly clean all unions and surrounding areas before dis‐

fo
en
g
connecting.
n
t.
yi Co
Cop py
♦ Place removed parts on a clean surface and cover. Use only
t. rig
gh ht
yri
lint-free cloths.
p by
co Vo
by lksw
cted agen
♦ Carefully cover opened components or seal if repairs cannot
Prote AG.
be carried out immediately.

♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
♦ Existing transport and protective packaging and sealing caps
must only be removed immediately prior to installation.
♦ When system is open: do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely nec‐
essary.
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
98 Rep. gr.20 - Fuel supply system

Touareg 2003 ➤
1.3 Assembly overview - fuel tank with attachments
1 - Fuel filler neck

2 - Metering line
❑ For additive tank wage
es n
olks ot g
❑ From particulate
byV filter ua
ed ran
additive
oris pump -V135- tee
⇒u Item 16 (page 122) .
a
th or
ac
ss
ce
e
nl
ing.
pt
du
an
itte
y li
❑ To pull off, press in se‐
erm
ab
curing ring.
ility
ot p
❑ Line is clipped onto fuel
wit
, is n
h re
tank
hole
spec
3 - Fuel tank
es, in part or in w
t to the co
❑ Schematic diagram of
fuel lines and compo‐
nents in fuel tank
rrectness of i
⇒ page 103 .
❑ Emptying fuel tank
l purpos
⇒ page 105 .
nform
ercia
⇒ page 109 .
m
at
om
4 - Flange
ion
c
in t
r
❑ Left side.
o
his
ate

do
priv
tion on fuel tank

um
for
⇒ page 100 .
en
ng
t.
yi Co
op py
5 - Locking ring, 145 Nm t. C rig
gh ht
yri by
❑ Remove and install us‐ cop Vo
by lksw
ing wrench -T10202- . cted agen
Prote AG.
ing.
6 - Fuel delivery unit
❑ Left side.
❑ Removing and installing ⇒ page 107 , Removing and installing fuel delivery unit, fuel gauge sender and
suction-jet pumps
❑ Checking fuel pumps ⇒ page 113
7 - Fuel gauge sender 3 -G237-
❑ Left side; flat, square float.
❑ Clipped into bottom of tank.
suction-jet pumps
❑ Checking ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.
8 - Suction-jet pump
❑ Left side.
❑ On fuel delivery unit.
suction-jet pumps
9 - Protective cover
❑ For bottom of fuel tank.

Touareg 2003 ➤
10 - Securing strap AG. Volkswagen AG d

agen oes
❑ Note installation position. Volksw not
gu
by ara
❑ Check for secure seating. rise
d
nte
tho eo
u ra
11 - 20 Nm + 1/4 turn (90°) further ss a c
ce
le
un
pt
12 - Protective cover
an
d
itte
y li
❑ For top of fuel tank rm
ab
pe
ility
ot
wit
, is n
❑ Left side.
h re
hole
spec
❑ Clipped into bottom of tank.
es, in part or in w
t to the co
suction-jet pumps
14 - Metering line
rrectness of i
❑ For additive tank
l purpos
❑ To junction piece ⇒ Item 8 (page 121)

nform
ercia
❑ To pull off, press in securing ring.

m
a
❑ Line is clipped onto fuel tank
com
tion in
r
te o
thi
s
iva
❑ Right side.
do
r
rp
cum
fo
en
ng
suction-jet pumps
t.
yi Co
Cop py
t. rig
16 - Fuel delivery unit opyri
gh by
Vo
ht
❑ Right side.
c by lksw
cted agen
Prote AG.
suction-jet pumps
❑ Checking fuel pumps ⇒ page 113
17 - Fuel gauge sender -G-
❑ Right side; round, ball float.
suction-jet pumps
❑ Checking ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.
18 - Flange
❑ Right side.
❑ Note installation position on fuel tank ⇒ page 100 .
19 - Retainer
❑ For breather line ( ⇒ Item 13 (page 121) ) and extraction line ( ⇒ Item 14 (page 122) ) of additive tank.
Installation position of fuel delivery unit flange

Insert sender flange with marking in direction of travel -arrow-.

Touareg 2003 ➤
AG. Volkswagen AG d
agen oes
ksw
1.4 Assembly overview - fuel filter
o l not
y V gu
d b ara
rise nte
Schematicaudiagram
tho
of fuel hoses in engine compartment e or a
⇒ page 104
ss c
ce
le
un
Coolant hose schematic diagram ⇒ page 88 .
pt
an
d
itte
y li
rm
ab
pe
ility
1 - Fuel line
ot
wit
, is n
❑ From fuel filter cover
h re
hole
spec
(marked with -RT- on
es, in part or in w
connection) to fuel cool‐
t to the co
er
⇒ Item 16 (page 102) .
rrectness of i
❑ Blue or with blue mark‐
ing.
l purpos

ing.
nform
ercia
2 - Fuel supply line

m
a
❑ From fuel tank to fuel fil‐
com
tion in
ter cover
r
te o
thi
s
iva
(marking on connection
do
r
rp
-VF-) cum
fo
en
ng
❑ White or with white

t.
yi Co
op
marking.
C py
t. rig
gh ht
yri
❑ Check for secure seat‐p by
co Vo
lksw
ing.
by
cted agen
Prote AG.
3 - Plug, 5 Nm
4 - Seal
❑ Renew.
5 - Water drainage connection
❑ To drain water, extract
approx. 100 cm3 fluid
using diesel extractor -
VAS 5226-
6 - Fuel filter cover
tion.
❑ Fitting possible in one
position only.
7 - Seal
❑ Renew.
8 - Fuel filter insert
❑ Observe change intervals ⇒ Maintenance ; Booklet 17.1
9 - 8 Nm
10 - Seal
❑ Note installation position.
❑ Renew.
11 - Fuel filter
❑ Secured to bracket ⇒ Item 12 (page 101)
12 - Bracket
❑ For fuel filter ⇒ Item 11 (page 101) and fuel cooler ⇒ Item 16 (page 102)

Touareg 2003 ➤
13 - 50 Nm + 1/4 turn (90°) further

wage es n
❑ Renew. yV
olks ot g
d b ua
ran
14 - Coolant hose ir se tee
tho
u or
❑ Check for secure seating. ss
a ac
ce
e
15 - Fuel return line
nl
pt
du
an
itte
❑ To junction piece ⇒ Item 8 (page 121)
y li
erm
ab
❑ Blue or with blue marking.
ility
ot p
wit
, is n
h re
hole
16 - Fuel cooler
spec
es, in part or in w
❑ Secured to bracket ⇒ Item 12 (page 101)
t to the co
❑ From connection on fuel pipe ⇒ Item 3 (page 104) to fuel filter cover ⇒ Item 6 (page 101) (marking on
rrectness of i
connection -RF-)
l purpos
❑ Blue or with blue marking.

nf
ercia
o
rm
m
atio
❑ From fuel filter cover ⇒ Item 6 (page 101) (marking on connection -VM-) to connection on fuel pipe
om
n in
or c
thi
e
❑ White or with white marking.

t
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.

Touareg 2003 ➤
1.5 Schematic diagram of fuel lines and components in fuel tank

-A-: left side of fuel tank
-Arrow-: direction of travel (forwards)
-B-: right side of fuel tank
1 - Supply line for suction-jet

pumps
❑ Left side.
2 - Supply line
❑ To fuel filter
3 - Return line
❑ From junction piece
4 - Flange
❑ Right side.
5 - Supply line for auxiliary
heater
6 - Supply line for suction-jet
pumps
❑ Right side.
❑ On right fuel delivery
unit.
8 - Fuel delivery unit agen
AG. Volkswagen AG d
oes
lksw not
❑ Right side. by Vo gu
ara
d
ise nte
9 - Suction-jet pump uthor eo
a ra
❑ Right side. ss c
ce
e
nl
pt
10 - Delivery line
du
an
itte
y li
❑ Black
erm
ab
ility
❑ To fuel delivery unit on

ot p
wit
left side.
, is n
h re
hole
11 - Delivery line
spec
es, in part or in w
❑ Black
t to the co
❑ To fuel delivery unit on

right side
rrectness of i
l purpos
❑ Left side.
13 - Fuel delivery unit
nform
ercia
❑ Left side.
m
at
om
ion
c
in t
r
❑ On left fuel delivery unit.

o
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 ➤
1.6 Schematic diagram of fuel hoses in en‐

gine compartment
WARNING
olkswagen AG
en AG. V
Always ensure that there is sufficient clearance to other com‐ olks
wag does
not
ponents and to the body when installing fuel lines andehoses.
d byV gu
ara
Leaks may otherwise result. ho
ris nte
eo
t
au ra
c
ss
ce
e
nl
pt
du
an
itte
1 - Test connection
y li
erm
ab
❑ For cylinder bank 2.
ility
ot p
wit
❑ Tighten sealing plug to
, is n
h re
27 Nm
hole
spec
❑ Not fitted on all vehicles
es, in part or in w
t to the co
❑ From connection on
cover of fuel filter
rrectness of i
l purpos
❑ White or with white

marking.
nf
ercia
or
ing.
m
m
atio
om
n in
or c
thi
❑ To connection on cover
te
sd
a
of fuel filter
iv
o
r
rp
cu
o
m
f
en
ng
t.
❑ Blue or with blue mark‐
yi Co
op
ing.
C py
ht. rig
rig ht
py by
co Vo
by lksw
ing. Prote
cted AG.
agen
4 - Fuel pipe
❑ Secured to cylinder
bank 2 intake manifold
5 - Fuel rail
6 - Test connection
❑ Tighten sealing plug to
27 Nm
7 - Fuel rail
8 - Tandem pump
❑ With vacuum pump
❑ Checking tandem pump and fuel pump ⇒ page 114
❑ Removing and installing tandem pump and fuel pump ⇒ page 116
❑ Must not be dismantled.
9 - Fuel temperature sender -G81-
❑ For cylinder banks 1 and 2

Touareg 2003 ➤
10 - Fuel pump
❑ Checking tandem pump and fuel pump ⇒ page 114
❑ Removing and installing tandem pump and fuel pump ⇒ page 116
1.7 Emptying fuel tank

♦ Fuel extractor -VAS 5190-
AG. Volkswagen AG d
♦ Wrench -T10202- 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
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Not illustrated:
rrectness of i

l purpos
Procedure
nform
ercia
– Note safety precautions before beginning work ⇒ page 98 .

m
– Open fuel flap and remove fuel tank cap.

a
com
tion in
r
te o
thi
Note
s
iva
do
r
rp
cum
fo
Secure earth wire of fuel extractor -VAS 5190- to a bare metal

en
ng
t.
yi
part on the body.
Co
Cop 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
ise nte
or eo
h
Touarega2003
ut ➤ ra
c
s
s
ce
e
nl
pt
du
an
– Push intake hose -arrow- of fuel extractor -VAS 5190- about itte
y li
erm
ab
170...180 cm into fuel filler neck and extract fuel.
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
When no more fuel is being extracted, the tank has been emptied
t to the co
just enough for the sender flange to be opened without danger.
The tank may be removed while containing remaining fuel. If work
must be performed on fuel pumps or fuel tank senders, proceed
rrectness of i
as follows:
l purpos
– Remove rear bench seat ⇒ General body repairs, interior;

Rep. gr. 72 ; Removing and installing bench seat .
nform
mercia
at
om
– Pull off connector for fuel pump and fuel gauge sender -4-.
ion
c
in t
or
– Pull return line -1-, supply line -2- and the supply line for sup‐
his
te
plementary heater -3- off right sender flange.

a
do
priv
cum
for
en
ng
t.
yi
Note
Co
Cop py
t. rig
gh ht
yri by
Press in securing ring to release fuel lines.
op Vo
by c lksw
cted agen
Prote AG.
– Now remove locking ring from sender flange using wrench -

T10202- .
– Carefully lever out sender flange and raise it slightly.
– Insert intake hose of fuel extractor -VAS 5190- as deeply as
possible into right and then left side of fuel tank and extract
fuel.
– For work on left side of fuel tank, proceed as described above.
– When pulling off fuel lines it is possible that the securing ring
of the hose couplings cannot be pressed in. Use assembly tool
-T10118- for this.
For further work on inside of fuel tank, sender flanges may remain
removed.
If fuel tank needed only to be emptied, install sender flanges
again.
– First check that sender flange seals are properly seated.
Note
Always renew seals if the fuel has caused them to swell.

Touareg 2003 ➤
– Insert sender flange with marking in direction of travel gen AG. Volkswagen AG
does
-arrow-. Vol
ksw
a
not
y gu
db ara
– Tighten locking rings on left and right usingoriwrench
se -T10202- nte
to 145 Nm. au
th eo
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
Note
rrectne
♦ Do not interchange supply and return hoses (return line -1-
s
blue, supply line -2- black).
s o
cial p
f in
♦ Ensure that fuel hose connections are tight.
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op
1.8 Removing and installing fuel delivery
C py
ht. rig
rig ht
unit, fuel gauge sender and suction-jet
py by
co Vo
by lksw
cted
pumps
agen
Prote AG.

♦ Wrench -T10202-

Touareg 2003 ➤
Prerequisites
• Fuel tank must be drained ⇒ page 105 , Draining fuel tank
• Connectors and wires for left and right sender flanges have
been removed
• Locking rings for left and right sender flanges have been un‐
screwed
Removing
– Note safety precautions before beginning work ⇒ page 98 .
– Pull off connectors -1- and -2- as well as hose couplings -3-,
-4- and -5- below right sender flange.
Note
Press in securing ring to release fuel lines.
– Remove sender flange.
– Unclip black filler hose -arrow- from fuel delivery unit housing
on left and right sides of fuel tank.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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
cted agen
Prote AG.

Touareg 2003 ➤
– Detach fuel supply line to suction-jet pumps from fuel delivery

unit -arrow- on left and right sides of fuel tank.
– Disconnect fuel supply and return lines between the two fuel
delivery units on the left side of the fuel tank.
– Unscrew fuel delivery unit in bottom of fuel tank by turning
about 90° to left.
Note
The fuel delivery unit housing is filled with fuel. Fuel may run out
if housing is tipped or canted.
– Now unclip fuel gauge senders on each side of fuel tank and
pull them out.
– Now unclip suction-jet pumps from bottom on each side and
remove with a slight turn.
– Pull out hose ends through left and right sender openings.
Installing
note the following:
♦ Connections for fuel lines must engage audibly when joined.
Volkswa AG. gen AG
agen does
♦ Route fuel hoses
yV
owithout
lksw kinking. not
gu
b ara
ed
♦ Ensure that
ho
risfuel hose connections are tight. nte
eo
t
au ra
c
ss
1.9 Removing and installing fuel tank with attached components
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤

equipment required
♦ Fuel extractor -VAS 5190-
♦ Wrench -T10202-
-V.A.G 1331-
Nm) -V.A.G 1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
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
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Not illustrated:
♦ Sealing tool -T10249-
rrectness of i
Removing
l purpos
nform
ercia
Note
m
at
♦ Note safety precautions before beginning work ⇒ page 98 .

om
ion
c
in t
or
♦ Fuel tank must be emptied ⇒ page 105 , Emptying fuel tank.

his
ate
do
priv
cum
– Remove rear silencer of exhaust system ⇒ page 152 .

for
en
ng
t.
yi
– Remove rear propshaft ⇒ Transfer box and final drive; Rep.
Co
Cop py
gr. 39 ; Removing and installing propshaft . ht. rig
rig ht
py by
o Vo
– Remove rear subframe ⇒ Running gear, axles, steering; Rep. by c lksw
cted agen
gr. 42 ; l - Assembly overview: subframe, anti-roll bar, stone
Prote AG.
deflector .
– Open fuel flap and remove fuel tank cap.
– Pull rubber gasket off filler neck.

Touareg 2003 ➤
– Remove securing bolts -1- on filler neck and pull off earth wire
-2-. en AG. V
olkswagen AG
ag does
ol body re‐ ksw not
– Remove rear right wheel housing liner ⇒ GeneralyV gu
db ara
pairs, exterior; Rep. gr. 66 ; Wheel housing
ris liner .
e nte
tho eo
s au ra
c
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
– Disconnect metering line -arrow- leading to particulate filter
additive pump -V135- .
rrectne
WARNING
ss
Observe the following for all removal and installation work:
o
cial p
f in
♦ Route all the various lines/wiring e.g. fuel lines, additive
form
mer
lines as well as electric wiring so that they are in their orig‐
atio
inal positions.
om
n
c
i
or
n
thi
te
hot components.
sd
iva
o
pr
cum
r
♦ The additive tank is also under pressure! Before opening

fo
en
ng
the system, place cloths around the connections. Then

t.
yi Co
op
carefully loosen connection to release the pressure! C py
t. rig
gh ht
yri by
♦ Wear protective glasses and fuel resistant gloves when op Vo
by c lksw
working on additive tank (avoid skin contact with additive)! cted agen
Prote AG.
♦ Only work on an open system in a well ventilated work

area!
Note
Press in securing ring to release metering line.
– Seal metering line with sealing tool -T10249- .

– Unclip breather and extraction lines of additive tank from re‐
tainer on fuel filler neck.
– Unbolt cover plate -arrows-.

Touareg 2003 ➤
– Fuel tank breather lines are attached to longitudinal member.

Unclip them at securing clip.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
u
– Unscrew securing nut for filler neck -arrow- in wheel
ss a housing. 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
rrectne
– Disconnect connector to fuel pumps on left next to fuel tank.
ss o
cial p
f
– Now remove securing straps to left and right with cover below
inform
fuel tank.
mer
atio
m
– Support fuel tank using engine and gearbox jack -V.A.G 1383
o
n
c
A- and remove securing strap at middle of fuel tank.
i
or
n thi
te
sd
a
– Carefully lower fuel tank about 30 cm.

iv
o
pr
cum
r
fo
– Reach between fuel tank and vehicle underbody and pull fuel
en
ng
t.
lines off sender flange, while holding a cloth around supply
yi Co
op
line.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Note
Prote AG.
This step saves cutting carpet in vehicle interior in vicinity of

sender flange.
– Unclip metering line of additive tank from fuel filler neck and
fuel tank.
– Lower and remove fuel tank.
Installing
note the following:

Touareg 2003 ➤
♦ Connector couplings for metering, breather and fuel lines must

engage audibly when joined. n AG. Volkswagen A ge G do
swa es
♦ Do not interchange supply and by
return
Vol
k
hose (return line -1- bluenot gua
or blue markings, supply -2-
ris black).
ed ran
te
tho eo
♦ Clip metering and fuel
ss
aulines onto fuel tank. ra
c
ce
e
♦ Install metering, breather and fuel hoses free of kinks.
nl
pt
du
an
itte
y li
♦ Ensure that metering and fuel lines are seated securely.
erm
ab
ility
ot p
♦ Replenish additive in additive tank if necessary ⇒ Mainte‐
wit
nance ; Booklet 17.1 .
, is n
h re
hole
spec
es, in part or in w
1.10 Checking fuel pumps
t to the co
rrectness of i
♦ Diode test lamp -V.A.G 1527 B-
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
♦ Hand multimeter -V.A.G 1526 C- or multimeter -V.A.G 1715- Prote AG.
Not illustrated:
♦ Auxiliary measuring set -V.A.G 1594 C-
Test prerequisites
• Fuses must be OK
• The battery voltage must be at least 11.5 V
• All electrical consumers, e.g. lights and rear window heating,
must be switched off.
Checking function and voltage supply
– Fold rear bench seat forwards.
– Briefly operate starter. Fuel pumps must be heard to run.
– Switch off ignition.

Touareg 2003 ➤
If the fuel pump does not start:

– Remove rear bench seat ⇒ General body repairs, interior;
Rep. gr. 72 ; Removing and installing bench seat.
Continuation for all vehicles
Check voltage supply of each fuel pump separately as follows:
– Pull 4-pin connector off right fuel delivery unit flange.
– Connect diode test lamp -V.A.G 1527 B- to outer contacts of
connector using auxiliary cables from adapter set -V.A.G 1594
C- .
– Switch on ignition; LED must light up for approx. 2 seconds.
If LED does not light up
– Check activation of fuel pump relay and wiring for open circuit
and short circuit ⇒ Vehicle diagnostic tester.
If LED lights up (voltage supply OK):
– Remove right fuel delivery unit ⇒ page 107 .
– Check that electrical wiring between flange and fuel pump is
connected and has continuity.
If no open circuit can be found:
– Right fuel pump is defective. Renew fuel delivery unit
⇒ page 107 .
– Repeat test on left fuel delivery unit.
Checking current draw of fuel pumps n AG. Volkswagen AG do
lkswage es n
o ot g
yV ua
– Check current draw of each fuel pump separately asir se
dfollows:
b ran
o tee
th or
au ac
– Connect multimeter -V.A.G 1715- pick-up clamp
ss to wire on
contact 1 of 4-pin connector -arrow- leading from wiring har‐
ce
le
un
pt
ness to right fuel delivery unit.
an
d
itte
y li
erm
ab
– Start engine and run at idling speed.
ility
ot p
wit
– Measure current draw of fuel pump. Specification: max. 8 Am‐
is n
h re
peres.
ole,
spec
If current draw is exceeded: t to the co

– Right fuel pump is defective. Renew fuel delivery unit
⇒ page 107 .
rrectne
– Repeat test on left fuel delivery unit.

s
1.11 Checking tandem pump and fuel pump

s o
cial p
f inform
mer
atio
Note
om
n
c
i
or
n thi
The tandem pump delivers fuel to cylinder bank 1 and the fuel
te
sd
a
pump delivers fuel to cylinder bank 2.

iv
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 ➤
♦ Tandem pump tester -VAS 5187- with adapter set -VAS

5187/6-
Not illustrated:
♦ Vehicle diagnosis, testing and information system -VAS 5051
A- with diagnosis lead
Test prerequisites
• Coolant temperature must be at least 85 °C.
n AG. Volkswagen A
• Unit injectors OK. olkswage G do
es n
ot g
y V ua
b
• Fuel filter andrisfuel
ed lines must not be blocked. ran
te
tho eo
Test procedure
ss
au ra
c
ce
le
– Connect tandem pump tester -VAS 5187- to test connection

un
pt
an
for cylinder bank 1 -1- or to test connection for cylinder bank

d
itte
y li
2 -2-.
erm
ab
ility
ot p
Connect Vehicle diagnosis, testing and information system -VAS

wit
is n
5051 A- as follows:
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
– Open cover -1-, if fitted, and connect connector of diagnosis

lead to diagnosis connector.
– Select “Vehicle self-diagnosis” mode in the Vehicle diagnosis,
. Volkswagen AG
testing and information system . Then access swagthe engine
en AG con‐ does
trol unit -J623- with the address word “01
by
Vo- Engine electronics”.
lk not
gu
a d ran
se
– Press diagnosis function “08-Read
tho measured value block”.
ri tee
or
au ac
– Enter “display group 1” usingss number block (key pad) and
ce
e
confirm entry with Q button.

nl
pt
du
an
itte
y li
– Read engine idling speed in “display zone 1”.
erm
ab
ility
ot p
– Increase engine speed to 1500 rpm.
wit
, is n
h re
– Observe pressure indicated on pressure gauge. Specification:
hole
at least 7.5 bar.
spec
es, in part or in w
t to the co
– Press ← key twice.
– Select “06-End output” function.
rrectness of i
If the specification is not attained:
l purpos
– Replace tandem pump or fuel pump ⇒ page 116
nform
ercia
Note
m
at
om
ion
After removing tandem pump tester , tighten supply line or sealing
c
in t
or
plug to 27 Nm.
his
ate
do
priv
cum
for
en
g
1.12 Removing and installing tandem pump

n
t.
yi Co
op py
and fuel pump
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
DANGER!
AG.
The tandem pump may, under no circumstances, be disman‐

tled as the vacuum part could otherwise malfunction. This
would result in the failure of the brake servo.


Touareg 2003 ➤
♦ Spring-type clip pliers -VAS 5024 A-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
Removing thor eo
au ra
ss c
ce
e
nl
pt
Note
du
an
itte
y li
erm
ab
The procedure for removing and installing the tandem pump is
ility
ot p
described. The procedure for the fuel pump is identical, except
wit
, is n
for the way in which the vacuum line is detached.
h re
hole
spec
es, in part or in w
t to the co
– Remove intake manifold ⇒ page 133 .
rrectness of i
– Pull vacuum line -1- from brake servo off tandem pump -5-.
l purpos
– Pull off central connector for unit injectors -3-.

– Pull fuel hose -2- off tandem pump -5-.
nf
ercia
or
– Remove securing bolts -arrows-.
m
m
atio
om
– Remove tandem pump -5- from cylinder head.
n in
or c
thi
e
– Pull tandem pump -5- upwards a little, unscrew the fuel hose
t
sd
iva
-4- and remove the tandem pump.
o
r
rp
cu
o
m
f
en
ng
Installing
t.
yi Co
Cop py
t. rig
gh ht
yri
note the following: p by
co Vo
by lksw
cted agen
Prote AG.
Note
♦ Ensure that tandem pump coupling seats properly in cam‐

shaft.
♦ Always replace tandem pump seals.

Touareg 2003 ➤
– Attach fuel line -4- together with new seals to tandem pump
-5- and tighten banjo bolt to 25 Nm.
– Install tandem pump and tighten securing bolts -arrows-.
Specified torque:
♦ M6: 8 Nm.
♦ M8: 20 Nm.
. Volkswage
– Attach fuel hose -2- and vacuum hose -1-lksto gen AG pump. n AG doe
watandem sn o ot g
yV ua
– Attach central connector for unit injectors.
ris
ed
b ran
tee
tho or
– Install bypass flap together with
au exhaust gas recirculation ac
ss
ce
le
un
pt
– Install intake manifold ⇒ page 133 .
an
d
itte
y li
erm
ab
– Carry out a road test and read fault memory ⇒ page 145 ,
ility
ot p
Reading and clearing fault memory of engine control units .
wit
is n
h re
ole,
spec
Note
t to the co
Disconnecting the central connector for unit injectors causes
faults to be stored. Therefore, read fault memory and clear if nec‐
rrectne
essary.
ss
1.13 Assembly overview - accelerator mechanism
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
1 - Bearing bracket
2 - Connector
❑ Black, 6-pin.
3 - 10 Nm
4 - Accelerator position sender wage
es n
s
-G79- yV
olk ot g
ua
d b ran
❑ Not adjustable. o
ir se tee
th or
❑ Remove footwell cover ss
au ac
to remove sender.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
2 Additive tank
AG. Volkswagen AG d
Note agen oes
o lksw not
byV gu
ara
ed
♦ Hose connections are secured with either couplings
thoris
or clamp- nte
eo
type clips. s au ra
c
s
ce
e
♦ Always renew clamp-type clips.
nl
pt
du
an
itte
y li
erm
Checking additive level and replenishing additive ⇒ Maintenance ;
ab
ility
Booklet 17.1 .
ot p
wit
, is n
Observe safety precautions when working on additive tank
h re
hole
⇒ page 120 .
spec
es, in part or in w
Assembly overview - additive tank ⇒ page 120 .
t to the co
Removing and installing additive tank ⇒ page 122 .
rrectness of i
2.1 Safety precautions when working on ad‐
ditive tank
l purpos
nform
ercia
WARNING
m
at
om
io
Observe the following for all removal and installation work:
n
c
in t
or
♦ Route all the various lines/wiring e.g. fuel lines, additive
his
ate
do
riv
lines as well as electric wiring so that they are in their orig‐

p
cum
inal positions.
for
en
ng
t.
yi
Co
Cop py
hot components. ht. rig
rig ht
py by
o Vo
♦ The additive tank is also under pressure! Before opening by c lksw
cted agen
the system, place cloths around the connections. Then
Prote AG.
carefully loosen connection to release the pressure!

♦ Wear protective glasses and fuel resistant gloves when
working on additive tank (avoid skin contact with additive)!
♦ Only work on an open system in a well ventilated work
area!
2.2 Assembly overview - additive tank

Touareg 2003 ➤
1 - Fuel additive tank sender -

G504-
tion on additive tank
❑ Connector must be be‐
tween marks
⇒ Item 4 (page 121) on
additive tank
❑ Tighten union nut to agen
AG. Volkswagen AG d
oes
25 Nm. Volksw not
gu
by ara
d
2 - Seal rise nte
tho eo
u
❑ Renew if damaged. ss a ra
c
ce
le
3 - Connector
un
pt
an
d
itte
❑ Black, 2-pin
y li
erm
ab
❑ For fuel additive tank
ility
ot p
sender -G504- .
wit
is n
h re
ole,
4 - Markings
spec
❑ For installation position
t to the co
of fuel additive tank
sender -G504- .
5 - Line coupling
rrectne
❑ For metering line.
s
❑ In rear right wheel hous‐
s o
ing.
cial p
f inform
mer
ing.
atio
om
❑ To pull off, press in se‐
n
c
i
or
n
curing ring.
thi
te
sd
va
❑ After disconnecting cou‐

i
o
pr
c
plings, seal connections
um
r
fo
en
ng
with sealing tool -

t.
yi Co
T10249- ⇒ page 122 , Cop py
t. rig
Removing and installing yri
gh by
ht
additive tank cop Vo
by lksw
cted agen
Prote
6 - Line coupling
AG.
❑ For metering line.

❑ Below fuel tank.
❑ Line is clipped onto fuel filler neck and fuel tank.
7 - Return line
❑ To fuel tank.
8 - Junction
❑ Below fuel tank.
9 - Return line
❑ From connection on fuel cooler ⇒ Item 15 (page 102) .
10 - Rubber mounting
11 - Spacer
12 - 10 Nm
13 - Breather line
❑ Smaller diameter.
❑ Clipped onto fuel tank filler neck bracket ⇒ Item 19 (page 100)
2. Additive tank 121

Touareg 2003 ➤
❑ Checking additive level and replenishing additive ⇒ Maintenance ; Booklet 17.1 .
14 - Extraction line
❑ Larger diameter.
❑ Clipped onto fuel tank filler neck bracket ⇒ Item 19 (page 100)
❑ Checking additive level and replenishing
wage
n AG. Volksadditive
wagen AG⇒ Maintenance ; Booklet 17.1 .
doe
ks s no
Vol t gu
15 - Connector ed
by ara
ris nte
❑ Black, 2-pin tho eo
au ra
❑ For particulate filter additive pump -V135-
ss c
ce
le
un
pt
16 - Particulate filter additive pump -V135-
an
d
itte
y li
❑ Observe installation position: arrow on pump points in direction of flow.
erm
ab
ility
ot p
17 - Rubber mounting
wit
is n
h re
❑ For particulate filter additive pump -V135-
ole,
spec
18 - Connecting line
t to the co
❑ Line is clipped onto retaining clip ⇒ Item 22 (page 122) .
rrectne
19 - Plug
❑ Larger diameter.
ss
❑ For extraction line of additive tank.
o
cial p
f in
❑ Before pulling it off, first pull off plug for breather line of additive tank ⇒ Item 20 (page 122) .
form
mer
atio
om

n
c
i
or
n thi
e
20 - Plug
t
sd
iva
o
pr
❑ Smaller diameter.
um
r
fo
en
ng
❑ For breather line of additive tank.

t.
yi Co
op py
❑ To pull off, press in securing ring. t. C rig
gh ht
yri by
❑ Check for secure seating. cop Vo
by lksw
cted agen
Prote
21 - Additive tank
AG.
❑ In rear right wheel housing.

22 - Securing clip
❑ For connecting line ⇒ Item 18 (page 122) .
23 - Retainer
❑ For wiring harness.
❑ Secured to additive tank ⇒ Item 21 (page 122) .
24 - Connector
❑ Black, 6-pin.
❑ For fuel additive tank sender -G504- and particulate filter additive pump -V135- .
❑ In rear right wheel housing.
2.3 Removing and installing additive tank


Touareg 2003 ➤
Not illustrated:
♦ Sealing tool -T10249-
Removing
lkswage es n
o ot g
Note d byV ua
ran
ir se tee
tho
Note safety precautionsu before beginning work ⇒ page 120 . or
a ac
ss
ce
e
nl
pt
– Remove rear right wheel housing liner ⇒ General body re‐
du
an
itte
pairs, exterior; Rep. gr. 66 ; Wheel housing liner .
y li
erm
ab
ility
– Disconnect metering line -arrow- leading to particulate filter
ot p
wit
additive pump -V135- .
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
Press in securing ring to release metering line.

rrectness of i
– Seal metering line with sealing tool -T10249- .

l purpos
– Unclip breather and extraction lines from bracket on fuel tank

filler neck.
nform
mercia
at
om
io
– Disconnect the black 6-pin connector -2- for fuel additive tank
n
c
in t
r
sender -G504- and particulate filter additive pump -V135- .

o
his
ate
do
riv
– Remove securing bolts -1- and remove additive tank.

p
cum
for
en
g
Installing
n
t.
yi Co
op py
t. C rig
gh ht
yri
note the following: p by
co Vo
by lksw
cted agen
Prote AG.
2. Additive tank 123

Touareg 2003 ➤
♦ Clip breather and extraction lines onto additive tank and brack‐
et fuel filler neck.
♦ Clip metering line onto fuel tank.
♦ Route lines free of kinks.
♦ The connector coupling for the metering line -arrow- must en‐
gage audibly when joined.
♦ Tighten additive reservoir securing bolts to 10 Nm.
♦ If necessary replenish additive ⇒ Maintenance ; Booklet 17.1 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
21 – Turbocharging/supercharging
1 Charge air system with turbocharger
Observe safety precautions ⇒ page 125 .
Note instructions for installing hose connections with
AG. Volkswagen Aconnector
couplings ⇒ page 126 . agen G do
es n
olksw ot
V y gu
db ara
Assembly overview - turbocharger
or
ise ⇒ page 127 . nte
h eo
ut ra
Assembly overview s-s acharge air cooling ⇒ page 129 c
ce
le
Checking charge air system for leaks ⇒ page 130

un
pt
an
d
itte
y li
1.1 Safety precautions
erm
ab
ility
ot p
wit
is n
h re
Caution
ole,
spec
t to the co
tions:
rrectne
ss o
cial p
f in
form
mer
atio
om
n
c
Observe following if test and measuring instruments are required

or
n thi
e
during a road test:

t
sd
iva
o
pr
♦ Test and measuring instruments must always be secured to

um
r
fo
en
ng
rear seat and operated by a second person from this location.

t.
yi Co
op py
If test and measuring instruments are operated from front pas‐
t. C rig
gh ht
yri
senger seat and the vehicle is involved in an accident, there is a p by
co Vo
possibility that the person sitting in this seat may receive serious
by lksw
cted agen
Prote
injuries when the airbag is triggered.
AG.
WARNING
Secure fault reader to rear seat and operate from this position.

When working on the turbocharger, pay careful attention to the
following “7 rules” for cleanliness:
connecting.
lint-free cloths.
tool boxes etc.).
1. Charge air system with turbocharger 125

AG. Volkswagen AG d
Touareg 2003 ➤ ksw
agen oes
not
Vol
db
y gu
ara
e nte
ris
tho eo
au ra
c
ss
ce
le
un
pt
♦ When making repairs, remove oil from connection and hose
an
d
itte
y li
ends.
rm
ab
pe
ility
ot
wit
, is n
h re
essary.
hole
spec
es, in part or in w
1.3 Installing hose connections with con‐
t to the co
nector couplings
rrectness of i
Caution
l purpos
The seal in the connector coupling may be damaged if the se‐
curing clip is in the locked position when fitting the connector.
nform
ercia
This can cause leakage. Observe installation instructions.
m
a
com
tion in
r
te o
Removing
thi
s
iva
do
r
– Release connector coupling by pulling out retaining clip

rp
cum
fo
-arrow-. Separate hose/pipe without tools.
en
ng
t.
yi Co
op
Installing C py
t. rig
gh ht
yri by
– If renewed, place seal in groove of charge air hose. Ensure op Vo
by c lksw
the seal is correctly seated in the groove. cted agen
Prote AG.
– Lubricate sealing surface and seal with oil.

– Bring retaining clip to release position -1-.
– Push charge air hose into coupling to stop.
– Bring securing clip to locking position -2- and then push charge
air hose again.
– Check if connector coupling seats correctly and is properly
engaged by pulling hose.
126 Rep. gr.21 - Turbocharging/supercharging

Touareg 2003 ➤
1.4 Assembly overview - turbocharger
Caution
When a mechanical fault is found on the turbocharger, e.g. a

destroyed compressor impeller, it is not only sufficient to renew
the turbocharger. To prevent this from causing further damage,
perform the following repairs:
♦ Check air filter housing, air filter element and intake hoses
for soiling.
♦ Check complete charged air routing and charge air cooler
for foreign objects.
If foreign objects are found in the charge air system, the charg‐
ed air routing must be cleaned and the charge air cooler must
be renewed, if necessary.
Note
♦ All hose connections are secured.

♦ Charge air system must be free of leaks.
♦ Renew self-locking nuts.
♦ Before screwing on oil supply line, fill turbocharger at connec‐
tion with engine oil.
♦ After installing turbocharger run engine for approx. 1 minute
at idling speed, do not rev engine. This ensures that the tur‐
bocharger is adequately lubricated.
♦ The components shown
wage here corresponddoto
n AG. Volkswagen AG
e cylinder bank 2.
They are mirror
by
Vimages
olks of the components of cylinder
s no
t gu bank 1.
ara
ed nte
ris
ho e
Observe safety
au
t precautions ⇒ page 125 . or
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
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
1 - To connecting pipe
❑ ⇒ Item 11 (page 155)
2 - Exhaust manifold
❑ Assembly overview - ex‐
haust manifold
⇒ page 149
3 - Temperature sender before
turbocharger , 45 Nm
Cylinder bank 1
❑ Exhaust gas tempera‐
ture sender 1 -G235-
Cylinder bank 2 olkswage es n
ot g
byV ua
❑ Exhaust gas tempera‐ ir se
d ran
tee
ture sender 1 for bank 2 utho
or
-G236- ss
a ac
ce
le
un
4 - Securing clamp, 8 Nm
pt
an
d
itte
y li
5 - Turbocharger
rm
ab
pe
ility
❑ Can be renewed only
ot
wit
with engine removed
, is n
h re
⇒ page 3 , Removing
hole
spec
and installing engine
es, in part or in w
❑ Tighten oil supply line to
t to the co
23 Nm.
❑ When installing, first
rrectness of i
tighten clamp (item 4),
then tighten turbocharg‐
l purpos
er.
6 - To front exhaust pipe with
nform
ercia
catalytic converter.
m
a
com
tion in
r
te o
thi
7 - 40 Nm
s
iva
do
r
8 - Servomotor for turbocharger

rp
cum
fo
en
g
❑ Integral part of turbocharger and cannot be replaced.

n
t.
yi Co
Cop py
Cylinder bank 1
t. rig
gh ht
pyri by
Vo
o
❑ Servomotor of turbocharger 1 -V280-
c by lksw
cted agen
Prote AG.
Cylinder bank 2
❑ Servomotor of turbocharger 2 -V281-
9 - Seal
❑ Renew.
❑ Before installing, check sealing surfaces for soiling and clean if necessary.
10 - 8 Nm
11 - Connecting pipe
12 - To charge air pipe
❑ ⇒ Item 8 (page 129)
13 - Seal

Touareg 2003 ➤
❑ From crankcase breather valve.
1.5 Assembly overview - parts of charge air

cooling
Note
♦ All hose connections are secured.

♦ For assembly use lubricant (water without additive) if neces‐
sary. Do not use lubricants containing oil.
♦ Charge air system must be free of leaks.
♦ Always observe installation instructions when removing and
installing connector couplings ⇒ page 126 .
♦ The components shown here correspond to cylinder bank 2.
They are mirror images of the components of cylinder bank 1.

1 - Air duct
2 - 8 Nm
3 - Spacer
4 - Charge air cooler
❑ To remove, remove
bumper cover ⇒ Gener‐
al body repairs, exterior;
Rep. gr. 63 ; Front gen AG
. Volkswagen AG
does
swa
bumper . yV
olk not
gu b ara
ed
5 - O-ring ho
ris nte
e
ut or
ss
a ac
ce
le
6 - 3 Nm
un
pt
an
d
itte
y li
7 - Charge air pressure sender

rm
ab
with intake air temperature

pe
ility
ot
sender
wit
, is n
h re
Cylinder bank 1
hole
spec
es, in part or in w
❑ Charge air pressure

t to the co
sender -G31- with in‐

take air temperature
sender -G42-
rrectness of i
Cylinder bank 2
l purpos
❑ Charge air pressure

sender 2 -G447- with in‐
nform
ercia
take air temperature

sender 2 -G299-
m
a
com
tio
8 - Charge air pipe

n in
r
te o
thi
9 - Retaining clip
s
iva
do
r
rp

um
fo
ing.
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
129
cted agen
Prote AG.
1. Charge air system with turbocharger
Touareg 2003 ➤
10 - To intake connecting pipe

❑ ⇒ Item 15 (page 155)
11 - Connecting hose
12 - 8 Nm
13 - From connecting pipe.
❑ ⇒ Item 11 (page 128)
1.6 Checking charge air system for leaks

♦ Charge air system tester -V.A.G 1687-

– Remove intake hose -1- from air filter.
– Insert adapter -1687/10- in intake hose -1- and secure with
clip.
AG. Volkswagen AG d
agen oes
Prepare charge air system tester -V.A.G 1687- as follows: Volksw not
gu
by ara
d
rise nte
tho eo
au 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
rrectnes
– Unscrew pressure regulating valve -2- and close valves -3-

s o
and -4-.
cial p
f inform
mer
atio
m
Note
o
n
c
i
or
n thi
e
To turn the pressure regulating valve -2- the knob must be pulled
t
sd
va
upwards.
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 ➤
– Connect charge air system tester -V.A.G 1687- to adapter

-1687/10- as shown.
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
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 compressed air hose -1- (compressed air source) to

charge air system tester -V.A.G 1687- .
nf
ercia
orm
m
atio
m
Note
o
n in
or c
thi
e
If there is water in the sight glass, drain at water drain screw -6-.
t
sd
iva
o
r
rp
cu
o
m
f
– Open valve -3-.

en
ng
t.
yi Co
op
– Adjust pressure to 0.5 bar with pressure regulating valve -2-.
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted
Caution
agen
Prote AG.
The pressure must not exceed 0.5 bar! If the pressure is too
high this can cause damage to the engine.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary readjust pressure to 0.5 bar.
– Check the charge air system for leaks by hearing, touching,
with commercially available leak detector spray or using ultra‐
sonic tester -V.A.G 1842- .
Note
♦ Slight leaks on the intake side of turbocharger are permissible,

as the intake hoses are not designed for high-pressure.
♦ A small amount of air escapes through the valves and enters
the engine. Therefore a holding pressure test is not possible.
♦ How to use the ultrasonic tester -V.A.G 1842- ⇒ operating
instructions .
♦ If leaks occur, when doing any repair work observe notes for
charge air system ⇒ page 126 .
♦ Depressurise test circuit by detaching coupling from adapter
-1687/10- before removing adapter.

Touareg 2003 ➤
23 – Mixture preparation - injection

1 Repairing diesel direct injection sys‐
tem
Note
The engine control units of the diesel direct injection systemenare . Volkswagen AG
g AG
equipped with a fault memory. The fault memory mustolkbe swaread does
not
before and after repairs or adjustments ⇒ page 145 d b ; Reading
y V gu
ara
and clearing fault memory of engine control unitho
rise. nte
e t or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
Removing and installing intake manifold ⇒ page 133 .
ility
ot p
wit
, is n
Assembly overview - intake connecting pipe ⇒ page 134 .
h re
hole
Assembly overview - air filter ⇒ page 136 .
spec
es, in part or in w
t to the co
Assembly overview - unit injector ⇒ page 138
Removing and installing unit injector ⇒ page 139
rrectness of i
Check and adjust position of pump plungers in unit injectors
⇒ page 141
l purpos
Renewing O-rings for unit injectors ⇒ page 143
nf
ercia
orm
m
atio
om
n in
c
Caution
or
thi
te
sd
iva
o
r
rp
cu
o

f
en
ng
t.
tions:
yi Co
Cop py
t. rig
gh ht
yri by
cop Vo
by lksw
cted
agen
Prote AG.

Observe following if test and measuring instruments are required

during a road test:
♦ Test and measuring instruments must always be secured to
rear seat and operated by a second person from this location.
If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there is a
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
WARNING
Secure fault reader to rear seat and operate from this position.
To prevent injuries to persons and/or damage to the injection and

glow plug system, the following must be noted:
132 Rep. gr.23 - Mixture preparation - injection

AG. Volkswagen AG d Touareg 2003 ➤
agen oes
olksw 10-cylinder diesel engine not Volkswagen R GmbH - Edition 09.2012
y V gu
d b ara
rise nte
♦ The ignition mustuthbe
o switched off before connecting or dis‐ eo
ra
connecting injection
ss a or glow plug system wiring or tester ca‐ c
bles.
ce
e
nl
pt
du
an
♦ Before disconnecting battery, obtain radio code for radios with itte
y li
anti-theft coding.
erm
ab
ility
ot p
♦ Disconnecting and reconnecting the battery must only be un‐
wit
, is n
dertaken when the ignition is switched off, otherwise the en‐
h re
hole
gine control units could be damaged.
spec
es, in part or in w
t to the co
When working on the fuel supply and injection system, observe
the following “7 rules” for cleanliness:
rrectness of i
l purpos
connecting.
nform
ercia
lint-free cloths.
m
at
om
i
on
c
in t
or
his
ate
do
priv
c
um
for
en
g
n
t.
yi Co
tool boxes etc.). t. Cop py
rig
gh ht
yri
♦ Existing transport and protective packaging and sealing caps p by
co Vo
by lksw
cted agen
Prote AG.
essary.
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
1.3 Removing and installing intake manifold

Prerequisites:
• Bypass flap with exhaust gas recirculation cooler removed
⇒ page 156
• Upper part of oil filter housing removed ⇒ page 74 , Assembly
overview - oil filter housing.
Note

♦ In order to remove the intake manifold without removing the
fuel rail, the bolts of the intake manifold must be taken out
completely.
1. Repairing diesel direct injection system 133

Touareg 2003 ➤
1 - Cylinder head
and installing cylinder
heads.
2 - Gasket
❑ Renew.
3 - Intake manifold
Assembly overview - intake
connecting pipe
❑ ⇒ page 134
4 - 20 Nm
5 - Fuel rail
AG. Volkswagen AG d
agen oes
ksw
6 - 8 Nm + 1/4 turn (90°) further by Vol not
gu
d ara
❑ Renew. rise nte
tho eo
au ra
7 - Seal ss c
ce
le
❑ Renew.
un
pt
an
d
itte
y li
8 - Connection
rm
ab
pe
ility
❑ Long.
ot
wit
, is n
❑ For supply flow
h re
hole
❑ Remove and install with
spec
pliers -VAS 6275-
es, in part or in w
t to the co
9 - Connection
❑ Short.
rrectness of i
❑ For return flow
l purpos
❑ Remove and install with

pliers -VAS 6275-
nform
ercia
10 - Glow plug , 15 Nm
m
a
Cylinder bank 1.
com
tion in
r
❑ Glow plugs 1…5 -Q10...Q14-

te o
thi
s
iva
do
Cylinder bank 2.
r
rp
cum
fo
en
❑ Glow plugs 6…10 -Q15...Q19-

ng
t.
yi Co
op py
Removing and installing, checking: t. C rig
gh ht
pyri by
❑ ⇒ page 162
co Vo
by lksw
cted agen
Prote AG.
1.4 Assembly overview - intake connecting

pipe
Note
♦ The intake manifold flap of the intake connecting pipe is closed

for approx. 3 seconds when stopping engine and then opens
again. This reduces the stop jolt.

Touareg 2003 ➤
1 - Bracket for test connection

❑ Cylinder bank 1
❑ Cylinder bank 2
2 - 8 Nm
3 - Seal
❑ Renew.
❑ Before installing, check
sealing surfaces for soil‐
ing and clean if neces‐
sary.
4 - Gasket
❑ Renew.
tion.
AG. Volkswagen AG d
5 - To bypass flap. ksw
agen oes
not
Vol
❑ ⇒ Item 16 (page 158) d by gu
ara
rise nte
o
6 - Connecting pipe auth eo
ra
ss c
7 - 20 Nm
ce
e
nl
pt
du
an
8 - From bypass flap
itte
y li
erm
ab
❑ ⇒ Item 17 (page 158)
ility
ot p
wit
9 - Retainer
, is n
h re
hole
For connecting pipe
spec
⇒ Item 10 (page 135) .
es, in part or in w
t to the co
rrectness of i
12 - 8 Nm
l purpos
13 - From exhaust manifold
nf
ercia
❑ ⇒ Item 2 (page 149)

orm
m
14 - Intake connecting pipe with intake manifold flap motor atio

om
n in
c
Cylinder bank 1
or
thi
te
sd
a
❑ Intake manifold flap motor -V157-

iv
o
r
rp
cu
o
Cylinder bank 2
f
en
ng
t.
yi Co
op
❑ Intake manifold flap 2 motor -V275-
C py
t. rig
gh ht
yri by
15 - Exhaust gas recirculation valve with exhaust gas recirculation potentiometer cop Vo
by lksw
cted agen
Prote
Cylinder bank 1
AG.
❑ Exhaust gas recirculation valve -N18- with exhaust gas recirculation potentiometer -G212-
Cylinder bank 2
❑ Exhaust gas recirculation valve 2 -N213- with exhaust gas recirculation potentiometer 2 -G466-
If the exhaust gas recirculation valve with exhaust gas recirculation potentiometer is renewed, the following
steps must be carried out:
– Switch ignition on and then off again.
– Then wait one minute for the control unit to run down.
– Start engine and run at idling speed for at least one minute.

Touareg 2003 ➤
– Then read fault memory of engine control unit ⇒ page 145 , Reading and clearing fault memory of engine
control unit
If a fault is stored in the fault memory:
– Repeat the work procedure.

AG. Volkswagen AG d
agen oes
lksw not
16 - Intake manifold by Vo gu
ara
d
❑ Removing and installing ⇒ hpagerise 133 . nte
t o eo
au ra
ss c
ce
e
nl
pt
du
1.5 Assembly overview - air filter
an
itte
y li
erm
ab
ility
ot p
wit
Note
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Connecting line to air suspension compressor ⇒ page 138 .
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
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
1 - Air filter lower part

2 - Filter element
3 - Air filter upper part
4 - Securing pins
⇒ page 137 .
5 - O-ring
6 - Intake manifold
7 - Air mass meter
Cylinder bank 1
❑ Air mass meter -G70-
Cylinder bank 2
❑ Air mass meter 2 -G246- AG. Volkswagen AG d
agen oes
8 - 6 Nm olksw not
V gu
d by ara
e nte
9 - Spring-type clip horis
eo
ut ra
❑ Remove and install us‐ ss a c
ing spring-type clip pli‐
ce
le
un
pt
ers -VAS 5024 A- .
an
d
itte
y li
erm
10 - Adapter
ab
ility
ot p
wit
is n
h re
ole,
12 - Connecting hose
spec
13 - To turbocharger.
t to the co
rrectness o
cial p
f in
Removing and installing securing pins
form
mer
atio
Removing
om
n
c
i
or
– Turn securing pins using appropriate bit until markings -A- on n thi
e
pins and -B- on housing align.

t
sd
iva
o
pr
cum
– Pull out pins upwards.

r
fo
en
ng
t.
yi Co
Installing t. Cop py
rig
gh ht
– Press pins into bores to stop and turn them by 180° using an yri
p by
o Vo
appropriate bit.
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
Connecting line to air suspension compressor

– Lever green locking ring -1- off line flange -3- using a screw‐
driver -C-.
– Push locking sleeve -2- in -direction of arrow- and pull line
-B- off air filter connection -A-.
1.6 Assembly overview - unit injector

Note
Always renew seals and O-rings.
1 - 20 Nm + 1/4 turn (90°) fur‐

ther
❑ Renew.
2 - Lock nut, 30 Nm agen
AG. Volkswagen AG d
oes
olksw not
V gu
3 - Adjuster screw d by ara
rise nte
❑ Renew each timeutit is
ho eo
ra
separated fromssball
a
pin c
ce
e
nl
4 - Rocker arm shaft

pt
du
an
itte
y li
❑ With rocker arms

erm
ab

ility
ot p
⇒ page 139 , removing

wit
, is n
h re
and installing unit injec‐

hole
tor
spec
es, in part or in w
5 - Tensioning block
t to the co
6 - 12 Nm + 3/4 turn (270°) fur‐

ther
rrectness of i
❑ Renew.
l purpos
7 - Unit injector
nform

ercia
⇒ page 139 .
m
at
om
❑ Renew ball stud each

ion
c
time it is separated from

in t
or
his
adjuster screw.
ate
do
priv
8 - O-ring
um
for
en
g

n
t.
yi Co
Cop py
9 - Heat shield seal
t. rig
gh ht
pyri by
❑ Renew.
co Vo
by lksw
cted agen
Prote AG.
10 - Circlip

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ut
ho eo
ra
Touareg 2003 ➤
a
ss 10-cylinder diesel engine cVolkswagen R GmbH - Edition 09.2012
ce
le
un
pt
1.7 Removing and installing unit injector
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
equipment required
ole,
spec
♦ Universal dial gauge brack‐
t to the co
et -VW 387-
♦ Socket XZN 10 -3410-
rrectne
♦ Special wrench, long reach
XZN 6 -T10054-
ss
♦ Puller -T10055-
o
cial p
f inform
mer
-V.A.G 1331-
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.
Not illustrated:
♦ Gauge -T10210-
♦ Dial gauge
1.7.1 Removing
cylinder head.
– Turn crankshaft until the cam pair point evenly upwards for the
unit injector which is to be removed.

Touareg 2003 ➤
– Loosen lock nut of adjustment screw -1- and screw the screw
out until the relevant rocker arm lies against the plunger spring
of the unit injector.
– Remove rocker arm securing bolts -2- (from outwards to in‐
wards) with socket XZN 10 -3410- and remove rocker arm
shaft.
– Remove tensioning block securing bolt -3- with special
wrench, long reach -T10054- and remove the block.
– Lever connector off unit injector using a screwdriver. Support
opposite side of connector with light finger pressure to prevent
canting.
– Insert puller -T10055- in slot on side of unit injector in place of

tensioning block.
– Pull unit injector out of cylinder head seat with gentle upward
taps.
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
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
1.7.2 Installing
l purpos
Note
nform
mercia
at
♦ If a new unit injector is installed, the appropriate adjustment
om
ion
screw in the rocker arm must also be renewed.
c
in t
or
his
te
♦ Each time work is performed which requires adjustment of the

a
do
riv
unit injector, the adjustment screw in the rocker arm and also
p
cum
or
the unit injector ball stud must be renewed.

f
en
ng
t.
yi Co
op
♦ New unit injectors are supplied with O-rings and heat shield
C py
ht. rig
seal. rig ht
py by
co Vo
by lksw
cted agen
Prote
– Heat insulating seal and O-rings must be renewed if old unit
AG.
injector is reused ⇒ page 143 .

– Check that the three O-rings and the heat shield seal along
with securing clip are seated correctly before installing unit in‐
jector.
Note
The seals must not be twisted.
– Oil the seals and fit the unit injector into the seat in cylinder
head with great care.

Touareg 2003 ➤
– Push the unit injector evenly into the cylinder head onto its limit
stop.
– Insert tensioning block in slot on side of unit injector.
Note
If the unit injector is not at right angles to the tensioning block the
securing bolt may loosen and this can damage the unit injector or
the cylinder head.
Therefore, align unit injector as follows:

– Screw new securing bolt into tensioning block only so far that
unit injector can still be turned easily.
– Position gauge -T10210- between mounting bracket and unit
injector as shown.
– Turn unit injector by hand against gauge .
– Align unit injector, if necessary, and tighten securing bolt as
follows: 12 Nm + 3/4 turn (270°) (further turning can be done
in several stages).
– Fit rocker arm shaft and tighten new securing bolts as follows.
. Volkswagen AG
gen AG does
– Tighten inner and then both outer bolts hand-tight. Then tight‐
olks
wa not
1 yV gu
en, in same sequence, to 20 Nm + /4 turn (90°) further.
ise
d b ara
nte
r
ho eo
aut ra
ss c
ce
e
– Fit dial gauge onto adjuster screw of unit injector as shown in

nl
pt
du
illustration.
an
itte
y li
erm
ab
– Turn the crankshaft in engine direction of rotation until the roll‐
ility
ot p
er of the rocker arm is positioned on the peak of the drive cam.
wit
, is n
h re
♦ Roller side -arrow A- positioned at highest point.
hole
spec
♦ Dial gauge -arrow B- positioned at lowest point.
es, in part or in w
t to the co
– Remove dial gauge .
– Now turn adjustment screw into rocker arm against spring
rrectness of i
pressure of unit injector until a firm resistance is felt (unit in‐
jector positioned at limit stop).
l purpos
– Turn adjustment screw 180° back off stop.

nform
ercia
– Hold adjuster screw in this position and tighten lock nut to 30

m
at
Nm.
om
ion
c
in t
r
– Reconnect connector to unit injector and install cylinder head

o
his
te
cover and acoustic cover.

a
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.8 Checking and adjusting position of pump plungers in unit injectors

Touareg 2003 ➤
. Volkswagen AG
swa
gen AG does
k not
Vol gu
d by ara
Special tools and workshop ris
e nte
equipment required utho eo
ra
a c
ss
♦ Clamp -T10199-
ce
e
nl
pt
du
an
♦ Bit XZN 16 -T10198-
itte
y li
erm
ab
♦ Crankshaft clamp -T10195-
ility
ot p
wit
, is n
♦ Socket -T10336-
h re
hole
spec
♦ Universal dial gauge brack‐
es, in part or in w
et -VW 387-
t to the co
♦ Dial gauge set, 4-part -VAS
6341-
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.
Prerequisites:
• Engine removed
Procedure
Note
Measurement and adjustment for cylinder bank 1 must be carried

out on cylinder 1. For cylinder bank 2 the engine must be turned
360° starting from TDC and measurement and adjustment must
be carried out on cylinder 7.

cylinder head.
– Remove fuel pump or tandem pump of respective cylinder
head ⇒ page 116 .
– Turn engine to TDC using counter-hold tool -T10172-
⇒ page 49 and remove vibration damper ⇒ page 30 .
– Fit crankshaft clamp -T10195- .

Touareg 2003 ➤
– Fit dial gauge from dial gauge set -VAS 6341- onto spring re‐
tainer of unit injector with universal dial gauge bracket -VW
387- and approx. 1 mm of pretension, as shown.
– Pull out the crankshaft clamp -T10195- pin and turn the engine
in direction opposite to normal direction of rotation until the
pointer of the dial gauge no longer moves.
– Set dial gauge to “0”.

– Now turn the engine in the normal direction of rotation to TDC
and insert the crankshaft clamping pin again.
– Read the value on the dial gauge.
Specified values
♦ 4.95 mm ± 0.1 mm
If specification is attained:
– Assemble the engine.
If the specification is not attained:
– Attach clamping device -T10199- to camshaft gear and tighten
bolts to 40 Nm .
– Undo bolt securing camshaft -B-, using socket -T10198- .

– Now, turn the camshaft with the help of the socket -T10336-
until the specification value is achieved.
G. Volkswagen AG d
– Tighten camshaft gear to level II ⇒ page 49 and repeat the lkswagen A oes
not
measurement. by
Vo gu
ara
ed nte
ris
– If the specification is now attained, retighten bolts of ucamshaft
tho eo
ra
gear to level III ⇒ page 49 . ss a c
ce
e
nl
– Reinstall cylinder head cover ⇒ page 44 and acoustic cover.

pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
1.9 Renewing O-rings for unit injectors
hole
spec
es, in part or in w

t to the co
♦ Assembly sleeves -T10056-

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
Removing
t. rig
gh ht
pyri by
Vo
o
by c
– Remove unit injector ⇒ page 139 .
lksw
cted agen
Prote AG.

Touareg 2003 ➤
– Lever old O-rings very carefully out of unit injector.

– Pay particular attention to ensure that seat of O-ring is not
damaged by burrs.
Installing
Note
♦ Always use the assembly sleeves -T10056- to fit the O-rings.

AG. Volkswagen
There is a danger of damaging the O-rings waifgethe sleeves are does n
n AG
olks
not used. db
y V ot g
ua
r e an
ris tee
♦ Gradual introduction of O-rings
ut without different coloured
ho or
markings. Note the correct sallocation
sa of O-rings to grooves: ac
the thickness of the rings reduces towards injector nozzle:
ce
le
un
pt
an
d
♦ Prevent O-rings from rolling when sliding them on. The O-rings
itte
y li
must not be twisted in their seats in unit injector.
rm
ab
pe
ility
ot
wit
, is n
– Pull heat shield seal off together with securing clip.
h re
hole
spec
– Clean seating surfaces for O-rings on unit injector very care‐
es, in part or in w
fully.
t to the co
– Place assembly sleeve -T10056/1- onto stop on unit injector.
– Push the upper, thicker O-ring carefully onto assembly sleeve
rrectness of i
and into seat on unit injector.
l purpos
– Remove assembly sleeve.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
– Place assembly sleeve -T10056/2- onto stop on unit injector. C py
t. rig
gh ht
yri by
– Slide the middle, thinner O-ring carefully onto assembly sleeve cop Vo
by lksw
and into seat on unit injector. cted agen
Prote AG.
– Place assembly sleeve -T10056/3- onto stop on unit injector.

– Push the lower O-ring carefully onto the assembly sleeve and
into the seat of the unit injector.
– Fit new heat shield seal together with securing clip.
– Install unit injector ⇒ page 139 .

Touareg 2003 ➤
2 Engine control units
Note
The engine control units of the diesel direct injection system are
equipped with a fault memory. The fault memory must be read
before and after repairs or adjustments ⇒ page 145 ; Reading
and clearing fault memory of engine control unit .

Reading and clearing fault memory of engine control units
⇒ page 145 .
Adapting functions and components ⇒ page 146 .
Removing and installing engine control units ⇒ page 147 .
2.1 Reading and clearing fault memory of

engine control units
♦ Vehicle diagnosis, testing and information system -VAS 5051
A- with diagnosis lead
AG. Volkswagen AG d
agen oes
olksw not
yV gu
Procedure ise d b ara
nte
or eo
h
Connect
s autVehicle diagnosis, testing and information system ra
c -VAS
5051 A-
s as follows:
ce
e
nl
pt
du

an
itte
y li

erm
ab
ility
ot p

wit
, is n
h re
Only when engine does not start:

hole
spec
– Switch on ignition.
es, in part or in w
t to the co
Selecting operating mode:

– Press button on display for “Vehicle self-diagnosis”.
rrectness of i
Selecting vehicle system:

l purpos
– Press button “01 - Engine electronics” on display to read en‐

gine control unit -J623- for cylinder bank 1 or button “11 -
nform
ercia
Engine electronics 2” to read engine control unit 2 -J624- for

cylinder bank 2.
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
145
cted agen
Prote
2. Engine control units
AG.
Touareg 2003 ➤
The engine control unit identification with code -2- as well as

chassis number and immobiliser identification number will be in‐
dicated in the centre section of the display.
Note
A print-out can be made if required. Press the Print button.
Select diagnostic function:

– Press “02 - Read fault memory” button on display.
– If no fault is stored in engine control unit , “0 fault(s) detected”
is displayed.
– If faults are stored in the engine control unit , these are shown
one below the other on the display.
– Press ← button.
– Press “05 - Clear fault memory” button on display.
– Select “06-End output” function.
2.2 Adapting functions and components

♦ Vehicle diagnosis, testing and information
n AGsystem
. Volkswa-VAS
gen AG 5051
A- with diagnosis lead wage does
olks not
yV gu
db ara
rise nte
tho eo
s au ra
c
s
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
Procedure
rrectness of i
Connect Vehicle diagnosis, testing and information system -VAS

5051 A- as follows:
l purpos

nf
ercia
orm
Select “Guided fault finding” in the Vehicle diagnosis, testing and

m
atio
m
information system -VAS 5051 A- .

o
n in
or c
When all control units have been read:

thi
te
sd
iva
o
r
– Press “GoTo” button.

rp
cu
o
m
f
en
ng
– Select “Function/component selection”.

t.
yi Co
Cop py
t.
– Select “Drive”.
rig
gh ht
pyri by
Vo
co
– Select “Engine code”.
by lksw
cted agen
Prote AG.
– Select “01 - Systems capable of self-diagnosis”.
– Select “engine control”.
– Select “Functions”.
– Select “Function or component”.

Touareg 2003 ➤
2.3 Removing and installing engine control

units
Caution
This vehicle is equipped with two engine control units that are
visually indistinguishable. The fault memory is unable to detect
whether an engine control unit has been installed in the wrong
place. It is therefore advisable to mark the engine control units
as well as the associated connectors in order to prevent a unit
from being installed in the wrong place.
– First read control unit identification and thereby the coding of

the installed engine control units before removing the engine
control units ⇒ page 145 ; Reading and clearing fault memory
of engine control units .
Procedure
– Switch off ignition.
– Remove right plenum chamber cover -D-.
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
rm
ab
pe
ility
ot
wit
, is n
h re
– Release and disconnect connectors of engine control unit -1-

hole
and/or -2-.
spec
es, in part or in w
t to the co
– Remove old control unit and insert new control unit.

– Check the previous coding and code the new control unit
⇒ page 146 , Adapting functions and components.
rrectness of i
– Then read the fault memory of the new engine control unit and
l purpos
if necessary, clear the fault memory ⇒ page 145 , Reading and

clearing fault memory of engine control units .
nform
ercia
– Carry out a road test.

m
a
com
– Read fault memory of engine control unit again.

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
o
by c lksw
cted agen
Prote AG.
2. Engine control units 147

Touareg 2003 ➤
26 – Exhaust system lksw

agen
AG. Volkswagen AG d
oes
not
o
byV gu
ara
ed
1 Removing and installing parts of ex‐ ris nte
ho eo
ut ra
haust system s a c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
♦ Lambda probe open ring spanner set -3337-
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
Caution
or
his
ate
do
riv

p
cum
or

f
en
ng
t.
yi
tions:
Co
Cop py
ht. rig
♦ Route all the various lines (e.g. for fuel, hydraulics, addi‐ rig ht
py by
co Vo
by lksw
cted
agen
Prote AG.

Note
♦ After working on the exhaust system, ensure that the system

is not under stress and that there is sufficient clearance to the
bodywork. If necessary, loosen double and single clamps and
align silencer and exhaust pipe so that sufficient clearance is
maintained to the bodywork and the support rings are evenly
loaded.
♦ Renew self-locking nuts.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and dam‐
age the lambda probe .
148 Rep. gr.26 - Exhaust system

Touareg 2003 ➤
Assembly overview - exhaust manifold ⇒ page 149

Assembly overview - front exhaust pipe with catalytic converter,
particulate filter and attachments ⇒ page 150
Assembly overview - silencers with mountings ⇒ page 152
1.1 Assembly
lksw
overview
agen - aexhaust
AG. Volksw gen AG
does manifold
n
o ot g
yV ua
edb ran
ris tee
Note tho or
au ac
ss
ce
e

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
1 - Cylinder head
h re
hole
spec
es, in part or in w
❑ Can be renewed only
t to the co
with engine removed
and installing engine
rrectness of i
l purpos
turbocharger , 45 Nm
Cylinder bank 1
nform
ercia

m
at
om
ture sender 1 -G235- ion

c
in t
or
Cylinder bank 2
his
ate
do
riv

p
cum
or
ture sender 1 for bank 2

f
en
ng
t.
yi
-G236-
Co
Cop py
ht. rig
4 - To turbocharger. rig ht
py by
co Vo
lksw
❑ ⇒ Item 5 (page 128)
by
cted agen
Prote AG.
5 - Spacer
6 - 23 Nm
❑ Renew.
7 - 4.5 Nm
8 - Heat shield
9 - To connecting pipe
❑ ⇒ Item 11 (page 155)
10 - Gasket
❑ Renew.
tion.
1. Removing and installing parts of exhaust system 149

Touareg 2003 ➤
Tightening sequence for securing nuts of exhaust manifold. Volkswa

AG. gen AG
agen does
– Tighten securing nuts in the sequence shown
Volin illustration:
ksw not
gu
by ara
ed
♦ Pre-tighten all nuts to 5 Nm. oris nte
eo
th
au ra
♦ Then tighten all nuts to 23 Nm. ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.2 Assembly overview - front exhaust pipe
with catalytic converter, particulate filter
rrectness of i
and attachments
l purpos
Note
nform
mercia
a
com
tio
n in
r
te o
thi
s
iva
do
r
rp
cum
1 - Turbocharger
fo
en
ng
t.
yi
❑ Assembly overview -
Co
Cop py
turbocharger
t. rig
gh ht
yri
⇒ page 127 . p by
co Vo
by lksw
cted agen
2 - Gasket Prote AG.
❑ Renew.
3 - 25 Nm
4 - Lambda probe , 50 Nm
❑ Can only be renewed
with engine removed
⇒ page 3 .
❑ Grease threads only
with high-temperature
paste -G 052 112 A3- ,
high-temperature paste
-G 052 112 A3- must not
get into the slots of
probe body.
❑ To remove use Lambda
probe open ring span‐
ner set -3337- .
Cylinder bank 1
❑ Lambda probe -G39-
Cylinder bank 2
❑ Lambda probe 2 -G108-
particulate filter , 45 Nm
Cylinder bank 1
ture sender 2 for bank 1
-G448-
Cylinder bank 2

Touareg 2003 ➤
❑ Temperature sender 2 before particulate filter -G498-
6 - Pressure line
Cylinder bank 1
❑ To exhaust gas pressure sensor 1 -G450- , fitting location ⇒ page 151 .
Cylinder bank 2
❑ To exhaust gas pressure sensor 2 -G451- , fitting location ⇒ page 151 .
7 - To rear silencer
❑ ⇒ Item 9 (page 152)
8 - Gearbox transverse support
9 - Mounting
10 - Particulate filter
❑ After renewing, adaptation of ash mass comparison must be set to “0” ⇒ Vehicle diagnostic tester.
11 - Front exhaust pipe with catalytic converter
❑ Can be renewed only with engine removed ⇒ page 3 , Removing and installing engine
12 - Bracket AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
Fitting location ofutpressure
ho sensors eo
ra
s a c
1 - Exhaust gas pressure sensor 1 -G450- s
ce
le
un
pt
2 - Exhaust gas pressure sensor 2 -G451-

an
d
itte
y li
rm
ab
3 - Pressure line, see note ⇒ page 151 .

pe
ility
ot
wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co
The pressure lines from the particulate filter to the pressure sen‐
sors G450 and G451 are checked for leaks, for this reason they
must be renewed only as a unit for each cylinder bank. The pres‐
rrectness of i
sure sensors are installed on a bracket above the gearbox and

can only be removed and installed with engine/gearbox assembly
l purpos
removed ⇒ page 3 .
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
1.3 Assembly overview - silencers with mountings
1 - Mounting
❑ On right in direction of
travel.
travel
⇒ Item 10 (page 151) .
3 - Double clamp
travel.
Thread M8:
❑ Tighten evenly to 25 Nm
Thread M10:
❑ On left in direction of
travel
⇒ Item 10 (page 151) . agen
AG. Volkswagen AG d
oes
olksw not
V
5 - Double clamp d by gu
ara
rise nte
❑ On left in direction of utho eo
ra
travel. ss a c
ce
e
nl
Thread M8:
pt
du
an
itte
y li
erm
ab
ility
ot p
Thread M10:
wit
, is n
h re
hole
spec
6 - 25 Nm
es, in part or in w
t to the co
7 - Mounting
❑ On left in direction of
travel. rrectness of i
l purpos
8 - Repair double clamp

❑ On left in direction of travel.
nform
ercia
Thread M8:
m
at
om
ion
c
in t
or
Thread M10:
his
ate
do
riv
p
cum
for
en
g
9 - Rear silencer
n
t.
yi Co
Cop py
10 - Mounting
t. rig
gh ht
yri by
❑ On left in direction of travel. cop Vo
by lksw
cted agen
Prote AG.
11 - Tailpipe
❑ On left in direction of travel.
❑ Centre in bumper cut-out
12 - Dimension -a- = approx. 10 mm
❑ Exhaust system must be cold
❑ Arrow indicates front of vehicle.

AG. Volkswagen AG d
ksw
agen Touareg
oes no 2003 ➤
ol
10-cylinder diesel dengine
by
V Volkswagen R GmbH - Edition t gu 09.2012
ara
e nte
ris
ho eo
13 - Clip s aut ra
c
s
❑ Tighten to 60 Nm
ce
e
nl
pt
du
an
itte
y li
erm
ab
14 - Dimension -a- = approx. 4 mm
ility
ot p
❑ Exhaust system must be cold
wit
, is n
h re
❑ Arrow indicates front of vehicle.
hole
spec
15 - Tailpipe
es, in part or in w
t to the co
❑ On right in direction of travel.
❑ Centre in bumper cut-out
rrectness of i
16 - Repair double clamp l purpos
❑ Double clamp as seen in direction of travel.
nform
ercia

m
at
❑ Double clamp as seen in direction of travel.
om
ion
c
in t
or
his
ate
18 - Double clamp
do
priv
cum
or
❑ Bolt heads must face towards gearbox.

f
en
ng
t.
yi
Co
Cop py
ht. rig
19 - Mounting
rig ht
py by
co Vo
by lksw
❑ On right in direction of travel. Prote
cted AG.
agen

❑ On right in direction of travel.
Thread M8:
Thread M10:
21 - Separating point
❑ For repair cases
❑ Marked by two indentations on circumference of respective exhaust pipe.
❑ As standard, exhaust pipe and rear silencers are installed as a single component. In the event of repair,
the exhaust pipe and rear silencer are supplied individually with a double clamp for connecting the two
components.
❑ Cut through exhaust pipes at right angles at separating point using pneumatic sabre saw -V.A.G 1523A- .

Touareg 2003 ➤
2 Exhaust gas recirculation system

Assembly overview - exhaust gas recirculation ⇒ page 155
Assembly overview - bypass flap with exhaust gas recirculation
Removing and installing bypass flap with exhaust gas recircula‐
tion cooler ⇒ page 158
AG. Volkswagen AG d
Vacuum hose schematic diagram ⇒ page 160
lksw
a.gen oes
not
o
yV gu
db
ara
e nte
ris
tho eo
au ra
c
ss
Caution
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
tions:
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
When working on the exhaust gas recirculation system, pay care‐

ful attention to the following “7 rules” for cleanliness:
m
a
com
tion in

r
te o
connecting.
thi
s
iva
do
r

rp
cum
fo
lint-free cloths.
en
ng
t.
yi Co
op
♦ Carefully cover opened components or seal if repairs cannot C py
ht. rig
be carried out immediately. rig ht
py by
co Vo
by lksw
♦ Install clean components only. Do not remove replacement cted agen
Prote AG.
tool boxes etc.).
♦ When making repairs, remove oil from connection and hose
ends.
essary.

Touareg 2003 ➤
AG. V10-cylinder
olkswagen AG
ddiesel engine Volkswagen R GmbH - Edition 09.2012
agen oes
olksw not
y V gua
db
2.3 Assembly overview - exhaust gas recir‐
ran
rise tee
ho
ut or
ss
a culation ac
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
♦ The exhaust gas recirculation system is controlled by engine
wit
, is n
control unit -J623- and engine control unit 2 -J624- via the ex‐
h re
hole
haust gas recirculation potentiometer -G212- and the exhaust
spec
gas recirculation potentiometer 2 -G466- .
es, in part or in w
t to the co
rrectness of i
♦ Assembly overview - bypass flap with exhaust gas recircula‐
tion cooler ⇒ page 156 .
l purpos
nf
ercia
o
1 - Bracket for test connection
rm
m
atio
❑ Cylinder bank 1:
om
n in
or c
thi
e
❑ Cylinder bank 2:
t
sd
iva
o
r
rp
cu
o
m
f
en
ng
2 - 8 Nm
t.
yi Co
op py
3 - Seal
t. C rig
gh ht
yri by
❑ Renew. cop Vo
by lksw
cted agen
❑ Before installing, check Prote AG.
sealing surfaces for soil‐

ing and clean if neces‐
sary.
4 - Gasket
❑ Renew.
tion.
5 - To bypass flap.
❑ ⇒ Item 16 (page 158)
6 - Connecting pipe
7 - 20 Nm
8 - From bypass flap
❑ ⇒ Item 17 (page 158)
9 - Retainer
For connecting pipe
⇒ Item 10 (page 155) .
12 - 8 Nm
13 - To turbocharger.
❑ ⇒ Item 5 (page 128)
❑ Assembly overview - exhaust manifold ⇒ page 149
15 - Intake connecting pipe with intake manifold flap motor
Cylinder bank 1
2. Exhaust gas recirculation system 155

Touareg 2003 ➤
AG. Volkswagen AG d
agen oes
ksw
❑ Intake manifold flap motor -V157- by Vol not
gu
ara
d
ise nte
Cylinder bank 2 thor eo
au ra
c
❑ Intake manifold flap 2 motor -V275- ss
ce
e
nl
pt
du
16 - Exhaust gas recirculation valve with exhaust gas recirculation potentiometer
an
itte
y li
erm
ab
Cylinder bank 1
ility
ot p
❑ Exhaust gas recirculation valve -N18- (electropneumatic) with exhaust gas recirculation potentiometer -
wit
, is n
h re
G212-
hole
spec
Cylinder bank 2
es, in part or in w
t to the co
❑ Exhaust gas recirculation valve 2 -N213- (electropneumatic) with exhaust gas recirculation potentiometer
2 -G466-
rrectness of i
If the exhaust gas recirculation valve with exhaust gas recirculation potentiometer is renewed, the following
steps must be carried out:
l purpos
– Switch ignition on and then off again.
nf
ercia
o
– Then wait one minute for the control unit to run down.
rm
m
atio
m
– Start engine and run at idling speed for at least one minute.
o
n in
or c
thi
te
– Then read fault memory of engine control unit ⇒ page 145 , Reading and clearing fault memory of engine
sd
iva
o
r
control unit
rp
cu
o
m
f
en
ng
t.
yi
If a fault is stored in the fault memory:
Co
Cop py
t. rig
gh ht
– Repeat the work procedure. yri
p by
co Vo
by lksw
cted agen
17 - Intake manifold
Prote AG.
2.4 Assembly overview - bypass flap with

exhaust gas recirculation cooler
Note
♦ Hose connections are secured with either spring-type or

clamp-type clips.
♦ Always renew clamp-type clips.
♦ Assembly overview - exhaust gas recirculation ⇒ page 155 .

Touareg 2003 ➤
1 - 8 Nm
2 - Vacuum pipe
3 - Vacuum line
ing.
❑ To exhaust gas recircu‐
lation cooler change‐
over valve 2 -N381- .
❑ Vacuum hose schemat‐
ic diagram
⇒ page 160 .
wage
4 - Vacuum hose Vo lks es n
ot g
by ua
❑ For cylinderir se bank 1.
d ran
tee
ho
❑ Checks au for secure seat‐
t or
ac
ing.
s
ce
e
nl
pt
❑ To exhaust gas recircu‐
du
an
itte
lation cooler change‐
y li
erm
ab
over valve -N345-
ility
ot p
❑ Vacuum hose schemat‐
wit
, is n
ic diagram
h re
hole
⇒ page 160 .
spec
es, in part or in w
5 - Coolant hose
❑ Between exhaust gas t to the co
recirculation cooler and
rrectness of i
bypass flap.
l purpos
ing.
6 - 40 Nm
nf
ercia
orm
7 - Coolant hose
m
atio
m

o
n in
or c
ing.
thi
te
sd
a
❑ Remove and install using spring-type clip pliers -VAS 5024 A- .

iv
o
r
rp
cu
o
8 - 5 Nm
f
en
ng
t.
yi Co
op
9 - Coolant pipe
C py
t. rig
gh ht
yri by
10 - Retainer cop Vo
by lksw
cted agen
❑ For coolant pipe ⇒ Item 9 (page 157) . Prote AG.
11 - 20 Nm
12 - Coolant hose
❑ To heat exchanger for heater unit.
13 - Vacuum actuator
❑ Test performance using hand vacuum pump -V.A.G 1390- at vacuum connection.
❑ From exhaust gas recirculation valve -N18- (electropneumatic) with exhaust gas recirculation potenti‐
ometer -G212- ⇒ Item 16 (page 156) .

Touareg 2003 ➤
❑ To exhaust manifold connecting pipe ⇒ Item 11 (page 155) .
❑ From exhaust gas recirculation valve 2 -N213- (electropneumatic) with exhaust gas recirculation poten‐
tiometer 2 -G466- ⇒ Item 16 (page 156) .
❑ To exhaust manifold connecting pipe ⇒ Item 11 (page 155) .
18 - Gasket
❑ Renew.
19 - Bracket
❑ For bypass flap ⇒ Item 20 (page 158) .
❑ Bolted to cylinder block.
20 - Bypass flap
❑ Remove and install together with exhaust gas recirculation cooler ( ⇒ Item 25 (page 158) )
⇒ page 158 .
olkswagen AG
en AG. V
21 - Vacuum actuator olks
wag does
not
yV gu
❑ For cylinder bank 2. ised b ara
nte
or
❑ Test performance using hand vacuum pump
au -V.A.G 1390- at vacuum connection.
th eo
ra
ss c
22 - Ball stud, 3 Nm
ce
le
un
pt
❑ Bolted to alternator flange.
an
d
itte
y li
erm
ab
23 - Rubber bush
ility
ot p
wit
24 - Bracket
is n
h re
ole,
❑ For exhaust gas recirculation cooler ⇒ Item 25 (page 158) .
spec
25 - Exhaust gas recirculation cooler
t to the co
❑ Remove and install together with bypass flap ( ⇒ Item 20 (page 158) ) ⇒ page 158
26 - Coolant hose
rrectne
ss o
cial p
❑ From coolant pipe

f inform
mer
atio
om
2.5 Removing and installing bypass flap

n
c
i
or
n thi
e
with exhaust gas recirculation cooler

t
sd
iva
o
pr
cum
r

fo
en
ng
t.
yi Co
– Separate all necessary connectors of engine wiring harness Cop py
. rig
above engine and lay harness to one side.
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
thor Touareg 2003 e➤
o
u
a engine Volkswagen R GmbH - Edition 09.2012r ac
10-cylinder diesel
ss
ce
e
nl
pt
du
– Remove vacuum pipe -A- together with its brackets from in‐
an
itte
y li
take manifold -arrows-.
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
ercia
– Remove securing pins -arrows- for engine cover panel on both
intake manifolds. m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Unscrew securing bolts -arrows-, open clamps and pull off

coolant hoses -1- and -2-.
– Remove securing bolt for coolant pipe behind bypass flap
-arrow-.
– Pull off coolant hose -2- and lay coolant pipe -1- aside to rear.

Touareg 2003 ➤
– Unscrew respective two securing bolts -arrow- of connecting

pipes for exhaust gas recirculation and remove intake con‐
necting pipes together with intake manifold flap motor -A- and
exhaust gas recirculation valve -B- from both intake manifolds.
– Unscrew securing bolts at connecting pipes for exhaust gas
recirculation in area of cylinder head covers and remove their
brackets ⇒ Item 9 (page 155) .
– Completely loosen securing bolt -arrow- of bypass flap, slightly

olkswagen AG
raise bypass flap at rear and remove bolt. swagen AG. V does
k not
Vol gu
– Pull bypass flap upwards out of brackets.
se
db
y ara
nte
i
th or eo
– Guide out bypass flap together with
au exhaust gas recirculation ra
c
pipes between engine bulkheads and intake manifolds.
s
ce
e
nl
pt
du
Installing
an
itte
y li
erm
ab
Install in reverse order. In the process, note the following:
ility
ot p
– Renew all seals and O-rings.
wit
, is n
h re
hole
– Reconnect all lines, hoses and connectors which were sepa‐
spec
es, in part or in w
t to the co
– Renew hexagon socket head bolt of bracket for vacuum pipe
on intake manifold of cylinder bank 2 by a hexagon bolt of the
same size and strength rating.
rrectness of i
– Filling cooling system ⇒ page 89 .
l purpos
2.6 Vacuum hose schematic diagram

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 ➤
1 - Vacuum actuator
2 - Vacuum actuator
3 - Vacuum pipe
4 - Exhaust gas recirculation AG. Volkswagen AG d
cooler changeover valve - agen oes
olksw not
V
N345- ed by gu
ara
ris nte
❑ For cylinder bank 1. ut
ho eo
ra
a
❑ Fitting location: in rear ss c
ce
le
right wheel housing.
un
pt
an
d
itte
5 - Exhaust gas recirculation
y li
rm
ab
cooler changeover valve 2 -
pe
ility
N381-
ot
wit
, is n
h re
hole
spec
❑ Fitting location: in front
es, in part or in w
right wheel housing.
t to the co
6 - Tandem pump
❑ Fitting location: cylinder
rrectness of i
bank 1
l purpos
❑ For fuel and vacuum

supply.
nform
mercia
7 - From brake servo
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
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
28 – Glow plug system

1 Glow plugs byV
olkswage es n
ot g
ua
ed ran
Removing, installing and checkingthor glow plugs ⇒ page 162 .
is tee
or
au ac
1.1 Removing, installing and checking glow ss
ce
le
un
pt
plugs
an
d
itte
y li
rm
ab
pe
ility
ot
1.1.1 Visual features of ceramic glow plugs
wit
, is n
h re
hole
spec
es, in part or in w
Caution
t to the co
Ceramic glow plugs are sensitive to knocks and bending. For
this reason a glow plug which has dropped from a small height
rrectness of i
(approx. 2 cm) must not be used, even if there is no obvious
damage. It is absolutely necessary to follow the installation in‐
l purpos
structions! Otherwise the heater pin of the glow plug can break
and cause engine damage.
nform
mercia
a
com
t
Visual features of ceramic glow plugs
ion in
r
te o
A - Ceramic glow plugs, phase step on top (see enlargement),
thi
s
iva
colour-coded white -arrow-
do
r
rp
cum
fo
B - Metal glow plug, colour-coded green -arrow- en

ng
t.
yi Co
op
Removing, installing and checking ceramic glow plugs C py
t. rig
⇒ page 162 .
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.1.2 Removing, installing and checking ceramic glow plugs
162 Rep. gr.28 - Glow plug system

gen AG
. Volkswagen AG
does Touareg 2003 ➤
swa
10-cylinder diesel
y Volk engine Volkswagen R GmbH
not
gua
- Edition 09.2012
db ran
rise tee
Special tools and workshop aut
ho or
ac
equipment required ss
ce
le
un
♦ Jointed spanner -3220-
pt
an
d
itte
y li
rm
ab
pe
-V.A.G 1331-
ility
ot
wit
, is n
♦ Hand-held multimeter -
h re
hole
V.A.G 1526 A-
spec
♦ Auxiliary measuring set - es, in part or in w
t to the co
V.A.G 1594 C-
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.
Not illustrated:
♦ Commercially available rubber hose with 3 mm inside diame‐
ter
Test prerequisites
• Engine is cold.
• Ignition is switched off.
1. Glow plugs 163

Touareg 2003 ➤
Removing
Note
♦ Observe optical characteristics of ceramic glow plugs

⇒ page 162 . n AG. Volkswagen AG do
kswage es n
♦ Do not cant ceramic glow plugs by Vwhen removing and installing. t gua
ol o
Remove any componentsorhindering
ise
d
assembly. ran
tee
th or
au ac
s
– Remove upper part of oil filter housing ⇒ page 74 .
s
ce
e
nl
pt
du
– Remove coolant connection ⇒ page 93 .
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Remove connector -A- off ceramic glow plugs using assembly
hole
tool -T10410- .
spec
es, in part or in w
t to the co
– Remove ceramic glow plugs using U/J extension and socket,
10 mm -3220- .
Installing
rrectness of i
l purpos
Note
nform
ercia
♦ Do not oil or grease thread of cylinder head bore or of ceramic

glow plugs.
m
at
om
ion
c
♦ Before installing, bore in cylinder head and threads must be

in t
or
completely cleaned of all deposits.

his
ate
do
priv
cum
or
– Fit a commercially available rubber hose with 3 mm inside di‐

f
en
ng
t.
ameter onto the glow plug and then screw the glow plug as far
yi Co
op
as possible into the cylinder head.
C py
t. rig
gh ht
yri by
– Then, tighten ceramic glow plugs to specified torque of 15 Nm
cop Vo
by lksw
cted
using U/J extension and socket, 10 mm -3220- .
agen
Prote AG.
Caution
After installing and before the engine is started, perform a re‐

sistance test on all ceramic glow plugs when engine is cold.
♦ Specification: max. 1.0 Ω

– If the specification is exceeded, renew the defective ceramic
glow plug.
Note
If the defective ceramic glow plug is broken, remove all fragments

from the engine, otherwise these can cause damage to the en‐
gine.
164 Rep. gr.28 - Glow plug system

Touareg 2003 ➤
– Apply connectors -A- for glow plugs using assembly tool -

AG. Volkswagen AG d
T10410- . Ensure they engage correctly. lkswagen oes
n o ot g
yV ua
– Install bypass flap together with exhaust
ris
ed
b
gas recirculation ran
tee
cooler ⇒ page 158 . utho
or
sa ac
– Install coolant connection ⇒ page
s
93 .
ce
e
nl
pt
du
– Install upper part of oil filter housing ⇒ page 74 .
an
itte
y li
erm
ab
– Filling cooling system ⇒ page 89 .
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
o
by c lksw
cted agen
Prote AG.
1. Glow plugs 165

K0058962920-10-Cylinder Diesel Engine Volkswagen R GMBH

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

K0058962920-10-Cylinder Diesel Engine Volkswagen R GMBH

Uploaded by

Copyright:

Available Formats

Service

Service Department. Technical Information

matter of course, be observed.

Copyright © 2015 Volkswagen AG, Wolfsburg K0058962920

1.4 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.1 Assembly overview - components in the V space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.3 Removing and installing gear train assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.5 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3.2 Assembly overview - oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

3.4 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

1.1 Assembly overview - radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

1.3 Parts of cooling system - body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

1.5 Parts of alternator and fuel cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . tion in 84

1.7 Assembly overview - thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

1.8 Assembly overview - coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

1.3 Installing hose connections with connector couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

1.1 Assembly overview - exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

1.3 Assembly overview - silencers with mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

2.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

2.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

2.6 Vacuum hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

1 Glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

1.1 Removing, installing and checking glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

The engine number consists of up to nine characters (alphanu‐

meric). The first part (maximum 3 characters) makes up the

“engine code”, and the second part (6 characters), the “serial

number”. If more than 999,999 engines with the same engine

end -C-. Cylinders are numbered sequentially on each side.

1.2 Engine data

2 Rep. gr.00 - Technical data

10 – Removing and installing engine

1.1 Removing engine

Special tools and workshop

♦ Basic kit for Touareg -VAS 6131/6-

1. Removing and installing engine 3

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

The procedure for disconnecting batteries must be strictly fol‐

and connecting battery .

– Remove left and right wiper arms ⇒ Electrical system; Rep.

gr. 92 ; Wiper system .

– Pull engine compartment seal off bulkhead.

– Remove covers -A-, -B- and -C- from engine compartment, if

fitted, and -D- for plenum chamber.

– Disconnect the smaller connectors -A- from engine control

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

Always observe installation instructions when removing and in‐

– Disconnect vacuum lines -1- for vacuum unit of bypass flap

– Disconnect following electrical connectors and move wiring

1 - Black 6-pin connector: for lambda probe -G39-

2 - Brown 6-pin connector: for lambda probe 2 -G108-

3 - Black 2-pin connector: for exhaust gas temperature sender 1

4 - Brown 2-pin connector: for exhaust gas temperature sender 1

– Disconnect connectors -arrows- for glow plugs of cylinder

– Secure suspension strut, as shown, with spring tensioner -VW

– Disconnect line -A- from power-assisted steering oil cooler on

6 Rep. gr.10 - Removing and installing engine