K0058961320 6 Cylinder Injection Engine

Service
Workshop Manual
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Service Department. Technical Information

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00 - Technical data
10 - Removing and installing engine
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13 - Crankshaft group
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15 - Cylinder head, valve gear

17 - Lubrication
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19 - Cooling
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20 - Fuel supply system
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24 - Mixture preparation - injection
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26 - Exhaust system
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28 - Ignition system
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg K0058961320

Touareg 2003 ➤
6-cylinder injection engine - Edition 02.2012
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.1 Assembly overview - chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2 Assembly overview - cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.3 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.4 Removing and installing engine bracket and engine mounting on left or right side . . . . . . 22
1.5 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2 Removing and installing sealing flanges and dual-mass flywheel . . . . . . . . . . . . . . . . . . . . 26
2.1 Assembly overview - sealing flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3 Removing and installing seal, flywheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4 Renewing crankshaft oil seal, vibration damper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.5 Renewing crankshaft sealing flange -vibration damper side- . . . . . . . . . . . . . . . . . . . . . . . . 31
3 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.1 Allocation of crankshaft bearing shells (classification) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4 Dismantling lks wageassembling pistons
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overview - pistons and conrods a.ra. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.2 Checking
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15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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1.3 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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1.4 Installing timing chains for intermediate shaft drive and camshaft drive . . . . . . . . . . . . . . 54
1.5 Installing camshaft adjuster with timing chain for camshaft drive . . . . . . . . . . . . . . . . . . . . 60
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1.6 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1.7 Assembly overview - removing and installing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
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1.8 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
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2.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

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2.2 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

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2.3 Removing and installing camshaft control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

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2.4 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

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2.5 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

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2.6 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
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1 Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
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1.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
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1.2 Dismantling and assembling oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.3 Dismantling and assembling oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Contents i
Touareg 2003 ➤
1.4 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

1.5 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.1 Assembly overview - radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.2 Assembly overview - radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.3 Assembly overview - parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.4 Assembly overview - thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.5 Removing and installing thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.6 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.7 Assembly overview - parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . 108
1.8 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.9 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.10 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
1.11 Removing and installing coolant pump . . . . . .ge. n. A.G. ..V.ol.ks. w. a.g.en. A. G. d. . . . . . . . . . . . . . . . . . . . 115
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1.12 Checking cooling system for leaks . . . y. V.o.lk.s . . . . . . . . . . . . . . . . . . . s. n.o.t g.u. . . . . . . . . . . . . . 116
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20 - Fuel supply system . . . . . . . . . a.ut.h . . . . . . . .
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1 Parts of fuel supply system . s. . . . . . . . . . . . .
.................................. 118
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1.1 Assembly overview - fuel tank with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
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1.2 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
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1.3 Schematic diagram of fuel lines and components in fuel tank . . . . . . . . . . . . . . . . . . . . . . 121
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1.4 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 123
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1.5 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
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1.6 Renewing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
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1.7 Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.8 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.9 Removing and installing fuel delivery unit, fuel gauge sender and suction jet pumps . . . . 130
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1.10 Removing and installing fuel tank with attached components . . . . . . . . . . . . . . . . . . . . . . 132
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1.11 Checking fuel pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

2 Electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
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3 Activated charcoal filter system (vehicles with engine code AZZ, BKJ, BMV or BRJ) . . . . 148
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3.1 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

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4 Activated charcoal filter system (vehicles with engine code BAA or BMX) . . . . . . . . . . . . 151
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4.1 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

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4.2 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

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24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
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1 Repairing injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
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1.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
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1.2 Assembly overview - fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
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1.3 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

1.4 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.5 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.6 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
2 Checking components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2.1 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2.2 Checking fuel pressure regulator and holding pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
3.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
3.2 Removing and installing anti-theft engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
ii Contents
Touareg 2003 ➤
1.1 Assembly overview - exhaust manifold with starter catalytic converters and attachments
........................................................................ 176
1.2 Silencer with mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1.3 Removing and installing exhaust manifolds and exhaust pipes with starter catalytic
converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
2.1 Assembly overview - parts of secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
2.2 Checking combination valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

1 Repairing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
1.1 Assembly overview - parts of ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
1.3 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
1.4 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 188
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Contents iii
Touareg 2003 ➤
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iv Contents
Touareg 2003 ➤
6-cylinder injection
AG. V oengine
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00 – Technical data
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1 Engine number
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The engine number („engine code“ and „serial number“) is located
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The engine number consists of up to nine characters (alphanu‐
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"engine code", and the second part (6 characters), the "serial
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Additionally, a sticker with the „engine code“ and „serial number“l purpos
is attached to the intake manifold or at the rear of the cylinder
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The engine code is also included on the vehicle data sticker.
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1. Engine number 1
Touareg 2003 ➤
2 Engine data
Edition 02.2012 version 13.0
Engine code AZZ BAA BKJ BMV BMX BRJ
Manufactured 07.02 ► 03.03 ► 06.03 ► 04.04 ► 04.04 ► 04.04 ►
Cylinder arrange‐ VR1) VR1) VR1) VR1) VR1) VR1)
ment
Cylinder angle 15.0° 15.0° 15.0° 15.0° 15.0° 15.0°
Capacity l 3.2 3.2 3.2 3.2 3.2 3.2
Output kW at 162/5400 162/6000 162/5400 177/6000 177/6000 177/6000
rpm
Torque Nm at 305/3200 300/4000 305/3200 310/3200 310/3200 310/3200
rpm
Bore ∅ mm 84.0 84.0 84.0 84.0 84.0 84.0
Stroke mm 95.9 95.9 95.9 95.9 95.9 95.9
Compression ra‐ 11.25 11.25 10.85 10.85 10.85 10.85
tio
Valves per cylin‐ 4 4 4 4 4 4
der
RON min. 98 unleaded 98 unleaded 98wunleaded
agen
AG. Volk98 unleaded
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does 98 unleaded 98 unleaded
2) 2) lks 2) 2) n 2) 2) o ot g
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System designa‐ Motronic Motronic Motronic Motronic Motronicris
e Motronic
tee
tion ME7.1.1 ME7.1.1 ME7.1.1 ME7.1.1 ho
ME7.1.1 ME7.1.1
aut or
ac
ss
Firing order 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4
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Knock control 2 knock sen‐ 2 knock sen‐ 2 knock sen‐ 2 knock sen‐ 2 knock sen‐ 2 knock sen‐
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sors sors sors sors sors sors
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Lambda control 4 probes 4 probes 4 probes 4 probes 4 probes 4 probes
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Self-diagnosis EOBD OBD II yes yes yes yes

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hole
Catalytic convert‐ yes yes yes yes yes yes

er spec
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Exhaust gas re‐ no no no no no no
circulation
Turbocharging/ no no no no no no
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supercharging
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Secondary air yes yes yes yes yes yes

system
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Electronic power yes yes yes yes yes yes

control
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Variable intake yes yes yes yes yes yes

on
c
manifold
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Camshaft timing yes3) yes3) yes3) yes3) yes3) yes3)

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Leakage diagno‐ no yes no no yes no

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1) VR = V-arrangement in compact in-line design
2) In exceptional circumstances min. 95 RON, however with reduced perform‐
ance.
3) Two independently variable camshafts
2 Rep. gr.00 - Technical data

Touareg 2003 ➤
10 – Removing and installing engine

1 Removing and installing engine
Removing engine ⇒ page 4 .
Securing engine to assembly stand ⇒ page 11 .
Installing engine ⇒ page 13 .
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Special tools and workshop rise
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♦ Lifting tackle -3033-
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♦ Spring tensioner -VW 552-
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♦ Engine and gearbox sup‐
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port -VAS 6095-
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♦ Drip tray -V.A.G 1306-
hole
spec
♦ Torque wrench (5…50 Nm)
es, in part or in w
t to the co
-V.A.G 1331-
♦ Torque wrench (40…200
Nm) -V.A.G 1332-
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1. Removing and installing engine 3

Touareg 2003 ➤
♦ Engine and gearbox jack -

V.A.G 1383 A-
♦ Spring-type clip pliers -VAS
5024A-
♦ Stepladder -VAS 5085-
♦ Diesel extractor -VAS
5226-
♦ Workshop hoist -VAS
6100-
♦ Scissor-type assembly
platform -VAS 6131-
♦ Not illustrated:
♦ Adapter -V.A.G 1318/20-
♦ Adapter -V.A.G 1318/20-1-
♦ Container for removed
parts -V.A.G 1698-
♦ Left support -
VAS 6131/6-1-
♦ Right support -
VAS 6131/6-2-
♦ Left running gear support -
VAS 6131/6-3-
♦ Right running gear support
-VAS 6131/6-4-
♦ Supports -VAS 6131/6-5-
(Qty. 2)
♦ Supports -VAS 6131/6-6-
(Qty. 2) AG. Volkswagen AG d
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♦ Gearbox support - byV
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VAS 6131/6-7- rised
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♦ V6 engine support -VAS 6131/7- ss a ra
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♦ Grease (vehicles with manual gearbox) -G 000 1000-

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♦ Cable ties
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1.1 Removing engine

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Procedure
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The engine is removed downwards with gearbox.

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WARNING
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Fuel supply lines are under pressure! Wear eye protection and
gloves to avoid injuries and skin contact. Before loosening
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hose connections, wrap a cloth around the connection. Then

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release pressure by carefully pulling hose off connection.

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Rep. gr.10 - Removing and installing engine
Touareg 2003 ➤
Note
♦ To enable the propshaft to rotate freely, move selector lever

to the „N“ position.
♦ Leave ignition key in ignition lock to prevent steering lock from
engaging.
♦ It is advisable to remove the front wheels before beginning
engine removal. The vehicle can then be lowered on hoist until
the brake disc splash plates are just above the floor. This pro‐
vides the most ergonomic working position regarding acces‐
sibility of engine compartment components.
♦ To prevent damage to removed components, place them in
the container for removed parts -V.A.G 1698- .
♦ 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.
– Read the fault memories of all control units before removing

engine ⇒ Vehicle diagnostic tester.
Disconnecting battery
The procedure must be strictly followed!
– Switch off ignition and all electrical consumers.
– First disconnect battery under driver seat ⇒ Electrical system;
Rep. gr. 27 ; Disconnecting and reconnecting batteries .
Procedure
– Remove left and right wiper arms: ⇒ Electrical system; Rep.
gr. 92 ; Wiper system . AG. Volkswagen AG d
agen oes
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– Pull bonnet seal off plenum chamber bulkhead.
by
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– Remove covers -A-, -B- and -C- from ho engine compartment and
r tee
ut or
-D- for plenum chamber, if fitted.
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– Screw adapter -V.A.G 1318/20-1- onto adapter -

l purpos
V.A.G 1318/20- .
– Turn valve (on T-piece) anti-clockwise until it is entirely open.
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Caution
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Fuel supply lines are under pressure! Before opening fuel sys‐
t
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tem, connect diesel suction pump -VAS 5226- and release

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pressure.
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– Remove protective cap from breather valve.
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– Connect adapter -V.A.G
s 1318/20- with adapter -
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V.A.G 1318/20-1- and diesel extractor -VAS 5226- to bleed
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valve -1-.
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– Screw valve (on T-piece) clockwise to stop into bleed valve.
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– When fuel pressure has been released, the fuel system may
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be opened.
hole
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– Wrap a cloth around the joint to collect fuel which flows out.
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– Separate fuel supply line -arrow-.
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– All cable ties which are opened or cut through when engine is
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removed must be replaced in the same position when engine
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is installed.
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– In engine compartment, disconnect breather line -arrow- to

activated charcoal filter solenoid valve 1 -N80- .
– Detach small connector -A- from engine control unit and dis‐
connect earth connection -arrow- of wiring harness.
6 Rep. gr.10 - Removing and installing engine

Touareg 2003 ➤
– 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.
– Disconnect starter wire -A- and alternator wire -B- and lay
them on engine.
– Pull vacuum hoses -1…3- off intake manifold.

Vehicles with engine code BAA
– Also pull vacuum hose -4- off intake manifold.
Continuation for all vehicles AG. Volkswagen AG d
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– Detach pressure hose -arrow- from secondary air pump.

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Touareg 2003 ➤
– Detach connectors -1…4- for Lambda probes and lay con‐

nectors on engine.
♦ Cylinders 1…3 = black
♦ Cylinders 4…6 = brown
– Separate line/wiring to air suspension compressor at air filter

-arrow- as follows:
– Carefully lever off green securing ring -1- using a screwdriver.
Then press clamping ring -2- in direction ofn -arrow-.
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– Now pull loosened line -B- off connection -A- on air filter.
spec
– Now remove upper part of air filter upwards ⇒ page 162 .
t to the co
– Unclip gearbox breather line from air filter housing.
– Extract air conditioning refrigerant ⇒ Heating, air conditioning; rrectne
Rep. gr. 87 .
– Remove noise insulation ⇒ General body repairs, exterior;
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Rep. gr. 50 ; Noise insulation .

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– Detach refrigerant lines -2 and 3- from air-conditioning com‐

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pressor.
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Steam may escape when expansion tank is opened. Wear eye Prote
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protection and protective clothing to avoid eye injuries and
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scalding. Cover cap with cloth and open carefully.
– Drain coolant ⇒ page 111 .

– Pull upper coolant hoses off radiator and lower coolant hose
off coolant pipe..
– Separate all necessary coolant hoses on expansion tank.
Note
Observe environmental regulations for disposal.

Touareg 2003 ➤
Volkswa
– Disconnect lines on lower right of radiator -arrow-
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– Now disconnect lower left hydraulic ho oil line from radiator. Col‐
ri tee
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lect escaping oil. ss
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– Undo earth connection -A- at longitudinal member.
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– Loosen double clamp between catalytic converter and centre
silencer and push clamp forwards.
l purpos
– Support rear silencer using engine and gearbox jack -

V.A.G 1383A- , unscrew rear mountings and lower exhaust
nform
ercia
system.
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at
– Unbolt catalytic converter hangers ⇒ Item 11 (page 177) from
om
ion
body.
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– Remove heat shield on steering box and separate universal

a
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joint ⇒ Running gear, axles, steering; Rep. gr. 48 ; Assembly

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or
overview - steering column .

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– Detach connectors -A- from gearbox and transfer box -B- and yri
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release selector lever cable: ⇒ Automatic gearbox 09D; Rep.
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gr. 37 ; Repairing selector mechanism . cted agen
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– Remove rear propshaft ⇒ Transfer box and final drive; Rep.

gr. 39 ; Removing and installing propshaft .
– Remove front wheels.
– Remove front wheel housing liners ⇒ General body repairs,
exterior; Rep. gr. 66 ; Removing and installing wheel housing
liner .
Note
– Separate brake lines at brake hoses in wheel housings and

collect brake fluid which runs out ⇒ Brake systems; Rep. gr.
46 ; Repairing front brakes.
– Separate all connectors between body and front axle in wheel
housings.
– Unbolt connecting lines of air suspension at suspension strut.

Touareg 2003 ➤
– Remove gearbox transverse support -A-.
– Secure suspension strut, as shown, with spring tensioner -VW

552.- .
– On each side of vehicle, remove the two upper suspension
strut bolts ⇒ Running gear, axles, steering; Rep. gr. 40 ; Re‐
pairing front suspension .
Preparing scissor-type assembly platform -VAS 6131- for further
procedure:
– Attach pulley-end supports -VAS 6131/6-1- left and -

VAS 6131/6-2- right -arrows show direction of travel- to scis‐
sor-type assembly platform -VAS 6131- and secure bolts . at
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♦ Left support -1-: A5, B4 and B5 ris
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♦ Right support -2-: G4, H4 and H5 s au ac
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– Bolt both running gear supports -VAS 6131/6-3- and -

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VAS 6131/6-4- -3- to scissor-type assembly platform in the

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following positions:
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♦ Left running gear support -3-: A6 and C6

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♦ Right running gear support -3-: F6 and H6

hole
spec
– Screw turntables of running gear supports downwards.

es, in part or in w
t to the co
– Place supports -VAS 6131/6-5- -4- for subframe and supports

-5- - VAS 6131/6-6- for gearbox bracket in appropriate posi‐
tions on scissor-type assembly platform .
rrectness of i
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– Position horizontal scissor-type assembly platform under en‐

nform
ercia
gine/gearbox assembly. Supports -1- must be guided into

corresponding receptacles on left and right -arrow-.
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Touareg 2003 ➤
– At same time, guide right and left supports for gearbox bracket
into corresponding bores -arrow-.
Volkswagen AG
When all four supports are in the receptacle holes without
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– Screw both turntables of running gearthosupports under sus‐
r eo
pension links (with slight preloading),
ss a until the spring tensioner
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-VW 552- can be removed.
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– Guide supports -2- into their respective receptacles in sub‐

frame, correcting support height as necessary with knurled
t to the co
nut.
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– Loosen subframe bolts -1-, -2- and -3- as well as gearbox
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transverse support -4-.

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After releasing the subframe, a wheel alignment check must be
carried out on the vehicle.
– Now slowly lower engine/gearbox assembly, constantly ob‐

serving the clearance.
1.2 Securing engine to assembly stand

Special tools and workshop equipment required

Touareg 2003 ➤
♦ Engine and gearbox support -VAS 6095-
Secure engine to engine and gearbox support -VAS 6095- to car‐

ry out repairs.
Procedure
– Unbolt gearbox. n AG. Volkswagen AG do
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Separating engine and gearbox: ⇒ Operating instructions for
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scissor-type assembly platform -6131- .
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Vehicles with automatic gearbox
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– Secure torque converter against „falling out“ after separating
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engine from gearbox.
spec
Continuation for all vehicles
t to the co
– Attach lifting tackle -3033- as follows and lift engine from scis‐
sor-type assembly platform -VAS 6100- using workshop crane
rrectne
-6131- .
♦ Vibration damper end: position 3.
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♦ Flywheel end: position 11.
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Note
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♦ The positions labelled 1…12 on the lifting tackle -3033- face

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flywheel side.
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♦ Adjust length of threaded spindles according to need.

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Touareg 2003 ➤
– Secure engine on engine and gearbox support -VAS 6095- .
1.3 Installing engine
Caution
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electricalGwiring in their original po‐
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♦ Ensure that there edis sufficient clearance to all moving orran
b a u
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♦ When fitting engine and gearbox to body, it is essential to po‐

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sition engine carrier against body with the aid of scissor-type

ole,
spec
assembly platform -VAS 6131- . »Pulling up« engine carrier

with securing bolts will damage threads.

t to the co
♦ If a new engine is installed, the 3 bores on the face end

-arrows- must be sealed by means of bolts.
rrectne
Procedure
ss
Install in reverse order. In the process, note the following:

o
cial p
f inform
Vehicles with manual gearbox.

mer
atio
– Check clutch release bearing for wear and renew if necessary

om
⇒ 6-speed manual gearbox 08D; Rep. gr. 30 ; Repairing

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clutch release mechanism .

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– Lightly grease input shaft splines with grease -G 000 1000- .

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– Check whether dowel sleeves for centring engine/gearbox
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have been fitted in cylinder block, insert if necessary. cop Vo
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If subframe with engine carrier has been removed from scissor-
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type assembly platform :

Touareg 2003 ➤
– Position subframe with engine carrier onto prepared scissor-

type assembly platform again.
– Set engine on subframe.
If gearbox is not yet bolted on:
– Support engine with support -VAS 6131/7- .
– Before installing unit, fit exhaust manifold with catalytickscon‐
wage es n
verters to engine ⇒ page 176 . y Vol ot g
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db e ran
ris tee
Vehicles with manual gearbox. utho or
a ac
ss
– When installing engine, first raise scissor-type assembly plat‐
ce
le
un
form only far enough to connect selector mechanism ⇒ 6-
pt
an
d
speed manual gearbox 08D; Rep. gr. 34 ; Repairing selector
itte
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mechanism .
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– Install hydraulic line to hydraulic clutch slave cylinder: ⇒ 6-
wit
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speed gearbox 08D; Rep. gr. 30 ; Repairing clutch control;
h re
ole,
Assembly overview - hydraulic system .
spec
– Bleed clutch system ⇒ 6-speed manual gearbox 08D; Rep.
t to the co
gr. 30 ; Repairing clutch mechanism .
rrectne
– When installing engine, first raise scissor-type assembly plat‐
form only far enough to clip in selector lever cable.
ss o
cial p
f
inform
mer
– Reconnect all lines, hoses and connectors which were sepa‐
atio
rated during removal.
om
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or
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– Reconnect air conditioning system lines: ⇒ Heating, air con‐
thi
te
ditioning; Rep. gr. 87 .
sd
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– Fill with power-assisted steering fluid ⇒ Running gear, axles,

fo
en
ng
steering; Rep. gr. 48 ; Vane pump; Bleeding steering system .

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– If necessary fill with engine oil ⇒ Maintenance ; Booklet 17.1 .
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– Electrical connections and routing ⇒ Current flow diagrams,
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Electrical fault finding and Fitting locations.
AG.
– Replenish coolant ⇒ page 111 .

– Top up ATF level ⇒ Automatic gearbox 09D; Rep. gr. 37 ;
Checking ATF level and topping-up.
Note
Perform wheel alignment after the installation of subframe ⇒

Running gear, axles, steering, front and four-wheel drive; Rep.
gr. 44 ; Wheel alignment .
– Carry out vehicle system test ⇒ Vehicle diagnostic tester „Gui‐

ded fault finding“.
– Finish the vehicle system test so that any fault entries stored
during assembly can be deleted automatically.
– Perform road test.
– Generate the readiness code in combination with a road test.

Touareg 2003 ➤
Note
Observe applicable safety precautions during road test

⇒ page 165 .
– Then carry out vehicle system test again and rectify any faults
which may have occurred.
1.3.1 Specified torques

Threaded connection Specified torque
Bolts, nuts M6 10 Nm
M7 15 Nm
M8 25 Nm
M10 40 Nm
M12 60 Nm
Deviations
Engine bracket to engine M10 75 Nm
mounting (nut) 4)
Engine mounting to engine car‐ M10 60 Nm
rier (bolt) 4) AG. Volkswag en AG do
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Engine carrier to body ksw
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(180°). rante
th eo
Drive shafts s auto gearbox ⇒ Running gear, r ac
s
axles, steering - front
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and four-wheel drive;

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Rep. gr. 40 ; Repair‐

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Gearbox carrier to body ⇒ Differential and final

wit
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drive; Rep. gr. 34 ; In‐

h re
stalling gearbox carri‐

hole
spec
er and console .
es, in part or in w
t to the co
4) Removing and installing engine bracket or engine mounting ⇒ page 22

rrectness of i
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Touareg 2003 ➤
13 – Crankshaft group
1 Dismantling and assembling engine
AG. Volkswagen AG d
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♦ Secure engine to engine and gearbox support -VASs6095- to
th
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carry out repairs. s c
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♦ Finding metal shavings or a large quantity of small metal par‐
an
itte
ticles during engine repair could indicate that the crankshaft
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bearings or conrod bearings are damaged. To prevent this
ility
from causing further damage, perform the following repairs: ot p
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♦ Thoroughly clean oil passages
hole
spec
♦ Renew oil non-return valve
es, in part or in w
t to the co
♦ Renew oil spray jets
♦ Renew engine oil cooler,
rrectness of i
♦ Renew oil filter.
l purpos
Assembly overview - chain drive ⇒ page 16 .
nf
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Assembly overview - cylinder block ⇒ page 19 .
rm
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Removing and installing engine bracket and engine mounting on

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left or right side ⇒ page 22

or
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Removing and installing poly V-belt ⇒ page 24 .
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Removing and installing sealing flange and dual-mass flywheel
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⇒ page 26 .
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Removing and installing crankshaft ⇒ page 34 .
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Assembly overview - dismantling and assembling pistons and
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conrods ⇒ page 38 .
1.1 Assembly overview - chain drive
16 Rep. gr.13 - Crankshaft group

Touareg 2003 ➤
1 - Valve timing housing AG. Volkswagen AG d

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❑ Lightly lubricate contact Volksw
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and valve timing hous‐ horis
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stalling. s
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❑ Removing and installing
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⇒ page 73 Removing
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and installing cam‐
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shafts.
wit
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❑ Dismantling and assem‐
h re
hole
bling ⇒ page 79 .
spec
es, in part or in w
❑ Before installing valve
t to the co
timing housing, check
strainer for soiling
⇒ page 79 .
rrectness of i
2 - 8 Nm
l purpos
❑ Renew.
3 - Camshaft timing chain
nf
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❑ Before removing, mark
m
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direction of rotation (in‐
om
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stallation position)
or c
thi
⇒ page 19 .
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❑ Installing ⇒ page 60 .
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4 - Exhaust camshaft adjuster

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❑ Identification: 32A.
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❑ Rotate engine only with
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5 - Intermediate shaft
6 - Thrust washer
❑ Not installed on all en‐
gines.
7 - 8 Nm
❑ Insert with locking fluid -D 000 600 A2- .
8 - Tensioning plate
❑ For camshaft timing chain ⇒ Item 3 (page 17)
9 - Pivot pin, 18 Nm
❑ For tensioning rail ⇒ Item 8 (page 17)
10 - Chain tensioner, 40 Nm
❑ Only rotate engine when chain tensioner is installed.
11 - Seal
❑ Renew if damaged or leaking.
12 - Chain sprocket
❑ For timing chain ⇒ Item 17 (page 18) .
13 - Chain sprocket
1. Dismantling and assembling engine 17

Touareg 2003 ➤
14 - 60 Nm + 1/4 turn (90°) further

❑ Renew.
❑ Lock with counterhold -T10069- when loosening and tightening crankshaft
15 - Chain tensioner with tensioning plate
❑ Before installing, release locking splines in chain tensioner using a small screwdriver and press tension‐
ing plate against chain tensioner.
16 - Drive sprocket
❑ Built into crankshaft.
❑ Ground down tooth aligned with main bearing joint = TDC No. 1 cylinder ⇒ page 54
17 - Timing chain
❑ Before removing, mark direction of rotation (installation position) ⇒ page 19 .
18 - Guide rail
❑ Removing and installing together with timing chain ⇒ page 54
19 - Locating pin without collar, 10 Nm
❑ For guide rail ⇒ Item 18 (page 18) .
AG. Volkswagen AG d
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20 - 18 Nm Volksw not
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21 - 23 Nm horis nte
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22 - Inlet camshaft adjuster ss c
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❑ Identification: 24E
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❑ Rotate engine only with camshaft adjuster installed. y li

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23 - 60 Nm + 1/4 turn (90°) further

h re
ole,
spec
❑ Renew.
❑ Contact surface of sender wheel must be dry around bolt head when installed.
t to the co
❑ To remove and install, counterhold using 32 mm open-end spanner on camshaft ⇒ page 73 , Removing
and installing camshafts.
rrectne
24 - Guide rail
ss o
cial p
25 - Exhaust camshaft control valve 1 -N318-

inform
mer
❑ For exhaust camshaft.

atio
m
❑ Before removing, mark connector belonging to component.

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26 - Inlet camshaft control valve 1 -N205-

thi
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❑ For inlet camshaft.

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27 - Guide rail
C py
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❑ For camshaft timing chain ⇒ Item 3 (page 17) p by
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❑ Clipped into valve timing housing.
agen
Prote AG.

Touareg 2003 ➤
Marking timing chains

– Mark roller chains before removing (e.g. with paint, arrow
pointing in direction of rotation).
Note
Do not mark chain by way of centre punch, notch or the like.
AG. Volkswagen AG d
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1.2 Assembly overview - cylinder block
wit
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hole
spec
left or right side ⇒ page 22 .
es, in part or in w
t to the co
1 - 8 Nm
❑ Secured to intake mani‐
rrectness of i
fold.
l purpos
2 - Guide tube
❑ For oil dipstick.
nform
ercia
❑ Secured with bolt to in‐

m
at
take manifold.
om
ion
c
in t
r
3 - Oil dipstick
o
his
ate
❑ The oil level must not be
do
priv
c
above the max. mark!
um
for
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❑ Markings ⇒ page 92 .
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t.
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Cop py
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4 - Oil non-return valve
rig
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❑ Note installation posi‐
co lksw
by
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tion. Prote AG.

⇒ page 92 .
❑ Clean if badly soiled or
renew if necessary.
❑ See note ⇒ page 16 .
5 - Knock sensor 1 -G61-
❑ Fitting location: be‐
tween cylinder 1 and
cylinder 3.
6 - 20 Nm
❑ The specified torque in‐
fluences the function of
the knock sensor.

Touareg 2003 ➤
7 - 10 Nm
8 - Oil pump drive cover
9 - O-ring
❑ Renew.
❑ Lubricate before installing.
10 - Oil pump drive
11 - Cylinder block
❑ Removing and installing sealing flange and dual-mass flywheel ⇒ page 26 .
❑ Removing and installing crankshaft ⇒ page 34 .
❑ Dismantling and assembling pistons and conrods ⇒ page 38 .
13 - Thrust washer
❑ Not installed on all engines.
14 - 10 Nm
15 - Drive shaft
❑ For oil pump drive.
16 - Engine speed sender -G28-
17 - Oil pump
❑ Dismantling and assembling ⇒ page 94 .
18 - 23 Nm
19 - 8 Nm
AG. Volkswagen AG d
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20 - Oil drain plug, 30 Nm olksw not
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❑ Renew. orise nte
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21 - Oil sump ss a c
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❑ Removing and installing ⇒ page 95 .

nl
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itte
22 - Oil level and oil temperature sender -G266-

y li
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❑ Only on vehicles with engine code „AZZ“

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23 - Seal
h re
hole
❑ Renew.
spec
es, in part or in w

t to the co
24 - 20 Nm
25 - Seal
rrectness of i
❑ Renew.
l purpos
26 - Oil filter housing / left engine bracket

nf
ercia

orm
❑ Coolant hose schematic diagram ⇒ page 110 .

m
atio
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❑ Removing left or right engine bracket and engine mounting ⇒ page 22 .

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Cop py
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Prote AG.

Touareg 2003 ➤
27 - 23 Nm
28 - To thermostat housing. agen
AG. Volkswagen AG d
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29 - 25 Nm d by gu
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30 - Fitted bolt, 25 Nm auth eo
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31 - Bracket for ancillaries
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❑ For alternator, air conditioner compressor and power-assisted steering vane pump
an
d
itte
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32 - Coolant pipe
pe
ility
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❑ Removing and installing ⇒ page 108 , Parts of cooling system - engine side.
wit
, is n
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33 - Knock sensor 2 -G66- hole
spec
❑ Fitting location: between cylinder 4 and cylinder 6.
es, in part or in w
t to the co
34 - Vibration damper
❑ Removing and installing poly V-belt ⇒ page 24 .
rrectness of i
l purpos
35 - 100 Nm + 1/2 turn (180°) further
nform
mercia
a
Note: If a new engine is installed, the 3 holes on the face end
com
tio
-arrows- must be sealed by means of bolts.
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Cop py
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co lksw
by
cted agen
Prote AG.
1.3 Removing and installing vibration damp‐

er
♦ Counterhold tool -T10069-

Touareg 2003 ➤
♦ Torque wrench -V.A.G 1601-
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ir se tee
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ss
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pt
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itte
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ab
ility
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wit
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hole
spec
Removing:
es, in part or in w
t to the co
– Remove poly V-belt ⇒ page 24 .
– Lock vibration damper using counterhold -T10069- .
rrectness of i
– Unscrew securing bolt for vibration damper and remove vi‐
l purpos
bration damper.
Installing:
nf
ercia
orm
m
atio
Caution
om
n in
or c
thi
Check rubber joint between inner and outer ring of vibration
te
sd
a
damper for cracks and separation. If rubber joint is damaged,

iv
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renew vibration damper.
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t.
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Cop py
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– Clean thread in crankshaft with a threaded chaser M18 x 1.5.
gh ht
pyri by
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co lksw
by
– Renew securing bolt for vibration damper. cted agen
Prote AG.

– Tighten securing bolt using torque wrench -V.A.G 1601- .
Specified torque: 100 Nm + 1/2 turn (180°).
Note
Turning further in several stages is permitted.
– Install poly V-belt ⇒ page 24 .
1.4 Removing and installing engine bracket

and engine mounting on left or right side
♦ Support bracket -10 - 222 A-
♦ Shackle -10 - 222 A /12-
♦ Adapter -10 - 222 A /16-

Touareg 2003 ➤
♦ Adapter -10 - 222 A /19-
Removing AG. Volkswagen AG d

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– Completely remove air filter with air mass by meter.
Vol
gu
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– Before removal, unscrew securing hor
nuts -2- from left and right eo
ut
engine bracket. ss a ra
c
ce
le
– Fit adapter -10 - 222 A- to support bracket -10 - 222 A /16- with
un
pt
an
d
the higher side for the spindle guide upwards, as illustrated.

itte
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ab
– Now fit adapter -10 - 222 A /19- to support bracket -10 - 222
pe
ility
A- on left and right. Set support bracket -10 - 222 A- on longi‐
ot
wit
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tudinal members.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Hook engine with two shackles -10 - 222 A /12- on adapter -10
l purpos
- 222 A /16- and slightly take up weight of engine.
nform
mercia
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com
tion in
r
te o
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by c lksw
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Prote AG.

Touareg 2003 ➤
– Now remove securing bolts -1- from left and right engine
mounting/subframe.
– Note the space available between cylinder head and plenum
chamber bulkhead.
– Now carefully raise engine with adapter -10 - 222 A /16- .
– To remove engine mounting, engine bracket must also be un‐
screwed from cylinder block, as engine cannot be raised high
enough.
Installing
Installation is basically the reverse of the removal procedure.
– When installing, ensure dowel pin of engine mounting is cor‐
rectly seated in engine bracket.
– First insert all bolts by hand and then tighten
agen
AGall
. Vobolts toenpre‐
lkswag AG do
scribed torque. Volksw es n
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Specified torque for securing bolt
ho
ris -1-: 60 Nm. tee
t or
au ac
ss
Specified torque for securing nut -2-: 75 Nm.
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Specified torque for securing bolts of oil filter housing/engine
itte
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bracket on left cylinder block: 23 Nm.
erm
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ility
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Specified torque for securing bolts of engine bracket on right of
wit
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cylinder block: 40 Nm.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
1.5 Removing and installing poly V-belt

nform
ercia

m
at
om
io
♦ Hexagon bolt M8 x 50
n
c
in t
or
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Removing poly V-belt

at
do
priv
– Mark direction of rotation of poly V-belt.

um
for
en
ng
t.
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– Press tensioning arm in -direction of arrow- using a suitable
Co
op py
screwdriver.
t. C rig
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pyri by
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by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
– Screw M8 × 50 bolt into threaded hole -A- and secure poly V-

belt tensioning roller.
Note
Screw in bolt only far enough to remove poly V-belt, as tensioning

roller housing may otherwise be damaged.
– Remove poly V-belt.

Installing poly V-belt
Note
♦ Before installing poly V-belt, ensure that all ancillary assem‐

blies (alternator, air conditioner compressor, vane pump) are
secured tightly.
♦ Check that idler roller turns easily.
♦ When installing poly V-belt, check direction of belt rotation and
proper seating of belt in pulleys.
– Install poly V-belt and remove M8 bolt from tensioning roller.

After completing repairs always:
– Start engine and check that belt runs properly.
AG. Volkswagen AG d
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t to the co
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mer
atio
om
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c
i
or
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te
sd
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pr
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fo
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Cop py
t. rig
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co lksw
by
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Prote AG.

AG. Volkswagen AG d
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Touareg 2003 ➤ Vol
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by
6-cylinder injection engine
ris
ed - Edition 02.2012 ara
nte
tho eo
s au ra
c
s
2 Removing and installing sealing
ce
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nl
pt
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flanges and dual-mass flywheel
itte
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ility
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Note
h re
hole
spec
♦ For repairs to clutch ⇒ 6-Speed manual gearbox 08D; Rep.
es, in part or in w
t to the co
gr. 30 ; Repairing clutch .
♦ Secure engine to engine and gearbox support -VAS 6095- to
carry out repairs.
rrectness of i
l purpos
Assembly overview - sealing flange ⇒ page 26 .

Removing and installing drive plate ⇒ page 27 .
nf
ercia
or
Removing and installing seal at flywheel end ⇒ page 28
m
m
atio
m
Renewing crankshaft oil seal, vibration damper end

o
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⇒ page 29
thi
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sd
iva
2.1 Assembly overview - sealing flange
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1 - 100 Nm + 1/2 turn (180°)
t. C rig
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further cop Vo
by lksw
cted agen
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2 - Vibration damper
AG.

poly V-belt ⇒ page 24 .
⇒ page 21 .
3 - 10 Nm
4 - Seal
❑ Renewing ⇒ page 29 .
5 - Sealing flange
❑ Coat sealing surfaces
with sealant -D 176 501
A1- .
6 - Cylinder block
crankshaft
⇒ page 34 .
bling pistons and con‐
rods ⇒ page 38 .
7 - Sealing flange
❑ Coat sealing surfaces
with sealant -D 176 501
A1- .
8 - Seal
❑ Remove using extractor
hook -T20143/2- .
❑ PTFE oil seal:
❑ Identification: Without
inner hose spring.
❑ Do not additionally oil or grease the oil seal sealing lip.

Touareg 2003 ➤
❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
9 - Dual-mass flywheel
10 - 60 Nm + 1/4 turn (90°) further
❑ Renew.
❑ Lock with counterhold -T10069- when loosening and tightening crankshaft
11 - 25 Nm
2.2 Removing and installing drive plate

♦ Counterhold tool -T10069- wage
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ss
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itte
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ility
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hole
spec
es, in part or in w
t to the co
♦ Torque wrench (40…200 Nm) -V.A.G 1332-
rrectness of i
l purpos
nf
ercia
orm
m
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om
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Cop py
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♦ Depth gauge yri
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by lksw
cted
Removing
agen
Prote AG.
– Remove drive plate. To do this, lock vibration damper using

counterhold -T10069- .
– Loosen drive plate securing bolts diagonally and remove.
– Remove drive plate.
Installing
– Attach drive plate to crankshaft using at least 3 old securing
bolts and tighten to 30 Nm.
2. Removing and installing sealing flanges and dual-mass flywheel 27

AG. Volkswagen AG d
agen oes
olksw not
V gu
Touareg 2003 ➤ d by ara
ise nte
r
6-cylinder injection engine - Edition 02.2012 ut
ho eo
ra
s a c
s
– Measure dimension -a- using depth gauge . Specification:
ce
le
un
pt
21.0…23.0 mm.
an
d
itte
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ab
If specification is not attained:
ility
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wit
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ole,
spec
t to the co
rrectness o
– Remove drive plate again and fit appropriate shim -1-. cial p
f inform
mer
atio
m
Note
o
n
c
i
or
n thi
e
Only one shim of the appropriate thickness may be used for com‐
t
sd
va
pensation.
i
o
pr
cum
r
fo
en
ng
t.
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When specification is attained:
Co
Cop py
t. rig
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– Insert new securing bolts and tighten by hand. yri
p by
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by c lksw
cted
– Tighten securing bolt to 60 Nm + 1/4 turn (90°) further (the
agen
Prote AG.
additional turn may be performed in several steps).
2.3 Removing and installing seal, flywheel

end
♦ Fitting tool -T10122-
♦ Puller hooks -T20143-

Touareg 2003 ➤
Removing oil seal at flywheel end

– Fit puller hooks -T20143/2- behind sealing lip of oil seal as
shown in illustration.
– Support puller hook -T20143/2- on sealing flange and lever
seal out in direction of -arrow-.
Installing oil seal at flywheel end
– Pull oil seal -A- by the outside over the sleeve -T10122/1- onto
pulling sleeve -T10122/2- .
– Separate the two fitting sleeves.
– Then set pulling sleeve -T10122/2- with dry oil seal onto crank‐
shaft journal.
AG. Volkswagen AG d
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es, in part or in w
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– Now drive it into sealing flange to stop using thrust piece -

T10122/3- .
rrectness of i
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nf
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orm
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2.4 Renewing crankshaft oil seal, vibration damper end

t.
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Cop py
t. rig
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pyri by
Vo
co lksw
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cted agen
Prote AG.

Touareg 2003 ➤
Special tools and workshop

equipment required
♦ Puller hooks -T20143/1-
♦ Socket -T10215-
♦ Torque wrench -V.A.G
1601-
♦ Torque wrench -V.A.G AG. Volkswagen AG d
1332- agen oes
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pe
ility
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wit
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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
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Note
If a plastic sealing flange is fitted, the sealing ring cannot be re‐

newed as a separate item; the sealing flange must be renewed
⇒ page 31 .
Removing
– Set lock carrier to service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Service position .

Touareg 2003 ➤
– Remove vibration damper. To do this, lock vibration damper

using counterhold -T10069- .
– Fit puller hooks -T20143/1- behind sealing lip of oil seal as
shown in illustration.
– Support puller hook -T20143/1- on sealing flange and lever

seal out in direction of -arrow-.
Installing agen
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– Remove oil residue from crankshaft journal
ed by using clean cloth. ara
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– Push guide sleeve -T10215/1- -1-auat
t front onto crankshaft jour‐
h
ra
nal. ss c
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nl
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– Now slide oil seal -2- carefully over guide sleeve as far as it
an
itte
will go.
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– Press oil seal in as far as stop with fitting sleeve -T10215/2-
es, in part or in w
t to the co
-3-. To do this, use an old vibration damper securing bolt -4-.
– Install vibration damper ⇒ page 21 .
rrectness of i
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nform
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at
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ion
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2.5 Renewing crankshaft sealing flange -vibration damper side-

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Touareg 2003 ➤

equipment required
♦ Assembly tool -T10215-
1601-
1332-
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Removing
Co
Cop py
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– Set lock carrier to service position ⇒ General body repairs,
ht
pyri by
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exterior; Rep. gr. 50 ; Service position . by c lksw
cted agen
Prote AG.
– Remove vibration damper. To do this, lock vibration damper
using counterhold -T10069- .
– Remove sump ⇒ page 95 .
– Unbolt sealing flange.
– Remove remaining sealant from sealing surfaces.
Installing
– Remove oil residue from crankshaft journal using clean cloth.

Touareg 2003 ➤
– Cut off tube nozzle at forward marking (∅ of nozzle approx. 3

mm).
– Apply sealant bead of about 2…3 mm as shown -arrows- to
clean sealing surface of sealing flange.
Note
♦ Before applying sealant bead, cover sealing ring with a clean

cloth.
♦ The sealing compound bead must not be thicker that 2…3 mm.
Otherwise excessive sealing compound will enter the sump
and may block the oil suction pipe strainer.
♦ Observe expiry date of sealing compound.
♦ The sealing flange must be installed within 5 minutes after ap‐
plying the silicone sealant.
– Push guide sleeve -T10215/1- -1- at front onto crankshaft jour‐

nal -3-.
– Now slide sealing flange with oil seal -2- carefully over guide
sleeve.
– Bolt sealing flange to crankcase. n AG. Volkswagen AG do

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– Install sump ⇒ page 95 . byV
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– Install vibration damper ⇒ page 21th .o tee
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s
– Install poly V-belt ⇒ page 24 . s
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ate
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Touareg 2003 ➤ byV ua
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6-cylinder injection engine - Edition t02.2012
ho tee
or
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3 Assembly overview - crankshaft
pt
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ab
Fitting sender wheel to crankshaft ⇒ page 35
ility
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Allocation of crankshaft bearing shells (classification)
is n
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⇒ page 35
ole,
spec
t to the co
Note
♦ Before removing crankshaft, ensure that a suitable surface for
rrectne
storing crankshaft is prepared to ensure that sender wheel
⇒ Item 6 (page 35) is not damaged or lies against any other
s
item.
s o
cial p
f in
♦ Secure engine on engine and gearbox support -VAS 6095- to
form
mer
carry out repairs.
atio
m
♦ When changing bearing shells, use only bearing shells of

o
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same colour code.
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1 - Bearing cap
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❑ Bearing cap 1: vibration
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❑ Bearing cap 5 with re‐ Prote
cted AG.
agen
cesses for thrust wash‐
ers.
❑ Bearing shell retaining
lugs in cylinder block
and bearing caps must
align.
2 - 30 Nm + 1/2 turn (180°) fur‐
ther
❑ Renew.
❑ 2 x 90° further is permit‐
ted.
3 - Bearing shells 1…7
❑ For bearing cap without
oil groove.
❑ For cylinder block with
oil groove.
❑ Do not interchange
used bearing shells
(mark).
4 - Thrust washer
❑ For bearing cap 5.
❑ Note fixing arrange‐
ment.
5 - Crankshaft
❑ If the crankshaft is re‐
newed, the crankshaft
bearing shells must be
reallocated
⇒ page 35 .
❑ Before removing, see notes ⇒ page 34 .
❑ Axial clearance new: 0.07…0.23 mm; wear limit: 0.30 mm.
❑ Check radial clearance with Plastigage, new: 0.02…0.06 mm, wear limit: 0.10 mm
❑ Do not rotate crankshaft when checking radial clearance.

Touareg 2003 ➤
Volkswa
❑ Crankshaft dimensions, agemain
n AG. bearing: 59.958…59.978
gen AG
does mm, conrod bearing: 53.958…53.978 mm. Re‐
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6 - Sender wheel ho
ri tee
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❑ For engine
ss speed sender -G28- .
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❑ Renew.
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7 - 10 Nm + 1/4 turn (90°) further
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❑ Renew.
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spec
8 - Oil spray jet
t to the co
❑ For crankshaft bearings 2…7
❑ For piston cooling.
❑ Opening pressure: 2.0 bar
rrectne
s
s o
cial p
f inform
mer
atio
Fitting sender wheel to crankshaft
om
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♦ Torque wrench (5…50 Nm) -V.A.G 1331-
♦ Locking fluid -D 000 600 A2-
Procedure
Ensure that contact surfaces of crankshaft and sender wheel are
free of oil and grease.
– Lightly coat contact surfaces of crankshaft and sender wheel
with locking fluid -D 000 600 A2- for additional security.
– Ensure during installation that marking -VR6- -arrow- is posi‐
tioned over single threaded hole.
– First tighten all new securing bolts lightly by hand.
– First tighten securing bolt -1- to 10 Nm + 1/4 turn (90°) further.
– Then tighten securing bolt -2- to 10 Nm + 1/4 turn (90°) further.
3.1 Allocation of crankshaft bearing shells

(classification)
Main bearing shells of the correct thickness are allocated to the
cylinder block and crankshaft at the factory. Coloured dots are
used to identify the thickness of the bearing shells.
If the cylinder block or crankshaft is changed, the crankshaft
bearing shells must be reallocated.
3. Assembly overview - crankshaft 35

Touareg 2003 ➤
Always insert bearing shell for cylinder block (upper bearing shell)
with yellow colour marking.
Determine the correct colour marking for the bearing shell in
bearing cap (lower bearing shell) with regard to the letters on the
cylinder block and crankshaft.
The first letter is allocated to bearing cap one, the second to bear‐
ing cap two, etc.
Cylinder block identification:
The letters are located on the sealing surface of sump.
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Crankshaft ut
identification:
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The letters are located on the outer crankshaft web of No. 1 cyl‐
nl
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– Make a note of the letters and determine the colour marking ab

ility
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Letter on cylinder block Letter on crankshaft web Colour marking of bearing Colour marking of bearing
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shell for bearing cap shell for cylinder block

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A, B, C, D, E R Red Yellow
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A, B, C, D, E G Red Yellow
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B Yellow Yellow
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A, B, C, D, E V Blue Yellow
G, H, I R Red Yellow
G, H, I G Red Yellow
G, H, I B Yellow Yellow
G, H, I V Blue Yellow
K, L, M R Red Yellow
K, L, M G Yellow Yellow
K, L, M B Blue Yellow
K, L, M V Purple Yellow

Touareg 2003 ➤
Example:
Bearing cap 1 2 3 4 5 6 7
Letters on cylinder block G H H H G E G
Letters on crankshaft web G B B V B B G
Colour marking of bearing shell Red Yellow Yellow Blue Yellow Yellow Red
for bearing cap
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3. Assembly overview - crankshaft 37

AG. Volkswagen AG d
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Touareg 2003 ➤ orise nte
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6-cylinder injectionauengine
t - Edition 02.2012 ra
c
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4 Dismantling and assembling pistons
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and conrods
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Assembly overview - pistons and conrods ⇒ page 38 .
h re
hole
spec
Checking pistons, piston rings and cylinder bores ⇒ page 39 .
es, in part or in w
t to the co
4.1 Assembly overview - pistons and con‐
rods
rrectness of i
Checking piston ring gap ⇒ page 39 .
l purpos
Checking ring-to-groove clearance ⇒ page 39 .

Checking piston ⇒ page 39 .
nform
mercia
Installing piston with piston fitting tool -T10147- ⇒ page 41 .
at
om
ion
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1 - Piston rings
at
do
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❑ Offset gaps by 120°.

p
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for
en
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❑ Use piston ring pliers to

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remove and install. Cop py
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❑ „TOP“ faces towards
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piston crown. by c lksw
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❑ Checking ring gap
⇒ page 39 .
❑ Checking ring-to-groove
clearance ⇒ page 39 .
2 - Piston
❑ Check ⇒ page 39 .
❑ Mark cylinder number
and installation position
relative to conrod.
❑ Low point of piston
crown faces to centre of
cylinder block.
❑ Install with piston fitting
tool -T10147-
⇒ page 41 .
3 - Circlip
4 - Conrod
❑ Renew as set only.
❑ Mark cylinder number
-B-.
❑ Installation position:
marks -A- must be
above one another.
5 - Bearing shell
tion.
❑ Do not interchange
used bearing shells.
❑ The lugs on bearing shells must fit tightly in the recesses.
❑ Axial clearance new: 0.05…0.31 mm; wear limit: 0.40 mm.
❑ Check radial clearance with Plastigage: new: 0.02…0.07 mm, wear limit: 0.10 mm. Do not rotate crank‐
shaft when checking radial clearance.

Touareg 2003 ➤
6 - Conrod bearing cap

❑ Mark cylinder number -B-.
❑ Installation position: marks -A- must be above one another.
7 - 30 Nm + 1/4 turn (90°) further
❑ Renew.
❑ Oil threads and contact surface.
❑ To measure radial clearance, tighten to 30 Nm but not further.
8 - Cylinder block
❑ Checking cylinder bores ⇒ page 39 .
❑ Removing and installing crankshaft ⇒ page 34 .
❑ Piston and cylinder dimensions ⇒ page 39 .
9 - Piston pin
❑ If difficult to remove, heat piston to 60°C.
❑ Remove and install using drift -VW 222 A-ge. n AG. Volkswagen AG d
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4.2 Checking pistons, piston rings and cyl‐ th eo
au ra
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inder bores
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nl
pt
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an
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Checking piston ring gap
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♦ Feeler gauges nform

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Test procedure
m
at
om
– Push ring at right angles from above down to approx. 15 mm

ion
c
from bottom end of cylinder. Push in using a piston without

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or
rings.
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Piston ring Ring gap

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New Wear limit
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Rectangular-section ring mm 0.20...0.40 1.0
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Tapered stepped ring mm 0.20...0.40 1.0
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Oil scraper ring mm 0.25...0.50 1.0
Checking ring-to-groove clearance
4. Dismantling and assembling pistons and conrods 39

AG. Volkswagen AG d
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Touareg 2003 ➤ autho eo
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6-cylinder injection engine - Edition 02.2012 ss c
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♦ Feeler gauges
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ility
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– Clean annular groove before check.
h re
hole
spec
Piston ring Clearance
es, in part or in w
t to the co
New Wear limit
Rectangular-section ring mm 0.04...0.09 0.15
Tapered stepped ring mm 0.03...0.06 0.15
rrectness of i
Oil scraper ring mm 0.02...0.06 0.15
l purpos
Checking piston
nform
ercia
m
a
com
t
♦ Micrometer 75 - 100 mm -VAS 6071-
ion in
r
te o
Measure approx. 6 mm from lower edge of skirt, at 90° to piston
thi
s
iva
pin axis.
do
r
rp
cum
fo
Deviation from nominal dimension max. 0.04 mm
en
ng
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Checking cylinder bores C py
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Prote AG.

♦ Cylinder gauge -VAS 6078-
Test procedure
Take measurements at 3 positions in both lateral direction -A- and
longitudinal direction -B-.
Difference between actual and nominal diameter max. 0.08 mm.
Note
Cylinder bores must not be measured when cylinder block is

mounted in engine and gearbox support -VAS 6095- , as meas‐
urements may be incorrect.
Piston and cylinder dimensions

Honing dimen‐ Piston ∅ Cylinder bore ∅
sion
Basic dimension mm 83.965 84.010

Touareg 2003 ➤
Installing pistons with piston fitting tool -T10147-
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tho equipment required tee
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♦ Piston fitting tool -T10147-
ss
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Procedure
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Note
wit
is n
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ole,
If a new piston fitting tool -T10147- is used to install the pistons,
spec
first pass piston with oiled piston rings twice through the tool and
t to the co
then remove any resulting metal shavings. Only then install piston
with piston rings.
rrectne
– Push piston into oiled piston fitting tool -T10147- by hand. Low
point of piston crown must face lug on piston fitting tool
s
-arrow-.
s o
cial p
f i
– Hold piston fitting tool (with piston inserted) on upper edge and
nform
press piston in with both thumbs.
mer
atio
m
– Push piston in until it protrudes approx. 15 mm from lower

o
n
c
edge of piston fitting tool .

i
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sd
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– Place piston in respective cylinder bore. Lug on fitting tool

iv
o
pr
-arrow- must face centre of cylinder block.

um
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fo
en
ng
t.
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– Hold fitting tool tightly against cylinder block and push piston
Co
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4. Dismantling and assembling pistons and conrods 41

Touareg 2003 ➤
AG. Volkswagen AG d
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15 – Cylinder head, valve gear

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1 Cylinder head
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Note
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♦ To remove cylinder head, engine must first be removed
ole,
spec
⇒ page 3 .
t to the co
♦ If an exchange cylinder head is installed, all the contact sur‐
faces between the supporting elements, roller rocker fingers
and the running surfaces of the camshafts must be oiled be‐
rrectne
fore the cylinder head cover is installed.
♦ The plastic protectors fitted to protect the open valves must be
ss
removed only immediately before the cylinder head is fitted.
o
cial p
f in
♦ When cylinder head or cylinder head gasket is renewed, the
form
mer
complete coolant must be renewed.
atio
om
n
c
i
Assembly overview - cylinder head ⇒ page 42 .
or
n thi
te
sd
va
Removing and installing cylinder head ⇒ page 46 .

i
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cum
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Checking valve timing ⇒ page 52 .
en
ng
t.
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op
Markings on valve timing housing on MPI engines ⇒ page 54
C py
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Installing timing chains for intermediate shaft drive and camshaft
op Vo
by c lksw
cted
drive ⇒ page 54
agen
Prote AG.
Removing and installing cylinder head cover ⇒ page 63 .

Removing and installing cover ⇒ page 65
Checking compression ⇒ page 68 .
Repairing valve gear ⇒ page 71
1.1 Assembly overview - cylinder head
42 Rep. gr.15 - Cylinder head, valve gear

Touareg 2003 ➤
1 - 10 Nm
2 - Bracket
❑ For wiring harness.
3 - 10 Nm
❑ With spacer sleeve and
seal.
❑ Renew seal if damaged.
4 - Cap
❑ Renew seal if damaged.
5 - Seal
6 - Cylinder head cover
⇒ page 63 .
❑ Renew if damaged.
7 - Lifting eye
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9 - Camshaft rtiming
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❑ Beforeaut removing, mark ra
c
direction
ss
of rotation (in‐
ce
e
stallation position)
nl
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⇒ page 19 .
itte
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ility
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10 - Combination valve
wit
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h re

hole
spec
⇒ page 181 , Removing

es, in part or in w
and installing parts of

t to the co
secondary air system.

rrectness of i
11 - O-ring
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❑ For sealing oil channel.

❑ Renew.
nf
ercia

orm
m
atio
12 - Hall sender 2 -G163-

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c

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14 - Seal Prote
cted AG.
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1. Cylinder head 43
Touareg 2003 ➤
17 - 8 Nm
18 - Seal
❑ For inlet camshaft control valve 1 -N205- ⇒ Item 15 (page 43) and exhaust camshaft control valve 1 -
N318- ⇒ Item 16 (page 43)
olkswagen AG
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19 - Thermostat housing olks
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❑ Dismantling and assembling ⇒ page
ise
d 105 .
b ara
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❑ Coolant hose schematic diagram
au
th ⇒ page 110 . eo
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ss c
20 - Seal
ce
le
un
pt
❑ Renew.
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21 - Hall sender -G40-
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spec
22 - Cover
t to the co
❑ If only cover has been removed, prepare cylinder head gasket for assembly ⇒ page 67 .
❑ With O-ring for sealing oil channel ⇒ Item 11 (page 43) .
rrectne
23 - 60 Nm + 1/4 turn (90°) further
❑ Renew.
ss o
cial p
f
inform
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atio
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❑ Rotate engine only with camshaft adjuster installed.
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25 - Guide rail gh ht
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❑ Clipped into valve timing housing.
26 - Inlet camshaft adjuster
27 - Lifting eye
28 - Cylinder head gasket
❑ Metal gasket.
❑ Renew.
❑ Preparing cylinder head gasket for assembly ⇒ page 67 .
❑ After renewing, renew entire coolant.
29 - Cylinder head
❑ Check for distortion ⇒ page 52 .
30 - Tensioning element
❑ For poly V-belt.
❑ Removing and installing poly V-belt ⇒ page 24 .

Touareg 2003 ➤
31 - Cylinder head bolt

❑ Renew.
❑ Refer to assembly instructions and sequence when loosening and tightening ⇒ page 46 Removing and
installing cylinder head.
32 - Gasket for cylinder head cover
❑ Note installation position.
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1. Cylinder head 45
Touareg 2003 ➤
1.2 Removing and installing cylinder head
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Touareg 2003 ➤

equipment required
♦ Lifting tackle -3033-
♦ Special wrench -3452-
♦ Camshaft bar -T10068 A-
-V.A.G 1331-
Nm) -V.A.G 1332-
5024A-
♦ Workshop hoist -
VAS 6100-
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1. Cylinder head 47
Touareg 2003 ➤
Not illustrated:
♦ Sealant -D 176 501 A1-

♦ Cable ties
Prerequisites
• The engine must be removed.
• The engine must be no more than warm to touch.
Removing
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When doing any repair work,
ss especially in the engine compart‐
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fluid and vacuum) and electrical wiring in their original po‐
, is n
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sitions.
hole
spec
♦ Ensure that there is sufficient clearance to all moving or
es, in part or in w
t to the co
hot components.
rrectness of i
– All cable ties which are opened or cut open when engine is
l purpos
is installed.
– Set crankshaft to TDC No. 1 cylinder marking -arrow- by turn‐
nf
ercia
o
ing crankshaft on the vibration damper securing bolt in direc‐
rm
tion of engine rotation.
m
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om
n in
c

or
thi
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– Now remove cylinder head cover and intake manifold

iv
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⇒ page 63 .
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– Unbolt connecting line -1- from bracket of intake manifold sup‐

port and pull knock sensor 1 -G61- connector -2- out of its
bracket.
– Then unclip wiring harness from its bracket on cylinder head.

Touareg 2003 ➤
– Now unscrew pressure pipe from combination valve -1- and

detach coolant hose -2- from cylinder head under combination
valve.
– Unbolt exhaust manifold from cylinder head.
– Pull connectors off inlet camshaft control valve 1 -N205- and
exhaust camshaft control valve 1 -N318- .
Note
Before removing connectors, mark each connector and compo‐

nent to which it belongs.
– Unbolt securing clips of wiring harness from bracket.

– Now remove thermostat housing ⇒ page 108 Parts of cooling
system - engine side.
AG. Volkswagen
– Remove chain tensioner for camshaft
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– You can now remove coverrise⇒d page 65 . ran
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The cover has a „hidden bolt“. This cannot be removed until ther‐
rm
ab
mostat housing has been removed.
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– Cover can be prised off carefully when all securing bolts have
hole
spec
been removed.
es, in part or in w
t to the co
– Now remove securing bolts from camshaft adjuster
⇒ Item 23 (page 44) .
rrectness of i
l purpos
Note
Counterhold only with 32 mm open-end spanner -arrow- on cam‐

nform
ercia
shaft when loosening or tightening camshaft adjuster. Camshaft

m
bar -T10068 A- must not be inserted.

a
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tion in
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te o
– Remove camshaft adjuster together with camshaft timing

thi
s
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chain from intake camshaft.

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– Then remove exhaust camshaft adjuster.

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– Remove securing bolts -arrows- and remove guide rail -1-.
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– Lay camshaft timing chain aside.
1. Cylinder head 49
Touareg 2003 ➤
– Loosen cylinder head bolts in the sequence given starting at

the outside and working inwards and then remove completely.
Note
Use key -3452- for Polydrive cylinder head bolts.
– Attach lifting tackle -3033- as shown and carefully lift off cyl‐
inder head with workshop crane -VAS 6100- or -
V.A.G 1202 A- :
Vibration damper end: position 3.
Flywheel end: position 11.
Note
♦ The positions labelled 1…12 on the lifting tackle -3033- face

flywheel side.
♦ Adjust length of threaded spindles according to need.
– Carefully remove cylinder head.

– Place clean cloths in cylinders so that no dirt or emery cloth
particles can get in between cylinder wall and piston.
– Also prevent dirt and emery cloth particles from getting into
coolant.
– Now carefully clean sealing surfaces of cylinder head and cyl‐
inder block. When doing this, ensure that surfaces are not gen AG
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does
scored or scratched (if abrasive paper is used, grade must notVolkswa not
be less than „100“). ed
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– Clean all tapped holes for cylinder head bolts. ho eo
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– Carefully remove metal particles, emery residue and cloths.

itte
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If the piston for No. 1 cylinder is not at TDC:

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hole
spec

es, in part or in w
tion of engine rotation. A second mechanic should guide the

t to the co
camshaft timing chain by hand when doing this.

rrectness of i
Note
l purpos
♦ Do not remove new cylinder head gasket from its packing until
immediately before installing.
nform
ercia
♦ Handle new gasket with extreme care. Damage will cause

m
at
leakage.
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– Fit new cylinder head gasket. Inscription (Part No.) must be

at
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readable.
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Rep. gr.15 - Cylinder head, valve gear Prote AG.
Touareg 2003 ➤
– Ensure that dowel sleeves are inserted into cylinder block

holes 12 and 20, and that cylinder head gasket is located.
AG. Volkswagen AG d
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– Position camshafts in cylinder head to TDC No. 1 cylinder.
Vol
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spec
– Camshaft bar -T10068 A- must engage in grooves in both urposes, in part or in wh
t to the co
shafts.
– Now prepare cylinder head gasket for assembly
rrectne
⇒ page 67 .
– Fit cylinder head, screw in new cylinder head bolts and tighten
ss
hand tight.
o
cial p
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mer
atio
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– Tighten cylinder head bolts in tightening sequence shown
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The longer cylinder head bolts must be inserted in the centre

holes of cylinder head.
– Pre-tighten all bolts to 30 Nm.

– Then tighten all bolts to 50 Nm.
– Then tighten all bolts 1/4 turn (90°) further using a rigid wrench.
– Then tighten all bolts again 1/4 turn (90°) further.
Further assembly is basically the reverse of the dismantling se‐

quence.
Adjusting valve timing ⇒ page 60 .
Note
Ensure that the O-ring for sealing the oil channel is fitted in the
cover.
– Install cylinder head cover and intake manifold ⇒ page 63 .

Filling with new coolant ⇒ page 111 .
Note
It is not necessary to retighten cylinder head bolts after repairs.
1. Cylinder head 51
Touareg 2003 ➤
Checking cylinder head for distortion

♦ Straight edge
♦ Feeler gauges
Max. permissible distortion: 0.05 mm.
1.3 Checking valve timing
Note AG. Volkswagen AG d

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The valve timing can be checked with the engine
ed by installed. gu
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Special tools and workshop equipment
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Test procedure
m
at
– Remove cylinder head cover and intake manifold

om
ion
⇒ page 63 .
c
in t
or
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– Remove front noise insulation: ⇒ General body repairs, exte‐

at
do
riv
rior; Rep. gr. 50 ; Body - front; Assembly overview - noise

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– Set crankshaft to TDC No. 1 cylinder marking -arrow- by turn‐ C py
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Touareg 2003 ➤
– Cams -A- of cylinder 1 must face each other.
– Insert camshaft bar -T10068 A- in both shaft grooves.
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The grooves of the camshafts might not be exactly vertical due to s
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le
the function of camshaft adjusters. Therefore, if necessary, move

un
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an
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the camshafts back and forth slightly when inserting the camshaft
itte
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bar -T10068 A- using an open-end spanner.

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Check setting marks of camshaft adjusters against marks on con‐

h re
trol housing:
ole,
spec
t to the co
– Marks -A- and -B- on camshaft adjusters must align with

rrectne
notches -arrows- in valve timing housing -C-. Markings on

valve timing housing ⇒ page 54
ss
– The distance between tooth -1- and tooth -2- of the camshaft
o
cial p
adjuster must be exactly 16 rollers of the camshaft roller chain.

inform
mer
atio
m
Note
o
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or
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sd
♦ Figure shows view with cover removed.

iva
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♦ On the control housing can also be markings for FSI engines,

fo
en
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depending on version. Observe only markings for MPI engines

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⇒ page 54 .
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If the markings do not align: Prote
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– Adjust valve timing ⇒ page 54 .

If the markings align:
1. Cylinder head 53
Touareg 2003 ➤
Markings on valve timing housing on MPI engines

On the control housing can also be markings for FSI engines,
depending on version. Observe only markings for MPI engines.
-A- View from flywheel end
-B- View from vibration damper end
The markings on camshaft adjusters must align with notches
-arrows-.
1.4 Installing timing chains for intermediate shaft drive and camshaft drive
Special tools and workshop agen

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♦ Camshaft bar -T10068 A- horis nte
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♦ Counterhold tool -T10069- ss c
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♦ Torque wrench -
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♦ Sealant -D 176 501 A1-

spec
es, in part or in w
t to the co
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Touareg 2003 ➤
Procedure
Caution

tions:
sitions.
♦ To avoid damage to lines/wiring, ensure sufficient clear‐
ance to all moving or hot components.
Note
The following procedure is only possible and described with en‐

gine removed. You can start with adjustments at the relevant
point, depending on how far the engine has been dismantled. The
sump is removed and may only be fitted after installing the sealing
flange.
Install timing chain and chain tensioner with tensioning plate for
intermediate shaft drive:
– First set crankshaft to TDC No. 1 cylinder. For this, the ground
down tooth of drive sprocket -arrow- must align with main
bearing joint. gen AG
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– Install both pins without
db
y V collar for guide rail and tighten
t gu to
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10 Nm. Fit guideoriserail on studs. nte
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ut or
– Turn intermediate
ss
a
shaft with flattened side upwards. ac
ce
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nl
– Insert timing chain into guide rail and place on crankshaft.

pt
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– Insert large chain sprocket into timing chain so that lug on

es, in part or in w
t to the co
chain sprocket aligns with marking behind on cylinder block

-arrow B-.
– Fit chain sprocket onto intermediate shaft.
rrectness of i
When installing, ensure that timing chain runs completely straight

l purpos
in guide rail from crankshaft to intermediate shaft.

• Ground tooth of drive sprocket must align with main bearing
nf
ercia
joint -arrow A-.

rm
m
atio
m
• Lug on chain sprocket of intermediate shaft must align with

o
n in
c
marking behind -arrow B-.

or
thi
te
sd
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– If large chain sprocket cannot be fitted, turn intermediate shaft

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slightly.
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If timing chain has already been used, note marking for direction Prote AG.
of rotation.
1. Cylinder head 55
Touareg 2003 ➤
– Fit small chain sprocket of intermediate shaft. Installation is

only possible in one position.
– Tighten bolt -arrow- hand-tight only as small chain sprocket
has to be taken off again.
– Now install chain tensioner.
– To do this, release locking teeth of chain tensioner -A- with a

small screwdriver and press tensioning plate against chain
tensioner.
AG. Volkswagen AG d
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– Install chain tensioner in this position and tighten to 8 Nm
, is n
h re
-arrows-.
hole
spec
Installing timing chain for camshaft drive:
es, in part or in w
t to the co
Prerequisite
rrectness of i
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nf
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orm
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atio
om
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or c
• The camshaft adjusters are installed thi

te
sd
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• Cams -A- of cylinder 1 must face each other.

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• Crankshaft is positioned at TDC

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Prote AG.

Touareg 2003 ➤
– Insert camshaft bar -T10068 A- in both shaft grooves.
– Remove small chain sprocket on intermediate shaft. The large

chain sprocket must not be pulled off.
– Route chain between tensioning bar and guide rail in direction
of valve timing housing.
– Fit timing chain onto camshaft adjuster such that 2 individual

copper-coloured chain links -4- align with markings on cam‐
shaft adjuster -3- and with markings on valve timing housing
-5-. Markings on valve timing housing
agen⇒ page 54
AG. Volkswagen AG d
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olks ot
– Fit small chain sprocket ofeintermediate
db
yV shaft into timing chain.guara
Marking -2- must alignhwith
oris middle copper-coloured chain link nte
eo
-1-. s aut ra
c
s
– Fit small chain sprocket with timing chain attached onto inter‐
ce
le
un
pt
mediate shaft. Installation is only possible in one position.

an
d
itte
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rm
ab
pe
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nform
mercia
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tion in
r
te o
thi
s
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Prote AG.
1. Cylinder head 57
Touareg 2003 ➤
– Tighten new securing bolt for intermediate shaft chain sprock‐

ets -arrow- to 60 Nm + 90° (1/4 turn further). (Further turning
can be done in several steps.)
– Check position of crankshaft to intermediate shaft
wage
n AGonce
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• Ground tooth of drive sprocket must align with main bearing
hole
spec
joint -arrow B-.
es, in part or in w
t to the co
• Lug on chain sprocket of intermediate shaft must align with
marking behind -arrow C-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cted agen
Prote AG.
– Check position of copper coloured chain links to adjustment
markings.
Note
The copper coloured chain links no longer align with the adjust‐
ment markings once the crankshaft has been turned.

Touareg 2003 ➤
– Apply sealant -D 176 501 A1- onto clean sealing surface of

sealing flange as shown.
Note
Observe dowel pins in cylinder block.

AG. Volkswagen AG d
agen oes
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– Immediately install sealing flange. byV gu
ara
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– Insert all securing bolts by hand and tighten to 10autNm.
h
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ss c
– Now install oil seal for crankshaft in sealing flange
ce
le
un
pt
⇒ page 28 .
an
d
itte
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– Now install sump ⇒ page 95 .
rm
ab
pe
ility
If seals in cover are to be renewed ⇒ page 67 . ot
wit
, is n
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– Clean sealing surface on cover and cylinder head.
hole
spec
es, in part or in w
t to the co
– Lubricate O-ring for oil channel seal -1- and insert in cover.
– Check that dowel sleeves -2- and -3- are inserted.
rrectness of i
– Insert O-ring -4- in cover.
l purpos
nform
mercia
a
com
tion in
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thi
s
iva
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en
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– Remove old sealant from 3 mm holes in cylinder head gasket

n
t.
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-arrows-. C py
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– Fill 3 mm holes in cylinder head gasket with sealant -D 176 copy Vo
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501 A1- . Coat sealing surfaces of cover with sealant -D 176 cted agen
Prote AG.
501 A1- and install cover without delay.
– First insert all securing bolts -arrows- and tighten lightly.

– Then tighten M8 securing bolts to 23 Nm and then tighten M6
securing bolts to 8 Nm.
1. Cylinder head 59
Touareg 2003 ➤
AG. Volkswagen AG d
agen oes
– Install chain tensioner for camshaft timingolkchain
sw -arrow- and not
yV gu
tighten to 40 Nm. s ed b ara
nte
ri
ho eo
– Turn crankshaft two full turns inutdirection of engine rotation ra
sa c
and check valve timing again ⇒ page 52 .
s
ce
le
un
pt
an
d
itte
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Note rm
ab
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ility
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The copper coloured chain links no longer align with the adjust‐
, is n
h re
ment markings once the crankshaft has been turned.
hole
spec
es, in part or in w
t to the co
1.5 Installing camshaft adjuster with timing
rrectness of i
chain for camshaft drive
l purpos
• Timing chain for intermediate shaft drive and sealing flange

are installed.
nform
ercia

m
a
com
tion in
r
te o
thi
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cum
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by lksw
cted agen
Prote AG.
– Cams -A- of cylinder 1 must face each other.
– Insert camshaft bar -T10068 A- in both shaft grooves. If nec‐

essary, move the camshafts back and forth slightly with an
open-end spanner.

Touareg 2003 ➤
Note
Both camshaft adjusters (marking: „24E“ on inlet side and „32A“

on exhaust side) can be screwed at camshaft mounting in one
position only -arrows- due to a dowel pin.
– Now turn sender wheel -1- on removed inlet camshaft adjuster

to right stop in -direction of arrow- and hold adjuster in this
position.
Note
If inlet camshaft adjuster is bolted to the camshaft, turn

agen adjuster
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with chain sprocket to left accordingly andbthen
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– Ensure the camshaft timing chain is »tight« against the guide
erm
ab
rail -1- and does not »sag«.
ility
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It must be possible to easily position adjuster and tighten it hand-
h re
ole,
tight with camshaft timing chain positioned »tautly« on inlet cam‐
spec
shaft.
t to the co
rrectness o
cial p
f inform
mer
• „Arrow“ -1- on the camshaft adjuster of the inlet camshaft must

atio
m
align with the left notch -2- on the control housing. Markings
o
n
c
on valve timing housing ⇒ page 54

or
n thi
te
sd
va
– Now, from the tooth that is aligned with the „24E“ marking,
i
o
pr
count exactly 16 rollers on the timing chain to the right. Mark

um
r
fo
en
ng
this roller with a coloured pen.

t.
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cted agen
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1. Cylinder head 61
Touareg 2003 ➤
– Turn sender wheel -1- of exhaust camshaft adjuster to right

onto stop -arrow- and hold adjuster in this position.
AG. Volkswagen AG d
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erm
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ility
ot p
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– Insert exhaust camshaft adjuster into camshaft timing chain
h re
with tooth on marking „32A“ so that the previously counted 16
hole
spec
rollers lie precisely between marking „24E“ and „32A“, and
es, in part or in w
markings align.
t to the co
– It must be possible to easily position the exhaust camshaft
adjuster onto the exhaust camshaft and tighten it hand-tight.
rrectness of i
– Check the position of both camshaft adjusters again to ensure
l purpos
the setting is correct.

– Remove camshaft bar -T10068 A- .
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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o
Note
r
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t.
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So that the camshaft timing chain does not jump a tooth when the
Co
op py
crankshaft is turned, the tensioner plate must be pressed against
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ht ht
rig
the camshaft timing chain by hand instead of with chain tensioner. py by
co Vo
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cted agen
Prote AG.
– Turn crankshaft two full turns in direction of engine rotation
and check valve timing ⇒ page 52 .
If the markings align:
– Hold camshaft which is to be tightened using a 32 mm open-

end spanner -arrow-.
Note
Camshaft bar -T10068 A- must be removed while this is done.
– Tighten securing bolts of inlet and exhaust camshaft adjusters

to 60 Nm + 90° (1/4 turn) further.
If seals in cover are to be renewed ⇒ page 67 .
– Clean sealing surface on cover and cylinder head.

Touareg 2003 ➤
– Lubricate O-ring for oil channel seal -1- and insert in cover.
– Check that dowel sleeves -2- and -3- are inserted.
– Insert O-ring -4- in cover.

-arrows-.
– Fill 3 mm holes in cylinder head gasket with sealant -D 176
501 A1- . Coat sealing surfaces of cover with sealant -D 176
501 A1- and install cover without delay.

Volkswa
– Install chain tensioner for camshaft timing
wagechain and tighten dto
n AG. gen AG
oes
40 Nm. Volks not
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ise
– Turn crankshaft two full turnsho in direction of engine rotation
r tee
ut or
and check valve timing sagain.
s a ac
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un
pt
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rm
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1.6 Removing and installing cylinder head cover

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
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Cop py
t. rig
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pyri by
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1. Cylinder head 63
Touareg 2003 ➤

equipment required
♦ Spring-type clip pliers -VAS AG. Volkswagen AG d
5024 A- agen oes
olksw not
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d by ara
♦ Torque wrench -V.A.G orise nte
1331- aut
h eo
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ss c
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nl
pt
du
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♦ Puller -T10095 A-
itte
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erm
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ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
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n in
or c
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Cop py
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Removing
– All cable ties which are opened or cut open when engine is
is installed.
– Remove engine covers.
– Remove ignition coils with output stages ⇒ page 188 .
– Remove intake hose between air mass meter -G70- and throt‐
tle valve module -J338- .
– Detach 6-pin connector from throttle valve module -J338- and
2-pin connector from activated charcoal filter solenoid valve 1
-N80- and crankcase breather valve.

Touareg 2003 ➤

Vehicles with engine code BAA or BMX
– Unscrew intake manifold support securing bolt -5-.
– Unscrew left and right intake manifold supports from intake
manifold.
– Remove crankcase breather hose from cylinder head cover.
AG. Volkswagen AG d
agen oes
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– Then unscrew securing bolts -1- and -2- from intake
thor manifold. eo
au ra
– Detach vacuum hose from intake manifold change-over
ss
vac‐ c
ce
le
uum actuator.
un
pt
an
d
itte
– Unscrew intake manifold from cylinder head.
y li
rm
ab
pe
ility
– Remove intake manifold and place it on a suitable surface so
ot
wit
that the vacuum unit will not be damaged.
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
Seal intake ports in intake manifold and in cylinder head with a
clean cloth.
rrectness of i
l purpos
– At front of cylinder head cover unscrew bracket for cables to

knock sensor 1 -G61- and oil level and oil temperature sender
-G266- .
nform
ercia
– Remove cylinder head cover.

m
a
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tion in
Installing
r
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Installation is carried out in the reverse order. When installing,
s
iva
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note the following:

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Note
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by
♦ Bolt intake manifold first to cylinder head. Then tighten two cted agen
Prote AG.
bolts for heat shield and bolts for intake manifold support.
♦ Ensure that fuel hose connections are tight.
Specified torques
Threaded connection Specified torque
Cylinder head cover to cylinder head 10 Nm
Intake manifold to cylinder head 13 Nm
Intake manifold to support 20 Nm
Heat shield to exhaust manifold 23 Nm
Dipstick guide tube to intake manifold 8 Nm
1.7 Assembly overview - removing and in‐

stalling cover
Installing cover seals ⇒ page 67 .
1. Cylinder head 65
Touareg 2003 ➤
Note
The cover can be removed or installed only with the engine re‐
moved.
1 - Cable guide
❑ For wiring harness.
2 - 8 Nm
3 - 8 Nm
❑ Before removing, mark
connector belonging to
component.
❑ For camshaft timing lkswage es n
o ot g
chain byV ua
d ran
⇒ Item 9 (page 43) ir se tee
tho
u or
❑ Only rotate engine when ss
a ac
chain tensioner is instal‐
ce
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nl
pt
led.
du
an
itte
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6 - Seal
erm
ab
ility
ot p
❑ Renew if damaged or
wit
, is n
leaking.
h re
hole
spec
7 - 8 Nm
es, in part or in w
t to the co
8 - Seal
❑ For inlet camshaft con‐
trol valve 1 -N205-
rrectness of i
⇒ Item 15 (page 43) and
exhaust camshaft con‐
l purpos
trol valve 1 -N318-

⇒ Item 16 (page 43)
nf
ercia
❑ Renew if damaged or
orm
leaking.
m
atio
m
o
n in
or c
thi
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9 - Bracket
t
sd
iva
o
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❑ For continued coolant

rp
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circulation pump -V51-

f
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t.
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❑ For activated charcoal filter system solenoid valve 1 -N80- . Cop py
t. rig
gh ht
yri
10 - Thermostat housing p by
co Vo
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cted
agen
Prote AG.
11 - 23 Nm
12 - Seal
13 - Cover
❑ Preparing cylinder head gasket for assembly ⇒ page 67 .

AG. Volkswagen AG d
agen oes
olksw not
V gu
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r
ut
ho eo
ra Touareg 2003 ➤
a c6-cylinder
ss injection engine - Edition 02.2012
ce
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nl
pt
du
an
15 - O-ring
itte
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erm
ab
❑ For sealing oil channel.
ility
ot p
❑ Renew.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Preparing cylinder head gasket for assembly
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
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Special tools and workshop equipment required Cop py
t. rig
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♦ Sealant -D 176 501 A1-
p by
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by c lksw
cted agen
Procedure
Prote AG.

-arrows-.
501 A1- and coat sealing surfaces on cover and sealing flange
with sealant -D 176 501 A1- . Fit cover immediately.
Note
With the cylinder head installed, the holes in the cylinder head
gasket are only half visible.
1.7.1 Installing cover seals

♦ Fitting sleeve -3378-
1. Cylinder head 67
Touareg 2003 ➤
♦ Fitting sleeve -3253/6- from assembly tool -3253-
Installing agen
AG. Volkswagen AG d
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– Do not lubricate seals. d by gu
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– Install oil seal with fitting sleeve -3378- in cover -1- and
aut pull in
h
ra
flush using fitting sleeve -3253/6- from assembly tool s -3253- .
s c
ce
le
un
pt
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d
itte
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ab
ility
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is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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1.8 Checking compression

i
o
pr
cum
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fo
en
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤

equipment required
-V.A.G 1331-
♦ Compression tester -
V.A.G 1763-
♦ Spark plug socket and ex‐
tension -3122 B-
AG. Volkswagen AG d
agen oes
olksw not
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aut ra
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nl
pt
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itte
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ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
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n in
or c
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te
sd
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t.
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Cylinder head 69
Touareg 2003 ➤
Test prerequisites
• Engine oil temperature must be at least 30°C.
• The battery voltage must be at least 11.5 V.
• All electrical consumers, e.g. lights and rear window heating,
must be switched off.
• If the vehicle is equipped with an air conditioner,nitAmust
G. Volkbe
swagen AG
switched off. olks
wage does
no
V t gu
by ara
• On vehicles with automatic gearboxristhe
ed selector lever must be nte
in „P“ or „N“ position. utho eo
ra
a c
ss
• Fuses -13- and -14-, -arrows- must be removed from their
ce
le
un
sockets.
pt
an
d
itte
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Test procedure
rm
ab
pe
ility
– Remove engine cover.
ot
wit
, is n
h re
– Remove ignition coils with output stages ⇒ page 188 .
hole
spec
– Remove spark plugs using spark plug socket and extension
es, in part or in w
t to the co
-3122 B- .
– Check compression using compression tester -V.A.G 1763- .
rrectness of i
l purpos
Note
Using compression tester ⇒ operating instructions .
nform
mercia
a
com
– Have a second mechanic fully depress accelerator and crank
tion in
engine.
r
te o
thi
s
– Operate starter until tester shows no further pressure in‐
iva
do
r
crease.
rp
cum
fo
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Compression pressures:
t.
yi Co
Cop py
ht. rig
New: 10…13 bar opy
rig by
Vo
ht
c lksw
Wear limit: 7.5 bar.
by
cted agen
Prote AG.
Maximum permissible difference between all cylinders: 3 bar.

– Insert spark plugs using spark plug socket and extension
-3122B- and tighten to 20 Nm.
After completing assembly work:
– Connect Vehicle diagnosis, testing and information system -
VAS 5052- .
– Carry out vehicle system test ⇒ Vehicle diagnostic tester „Gui‐
ded fault finding“.
– Finish the vehicle system test so that any fault entries stored
during assembly can be deleted automatically.
– Carry out road test.
– Generate readiness code in combination with road test.
Observe applicable safety precautions during road test.
– Then carry out vehicle system test again and rectify any faults
which may have occurred.

Touareg 2003 ➤
2 Valve gear
Assembly overview ⇒ page 71 .
Removing and installing camshafts ⇒ page 73 .
Renewing valve stem seals ⇒ page
gen A84 . olkswagen AG d
G. V
wa oes
olks not
Checking valve guides d⇒bypage
V 85 . gu
ara
e nte
ris
Reworking valve seats
ut
ho ⇒ page 86 . eo
ra
a c
ss
Valve dimensions ⇒ page 88 .
ce
e
nl
pt
du
an
2.1 Assembly overview
itte
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erm
ab
ility
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1 - 5 Nm + 1/8 turn (45°) further
h re
hole
spec
2 - Exhaust camshaft bearing
es, in part or in w
cap
t to the co
❑ Installation position
⇒ page 73 .
rrectness of i
❑ Lightly coat contact sur‐
face of bearing cap 8
l purpos
with grease -G 052 723

A2- before installing
⇒ page 73 .
nform
ercia
❑ Installation sequence
m
at
om
⇒ page 73 Removing
ion
c
and installing camshaft. in t

or
his
ate
3 - Seal
do
priv
cum
❑ Renew if leaking.
for
en
ng
t.
❑ When installing valve
yi Co
op py
timing housing, lightly t. C rig
gh ht
lubricate contact surfa‐ yri
p by
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ces of seal. by c lksw
cted agen
Prote AG.
❑ When replacing seals,
do not spread too wide‐
ly.
4 - Exhaust camshaft
❑ Checking radial clear‐
ance with Plastigage;
wear limit: 0.1 mm.
❑ Runout: max. 0.01 mm.
❑ Checking axial clear‐
ance ⇒ page 80 .
❑ Identification
⇒ page 80 .
⇒ page 73 .
5 - Valve timing housing
❑ Lightly lubricate contact surfaces of oil seals before installing.
❑ Before installing valve timing housing, check strainer for soiling ⇒ page 79 .
❑ Removing and installing ⇒ page 73 Removing and installing camshafts.
❑ Markings on valve timing housing ⇒ page 54
6 - Camshaft timing chain
❑ Before removing, mark direction of rotation (installation position) ⇒ page 19 .
2. Valve gear 71
Touareg 2003 ➤

8 - 60 Nm + 1/4 turn (90°) further
❑ Renew.
10 - Cylinder head height
❑ Minimum height: a = 139.9 mm. AG. Volkswagen AG d
agen oes
lksw not
11 - Valves d byV
o gu
ara
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❑ Do not rework, only lapping-inthois permitted.
r eo
u ra
❑ Valve dimensions ⇒ page s88 .
s a c
ce
le
un
12 - Cylinder head
pt
an
d
itte
y li
❑ Check for distortion ⇒ page 52 .
erm
ab
ility
ot p
wit
is n
❑ Reworking valve seats ⇒ page 86 .
h re
ole,
spec
13 - Support element
t to the co
❑ Before installing, check camshaft axial clearance ⇒ page 80 .
❑ Do not interchange.
rrectne
❑ With hydraulic valve clearance compensation.
s
14 - Valve stem seal

s o
cial p
inform
mer
15 - Securing clip
atio
m
❑ Check for secure seating.

o
n
c
i
or
n thi
16 - Roller rocker finger

te
sd
iva
❑ Before installing, check camshaft axial clearance ⇒ page 80 .

pr
cum
r
fo
en
❑ Do not interchange.
ng
t.
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op
❑ Check roller bearing for ease of movement. C py
ht. rig
rig ht
❑ Oil contact surface. py by
co Vo
by lksw
❑ When installing, secure to supporting element using securing clip.
cted agen
Prote AG.
17 - Valve spring
❑ Removing and installing ⇒ page 84 , Renewing valve stem seals.
18 - Valve spring plate
19 - Valve cotters
20 - Inlet camshaft bearing cap
❑ Installation position ⇒ page 73 .
❑ Lightly coat contact surface of bearing cap 7 with grease -G 052 723 A2- before installing ⇒ page 73 .
❑ Installation sequence ⇒ page 73 Removing and installing camshaft.

Touareg 2003 ➤
21 - Inlet camshaft
❑ Checking radial clearance with Plastigage; wear limit: 0.1 mm.
❑ Runout: max. 0.01 mm.
❑ Checking axial clearance ⇒ page 80 .
❑ Identification ⇒ page 80 .
Fitting position of camshaft bearing caps agen

AG. Volkswagen AG d
oes
olksw not
Points of bearing caps -arrow A- of inlet and outlet
ed by V camshafts face gu
ara
outwards. horis nte
eo
aut ra
ss c
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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
Lightly coat contact surfaces of bearing caps 7 and 8 with grease
at
om
i
-G 052 723 A2- before installing.
on
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.
2.2 Removing and installing camshafts

Removing camshafts ⇒ page 74 .
Installing camshafts ⇒ page 76 .
Camshafts, checking axial clearance ⇒ page 80
Camshaft identification ⇒ page 80 .
Renewing valve stem seals ⇒ page 84 .
Checking valve guides ⇒ page 85 .
Reworking valve seats ⇒ page 86 .
Valve dimensions ⇒ page 88 .
2. Valve gear 73
Touareg 2003 ➤

equipment required
-V.A.G 1331-
Nm) -V.A.G 1332-
♦ Sealant -D 176 501 A1-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
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tho eo
au ra
ss c
ce
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un
pt
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ility
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2.2.1 Removing camshafts

h re
hole
spec
es, in part or in w
t to the co
Note
Camshafts can be removed only when engine or cylinder head is

rrectness of i
removed.
l purpos
Caution
nform
mercia

a
com
tio

n in
tions:
r
te o
thi
s
iva
do
r
rp
cum

fo
en
g

n
t.
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sitions. Cop py
t. rig
gh ht
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p by
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by lksw
hot components. Prote
cted AG.
agen

Touareg 2003 ➤
Procedure
Volkswa
– Set crankshaft to TDC No. 1 cylinder
agen marks -arrow-
AG. gen AG
dby
oesturning
ksw
crankshaft on the vibration
by V damper securing bolt in direction
ol not
gu
ara
of engine rotation: rised
nte
tho eo
– Now remove cylinder
ss
au head cover and intake manifold ra
c
⇒ page 63 .
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 chain tensioner for camshaft timing chain -arrow-.
rrectness of i
– Now unscrew camshaft cover.
l purpos
Note
nform
ercia
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op py
– Mark camshaft timing chain before removing (e.g. with paint/
. C rig
ht ht
rig
coloured mark, arrow pointing in direction of rotation). py by
co Vo
by lksw
cted agen
Prote AG.
Note
Do not mark chain by way of centre punch, notch or the like.
– First remove exhaust camshaft adjuster.
Note
Counterhold only with 32 mm open-end spanner -arrow- on cam‐

shaft. The camshaft bar -T10068 A- must not be fitted when
camshaft adjuster is loosened or tightened.
– Remove camshaft adjuster together with camshaft timing

chain from intake camshaft.
– Lay camshaft timing chain aside.
2. Valve gear 75
Touareg 2003 ➤
– Unbolt control housing from cylinder head -arrows-.

n AG . Volkswage
– Carefully detach valve timing housingksfrom
wage camshaft seals. does n
n AG
ol ot g
yV ua
edb ran
ris tee
Note tho or
au ac
ss
ce
If you have to disassemble the valve timing housing or clean the e
nl
pt
du
an
strainer ⇒ page 79 and ⇒ page 79
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
-A- Inlet camshaft
t to the co
– First remove bearing caps 1 and 13.
rrectness of i
– Remove bearing caps 3 and 11.
l purpos
– Remove bearing cap 7.

– Loosen bearing caps 5 and 9 alternately and diagonally.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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f
en
ng
-B- Exhaust camshaft

t.
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op py
– First remove bearing caps 2 and 14.
t. C rig
gh ht
pyri by
Vo
o
– Remove bearing caps 4 and 12. by c lksw
cted agen
Prote AG.
– Remove bearing cap 8.
– Loosen bearing caps 6 and 10 alternately and diagonally.
Continuation for both camshafts
– Carefully remove camshafts and lay aside on clean surface.
– Remove roller rocker fingers together with support elements
and lay aside on a clean surface.
– Ensure that roller rocker fingers and support elements are not
interchanged.
2.2.2 Installing camshafts

Prerequisite
• When camshafts are installed, cams for No. 1 cylinder must
point upwards.

Touareg 2003 ➤
Procedure
– Lightly coat contact surfaces of bearing caps 7 and 8 with
grease -G 052 723 A2- before installing.
– Install supporting elements in cylinder head and fit respective

roller rocker finger onto respective valve stem end or support‐
ing element.
– Ensure that all roller rocker fingers -1- seat properly on valve
stem ends and are clipped into their respective support ele‐
ments -2-.
– Oil running surfaces of camshafts.
– Carefully place each camshaft in its respective bearing in the
cylinder head. When doing this, observe camshaft identifica‐
tion ⇒ page 80 .
Note
♦ Observe fitting position of bearing caps:olkswagen AG

en AG. V ag does
ksw
♦ Points of bearing caps -arrow
Vol A- of inlet and outlet camshafts
ot g n
by ua
face outwards. ris
ed ran
tee
tho or
♦ Identification onss bearing caps is right side up when viewed au ac
from inlet side.
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
-A- Inlet camshaft

– Tighten bearing caps 5 and 9 alternately and diagonally to
nf
ercia
5 Nm + 1/8 turn (45°) further.

orm
m
atio
m
– Install bearing caps 1 and 13 and tighten to 5 Nm + 1/8 turn

o
n in
or c
(45°) further.
thi
te
sd
iva
– Install bearing cap 7 and tighten to 5 Nm + 1/8 turn (45°) fur‐

o
r
rp
cu
o
ther.
f
en
ng
t.
yi Co
op
– Install bearing caps 3 and 11 and also tighten to 5 Nm + 1/8 C py
ht. rig
ht
turn (45°) further.
rig by
copy Vo
by lksw
cted agen
Prote AG.
2. Valve gear 77
Touareg 2003 ➤
-B- Exhaust camshaft

– Tighten bearing caps 6 and 10 alternately and diagonally to
5 Nm + 1/8 turn (45°) further.
– Install bearing caps 2 and 14 and tighten to 5 Nm + 1/8 turn
(45°) further.
– Install bearing cap 8 and tighten to 5 Nm + 1/8 turn (45°) fur‐
ther.
– Install bearing caps 4 and 12 and also tighten to 5 Nm + 1/8
turn (45°) further.
Continuation for both camshafts agen
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– Position camshafts in cylinder head byV
to TDC No. 1 cylinder. gu
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– Camshaft bar -T10068 A-smust
s a engage in grooves in both c
shafts.
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– Before installing, check valve timing housing strainer for soil‐

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ing ⇒ page 79 .
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– Before installing valve timing housing, lightly lubricate valve
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timing housing surfaces contacting camshaft seals.
h re
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spec
– Lightly lubricate contact surfaces of camshaft seals and slowly
push valve timing housing over camshaft seals.
t to the co
rrectnes
– Install control housing -arrows- and tighten to 8 Nm.
s o
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f i
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Touareg 2003 ➤

-arrows-.
Note
– Fill 3 mm drillings in cylinder head gasket with sealant -D 176

501 A1- and apply a raised drop of sealant at each of these
points.
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Sealant -D 176 501 u A1- hardens quickly.
th or
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– Lubricate O-ring for oil channel seal and insert into cover.
du
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– Coat sealing surface of cover with sealant -D 176 501 A1- and
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immediately install.
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– First insert all securing bolts and tighten lightly.
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– Install chain tensioner for camshaft timing chain and tighten to
40 Nm.
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Dismantling and assembling valve timing housing

nform
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1 - Guide rail: clipped into control housing

m
at
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2 - Valve timing housing

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5 - 8 Nm
n
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Removing and installing camshaft control valves ⇒ page 80 .
t. rig
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Checking valve timing housing strainer for soiling.

– Unclip strainer -2- from back of valve timing housing -1- and
remove any dirt.
2. Valve gear 79
Touareg 2003 ➤
2.2.3 Camshafts, checking axial clearance

♦ Universal dial gauge bracket -VW 387-
♦ Dial gauge
Test procedure
Perform measurements with support elements and roller rocker
fingers removed.
Middle bearing cap of respective camshaft installed.
– Screw universal dial gauge bracket -VW 387- with fitted gauge
to cylinder head as shown and measure axial clearance.
Wear limit: max. 0.10 mm
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2.2.4 Camshaft identification

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Identification between cam pair for cylinders 4 and 5 of respective

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camshaft.
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Camshaft Identification
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A - exhaust camshaft 022 101 Index

B - inlet camshaft 022 102 Index
rrectne
Valve timing at 1 mm valve lift

ss
Inlet valve Exhaust valve

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Opens BTDC --- 211.5°

form
mer
Closes BTDC --- 6.5°

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Opens ATDC 18.50° ---

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Closes ATDC 223.5° ---

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2.3 Removing and installing camshaft control valves

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Touareg 2003 ➤

equipment required
1783-
♦ Torx bit set -V.A.G 1766-
♦ 1/4" drive ratchet -VAS
6234-
♦ Special wrench, long reach
-T10072-
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Not illustrated:
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♦ Sealant -D 176 501 A1-

form
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Removing:
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n
c
Prerequisites
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or
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• The engine must be removed.

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– Remove cylinder head cover ⇒ page 63 .

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Before removing connectors, mark each connector and compo‐
nent to which it belongs.
– Disconnect connectors from following components of cover:

♦ Inlet camshaft control valve 1 -N205-
♦ Exhaust camshaft control valve 1 -N318-
♦ Hall sender -G40-
♦ Hall sender 2 -G163-
2. Valve gear 81
Touareg 2003 ➤
– Move wiring harness clear.

Note
– Remove chain tensioner for camshaft timing chain -arrow-.
– Remove securing bolts -arrows- from cover.

– Cover can be prised off carefully when all securing bolts have
been removed.
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♦ Cover lower chain horishousing carefully so that no parts can nte
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fall into it. s aut ra
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♦ Securing bolts for camshaft timing control valves must not
ce
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be completely removed at first, so that the valve is not

an
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canted during removal.

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Prote AG.

Touareg 2003 ➤
– Unscrew securing bolts for camshaft control valves approx.

3 mm (5 turns) with socket -T10072- -arrows-.
– Pull camshaft control valve out of seat in control housing and
slide it along loosened bolts.
– Completely remove securing bolts and pull camshaft control
valve out of control housing.
Installing:
Caution
♦ The valve seat in the control housing must not be scored

or scratched.
♦ The camshaft control valves and the control housing must
be free of dirt and soiling.
♦ Ensure the camshaft control valves are protected from
knocks and impacts.
♦ Only unpack the new camshaft control valves immediately
prior to installation.
♦ The camshaft control valves must not be pulled into their
seat with the securing bolts. Only insertion by hand is per‐
mitted.
– Moisten seals with clean engine oil.

– Carefully insert camshaft control valve into housing and push
vertically to valve axis to stop by hand.
– Tighten securing bolts -arrows- to 3.8 Nm.

-1- Camshaft control valve 1 -N205- colour of connector: black.
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-2- Exhaust camshaft control valve 1 -N318-Vocolour
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– Clean sealing surface on coverauand
th cylinder head. ra
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– If seals in cover are to be renewed ⇒ page 67 .
ce
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– Lubricate O-ring for oil channel seal ⇒ Item 15 (page 67) and
itte
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insert in cover.
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– Insert O-ring ⇒ Item 12 (page 66) in cover.

wit
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-arrows-.
t to the co

501 A1- and coat sealing surfaces on cover and sealing flange
rrectne
with sealant -D 176 501 A1- .

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mer
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– Fit cover as quickly as possible.

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2. Valve gear 83
Touareg 2003 ➤

– Then tighten M8 securing bolts ⇒ Item 11 (page 66) to 23 Nm
and M6 securing bolts ⇒ Item 7 (page 66) to 8 Nm.
– Install chain tensioner for camshaft timing chain
⇒ Item 5 (page 66) and tighten to 40 Nm.
– Install cylinder head cover ⇒ page 63 and intake manifold.
quence.
2.4 Renewing valve stem seals

equipment required
♦ Valve lever -VW 541/1 A-
with press tool -VW 541/6- n AG. Volkswagen AG do
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♦ Valve assembly device byV
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-2036- with adapter plates o
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tee
-2036/1- auth or
ac
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♦ Spark plug socket and ex‐
ce
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nl
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tension -3122 B-
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♦ Valve stem seal puller
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-3364-
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♦ Valve stem seal fitting tool
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-3365-
spec
es, in part or in w
♦ Adapter -T40012/1-
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Prote AG.

Touareg 2003 ➤
Torque wrench (5…50 Nm) -V.A.G 1331-

Removing
– Remove camshafts ⇒ page 73 .
– Remove roller rocker fingers together with support elements
and lay aside on a clean surface.
– Ensure that roller rocker fingers and support elements are not
interchanged.
– Remove spark plugs using spark plug socket and extension
-3122 B- .
– Set piston of respective cylinder to „bottom dead centre“.
– Set-up valve assembly device -2036- with adapter plates

-2036/1- and adjust mounting.
– Screw adapter -T40012/1- into spark plug thread, connect to
compressed air line with commercially available adapter and
apply constant pressure. At least 6 bar.
– Remove valve springs using valve levern-VW
AG. V541/1
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press tool -VW 541/6- . olkswage G do
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Tight valve cotters can be loosened by tapping lightly on assem‐
pt
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– Pull off valve stem seals using valve stem seal puller -3364- .
wit
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Installing
hole
spec
es, in part or in w
– To prevent damage to new valve stem seals, place plastic t to the co

sleeve -A- on valve stem.
– Lubricate sealing lip of valve stem seal -B-, place it in the valve
rrectness of i
stem oil seal fitting tool -3365- and push carefully onto valve
guide.
l purpos
– Install camshafts ⇒ page 73 .

nf
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2.5 Checking valve guides

2. Valve gear 85
Touareg 2003 ➤
♦ Universal dial gauge bracket -VW 387-
♦ Dial gauge
Test procedure
– Insert new valve into guide. The end of the valve stem must
be flush with the guide. On account of differing stem diame‐
ters, only use inlet valve in inlet guide and exhaust valve in
exhaust guide.
– Determine rock. Wear limit: 0.8 mm.
If rock tolerance is exceeded:
– Renew cylinder head.
2.6 Reworking valve seats agen

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Valve dimensions ⇒ page 88 . d by gu
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Special tools and workshop equipment
auth required ra
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♦ Depth gauge
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♦ Valve seat refacing tool

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Procedure
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Note
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♦ When repairing engines with leaking valves, it is not sufficient

to rework or renew valve seats and valves. Particularly on high
mileage engines, it is necessary also to check valve guides for
rrectne
wear ⇒ page 85 .
♦ Valve seats are only to be reworked to the extent required to
ss
yield a proper surface appearance. Before beginning to rework

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valve seats, calculate the maximum permissible reworking di‐

inform
mensions. If the reworking dimension is exceeded, the hy‐

mer
draulic valve clearance compensation can no longer be

atio
m
guaranteed and the cylinder head must be renewed.

o
n
c
i
or
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sd
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– Remove camshafts ⇒ page 73 .

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The max. permissible reworking dimension is calculated as fol‐

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– Insert valve and press firmly against seat.
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Vo
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Prote AG.

Touareg 2003 ➤
Note
If the valve is to be renewed as part of a repair, use a new valve

for the calculation.
– Measure distance -a- between end of valve stem and upper

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edge of cylinder
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– Calculateed maximum permissible reworking dimension
b ua
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measured distance -a- and minimum dimension.tee
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Minimum dimension:
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Short inlet valve mm 31.8
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Long inlet valve mm 10.2
ility
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Short exhaust valve mm 31.8
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Long exhaust valve mm 10.2
hole
spec
es, in part or in w
Measured distance -a- minus minimum dimension = maximum
t to the co
permissible reworking dimension.
Example:
rrectness of i
Measured distance 10.6 mm
l purpos
— Minimum dimension 10.2 mm

= Max. permissible reworking dimension 0.4 mm
nf
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5) The maximum permissible reworking dimension is shown as dimension -b- in

o
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following figures for reworking valve seats.

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a
Reworking inlet valve seat

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a - = ∅ 32.8 mm
en
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b - = max. permissible reworking dimension
C py
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c - = 0.9…1.5 mm co Vo
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d - = max. ∅ 38.0 mm
r2 - = radius 2.0 mm
Z - = bottom surface of cylinder head
α - 45° valve seat angle
β - 30° upper correction angle
γ - 60° lower correction angle
Reworking exhaust valve seat

a - = ∅ 29.8mm
b - = max. permissible reworking dimension
c - = 1.2…1.7 mm
d - = max. ∅ 35.0 mm
r2 - = radius 2.0 mm
Z - = bottom surface of cylinder head
α - 45° valve seat angle
β - 30° upper correction angle
γ - 60° lower correction angle
2. Valve gear 87
Touareg 2003 ➤
2.6.1 Valve dimensions
Note
Valves must not be reworked. Only lapping-in is permitted.
Valve dimensions for inlet valves AG. Volkswagen AG d

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Dimension Short inletbyvalve
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-∅ a- mm th33.20
or
33.20 eo
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-∅ b- mm ss 5.98 5.98 c
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nl
-c- mm 102.46 136.36
pt
du
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-α- ∠° 44° 40´ 44° 40´
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Valve dimensions for exhaust valves
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Dimension Short exhaust valve Long exhaust
hole
spec
valve
es, in part or in w
t to the co
-∅ a- mm 30.20 30.20
-∅ b- mm 5.97 5.97
rrectness of i
-c- mm 102.20 136.20
l purpos
-α- ∠° 44° 40´ 44° 40´
nform
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do
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for
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Cop py
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Prote AG.

Touareg 2003 ➤
17 – Lubrication
1 Removing and installing parts of lu‐
brication system
Note
♦ Secure engine to engine and gearbox support -VAS 6095- to

carry out repairs.
♦ The oil level must not be above the max. mark - danger of
damage to catalytic converter!
♦ Finding metal shavings or a large quantity of small metal par‐
ticles during engine repair could indicate that the crankshaft
bearings or conrod bearings are damaged. To prevent this
from causing further damage, perform the following repairs:
AG. Volkswagen AG d
agen
♦ Thoroughly clean oil channels. Volksw
oes
not
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♦ Renew oil non-return valve.orise nte
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♦ Renew oil spray jets ss a c
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nl
♦ Renew engine oil cooler
pt
du
an
itte
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♦ Renew oil filter
erm
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Assembly overview ⇒ page 89 .
, is n
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hole
Checking oil pressure and oil pressure switch ⇒ page 97
spec
es, in part or in w
Renew oil non-return valve ⇒ page 92 .
t to the co
Oil capacities:
With oil filter 6.6 l rrectness of i
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Engine oil specifications:

Use „long-life engine oil“ conforming to VW standard -503 00- .
nf
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atio
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Note
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♦ The engine is filled at the factory with engine oil conforming to

t
sd
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VW standard -503 00- .

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ng
♦ Engine oils conforming to VW standard -500 00- , -501 01- and

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-502 00- may continue to be used. These oils must be changed Cop py
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every 12 months or 15,000 kilometres. opyri
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♦ Engine oil „ILSAC GF3 with viscosity class SAE5W-40“ may
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be used to change or top up oil. The service interval display
AG.
must be programmed accordingly. Procedure: ⇒ Mainte‐

nance ; Booklet 17.1
♦ Engine oil „ILSAC GF3 with viscosity class SAE5W-30“ may
be used to top up oil.
1.1 Assembly overview

left or right side ⇒ page 22
1. Removing and installing parts of lubrication system 89

Touareg 2003 ➤
1 - 8 Nm
❑ Secured to intake mani‐
fold.
2 - Oil dipstick
❑ The oil level must not be
above the max. mark!
❑ Markings ⇒ page 92 .
3 - Guide tube
❑ For oil dipstick.
❑ Secured with bolt to in‐
take manifold.
4 - Cylinder block
sealing flange and dual-
mass flywheel
⇒ page 26 .
crankshaft ⇒ page 34 .
bling pistons and con‐ AG. Volkswagen
rods ⇒ page 38 .lkswagen AG do
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5 - Oil non-return ris
evalve
db ran
tee
o
❑ Note installation
au
th
posi‐ or
ac
tion.ss
ce
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nl
❑ Renew if badly soiled.

pt
du
an
itte
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erm
ab
⇒ page 92 .
ility
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6 - 8 Nm
spec
es, in part or in w
7 - Oil pump drive cover

t to the co
8 - O-ring
❑ Renew.
rrectness of i

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9 - Oil pump drive

nform
ercia
m
11 - Thrust washer
at
om
ion
c
12 - 10 Nm
in t
or
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or
13 - Oil spray jet

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t.
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❑ For piston cooling.
Co
Cop py
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❑ Installed in crankshaft bearings 2…7 opyri
gh by
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❑ Opening pressure: 2.0 bar

c by lksw
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Prote AG.
14 - Drive shaft
15 - Oil pump
90 Rep. gr.17 - Lubrication

Touareg 2003 ➤
16 - 23 Nm
17 - Oil drain plug, 30 Nm
❑ Renew with captive seal.
18 - Oil sump
19 - Oil level and oil temperature sender -G266-
❑ Only on vehicles with engine code AZZ or BKZ
20 - 12 Nm
21 - Baffle plate
22 - 8 Nm
23 - Seal
❑ Renew.
24 - Oil filter housing / left engine bracket
25 - 23 Nm
AG. Volkswagen AG d
agen oes
1.1.1 Removing and installing oil spray jet d by
Volksw not
gu
ara
ise nte
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Special tools and workshop equipment requiredutho eo
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s a c
♦ 4 mm ∅ drift s
ce
le
un
pt
♦ 6 mm ∅ drift
an
d
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rm
ab
pe
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Note
wit
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hole
spec
Oil spray jets are installed in main bearings 2…7.
es, in part or in w
Removing t to the co
– Press oil spray jet out towards bearing using a 4 mm ∅ drift.
rrectness of i
Installing
l purpos
– To install, press oil spray jet in by hand using a 6 mm ∅ drift

-arrow-.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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Prote AG.

Touareg 2003 ➤
1.1.2 Removing andolkinstalling oil non-return

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Removing aut or
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– Screw commercially available M8x1.5 bolt about 4 full turns
ce
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un
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into valve -arrow- and withdraw it from bore.
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Installing
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– Before installing, moisten O-ring with oil. Press valve into oil
is n
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channel -arrow- by hand.
ole,
spec
t to the co
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1.1.3 Markings on oil dipstick
f inform
mer
1 - Max. mark
atio
om
n
2 - Min. mark
c
i
or
n thi
te
a - Area above hatched field up to max. mark: Do not top up with
sd
iva
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engine oil!
p
cum
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fo
en
ng
b - Oil level within hatched field: can be topped up with engine oil.
t.
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c - Area from min. mark up to hatched field: Must be topped up,
t
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max. 0.5 l of engine oil! cop Vo
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cted agen
Prote AG.
1.2 Dismantling and assembling oil filter housing

Touareg 2003 ➤
1 - Oil filter housing / left engine

bracket
❑ To remove, the engine
bracket must be loos‐
ened from left and right
engine mounting
⇒ page 22 .
2 - Seal
❑ Renew.
❑ Lubricate before instal‐
ling.
3 - Oil cooler seal
❑ Renew.
❑ Lubricate before instal‐
ling.
4 - Engine oil cooler
❑ Ensure clearance to ad‐
jacent components.
❑ Coolant hose schematic
diagram ⇒ page 110 .
AG. Volkswagen AG d
5 - Oil cooler cover, 25 Nm lksw
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not
Vo gu
by
6 - Oil pressure switch -F1- ,ri20
sed ara
nte
Nm ut
ho eo
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a
❑ Black ss c ce
e
nl
❑ Switch point 1.4 bar.

pt
du
an
itte
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❑ If seal is leaking, nip
erm
ab
open and renew.

ility
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wit
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h re
hole
7 - Oil filter element

spec
es, in part or in w
❑ Observe change inter‐

t to the co
vals ⇒ Maintenance ;
Booklet 17.1
rrectness of i
8 - Oil filter lower part, 25 Nm

l purpos
❑ Drain before removing.

❑ With bypass valve, opening pressure: 2.50 bar
nform
ercia
9 - Oil drain plug, 10 Nm

m
at
om
ion
10 - 23 Nm
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
1.3 Dismantling and assembling oil pump
1 - Drive shaft
2 - Oil pump housing
3 - 23 Nm
4 - Gears
❑ Checking backlash
⇒ page 94 .
❑ Checking axial clear‐
ance ⇒ page 95 .
5 - Oil pump cover with pres‐
sure relief valve
❑ Opening pressure:
5.3…5.7 bar
❑ Clean strainer if soiled.
6 - 8 Nm
❑ Renew.
7 - Oil pressure pipe
❑ To install or remove oil
pressure pipe, oil pump
must be loosened.
❑ Secure only with new
„microencapsulated“
bolts
Note agen
AG. Volkswagen AG d
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To install, first hand-tighten all se‐ d ara
ise nte
r
curing bolts. Next tighten oil pres‐ ut
ho eo
ra
sure pipe at cylinder block and then ss a c
at oil pump ⇒ Item 6 (page 94) . Fi‐
ce
le
un
pt
nally tighten oil pump with securing
an
d
itte
bolts ⇒ Item 3 (page 94) .

y li
rm
ab
pe
ility
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8 - 8 Nm
wit
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9 - Seal
hole
spec
es, in part or in w
t to the co
Checking oil pump backlash

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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do
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cum
fo
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t.
yi Co
Cop py
t. rig
gh ht
yri by
Special tools and workshop equipment required op Vo
by c lksw
cted agen
Prote
♦ Feeler gauges
AG.

Touareg 2003 ➤
Wear limit: 0.20 mm.

Checking oil pump axial clearance

♦ Straight edge
♦ Feeler gauges
Wear limit: 0.10 mm.
1.4 Removing and installing oil sump

♦ Support bracket -10 - 222 A-
♦ Shackle -10 - 222 A /12-
♦ Adapter -10 - 222 A /16-
♦ Adapter -10 - 222 A /19-
AG. Volkswagen AG d
agen oes
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aut ra
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un
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Not illustrated:
wit
is n
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ole,
♦ Used oil collection and extraction unit -V.A.G 1782-

spec
♦ Silicone sealant -D 176 501-

t to the co
♦ Hand drill with plastic brush attachment

rrectne
♦ Flat scraper
♦ Eye protection
ss o
Removing
cial p
f inform
– Drain engine oil.

mer
atio
om
n
c
i
or
Note
thi
te
sd
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pr

um
r
fo
en
ng
t.
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op
– Separate line/wiring to air suspension compressor at air filter C py
t. rig
⇒ page 164 .
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
6-cylinder injection engine - Edition
olksw
02.2012
AG. V agen AG
agen does
lksw not
– Completely remove air db
yfilter
V o
with air mass meter. gu
ara
ise nt
r
– Before removal,utunscrew securing nuts -2- from left and right ee or
ho
engine bracket.
ss
a ac
ce
le
– Fit adapter -10 - 222 A- to support bracket -10 - 222 A /16- with
un
pt
an
d
the higher side for the spindle guide upwards, as illustrated.

itte
y li
rm
ab
– Now fit adapter -10 - 222 A /19- to support bracket -10 - 222
pe
ility
ot
A- on left and right. Set support bracket -10 - 222 A- on longi‐
wit
, is n
tudinal members.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Hook engine with two shackles -10 - 222 A /12- on adapter -10
l purpos
- 222 A /16- and slightly take up weight of engine.

– Remove subframe ⇒ Running gear, axles, steering; Rep. gr.
nform
ercia
40 ; Removing and installing subframe .

m
a
com
ti
– Remove engine carrier. The engine carrier can remain bolted
on in
to the engine carrier.
r
te o
thi
s
iva
– Pull 3-pin connector off oil level and oil temperature sender -
do
r
rp
c
G266- .
um
fo
en
ng
t.
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– Remove sump.
Co
Cop py
t. rig
gh
– Loosen sump with light blows of a rubber headed hammer if
ht
pyri by
necessary.
o Vo
by c lksw
cted agen
Prote AG.
– Remove sealant residue from cylinder block with a flat scraper.
– Remove sealant residue on sump with a rotating brush, e.g.

an electric hand drill with a plastic brush attachment (wear eye
protection).
– Clean sealing surfaces; they must be free of oil and grease.
Installing
Note
♦ Note the expiry date of the sealant .

♦ Install sump within 5 minutes of applying silicone sealant .
– Cut off tube nozzle at forward marking (∅ of nozzle approx. 3

mm).
– Apply silicone sealant -D 176 404 A2- , as shown, to clean
sump sealing surface. Sealant bead must be:
♦ 2…3 mm thick.
♦ Run bead along inner side of bolt holes -arrows-.
Note
The sealant bead must not be thicker, otherwise excessive seal‐

ant enters the sump and may block the oil suction pipe strainer.

Touareg 2003 ➤
– Apply silicone sealing compound -D 176 404 A2- to clean

sealing surface of sump, as shown in diagram.
– Install sump immediately and tighten all sump bolts lightly.
– Then tighten oil sump bolts to 12 Nm.
Note
Allow sealant to dry for approx. 30 minutes after installing sump.

Only then fill with engine oil.

quence.
Specified tightening torque for engine mountings ⇒ page 15 .
1.5 Checking oil pressure and oil pressure switch

equipment required
♦ Oil pressure tester -V.A.G
1342-
♦ Voltage tester -V.A.G
1527B-
♦ Auxiliary measuring set -
V.A.G 1594C-
♦ Current flow diagram AG. Volkswagen AG d
agen oes
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aut ra
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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
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rp
cu
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m
f
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
97
by lksw
cted agen
Prote 1. Removing and installing parts of lubrication system
AG.
Touareg 2003 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
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Note thor eo
au ra
ss c
Functional check and repair of the optical and acoustic oil pres‐
ce
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nl
pt
sure warning: ⇒ Current flow diagrams, Electrical fault finding and
du
an
itte
Fitting locations
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erm
ab
ility
ot p
Checking oil pressure switch ⇒ page 98
wit
, is n
h re
Checking oil pressure ⇒ page 98
hole
spec
es, in part or in w
t to the co
1.5.1 Checking oil pressure switch
Checking oil pressure ⇒ page 98
rrectness of i
Test prerequisites
l purpos
• Oil level OK, checking ⇒ page 92
nf
ercia
• Engine oil temperature at least 80°C (radiator fan must have
or
run once)
m
m
atio
m
• On vehicles with automatic gearbox the selector lever must be

o
n in
or c
in „P“ or „N“ position.
thi
te
sd
iva
Procedure
o
r
rp
cu
o
m
f
– Remove oil pressure switch -F1- ⇒ Item 6 (page 93) and screw
en
ng
t.
yi Co
into tester. t. Cop py
rig
gh ht
– Screw oil pressure tester -V.A.G 1342- into oil filter housing in yri
p by
co Vo
place of oil pressure switch ⇒ Item 6 (page 93) using adapter
by lksw
cted agen
-V.A.G 1342/14- .
Prote AG.
Note
Observe installation position of adapter -V.A.G 1342/14- : the

conical connecting piece of the adapter must be screwed into the
pressure hose of the oil pressure tester -V.A.G 1342- .
– Connect brown wire of oil pressure tester -V.A.G 1342- to

earth (-).
– Connect voltage tester -V.A.G 1527B- to battery positive (+)
and oil pressure switch -F1- using cables from auxiliary test
set -V.A.G 1594C- . LED must not light up.
If the LED lights up:
– Renew oil pressure switch -F1- ⇒ Item 6 (page 93) .
If LED does not light up:
– Start engine and run at idling speed.
At 1.2…1.6 bar the LED must light up, otherwise renew oil pres‐
sure switch -F1- ⇒ Item 6 (page 93) .
1.5.2 Checking oil pressure

Test prerequisites
• Oil level OK, checking ⇒ page 92
• Engine oil temperature at least 80°C (radiator fan must have
run once)
• On vehicles with automatic gearbox the selector lever must be
in „P“ or „N“ position.

Touareg 2003 ➤
Procedure
– Check oil pressure at different
wage revolutions:
es ks not
Vol gu
♦ 1500 rpm: at leasted1.7
by bar ara
nte
is
or eo
♦ 2000 rpm: 3.0…5.5
au
th bar ra
ss c
♦ Over 2000 rpm: maximum 7.0 bar
ce
le
un
pt
an
d
If the specifications are not attained:

itte
y li
erm
ab
– Check strainer in oil suction pipe for contamination/soiling.
ility
ot p
wit
is n
– Check pressure pipe between oil pump and cylinder block for
h re
ole,
leaks.
spec
t to the co
Note
rrectne
Mechanical damage, e.g. to bearings, could also be the cause for
oil pressure being too low.
ss o
If no fault can be found despite oil pressure being too low:
cial p
f inform
– Renew oil pump ⇒ page 94 .
mer
atio
m
Oil pressure must not exceed 7.0 bar.

o
n
c
i
or
n thi
If 7.0 bar is exceeded:
te
sd
iva
o
r
– Check oil channels.

p
cum
r
fo
en
ng
Pressure relief valve in oil pump may be stuck.

t.
yi Co
Cop py
t. rig
– Renew oil pump. opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.

Touareg 2003 ➤
19 – Cooling
1 Removing and installing parts of cool‐
nA AG do G. Volkswagen
wage es n
Volks ot g
ing system orised by ua
ran
te eo
th
au ra
c
ss
WARNING
ce
le
un
pt
an
d
itte
Steam may escape when expansion tank is opened. Wear eye
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Caution
rrectness of i
tions:
l purpos
nform
ercia

sitions.
m
a
com
tion in
r
te o
hot components.
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
100 Rep. gr.19 - Cooling

Touareg 2003 ➤
Note
♦ Hoses are secured withagspring-type

en AG. V
olkswclips.
agen AGIndocase of repair,
only use spring-type
yV
olkclips.
sw es n
ot g
b ua
ed ra
♦ Spring-typehoclip
ris pliers -VAS 5024 A- are recommendedntefore o in‐
stallations aof
ut spring-type clips. ra
c
s
♦ When installing coolant hoses, route stress-free so that they
ce
e
nl
pt
du
do not come into contact with other components (observe
an
itte
markings on coolant connection and hose).
y li
erm
ab
ility
ot p
Test for leaks in cooling system using cooling system tester -
wit
, is n
h re
V.A.G 1274- and adapters -V.A.G 1274/8- and - V.A.G 1274/9- .
hole
spec
⇒ „1.1 Assembly overview - radiator“, page 101
es, in part or in w
t to the co
⇒ „1.2 Assembly overview - radiator fan“, page 103
⇒ „1.3 Assembly overview - parts of cooling system, body side“,
rrectness of i
page 103
l purpos
⇒ „1.4 Assembly overview - thermostat housing“, page 105

⇒ „1.5 Removing and installing thermostat housing“, page 106
nf
ercia
o
⇒ „1.6 Removing and installing thermostat“, page 107
rm
m
atio
m
⇒ „1.7 Assembly overview - parts of cooling system, engine side“,

o
n in
c
page 108
or
thi
te
sd
iva
⇒ „1.8 Coolant hose schematic diagram“, page 110

o
r
rp
cu
o
m
f
⇒ „1.9 Draining and filling coolant“, page 111

en
ng
t.
yi Co
op
⇒ „1.10 Removing and installing radiator“, page 114
C py
t. rig
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yri by
⇒ „1.11 Removing and installing coolant pump“, page 115
op Vo
by c lksw
cted agen
Prote AG.
⇒ „1.12 Checking cooling system for leaks“, page 116
1.1 Assembly overview - radiator
1. Removing and installing parts of cooling system 101

Touareg 2003 ➤ agen
AG. Volkswagen AG d
oes
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6-cylinder injection engine - Edition 02.2012 by
Vol not
gu
d ara
ise nte
or
1 - Upper coolant hose aut
h eo
ra
s c
❑ Secured to radiator with s
ce
le
retaining clip.
un
pt
an
d
itte
❑ Check for secure seat‐
y li
rm
ab
ing.
pe
ility
ot
wit
2 - Radiator/cooler
, is n
h re
hole
spec
⇒ page 114 .
es, in part or in w
t to the co
❑ Entire coolant system
must be renewed if radi‐
ator is renewed.
rrectness of i
3 - Condenser
l purpos
4 - Oil cooler
❑ For gear oil
nform
ercia
5 - Oil cooler
m
a
com
ti
❑ For power-assisted
on in
steering
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thi
s
iva
do
6 - Lock carrier
r
rp
cum
fo
7 - 10 Nm
en
ng
t.
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op
8 - Low-temperature cooler
C py
t. rig
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❑ For alternator and fuel.
p by
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by c lksw
cted
❑ Only with certain equip‐
agen
Prote AG.
ment
9 - 10 Nm
10 - Rubber bush
❑ For lock carrier
11 - Retaining clip
ing.
12 - Rubber bush
❑ For bottom of radiator
13 - Lower coolant hose
❑ Secured to radiator with retaining clip.
14 - Coolant hose
❑ Secured to radiator at top.
15 - To coolant expansion tank

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

2 - Fan support
3 - 10 Nm
4 - 10 Nm
5 - Radiator fan 2 -V177-
6 - Radiator fan control unit -
J293-
7 - 10 Nm
lkswage es n
o ot g
byV ua
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ir se tee
tho
u or
a ac
ss
ce
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un
pt
an
d
itte
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ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f in
1.3 Assembly overview - parts of cooling

form
mer
system, body side

atio
om
n
c
i
or
n thi
e
Caution
t
sd
iva
o
pr
cum
r
fo

en
ng
t.
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Co
op py
tions: t. C rig
gh ht
pyri by
co Vo
by lksw
cted
agen
Prote AG.
sitions.
♦ To avoid damage, particularly to coolant hoses
⇒ Item 2 (page 104) and ⇒ Item 3 (page 104) , ensure
sufficient clearance between individual hoses and to all
moving or hot components.

Touareg 2003 ➤
1 - Continued coolant circula‐

tion pump -V51-
❑ Installation location of
pump ⇒ page 105
2 - Coolant hose
ing.
❑ To continued coolant
circulation pump -V51- .
3 - Coolant hose
ing.
❑ From cylinder head
4 - From radiator
5 - Coolant expansion tank
❑ Check cooling system
for leaks with cooling
system tester -V.A.G
1274- and adapter -
V.A.G 1274/8- .
❑ Depending on equip‐
ment, connection may
be sealed with a blank‐ agen
AG. Volkswagen AG d
oes
ing plug Volksw not
gu
by ara
d
6 - Cap rise nte
tho eo
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❑ Check using cooling ss a ra
c
system tester -V.A.G
ce
le
un
1274- and adapter - pt

an
d
itte
V.A.G 1274/9- . y li
erm
ab
❑ Test pressure: 1.4…1.6 ility
ot p
bar.
wit
is n
h re
7 - Coolant hose
ole,
spec

t to the co
ing.
❑ From heat exchanger for heater unit
rrectne
8 - Coolant hose
ss
❑ From continued coolant circulation pump -V51- .

o
cial p
f in
9 - To heat exchanger for heater unit.

form
mer
10 - From heat exchanger for heater unit

atio
om
n
c
11 - To thermostat housing.
i
or
n thi
te
sd
iva
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pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
aut
h
ra Touareg 2003 ➤
s c
s 6-cylinder injection engine - Edition 02.2012
ce
le
un
pt
an
d
Location of continued coolant circulation pump -V51-
itte
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rm
ab
pe
The continued coolant circulation pump -V51- -2- is clipped with
ility
ot
damping rings to the bracket behind the cylinder head under sol‐
wit
, is n
enoid valve 1 for the activated charcoal filter -N80- .
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
1.4 Assembly overview - thermostat hous‐

m
a
com
t
ing
ion in
r
te o
thi
s
iva
do
Caution
r
rp
cum
fo
en
ng
t.
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op
C py
ht. rig
tions:
rig ht
py by
co Vo
by lksw
cted
agen
Prote AG.
sitions.
hot components.
Note
Routing of coolant hoses on thermostat housing ⇒ page 108 .

Touareg 2003 ➤
1 - O-ring
❑ Renew.
2 - Retaining clip
ing.
3 - Thermostat housing
⇒ page 106 .
4 - 8 Nm
5 - Thermostat
⇒ page 107 .
❑ Check ⇒ Vehicle diag‐ AG. Volkswagen AG d
agen oes
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nostic tester; ;„Guidedby V ol not
gu
ara
function“ . rised
nte
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❑ Opening begins aut at ap‐ ra
c
prox. 80 °C. s s
ce
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nl
❑ Ends at approx. 105 °C.
pt
du
an
itte
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6 - Connection
erm
ab
ility
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7 - Seal
wit
, is n
h re
❑ Renew.
hole
spec
8 - Coolant temperature send‐
es, in part or in w
t to the co
er -G62-
❑ For engine control unit .
❑ With coolant tempera‐
rrectness of i
ture display sender -

l purpos
G2- .
❑ Before removing, re‐
lease pressure in cool‐
nf
ercia
ing system if necessary.

rm
m
atio
m
9 - Plug
o
n in
or c
❑ Before removing, release pressure in cooling system if necessary.

thi
te
sd
iva
o
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f
en
ng
1.5 Removing and installing thermostat

t.
yi Co
op py
housing
t. C rig
gh ht
pyri by
Vo
o
by c lksw
Special tools and workshop equipment required Prote
cted AG.
agen
♦ Hose clip pliers -V.A.G 1921-

Touareg 2003 ➤
♦ Drip tray for workshop hoist -VAS 6208-
Removing AG. Volkswagen AG d

agen oes
ksw
– Remove intake manifold. by Vo l not
gu
d ara
ise n
– Remove wiper arms th⇒o Electrical system; Rep. gr. 92 ; Wind‐ tee o
r
screen wiper system;
ss
au
Removing and installing wiper arms . ra
c
ce
e
– Removing plenum chamber cover ⇒ General body repairs,

nl
pt
du
an
exterior; Rep. gr. 64 ; Removing and installing plenum cham‐
itte
y li
ber cover
erm
ab
ility
ot p
– Removing plenum chamber bulkhead ⇒ General body repairs,
wit
, is n
exterior; Rep. gr. 50 ; Plenum chamber bulkhead .
h re
hole
spec
es, in part or in w
t to the co
– Detach all electrical connectors and coolant hoses from ther‐
mostat housing and place to one side.
– Unscrew securing bolts for thermostat housing
rrectness of i
⇒ Item 4 (page 106) .
l purpos
Caution
nform
ercia
Use lever to push coolant pipe in direction of coolant pump

m
at
om
when pulling off thermostat housing so that pipe is not pulled

ion
c
off as well.
in t
or
his
ate
do
priv
cum
or
– Pull off thermostat housing -2-. To do this, use lever to push

f
en
ng
coolant pipe -1- in direction of coolant pump.

t.
yi Co
Cop py
t. rig
Installing opyri
gh by
Vo
ht
by c
lksw
cted agen
Prote
note the following:
AG.
Specified torques ⇒ page 105 .

– Renew seals and gaskets.
– Fill with coolant ⇒ page 111 .
1.6 Removing and installing thermostat

Removing
Note
Collect drained coolant in a clean container for re-use or disposal.
– Remove thermostat housing ⇒ page 106 .

Touareg 2003 ➤
– Unscrew bolts -arrows- and remove union -1-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e
– Remove O-ring -3- with thermostat -2- from thermostat
horis hous‐ nte
eo
ing -1-. s aut ra
c
s
Installing
ce
e
nl
pt
du
an
itte
y li
erm
ab
note the following:
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
Renew gaskets and seals.
t to the co
– Clean sealing surface for O-ring.
rrectness of i
– Insert thermostat.
l purpos
• Installation position: Align breather valve -arrow- as shown in
nform
ercia
illustration.
m
– Moisten new O-ring -3- with coolant.
at
om
ion
c
– Screw union onto thermostat.
in t
or
his
ate
– Install thermostat housing ⇒ page 106 .
do
priv
cum
or
Specified torque
f
en
ng
t.
yi Co
op py
Component Nm t. C rig
gh ht
yri by
Union to thermostat housing 8
op Vo
by c lksw
cted agen
Prote AG.
1.7 Assembly overview - parts of cooling system, engine side

Touareg 2003 ➤
1 - Coolant pipe
❑ Between thermostat
housing and coolant
hose at bottom.
❑ Attached to cylinder
block
❑ To remove, the exhaust
manifold must be de‐
tached ⇒ page 179
wage es n
2 - To coolant expansionyV
olks tank ot g
ua
d b ran
e
3 - Thermostat horishousing tee
ut or
❑ Removing
ss
a and installing ac
⇒ page 106 .
ce
le
un
pt
an
d
4 - To cylinder block
itte
y li
rm
ab
5 - Union for engine oil cooler
pe
ility
ot
wit
❑ ⇒ Item 4 (page 93)
, is n
h re
hole
6 - Coolant pipe
spec
es, in part or in w
❑ Between coolant pump
t to the co
and thermostat housing.
7 - Upper coolant hose
rrectness of i
❑ Secured to radiator with
quick-release coupling.
l purpos

ing.
nform
ercia
❑ Coolant hose schematic

m
diagram ⇒ page 110 .

com
tion in
8 - Plug, 3 Nm
r
te o
thi
s
iva
do
9 - O-ring
r
rp
cum
fo
❑ Renew.
en
ng
t.
yi Co
op
10 - From coolant pump C py
ht. rig
rig ht
11 - 20 Nm
py by
co Vo
by lksw
cted
❑ To loosen and tighten, counterhold belt pulley with drift through bores
agen
Prote AG.
12 - Belt pulley
❑ For coolant pump.
13 - 8 Nm
14 - Coolant pump
❑ Check for ease of movement.
15 - From bottom of radiator.
17 - 8 Nm

Touareg 2003 ➤
1.8 Coolant hose schematic

swa
gen AG
. Volksdiagram
wagen AG
does
k not
Vol gu
d by ara
ise nte
1- Radiator/cooler uthor eo
a ra
ss c
2- Oil cooler
ce
le
un
pt
❑ For gear oil
an
d
itte
y li
3 - Cylinder head
rm
ab
pe
ility
ot
4 - Coolant expansion tank
wit
, is n
h re
5 - Thermostat housing
hole
spec
es, in part or in w
6 - Heat exchanger for heater
t to the co
unit
7 - Continued coolant circula‐
rrectness of i
tion pump -V51-
l purpos
8 - Engine oil cooler

9 - Upper coolant hose
nform
ercia
10 - Coolant pipe
m
a
com
t
11 - Cylinder block
ion in
r
te o
thi
s
iva
do
r
13 - Coolant pump
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 ➤
1.9 Draining and filling coolant

AG. Volkswagen AG d
agen oes
olksw not
Special tools and workshop ed by
V gu
ara
equipment required horis nte
eo
aut ra
♦ Refractometer -T10007- ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
-V.A.G 1331-
ility
ot p
wit
is n
h re
ole,
5024 A-
spec
t to the co
♦ Cooling system charge unit
-VAS 6096-
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.
Draining coolant
WARNING
Steam may escape when expansion tank is opened. Wear eye

– Open cap on coolant expansion tank.

– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation .

Touareg 2003 ➤
– Pull off lower coolant hose retaining clip -arrow- and remove
coolant hose from radiator. Volkswa AG. gen AG
agen does
olksw not
yV gu
db ara
Note rise nte
tho eo
au ra
Follow disposalssregulations for coolant!
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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
– To drain coolant from engine, also remove coolant hose from

engine oil cooler -arrow-.
Filling with coolant
Caution
Only potable water may be used for mixing. Soiled water does
not have the required quality to ensure the coolant's function.
Note
♦ Use only coolant additives in accordanceAGwith

. Volkthe
swa⇒
genElectronic
parts catalogue (ETKA) . Other lcoolant
ksw
agen additives may reduce
AG do
es n
corrosion protection substantially.
by Vo The resulting damage could ot g
ua
lead to loss of coolant and
oris subsequent severe damage to the
ed ran
tee
engine. au
th or
a
ss c
♦ The correct coolant solution ratio helps prevent damage from
ce
le
un
pt
freezing and corrosion as well as scaling. Moreover, the boil‐
an
d
itte
ing temperature is raised. Therefore, the cooling system must
y li
erm
ab
be filled all year round with coolant additive.
ility
ot p
♦ Because of its higher boiling point, the coolant improves en‐
wit
is n
h re
gine reliability under heavy loads, particularly in countries with
ole,
tropical climates.
spec
♦ Frost protection must be guaranteed down to about -25 °C (in
t to the co
countries with Arctic climates: down to about -35 °C).
♦ The coolant concentration must not be reduced by adding wa‐
rrectne
ter even in warmer seasons and in warmer countries. The
coolant additive concentration must be at least 40%.
ss
♦ If a stronger anti-freeze mixture is necessary due to harsher
o
cial p
f i
weather conditions, the coolant additive content can be in‐

nform
creased. However, this is only permitted to 60% (antifreeze

mer
protection to about -40°C). Otherwise, the antifreeze protec‐

atio
om
tion will be reduced again and the cooling effect will be im‐
n
c
i
or
paired.
thi
te
sd
va
♦ If radiator, heat exchanger, cylinder head or cylinder head

i
o
pr
cum
r
gasket is renewed, do not reuse old coolant.

fo
en
ng
t.
yi Co
♦ The Refractometer -T10007- is recommended for determining Cop py
t. rig
the current anti-freeze density. opyri
gh by
Vo
ht
by c lksw
cted agen
Recommended mixture ratios: Prote AG.
Frost protection Anti-freeze quanti‐ Coolant Water6)

to ty additive
6)
-25°C 40 % 4.0 l 5.0 l

-35°C 50 % 4.5 l 4.5 l
6) The quantity of coolant can vary depending upon vehicle equipment.
Procedure
– Install coolant hoses and secure.

Touareg 2003 ➤
– Screw adapter -V.A.G 1274/8- onto coolant expansion tank.

– Fill coolant circuit using cooling system charge unit -
VAS 6096- ⇒ Operating instructions for cooling system charge
unit 6096 .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
1.10 Removing and installing radiator
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
c
♦ Torque wrench -V.A.G 1331-

or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing
– Pull out retaining clips from quick-release coupling for coolant
hose at top and bottom and detach coolant hoses from radia‐
tor.
– Remove front bumper ⇒ General body repairs, exterior; Rep.
gr. 63 ; Assembly overview - front bumper
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front; Lock carrier - service po‐
sition .
– Remove fans together with fan support ⇒ page 103 .

Touareg 2003 ➤
– Loosen retaining clips for condenser and gearbox oil cooler.

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

AG. Volkswagen AG d
agen oes
lksw not
Special tools and workshop d by Vo gu
ara
equipment required orise nte
th eo
u ra
♦ Drip tray -V.A.G 1306- ss a c
ce
le

un
pt
an
d
-V.A.G 1331-
itte
y li
erm
ab
♦ Water pump wrench -V.A.G
ility
ot p
1590-
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.
Removing

Touareg 2003 ➤
Note
To remove coolant pump, pulley need not be removed.
– Remove coolant pump securing bolts through holes in belt

pulley -arrows- and remove coolant pump. Volkswa AG. gen AG
agen does
If coolant pump must be renewed: yV
olksw not
gu
db ara
rise nte
tho eo
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
– Remove belt pulley. To do this, hold pulley using water pump
t to the co
spanner -V.A.G 1590- .
Installing
rrectness of i
l purpos
note the following:

– Moisten new O-ring with coolant.
nf
ercia
o
– Fit coolant pump.
rm
m
atio
m
– Tighten securing bolts. Specified torque: 8 Nm

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
1.12 Checking cooling system for leaks
C py
ht. rig
rig ht
py by
Vo
co lksw
by
cted agen
Prote AG.
♦ Cooling system tester -V.A.G 1274-

Touareg 2003 ➤
♦ Adapter for cooling system tester -V.A.G 1274/8-
♦ Adapter for cooling system tester -V.A.G 1274/9-

– Attach cooling system tester -V.A.G 1274- with cooling system
tester adapter -V.A.G 1274/8- to expansion tank as shown.
– Operate pump on tester and build-up pressure of between 1.4
and 1.6 bar.
– Check cooling system for leaks.
– In addition, check sealing cap.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
– To do so, screw cooling system tester adapter -V.A.G 1274/9-

un
pt
an
d
to cooling system tester -V.A.G 1274- .

itte
y li
rm
ab
– Operate pump on tester and build-up pressure of between 1.4
pe
ility
ot
and 1.6 bar.
wit
, is n
h re
– Pressure relief valve must not open below 1.4 bar.
hole
spec
es, in part or in w
– If valve in sealing cap opens before test is complete, renew
t to the co
sealing cap.
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 ➤
20 – Fuel supply system

1 Parts of fuel supply system
Caution

tions:
sitions.
hot components.
Note
♦ Hose connections are secured with either 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 5024 A- or pliers -V.A.G 1921- are
recommended for installation of spring-type clips.
♦ Fuel system must be bled if fuel delivery unit is renewed
⇒ page 125 . agen
AG. Volkswagen AG d
oes
olksw not
y V gu
b ara
Observe safety precautions ⇒ page 123 . rise
d
nte
tho eo
u
Observe rules for cleanliness ⇒ page 123 . ss a ra
c
ce
e
Assembly overview - fuel tank with attachments ⇒ page 119 .

nl
pt
du
an
itte
y li
Assembly overview - fuel filter ⇒ page 121

erm
ab
ility
ot p
Schematic diagram of fuel lines and components in fuel tank

wit
, is n
⇒ page 121 .
h re
hole
Renew fuel filter ⇒ page 124 .

spec
es, in part or in w
t to the co
Bleeding fuel system ⇒ page 125 .

Draining fuel tank ⇒ page 127
rrectness of i
Removing and installing fuel delivery unit, fuel gauge sender and
suction jet pumps ⇒ page 130
l purpos
Removing and installing fuel tank with attachments ⇒ page 132

nform
ercia
Checking fuel pumps ⇒ page 135

m
at
Parts of activated charcoal filter system:

om
ion
c
in t
r
♦ Vehicles with engine code AZZ, BKJ, BMV or BRJ

o
his
e
⇒ page 148
at
do
priv
cum
♦ Vehicles with engine code BAA or BMX ⇒ page 151 .

for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
118 Rep. gr.20 - Fuel supply system

Touareg 2003 ➤
1.1 Assembly overview - fuel tank with agen

at‐
AG. Volkswagen AG d
oes
ksw
tachments db
y Vol not
gu
ar
e an
ris tee
utho or
Caution ss
a ac
ce
e
nl
pt
du
Observe the following for all removal and installation work on
an
itte
y li
fuel tank:
erm
ab
ility
ot p
♦ Route all the various lines (e.g. for fuel, activated charcoal
wit
, is n
filter system and vacuum) and electrical wiring in their
h re
original positions.
hole
spec
es, in part or in w
♦ Ensure earth cable is correctly installed and tight between
t to the co
fuel filler neck and body to prevent build-up of an electro‐
static charge.
rrectness of i
hot components.
l purpos
nf
ercia
or
1 - Fuel tank filler neck
m
m
atio
m
❑ With connection for

o
n in
c
earth cable to body

or
thi
te
sd
iva
o
r
ing.
rp
cu
o
m
f
en
ng
2 - To activated charcoal filter.

t.
yi Co
Cop py
t.
3 - Fuel tank
rig
gh ht
pyri by
Vo
❑ When removing, sup‐
co lksw
by
cted agen
port using engine and Prote AG.
gearbox jack -
V.A.G 1383 A- .
4 - Fuel filter
bling ⇒ page 121 .
5 - Locking ring, 110 Nm
❑ Remove and install us‐
ing wrench -T10202- .
ing.
6 - Fuel pump -G23-
❑ Left side.
❑ Checking fuel pump
⇒ page 135 .
7 - Fuel gauge sender
❑ Left side.
❑ Flat, square float
❑ Clipped into bottom of
tank.
8 - Suction-jet pump
❑ Left side.
❑ Clipped into bottom of
tank.
9 - Protective cover
❑ For bottom of fuel tank.
1. Parts of fuel supply system 119

Touareg 2003 ➤
10 - Securing strap
11 - 20 Nm + 1/4 turn (90°) further
12 - Protective cover
❑ For top of fuel tank
❑ Right side.
❑ Clipped into bottom of tank.
14 - Fuel system pressurisation pump -G6-
❑ Right side.
❑ Checking fuel pump ⇒ page 135 .
15 - Fuel gauge sender -G-
❑ Right side.
❑ Round, ball float
❑ Clipped into bottom of tank.
16 - Flange
❑ Right side.
❑ With fuel pressure regulator.
❑ With gravity valve
❑ Individual parts ⇒ page 120
❑ Note installation position on fuel tank ⇒ page 121 .
17 - Breather line
❑ Check for secure seating.en AG. Volkswagen AG
ag does
ksw not
18 - Expansion tank y Vol gu
b ara
ed nte
ris
19 - Gravity valve
ut
ho eo
ra
sa c
20 - To pressure retention valve
s
ce
le
un
pt
an
d
itte
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rm
ab
Individual flange parts, right side

pe
ility
ot
wit
, is n
1 - Connectors for fuel pump -G23- and fuel gauge sender -G-
h re
hole
2 - Fuel pressure regulator (4 bar)

spec
es, in part or in w
t to the co
3 - Earth wire
4 - Pressure regulator inlet (from fuel filter)
rrectness of i
5 - Connection to left and right fuel delivery units (no pressure)

l purpos
6 - Gravity valve
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 ➤
agen 6-cylinder
AG. Volkswagen AG does injection engine - Edition 02.2012
olksw not
y V gua
b
Fitting position of sender flange
ris
ed on fuel tank ran
tee
tho
or
– Insert sender flangess with marking -arrow- in direction of travel.
au ac
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
1.2 Assembly overview - fuel filter
l purpos
1 - Connection
nform
ercia
❑ For breather line.

m
a
com
ti
2 - Flange
on in
r
te o
❑ Left side.
thi
s
iva
do
❑ With fuel filter housing
r
rp
cum
fo
en
ng
t.
yi
tion on fuel tank
Co
op py
⇒ page 121 . t. C rig
gh ht
pyri by
3 - Filter element
o Vo
by c lksw
cted agen
Prote AG.
4 - Seal
❑ Renew.
5 - Earth wire
ing.
6 - 10 Nm
7 - Supply line
❑ To fuel pressure regula‐
tor.
8 - Connection
❑ Filter supply from left
fuel delivery unit.
9 - Union
❑ Filter supply from right
fuel delivery unit.
10 - Earth connection
11 - Cap
❑ For filter housing
12 - Locating pin
1.3 Schematic diagram of fuel lines and

components in fuel tank
-A- left side of fuel tank
-Arrow- points in direction of travel
-B- Right side of tank

Touareg 2003 ➤
1 - Gravity valve
❑ Left side.
2 - Flange
❑ Left side.
3 - Fuel filter
4 - Gravity valve
❑ Right side.
5 - Supply line
❑ To fuel rail.
6 - Supply line for auxiliary
heater
7 - Flange
❑ Right side.
AG. Volkswagen AG d
8 - Fuel pressure regulator lksw
agen oes
not
o
yV gu
9 - Return line rised b ara
nte
o eo
❑ From fuel pressureaureg‐
th ra
ulator. ss c
ce
e
nl
❑ To fuel delivery unit on
pt
du
an
left and right sides.
itte
y li
erm
ab
10 - Supply line for suction-jet
ility
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pumps
wit
, is n
h re
11 - Fuel delivery unit
hole
spec
❑ Right side.
es, in part or in w
t to the co
with
❑ Fuel gauge sender -G-
rrectness of i
❑ Fuel system pressurisa‐

l purpos
tion pump -G6-

nf
ercia
❑ Right side.
rm
m
atio
m
13 - Delivery line
o
n in
or c
❑ Black
thi
te
sd
a
❑ To fuel delivery unit, left side

iv
o
r
rp
cu
o
14 - Delivery line
f
en
ng
t.
yi Co
❑ Black ht. Cop py
rig
❑ To fuel delivery unit, right side rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
❑ Left side.
16 - Fuel delivery unit
❑ Left side.
with
❑ Fuel gauge sender
❑ Fuel pump -G23-

Touareg 2003 ➤
1.4 Safety precautions when working on

fuel supply system
Caution

fuel tank:
original positions.
static charge.
hot components.
♦ For safety reasons, fuse nos. -13- and -14- -arrows- must be
removed from the fuse holder before opening the fuel system.
Otherwise, the fuel pump could be activated by the driver's
door contact switch.
♦ Fuse nos. 13 and 14 are located in the E-box fuse holder in
the left plenum chamber.
When removing and installing fuel gauge sender or fuel pump
(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
WARNING
release pressure by carefully pulling hose off connection. en AG. Volkswagen AG
ag does
ksw not
y Vol gu
db ara
se nte
♦ Even before work commences, the extraction thorihose of an ac‐ eo
tivated fume extraction system has to be placed
s au in the vicinity ra
c
of the assembly opening of the fuel tank to trap any escaping
s
ce
le
fumes. If no exhaust gas extraction system is available, a ra‐

un
pt
an
d
dial fan with a displacement greater than 15 m3/h can be used

itte
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rm
ab
providing that motor is not in air flow.

pe
ility
ot
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!

wit
, is n
h re
hole
spec
1.5 Rules for cleanliness

es, in part or in w
t to the co
When working on the fuel supply and injection system, pay careful
attention to the following „five rules“ for cleanliness:
rrectness of i
♦ Thoroughly clean all unions and surrounding areas before dis‐

connecting.
l purpos
♦ Place removed parts on a clean surface and cover. Use only

lint-free cloths.
nform
ercia
♦ Carefully cover opened components or seal if repairs cannot

m
a
com
be carried out immediately.

ion in
r
te o
♦ Install clean components only. Do not remove replacement

thi
s
iva
parts from packing until immediately before installing. Do not

do
r
rp
use parts that have not been stored in their packing (e.g. in
um
fo
tool boxes etc.).

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
123
cted agen
Prote
1. Parts of fuel supply system
AG.
Touareg 2003 ➤
♦ When system is open: do not work with compressed air if this

can be avoided. Do not move vehicle unless absolutely nec‐
essary.
1.6 Renewing fuel filter

♦ Special wrench -T10202-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
Prerequisites
ab
ility
ot p
• Fuel tank must be emptied ⇒ page 127 , Emptying fuel tank.
wit
is n
h re
ole,
spec
sockets.
t to the co
WARNING rrectne
s

s o

cial p
f inform
mer
atio
m
Procedure
o
n
c
i
or
n thi
– Note safety precautions before beginning work ⇒ page 123 .

te
sd
iva
o
pr
cum
r
fo
– Cut open carpet on left side from point -A- to -B- in the pre-cut
en
ng
t.
area -arrows-. Cop
yi Co
py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
– Remove nuts -1- from cover. If necessary, unscrew backrest

agen
AG. Volkswagen AG d
oes
mounting -2- or support mounting ⇒ General bodyVorepairs,
lksw not
gu
y
interior; Rep. gr. 72 ; Rear seats . se
d b ara
n ri tee
ho
– Unscrew locking ring from left sender flange
au using wrench -
t or
ac
T10202- . ss
ce
le
un
pt
– Completely remove flange on left side of tank.
an
d
itte
y li
erm
ab
– Empty fuel filter housing.
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Mark installation position of filter cover -2- using coloured felt
tip marker pen.
rrectne
– Pull off earth wire -1- and unscrew filter cover -arrows- from
housing.
ss o
If filter element is changed, ensure that earth connection contacts
cial p
f in
are not bent and have sufficient preloading.
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op py
1.7 Bleeding fuel system t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤

equipment required
♦ Hose clips up to 25 mm Ø
-3094-
♦ Remote control for V.A.G
1348 -V.A.G 1348/3A-
5226-
♦ Adapter -V.A.G 1318/20-1-
♦ Adapter cable -V.A.G
1348/3-3-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Prerequisites
• The battery voltage must be at least 11.5 V.
rrectness of i
• Fuel pump relays -1- for right fuel delivery unit and -2- for left
l purpos
fuel delivery unit must be removed from their sockets.

Procedure
nf
ercia
or

m
m
atio
om
– Remove fuse holder cover.

n in
or c
thi
te
sd
iva
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r
rp
cu
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f
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ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
– Connect remote control -V.A.G 1348/3A- with adapter -

V.A.G 1348/3-3- to connection -arrow- of fuel pump relay for
right fuel delivery unit.
– Connect positive terminal of remote control to positive pole in
engine compartment.

V.A.G 1318/20- .
– Turn valve on T-piece -arrow- anti-clockwise until it is entirely
open.
WARNING
pressure.
lksw
– Remove protective cap from sbreather
wage
Vo
n AG.valve. agen AG
does
olk not
yV gu
db ara
– Connect adapter -V.A.G
rise 1318/20- with adapter - nte
tho diesel extractor -VAS 5226-
V.A.G 1318/20-1-auand to bleed
eo
ra
c
valve -1-. ss
ce
e
nl
pt
du

an
itte
y li
erm
– Check adapter and hose connections for leaks.

ab
ility
ot p
– Operate remote control -V.A.G 1348/3A- until fuel flows free

wit
, is n
of air bubbles out of bleed valve.

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Turn valve on T-piece -arrow- anti-clockwise until it is fully

l purpos
open again.
– Clamp off hose from diesel extractor -VAS 5226- (e.g. using
nform
ercia
hose clips up to Ø 25 mm -3094- and detach it from adapter -

V.A.G 1318/20-1- .
m
at
om
io
– Unscrew adapter -V.A.G 1318/20- from bleed valve.

n
c
in t
or
his
e
– Screw protective cap onto bleeder valve again.

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

Touareg 2003 ➤
AG. Volkswagen AG d
agen oes
♦ Fuel extractor -VAS 5190- 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
o
c by lksw
cted agen
Prote AG.
Procedure
WARNING

– Open fuel tank filler flap.
– Push suction hose -arrow- of fuel extractor -VAS 5190- about
170…180 cm into fuel filler neck and extract fuel.
Note
♦ When no more fuel is extracted, the fuel tank is emptied just

enough for the sender flanges 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 as follows:

Touareg 2003 ➤
– Cut carpet open from point -A- to point -B- in the pre-cut area
-arrows-.
– Remove nuts -1- from cover. If necessary, unscrew backrest

mounting -2- or support mounting ⇒ General body repairs,
interior; Rep. gr. 72 ; Rear seats .
WARNING
– Hold a cloth on connections for fuel supply line and auxiliary

heater and pull off hose couplings.
AG. Volkswagen AG d
agen oes
ksw not
Note by Vol
gu
ara
d
rise nte
o eo
Release connection by pressing button
auth
on hose coupling. ra
c
ss ce
le
un
– Detach connector for fuel pump and fuel gauge sender.

pt
an
d
itte
y li
erm
ab
– Now remove locking ring from sender flange using wrench -

ility
ot p
T10202- .
wit
is n
h re
– Carefully lever out sender flange and raise it slightly.

ole,
spec
– Insert suction hose of fuel extractor -VAS 5190- as deeply as

t to the co
possible into right or left side of fuel tank and extract fuel.
– For work on left side of fuel tank, proceed as described above.
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.

lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Touareg 2003 ➤ auth or
ac
ss
ce
e
nl
pt
du
an
– When breather lines are pulled off, buttons of hose couplings
itte
y li
sometimes cannot be pressed in. Use assembly tool -T10118-
erm
ab
ility
-arrow- to press in button.
ot p
wit
, is n
For further work on inside of fuel tank, sender flanges may remain
h re
hole
removed.
spec
es, in part or in w
If fuel tank needed only to be emptied, install sender flanges
t to the co
again.
– First check that sender flange seals are properly seated.
rrectness of i
l purpos
Note
nf
ercia
Always renew seals.
orm
m
atio
om
n in
c
– Insert sender flange with locating tab in direction of travel

or
thi
e
-arrow-.
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.
– Tighten locking rings on left and right using wrench -T10202-

to 110 Nm.
1.9 Removing and installing fuel delivery

unit, fuel gauge sender and suction jet
pumps

Touareg 2003 ➤
AG. Volkswagen AG d
agen oes
lksw not
Prerequisites byV
o gu
ara
ed
is nte
• Fuel tank must ut
h be emptied ⇒ page 127 , Emptying fuel tank.
or eo
a ra
s c
• Fuses -13-sand -14-, -arrows- must be removed from their
ce
e
sockets.
nl
pt
du
an
itte
y li
• Connectors and wires for left and right-hand sender flanges
erm
ab
have been removed.
ility
ot p
wit
, is n
• Locking rings for left and right sender flanges have been re‐
h re
moved.
hole
spec
es, in part or in w
Procedure
t to the co
rrectness of i
– Detach connectors -1- and -2- as well as hose couplings -3-
l purpos
and -4- below right sender flange.

– Remove sender flange with pressure regulator.
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
– Unclip black filler hose -arrow- from fuel pump unit housing on
AG.
left and right sides of fuel tank.
– Pull fuel supply line, to suction-jet pumps, off fuel delivery unit
-arrow- on left and right sides of fuel tank.
– Unscrew fuel delivery unit in bottom of fuel tank by turning ap‐
prox. 90° to left.
Note
The fuel pump housing is filled with fuel. Fuel may run out if hous‐
ing 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.

Touareg 2003 ➤
1.10 Removing and installing fuel tank with

. Volkswagen AG
gen AG
attached components
Vol
kswa does
not
g
by ua
ed ran
oris tee
Caution
au
th or
ac
ss
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nl
pt
du
an
fuel tank:
itte
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erm
ab
ility
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wit
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original positions.
h re
hole
spec
es, in part or in w
t to the co
static charge.
rrectness of i
hot components.
l purpos
nform
ercia

equipment required
m
at
om
io
n
c
in t
or
his
e

at
do
riv
-V.A.G 1331-
p
cum
for
en
g

n
t.
yi Co
op
Nm) -V.A.G 1332- C py
t. rig
gh ht
yri
♦ Engine and gearbox jack -
p by
co Vo
by lksw
V.A.G 1383/A- Prote
cted AG.
agen
♦ Fuel extractor -VAS 5190-

5226-
♦ Adapter -V.A.G 1318/20-1-

Touareg 2003 ➤
Prerequisites
• Fuel tank must be emptied ⇒ page 127 , Emptying fuel tank.
sockets.
Removing
First, reduce the fuel pressure as follows:

V.A.G 1318/20- .
– Turn valve on T-piece -arrow- anti-clockwise until it is entirely
open.
– Screw adapter -V.A.G 1318/20- hand-tight onto bleeder valve.

– Connect hose of diesel extractor -VAS 5226- as illustrated.
– Turn valve on T-piece clockwise into bleed valve to stop.
Once the fuel pressure has been reduced: AG. Volkswagen AG d
agen oes
lksw not
– Unscrew adapter -V.A.G 1318/20-byfrom Vo bleed valve. gu
ara
d
ise nte
– Screw protective cap onto bleeder
uthor
valve again. eo
a ra
s c
– Remove silencers and mountings
s ⇒ page 178 .
ce
e
nl
pt
du
– Remove rear propshaft ⇒ Transfer box and final drive; Rep.

an
itte
y li
gr. 39 ; Removing and installing propshaft .

erm
ab
ility
ot p
– Remove rear axle ⇒ Running gear, axles, steering; Rep. gr.

wit
, is n
42 ; Repairing rear axle .

h re
hole
– Open fuel flap and remove fuel tank cap.

spec
es, in part or in w
t to the co
– Pull rubber gasket off fuel tank filler neck.

rrectness of i
– Remove securing bolts -1- on filler neck and pull off earth wire
-2-.
l purpos
– Remove rear right wheel housing liner ⇒ General body re‐

pairs, exterior; Rep. gr. 66 ; Removing and installing wheel
nform
ercia
housing liner .
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.

lkswage es n
o ot g
byV ua
Touareg 2003 ➤ rised ran
tee
o
6-cylinder injection
au engine - Edition 02.2012
th or
ac
ss
ce
le
– Unbolt cover plate -arrows-.
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
– Unclip fuel tank breather lines attached to longitudinal mem‐
inform
ber.
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.
– Remove securing bolts for filler neck -1- and activated char‐
coal filter -2- in wheel housing.
– Now bend filler neck slightly downwards and pull off breather
line connections to activated charcoal filter.
Note
Release connection by pressing button on hose coupling.

– Pull 3-pin connector off fuel system diagnostic pump -V144-
and 2-pin connector off activated charcoal filter solenoid valve
2 -N115- .
– Pull off earth wire clipped to activated charcoal filter and re‐
move activated charcoal filter.

Touareg 2003 ➤
– Disconnect connector to fuel pumps on left next to fuel tank.

– Now remove securing straps to left and right with cover below
fuel tank.
– Support fuel tank using engine and gearbox jack -
V.A.G 1383 A- and remove securing strap at middle of fuel
tank.
– Carefully lower fuel tank about 30 cm.
WARNING
– Reach between fuel tank and vehicle underbody and pull sup‐
ply and breather lines off sender flange, while holding a cloth
around supply line.
Note
This step saves cutting carpet in vehicle interior in vicinity of

sender flange.
– Lower fuel tank.

Installing
note the following:
. Volkswage
♦ Connections for breather and fuel lines
ksw
amust
gen AGengage audibly
n AG d
oes
not
when joined. by
Vol
gu
a d ran
ise
♦ Install breather and fuel hoses
tho
r
free of kinks. tee
or
u ac
sa
♦ Secure fuel hoses with sspring-type clips.
ce
e
nl
pt
du
♦ Ensure that fuel hose connections are tight.

an
itte
y li
erm
ab
♦ Ensure that earth wire on fuel filler neck -2- is secured tight to
ility
ot p
body.
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
Before bolting on fuel tank, check that supply and breather lines
are still clipped onto fuel tank.
rrectness of i
l purpos
1.11 Checking fuel pumps

Checking fuel delivery rate ⇒ page 137 .
nf
ercia
orm
Checking current draw of pumps ⇒ page 139 .

m
atio
om
n in
Checking fuel pump non-return valves ⇒ page 140

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 ➤

equipment required
♦ Pressure tester -V.A.G
1318-
♦ Adapter -V.A.G 1318/9- AG. Volkswagen AG d
agen oes
ksw
♦ Hose -V.A.G 1318/13- by Vol not
gu
ara
d
ise nte
♦ Adapter set -V.A.G thor eo
1318/17- ss au ra
c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
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 ➤

1348 -V.A.G 1348/3A-
♦ Multimeter -V.A.G 1715-
5024A-
AG. Volkswagen AG d
♦ Diesel extractor -VAS agen oes
olksw not
5226- byV gu
ara
ed
ris nte
o
♦ Not illustrated: aut
h eo
ra
ss c
ce
le
un
pt
an
d
♦ Adapter -V.A.G 1318/20-1-
itte
y li
rm
ab
♦ Hose -V.A.G 1318/24-
pe
ility
ot
wit
, is n
h re
1348/3-3-
hole
spec
es, in part or in w
♦ Measuring container
t to the co
♦ Current flow diagram
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.
1.11.1 Checking fuel delivery rate

Test prerequisites

Touareg 2003 ➤

sockets.
• Fuel pump relays -1- for right fuel delivery unit and -2- for left
fuel delivery unit must be removed from their sockets.
• Battery voltage at least 11.5 V.
Test procedure
– Remove filler cap from fuel tank filler neck.
– Connect remote control for V.A.G 1348 -V.A.G 1348/3A- with

adapter cable -V.A.G 1348/3-3- to connection -arrow- of fuel
pump relay for right fuel delivery unit.
– Connect positive terminal of remote control to positive pole in
engine compartment.

V.A.G 1318/20- .
– Turn valve (on T-piece) anti-clockwise until it is entirely open.
AG. Volkswagen AG d
agen oes
olksw not
V gu
WARNING ed by ara
nte
ris
ho eo
ut ra
Fuel supply lines are under pressure! Before opening
ss a fuel sys‐ c
tem, connect diesel suction pump -VAS 5226- and release ce
le
un
pressure. pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
– Connect adapter -V.A.G 1318/20- with adapter -

spec
V.A.G 1318/20-1- and diesel extractor -VAS 5226- to bleed

es, in part or in w
t to the co
valve -1-.
rrectness of i
– When fuel pressure has been released, the fuel system may
be opened.
l purpos
Checking right fuel pump delivery rate.

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 ➤
– Pull fuel supply hose -1- off fuel rail.

– Hold hose in measuring container -2- with minimum capacity
of 1000 cm3.
– Empty measuring container before making measurement.
– Operate remote control for 15 seconds. At least 800 cm3 fuel
per 15 seconds must be delivered.
Checking left fuel pump delivery rate.
– Then connect remote control for V.A.G 1348 -V.A.G 1348/3A-

with adapter -V.A.G 1348/3-3- to connection -arrow- of fuel
pump relay for left fuel delivery unit.
– Empty measuring container before making measurement.
– Operate remote control 15 seconds again. At least 800 cm3
fuel per 15 seconds must be delivered.
– In addition, check both fuel delivery units.
– To do so, connect adapter -V.A.G 1348/3-3- to connection for
relays of left and right fuel delivery units. n AG. Volkswagen AG
age does
ksw
– Operate remote control 10 seconds.y V At least 800 cm3 fuel per
ol not
gu
db ara
10 seconds must be delivered.
or
ise nte
h eo
ut ra
If the minimum delivery ratessisa not attained: c
ce
e
nl
– Check fuel lines for possible restrictions (kinks) or blockages.

pt
du
an
itte
y li
If fuel lines are ok:
erm
ab
ility
ot p
– Renew fuel filter.

wit
, is n
h re
If fuel delivery rate has been attained, but nevertheless you sus‐
hole
spec
pect a fuel supply system fault (e.g. intermittent failure of fuel
es, in part or in w
supply system):
t to the co
– Check current draw of fuel pumps ⇒ page 139 .

rrectness of i
1.11.2 Checking current draw of pumps

l purpos
Checking current draw of left fuel pump

– Reconnect all disconnected fuel lines.
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 ➤
– Connect multimeter -V.A.G 1715- pick-up clamp to wire for

contact -1- -arrow- of 4-pin connector of wiring harness to left
AG. Volkswagen AG d
fuel delivery unit. lkswagen oes
n o ot g
yV ua
– Start engine rand
ise run at idling speed.
db ran
tee
tho o
– Measures acurrent
u draw of fuel pump. Specification: max. 11r ac
amps. s
ce
e
nl
pt
du
an
itte
y li
erm
Note
ab
ility
ot p
wit
, is n
♦ The start-up current may be briefly above the specification.
h re
hole
spec
♦ If the fuel system malfunction is intermittent, you can perform
es, in part or in w
the check during a road test, but a 2nd person is necessary.
t to the co
If current draw is exceeded:
rrectness of i
– Left fuel pump is defective, renew fuel delivery unit
⇒ page 130 .
l purpos
Checking current draw of right fuel pump
nf
ercia
or
– Connect current pick-up of multimeter -V.A.G 1715- to line of
m
m
atio
contact -1- -arrow- of 4-pin connector of wiring harness to right
om
n in
fuel pump unit.
or c
thi
te
sd
iva
o
r
rp
cu
Note
o
m
f
en
ng
t.
yi Co
op
The right fuel pump is not actuated in all operating modes. For C py
t. rig
this reason, actuation takes place via the final control diagnosis.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
– Connect the vehicle diagnosis, testing and information system
AG.
-VAS 5051- .
– Switch on ignition.
– Press buttons on display one after the other for „Vehicle self-
diagnosis“, „Engine electronics“ and „Final control diagnosis“.
– On the display press the right arrow key until the „Relay for
electric fuel pump 2 - J49“ actuator test is reached to initiate
actuation of the fuel pump.
– Measure current draw of fuel pump. Specification: max. 11
amps.
Note
The start-up current may be briefly above the specification.
If current draw is exceeded:

– Right fuel pump is defective, renew fuel delivery unit
⇒ page 130 .
1.11.3 Checking fuel pump non-return valves

Prerequisite
• The remote control -V.A.G 1348/3A- for V.A.G 1348 is still
connected.

Touareg 2003 ➤
Note
At the same time, this test nchecks

AG. Volkfor
swaleaks
gen AG in the fuel supply line
connections from the l wagedelivery unit to the
ksfuel
does
point
not at which the
o
yV
pressure tester
sed-V.A.G 1318- is connected.
b gu
ara
n
ri tee
ho
ut or
Test procedure
ss
a ac
ce
e
nl
– First turn valve on T-piece of adapter -V.A.G 1318/20- anti-
pt
du
an
clockwise until it is entirely open.
itte
y li
erm
ab
– Then connect pressure tester -V.A.G 1318- to bleed valve
ility
ot p
-1- with adapters -V.A.G 1318/20- , -V.A.G 1318/20-1- , -
wit
, is n
V.A.G 1318/9- and diesel extractor -VAS 5226- as shown.
h re
hole
spec
– Screw valve on T-piece of adapter -V.A.G 1318/20- clockwise
es, in part or in w
into bleed valve to stop.
t to the co
– Open shut-off tap of pressure tester and operate remote con‐
trol briefly to bleed.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
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en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
– Then close pressure tester shut-off tap -arrow- (lever at right

angles to direction of flow).
– Operate remote control at short intervals until a pressure of
approx. 4 bar has built up.
WARNING
Danger of spray when opening shut-off valve; diesel extractor

AG. Volkswagen AG d
-VAS 5226- must be connected. olkswagen oes
no
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db ara
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– If pressure builds up too
aut high, relieve excess pressure by ra
c
ss
carefully opening shut-off tap.
ce
le
un
pt
– Watch pressure drop on pressure gauge. After 10 minutes,
an
d
itte
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pressure must not drop below 3.0 bar.
rm
ab
pe
ility
If pressure drops:
ot
wit
, is n
h re
– Check fuel lines and connections to fuel tank for leaks.
hole
spec
If no fault in lines is detected:
es, in part or in w
t to the co
WARNING
rrectness of i
l purpos

pressure.
nform
mercia
– Wrap a cloth around the joint to collect fuel which flows out.
a
com
tion in
– Remove pressure tester -V.A.G 1318- with adapters as
r
te o
thi
shown.
s
iva
do
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rp
Checking non-return valve of right pump

um
fo
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t.
Test prerequisite
yi Co
Cop py
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• Fuel pump relays -1- for right fuel delivery unit and -2- for left cop Vo
by lksw
fuel delivery unit must be removed from their sockets. cted agen
Prote AG.
Test procedure
– Disconnect 4-pin connector from left flange.
– Now unscrew locking ring from flange (fuel filter) using wrench
-T10202- .
– Carefully lever flange and raise it slightly.
– Briefly detach connector next to fuel filter for connecting pres‐
sure tester -V.A.G 1318- .

Touareg 2003 ➤
– Then detach fuel supply hose -2- leading from right fuel deliv‐
ery unit from fuel filter -1-.
– Allow fuel from nozzle -1- to flow back into fuel tank.
AG. Volkswagen AG d
agen oes
olksw not
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aut ra
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
– Close pressure tester shut-off tap -arrow- (lever at right angles
h re
to direction of flow).
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
– Connect pressure tester -V.A.G 1318- with adapter - thi

te
sd
a
V.A.G 1318/7- , hose -V.A.G 1318/13- and adapter set -V.A.G

iv
o
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rp
cu
1318/17- as shown.
o
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f
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ng
t.
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Cop py
Note
ht. rig
rig ht
py by
co Vo
by lksw
cted
Ensure that fuel supply line connection engages audibly when
agen
Prote AG.
joined.
– Reconnect detached connectors to filter housing and flange.

pump relay for right fuel delivery unit.
If pressure drops:
– Right fuel pump is defective, renew right fuel delivery unit
⇒ page 130 .
To convert the pressure tester for the left fuel pump:

Touareg 2003 ➤
– Open lever of pressure tester and let fuel flow back to fuel tank
through hose -V.A.G 1318/13- .
Checking non-return valve of left pump
– Then detach fuel supply hose -2- leading from left fuel delivery
unit from fuel filter -1-.
– If necessary, detach connectors from flange and filter housing
to connect pressure tester -V.A.G 1318- .
– Close pressure tester shut-off tap -arrow- (lever at right angles

to direction of flow).
AG. Volkswagen AG d
agen oes
olksw not
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ara
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ris nte
ho eo
aut ra
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ce
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– Connect pressure tester -V.A.G 1318- with adapter -

nl
pt
du
V.A.G 1318/7- , hose -V.A.G 1318/13- and adapter -

an
itte
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V.A.G 1318/24- as shown.

erm
ab
ility
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wit
, is n
Note
h re
hole
spec
es, in part or in w
Ensure that fuel supply line connection engages audibly when

t to the co
joined.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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Cop py
ht. rig
rig ht
py by
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144
by lksw
cted agen
Rep. gr.20 - Fuel supply system Prote AG.
Touareg 2003 ➤

pump relay for left fuel delivery unit.
If pressure drops:
– Left fuel pump is defective, renew left fuel delivery unit
⇒ page 130 .
– Open lever of pressure tester and let fuel flow back to fuel tank
through hose -V.A.G 1318/13- .
– Remove pressure tester -V.A.G 1318- with adapters as
shown.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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nl
pt
du
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
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n in
or c
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sd
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Cop py
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pyri by
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co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
2 Electronic power control (EPC)
1 - Bearing bracket
2 - Connector
❑ Black, 6-pin.
AG. Volkswagen AG d
3 - 10 Nm ksw
agen oes
not
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4 - Accelerator position sender ised b ara
nte
-G79- and accelerator position ut
hor eo
sender 2 -G185- ss a ra
c
❑ Not adjustable.
ce
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un
pt
an
d
❑ Remove footwell cover
itte
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to remove sender.
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
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rp
cum
fo
en
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t.
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Cop py
ht. rig
rig ht
py by
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by lksw
cted agen
Prote AG.
Function of EPC system

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

Touareg 2003 ➤
When the engine is running (under load), the engine control unit
can open or close the throttle valve independently of the accel‐
erator position sender.
This means that the throttle valve can already be completely open
even though the accelerator is only depressed half way. This has
the advantage of preventing throttling losses at the throttle valve.
This also results in significantly improved consumption and ex‐
haust emission values under certain load conditions.
After evaluating the torque requirements of various components
(e.g. air conditioning system, automatic gearbox, ABS/ESP and
so on), the engine control unit calculates the optimal throttle valve
opening angle for the respective situation.
Observe safety precautions ⇒ page 123 .
Observe rules for cleanliness ⇒ page 123 .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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aut ra
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un
pt
an
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cum
fo
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t.
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Cop py
ht. rig
rig ht
by
147
copy Vo
by lksw
cted agen 2. Electronic power control (EPC)
Prote AG.
Touareg 2003 ➤
3 Activated charcoal filter system (ve‐

hicles with engine code AZZ, BKJ,
BMV or BRJ)
Assembly overview - parts of activated charcoal filter system
⇒ page 149 .
Function
Fuel vapour forms above the surface of the fuel in the fuel tank;
the quantity depends upon the air pressure and ambientwtemper‐
agen
AG. Volkswagen AG d
oes
ature. yV
olks not
gu b ara
ed
The activated charcoal filter system prevents hthese
or
is HC emissions nte
e
escaping to the atmosphere. s aut or
ac
s
Fuel vapours pass from the highest point in the tank (on filler neck)
ce
e
nl
pt
du
through the expansion tank and into the activated charcoal filter.
an
itte
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erm
ab
The activated charcoal stores these vapours like a sponge.
ility
ot p
wit
When the car is being driven and the Lambda control is active
, is n
h re
(engine warm), the activated charcoal filter solenoid valve 1 -N80-
hole
is activated (pulsed) by the engine control unit depending upon
spec
es, in part or in w
load and engine speed. The opening period depends on the input
t to the co
signals.
During the purging procedure (regeneration of activated char‐
coal), the intake manifold vacuum draws fresh air through the vent
rrectness of i
of the activated charcoal filter. The fuel vapours stored in the ac‐
l purpos
tivated charcoal and fresh air are fed to combustion in metered

quantities.
nf
ercia
The activated charcoal filter system solenoid valve 1 -N80- is
or
closed when it is not supplied with current (e.g. open circuit). The
m
m
atio
activated charcoal filter will not be purged.
om
n in
or c
thi
te
sd
iva
Note
o
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ng

t.
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op
clamp-type clips.
C py
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♦ Always renew clamp-type clips with spring-type clips.
op Vo
by c lksw
cted agen
Prote
♦ Spring-type clip pliers -VAS 5024A- or pliers -V.A.G 1921- are
AG.

Touareg 2003 ➤
3.1 Assembly overview - activated charcoal

filter system
Caution

fuel tank:
original positions.
static charge.
hot components.
1 - Expansion tank
❑ Right side.
2 - Gravity valve
❑ With connection for
earth cable to body
4 - Pressure retention valve
❑ Function ⇒ page 150 .
5 - Connecting hose
❑ Between air filter and
activated charcoal filter.
❑ Check for secure seat‐ n AG. Volkswagen AG do
kswage es n
ing. byV
ol ot g
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ir se
6 - 5 Nm tho tee
or
au ac
7 - Air filter ss
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❑ Clean if soiled.
an
d
itte
8 - Activated charcoal filter y li

rm
ab
pe
❑ Location: in rear right ility

ot
wit
, is n
wheel housing. h re
hole
spec
9 - 9 Nm
es, in part or in w
t to the co
10 - Breather line
❑ To connection on intake
manifold
rrectness of i
⇒ Item 11 (page 161) .

l purpos

ing.
nform
ercia
11 - Connector
❑ Black, 2-pin.
m
a
com
tion in
12 - Activated charcoal filter

r
te o
thi
solenoid valve 1 -N80-

s
iva
do

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rp
cum
fo
en
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13 - Rubber bracket
n
t.
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op
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Activated charcoal filter system (vehicles with engine code AZZ, BKJ, BMV or BRJ) 149
Touareg 2003 ➤
14 - Breather line
Function of pressure retention valve

As seen from the gravity valve (located on the expansion tank),
the pressure retention valve allows flow in both directions
(-arrow 1- corresponds to the side oriented towards the expansion
tank).
On the opposite side, flow is possible in only one direction
-arrow 2-. This side corresponds to the activated charcoal filter.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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un
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an
d
itte
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erm
ab
ility
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wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
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c
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or
n thi
te
sd
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pr
cum
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t.
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Cop py
t. rig
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pyri by
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o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
4 Activated charcoal filter system (ve‐

hicles with engine code BAA or BMX)
Assembly overview - parts of activated charcoal filter system
⇒ page 152 .
Checking fuel system for leaks ⇒ page 153
Function
Fuel vapour forms above the surface of the fuel in the fuel tank;
the quantity depends upon the air pressure and ambient temper‐
ature.
The activated charcoal filter system prevents these HC emissions
escaping to the atmosphere.
Fuel vapours pass from the highest point in the tank (on filler neck)
through the expansion tank and into the activated charcoal filter.
The activated charcoal stores these vapours like a sponge.
When the vehicle is being operated and the Lambda control is
active (engine warm), the activated charcoal filter system sole‐
noid valve 1 -N80- is activated (pulsed) by the engine control unit
-J623- depending on load and engine speed. The opening period
depends on the input signals.
During the purging procedure (regeneration of activated char‐
coal), the intake manifold vacuum draws fresh air through the vent
of the activated charcoal filter. The fuel vapours stored in the ac‐ wagen AG. Volkswagen AG does
tivated charcoal and fresh air are fed to combustion in metered olks not
yV gu
quantities. ris
edb ara
nt ee
tho or
The activated charcoal filter system solenoid valve 1s -N80-
au is ac
closed when it is not supplied with current (e.g. opens circuit). The
ce
e
nl
activated charcoal filter will not be purged.
pt
du
an
itte
y li
Description of leakage diagnosis
erm
ab
ility
ot p
The activated charcoal filter system (including fuel tank) is equip‐
wit
, is n
ped with leakage diagnosis which can detect if there is a leak in
h re
the system.
hole
spec
es, in part or in w
The diagnosis is based on a pressure method and indicates leaks
t to the co
with a diameter greater than 0.5 mm.
During the diagnosis, the fuel system diagnostic pump -V144-
rrectness of i
builds up pressure in the activated charcoal system. For this, the
activated charcoal filter solenoid valve 2 -N115- is closed. Once
l purpos
the pressure is attained, the pump switches off. If the pressure

drops below a certain value, the pump switches on again. Self-
diagnosis monitors the intervals at which the pump is switched on
nf
ercia
or off and if the intervals are too short, writes a fault to the fault
rm
m
memory.
atio
om
n in
or c
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Cop py
ht. rig
rig ht
py by
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by lksw
cted agen
Prote AG.
4. Activated charcoal filter system (vehicles with engine code BAA or BMX) 151
Touareg 2003 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
Note horis nte
eo
aut ra
ss c
ce
le
un
clamp-type clips.
pt
an
d
itte
y li
♦ Use spring-type clip pliers -VAS 6340- for installation of spring-
erm
ab
type clips
ility
ot p
wit
♦ or space-saving hose clip pliers -VAS 6362- . is n
h re
ole,
spec
t to the co
rrectne
4.1 Assembly overview - activated charcoal filter system
ss o
cial p
1 - Expansion tank
f inform
❑ Right side.
mer
atio
m
2 - Gravity valve
o
n
c
i
or
n
thi
te
sd
iva
o
r
4 - 5 Nm
p
cum
r
fo
en
ng
5 - Bracket
t.
yi Co
Cop py
.
6 - Vacuum line
ht rig
rig ht
py by
Vo
❑ For vacuum supply of
co lksw
by
cted agen
fuel system diagnostic Prote AG.
pump -V144-
❑ To connection on intake
manifold
⇒ Item 9 (page 161) .
ing.
7 - Fuel system diagnostic
pump -V144-
❑ Checking fuel system
for leaks ⇒ page 153
❑ Black connector, 3-pin
8 - Connecting hose
❑ Between air filter, fuel
system diagnostic pump
-V144- and activated
charcoal filter solenoid
valve 2 -N115-
ing.
9 - 5 Nm
10 - Air filter
❑ Clean if soiled.
11 - Rubber bush
12 - Activated charcoal filter solenoid valve 2 -N115-

Touareg 2003 ➤

❑ Location: in rear right wheel housing.
14 - Securing bolts
❑ Qty. 3.
❑ 9 Nm
15 - Breather line
❑ To connection on intake manifold ⇒ Item 11 (page 161) .
16 - Connector
❑ Black, 2-pin.
17 - Activated charcoal filter solenoid valve 1 -N80-
AG. Volkswagen AG d
agen
18 - Rubber bracket olksw
oes
not
byV gu
ara
❑ Note installation position. rised
nte
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19 - Breather line ss a ra
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nl
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ab
❑ Function ⇒ page 153 .
ility
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wit
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hole
spec
Function of pressure retention valve
es, in part or in w
t to the co
From gravity valve (on expansion tank) the pressure retention
valve is open in both directions of flow. -Arrow 1- is the side to
expansion tank.
rrectness of i
On the other side it is only open for flow in one direction.
l purpos
-Arrow 2- is the side to activated charcoal filter.
nform
mercia
at
om
ion
c
in t
or
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ate
do
riv
4.2 Checking fuel system for leaks

p
cum
for
en
ng
t.
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Special tools and workshop equipment required . Cop py
rig
ht ht
♦ Fuel system tester (so-called smoke tester) -KLI 9210-
rig by
copy Vo
by lksw
cted
♦ Adapter hose -KLI 9210/55-2-
agen
Prote AG.
♦ Vehicle diagnosis tester -VAS 5051B- , -VAS 5052- or -VAS

5053-
♦ Hose clamps up to 25 mm -3094-
Test prerequisite:
• A leak has been detected by the fuel system diagnostic pump
-V144- .
• Guided fault finding has been performed with the vehicle di‐
agnosis tester .
Touareg 2003 ➤
AG. Volkswagen AG d
agen oes
Preparation of fuel system tester -KLI 9210- : olksw not
byV gu
ara
ed
ris nte
ho eo
ut ra
Note ss a c
ce
e
nl
pt
du
The fuel system tester -KLI 9210- may differ in appearance de‐
an
itte
pending on the version.
y li
erm
ab
ility
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– Check on fuel system tester -KLI 9210- if there is enough fluid
wit
, is n
h re
in smoke generator.
hole
spec
– Set valve -D- to „Hold“.
es, in part or in w
t to the co
– Open nitrogen bottle -H-.
– Connect test hose -G- to self-test connection -B-.
rrectness of i
– Set valve -D- to „Test“.
l purpos
– Regulate pressure to 25 mbar (10 in. H2O) with pressure re‐

ducer -J-.
nform
ercia
– Set valve -D- to „Hold“.

m
at
om
i
– Now pressure must be maintained for at least 2 minutes.
on
c
in t
Check tester if pressure is not maintained.
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.
Checking fuel system for leaks:

– In engine compartment, disconnect breather line -arrow- to
activated charcoal filter solenoid valve 1 -N80- .
– Connect adapter hose -KLI 9210/55-2- between activated

charcoal filter solenoid valve 1 -N80- and breather line as il‐
lustrated.
– Connect measuring hose -G- from fuel system tester -KLI
9210- to adapter hose -KLI 9210/55-2- .
– Connect fuel system tester -KLI 9210- to vehicle battery.

Touareg 2003 ➤
– Connect vehicle diagnosis tester to vehicle.

– On vehicle system tester, select operating mode OBD .
– Now select diagnostic mode 8 „Tank leak test“.
– Select entry „Tank leak test“ and press right arrow button ► to
initiate test.
Note
♦ Once the diagnostic mode 8 „Tank leak test“ has been acti‐
vated, the diagnostic pump and the activated charcoal filter
solenoid valve 2 -N115- are closed for max. 1,000 seconds.
The activated charcoal filter solenoid valve 1 -N80- is not ac‐
tivated. Now the entire system is closed.
♦ If the engine control unit cancels the test, it is possible to ini‐
tiate it again by switching off and restarting the engine.
– Set valve -D- to „Test“. The fuel system will now be filled with
nitrogen.
– Observe pressure gauge -C- and flow meter -E-. When the
throughput quantity decreases and the pressure increases to
25 mbar (10 in. H2O), the fuel system is filled.
Note
Depending on the filling level of the fuel tank, this process can
take up to 3 minutes.
– Once pressure has stabilised, set valve -D- to „Hold“.

• After 5 minutes the pressure must notAdrop
G. Volkbelow
swagen20 mbar
AG do
(8 in. H2O). lkswagen es n
o Vo t gu
by
If pressure does not drop, rexit
ise from diagnostic mode 8 and check ante
d ar
if fuel system diagnosticut pump -V144- can build up pressure
ho eo
ra
⇒ page 158 . ss a c
ce
e
nl
If no pressure builds up or the pressure is not held for at least 5

pt
du
an
minutes, localise leak as follows:

itte
y li
erm
ab
Leave engine running at idling speed for at least 8 minutes with

ility
ot p
activated diagnostic mode 8.

wit
, is n
h re
hole
spec
– First check activated charcoal filter solenoid valve 1 -N80- for

es, in part or in w
leaks. To do this, clamp off hose to activated charcoal filter

t to the co
solenoid valve 1 -N80- using a hose clip -arrow-. Also refer to

⇒ Item A (page 157) .
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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cu
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f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
155
cted agen
Prote
4. Activated charcoal filter system (vehicles with engine code BAA or BMX)
AG.
Touareg 2003 ➤
– Repeat pressure test by setting valve -D- again to „Test“.

– Observe pressure gauge and flow meter. When the through‐
put quantity decreases and the pressure increases to 25 mbar
(10 in. H2O), the fuel system is filled.
– Once pressure has stabilised, set valve -D- to „Hold“.
– If the pressure does not drop again, renew activated charcoal
filter solenoid valve 1 -N80- .
If pressure still drops:
– Set valve -D- again to „Test“.
– While fuel system is being filled, press button -I- for smoke
generator for approx. one minute.
The fuel system is now pressurised and filled with smoke.
– Check whether smoke escapes from any visible fuel system
line or hose. Also check fuel tank cap.
Note
♦ Light up the components and hoses with a strong floodlight. In

the floodlight, smoke is more visible.
♦ For leak detection in accessible areas,AGalso
. Volkuse
swagultrasonic
en de‐
tector or commercially available
lkswleak detecting spray. es no
agen AG do
Vo t gu
by
♦ Depending on how long
ris
ethe
d fault finding takes, it may be nec‐ ara
nt
essary to press the usmoke
tho generator button from time to time. ee
or
This ensures thatsssufficient
a smoke is present in the fuel sys‐ ac
tem.
ce
e
nl
pt
du
an
itte
y li
If no fault is found:
erm
ab
ility
ot p
– Remove rear right wheel housing liner.

wit
, is n
h re
If smoke escapes from air filter ⇒ Item 7 (page 157) :

hole
spec
es, in part or in w
– Clamp off hose between activated charcoal filter solenoid

t to the co
valve 2 -N115- and air filter -arrow-. Also refer to

⇒ Item B (page 158) .
rrectness of i
– Observe air filter. If smoke no longer escapes, activated char‐

coal filter solenoid valve 2 -N115- is leaking. Renew activated
l purpos
charcoal filter system solenoid valve 2 -N115- .

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

Touareg 2003 ➤
If smoke still escapes from air filter: lkswage es n
o ot g
byV ua
ed ran
– Clamp off hose between fuel system diagnostic pump oris -V144- tee
and air filter -arrow-. Also refer to ⇒ Item C (pageau 158) .
th or
ac
ss
– Observe air filter. If smoke no longer escapes, shut-off valve
ce
e
nl
pt
in fuel system diagnostic pump -V144- is leaking. Renew fuel
du
an
itte
system diagnostic pump -V144- .
y li
erm
ab
ility
If no smoke escapes from air filter ⇒ Item 7 (page 157) :
ot p
wit
, is n
– Check whether smoke escapes from any fuel system compo‐
h re
hole
nent or hose.
spec
es, in part or in w
To inspect flanges for fuel pump and fuel filter, open assembly
t to the co
openings in vehicle interior.
– Renew leaking hoses or components.
rrectness of i
After completing work, perform guided function „checking fuel
l purpos
tank breather system for leaks“ using ⇒ Vehicle diagnostic tester.
nf
ercia
4.2.1 Overview of activated charcoal filter system
orm
m
atio
om
n in
c

or
thi
te
sd
a
2 - Location of adapter hose -

iv
o
r
rp
cu
KLI 9210/55-2-
o
m
f
en
ng
❑ For leak detection in fuel

t.
yi Co
op
system
C py
t. rig
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3 - Activated charcoal filter sol‐ cop Vo
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enoid valve 1 -N80-
cted agen
Prote AG.
4 - Breather line
❑ To intake manifold.
5 - Solenoid valve
❑ For fuel system diag‐
nostic pump -V144-
6 - Vacuum line
❑ To intake manifold.
7 - Air filter
❑ For fuel system diag‐
nostic pump -V144-
8 - Fuel system diagnostic
pump -V144-
9 - Fuel tank
10 - Cap
solenoid valve 2 -N115-
A - Clamp off in this area
❑ For leak detection in fuel
system
❑ For checking activated
charcoal filter solenoid
Touareg 2003 ➤
valve 1 -N80- .
B - Clamp off in this area
❑ For leak detection in fuel system
❑ For checking activated charcoal filter solenoid valve 2 -N115- .
C - Clamp off in this area
❑ For leak detection in fuel system
❑ For checking fuel system diagnosis pump -V144- .
4.2.2 Checking build-up of pressure of fuel

system diagnostic pump -V144-
Test prerequisite:
• Fuel system tester -KLI 9210- is connected to vehicle via
adapter hose -KLI 9210/55-2- .
• Valve -D- is set to „Hold“.
• Diagnostic mode 8 is completed and engine is running at idling
speed. Volkswa AG. gen AG
agen do
Fuel system must not be under olpressure
ksw for test. Proceedesas
not fol‐
yV gu
lows to reduce residual pressure:
sed b ara
n ri tee
ho
aut or
ac
ss
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le
un
pt
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itte
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erm
ab
ility
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wit
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h re
ole,
spec
t to the co
– Briefly open quick-release coupling -arrow- for adapter hose -

rrectne
KLI 9210/55-2- to release pressure in fuel system. Pressure

gauge -D- must drop to 0 in. H2O.
ss o
– On vehicle diagnosis tester, select operating mode Guided

cial p
f in
functions .
form
mer
atio
– Select guided function „Checking tank ventilation system for

om
leaks“.
c
i
or
n thi
te
– Initiate test.
sd
iva
o
pr
cum
r
– Observe pressure gauge while test is running.

fo
en
ng
t.
yi Co
– Fuel system diagnostic pump -V144- must pump up pressure Cop py
t.
in fuel system at least to 18 mbar (7 in. H2O).
rig
gh ht
pyri by
Vo
o
by c
– If pressure is not reached, check vacuum supply of fuel system
lksw
cted agen
Prote
diagnostic pump -V144- ⇒ page 158 .
AG.
– If fuel system is free of leaks and vacuum supply of fuel system

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

diagnostic pump -V144-

Touareg 2003 ➤
♦ Turbocharger tester -V.A.G 1397A-
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
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aut ra
ss c
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un
pt
♦ T piece -251 201 346-
an
d
itte
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erm
ab
♦ Hose ∅ 6mm
ility
ot p
wit
is n
h re
ole,
Note
spec
Fitting location of fuel system diagnosis pump -V144- : in rear right
t to the co
wheel housing under wheel housing liner.
rrectne
– Remove rear right wheel and wheel housing liner.
– Remove securing bolts ⇒ Item 14 (page 153) of activated
ss
charcoal filter and lower filter to have better access to vacuum
o
cial p
f
line.
inform
mer
atio
m
Caution
o
n
c
i
or
n thi
e
Support activated charcoal filter to prevent its hanging down

t
sd
va
from hoses and lines. This prevents damages.

i
o
pr
cum
r
fo
en
ng
t.
yi Co
op py
– Disconnect vacuum line -1- from fuel system diagnostic pump t. C rig
gh ht
-V144- . yri
p by
o Vo
by c lksw
cted
– Connect turbocharger tester -V.A.G 1397A- with T-piece and
agen
Prote AG.
hose ∅ 6mm, between vacuum line -1- and fuel system diag‐
nostic pump -V144- -2-.
– Switch on measuring range I (absolute pressure measure‐
ment).
– Connect vehicle diagnosis tester and start engine.
– On vehicle diagnosis tester, select operating mode Guided
functions .
– Select guided function „Checking tank ventilation system for

leaks“.
– Observe display on turbocharger tester -V.A.G 1397A- while
test is running.
• Pressure must pulsate and must not exceed 0.7 bar during
test.
– If pressure exceeds 0.7 bar during test, vacuum supply is too
low. Check vacuum line to intake manifold for possible kinks
or blockages.
Touareg 2003 ➤
24 – Mixture preparation - injection

1 Repairing injection system
General notes on injection
♦ Fuel hoses in engine compartment must be secured only with
spring-type clips. The use of clamp or screw-type clips is not
permissible.
♦ Spring-type clip pliers -VAS 5024 A- or pliers -V.A.G 1921- are
♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 V is necessary.
♦ Do not use sealants containing silicone. Silicone particles
drawn into the engine will not be burnt in the engine and will
damage the Lambda probes.
Assembly overview - intake manifold ⇒ page 160 .
Assembly overview - fuel rail ⇒ page 162
Assembly overview - air filter ⇒ page 162 .
Volkswa AG. gen AG
agen does
Safety precautions ⇒ pageVo165
lksw . not
gu
by ara
ed
Rules for cleanliness
ho
ris⇒ page 165 . nte
eo
t
au ra
Technical data ⇒
ss page 166 . c
ce
le
un
pt
an
d
1.1 Assembly overview - intake manifold

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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
160 Rep. gr.24 - Mixture preparation - injection

Touareg 2003 ➤
1 - Intake manifold
2 - To cylinder head cover.
3 - Seal
❑ Renew.
4 - Crankcase breather valve
❑ With heater element for
crankcase breather -
N79- .
5 - 10 Nm
6 - Bearing cap
❑ For intake manifold
change-over barrel
7 - 20 Nm
8 - Vacuum connection
❑ For brake servo or brake
vacuum pump -V192-
for vehicles with auto‐
matic gearbox
❑ For vehicles with engine
code BAA or BMX for
fuel system diagnostic
pump -V144-
❑ For vehicles with engine
code AZZ, BKJ, BMV or
BRJ sealed with bung
❑ For secondary air inlet
valve -N112- and intake
manifold changeover
valve -N156- gen AG. Volkswagen AG
a does
lksw n
11 - Vacuum dconnection
by
Vo ot g
ua
e ran
❑ For thoactivated
ris charcoal filter system solenoid valve
tee 1 -N80- .
or
u
❑ ssVehicles with engine code AZZ, BKJ, BMV or BRJac⇒ Item 10 (page 149)
a
ce
le
❑ Vehicles with engine code BAA or BMX ⇒ Item 15 (page 153) .

un
pt
an
d
itte
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12 - 20 Nm
rm
ab
pe
ility
13 - Throttle valve module -J338-

ot
wit
, is n
❑ Gold-plated connector contacts

h re
hole
❑ If renewed, adapt engine control unit to throttle valve module ⇒ Vehicle diagnostic tester; ;„Guided func‐
spec
es, in part or in w
tions“ .
t to the co
14 - 10 Nm
15 - Vacuum actuator
rrectness of i
❑ For intake manifold change-over.

l purpos
16 - To intake manifold changeover valve -N156-

nform
ercia
17 - 10 Nm
m
18 - Positioning lever
a
com
tion in
❑ For change-over barrel.

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
161
by c lksw
cted
1. Repairing injection system
agen
Prote AG.
Touareg 2003 ➤
19 - Change-over barrel
20 - Gasket
❑ Renew if damaged. wage
es n
olks ot g
21 - Dowel sleeve byV ua
d ran
ir se tee
❑ To secure intake manifold. utho
or
a ac
❑ To locate seal. ss
ce
e
nl
pt
du
22 - 13 Nm
an
itte
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erm
ab
ility
ot p
wit
1.2 Assembly overview - fuel rail
, is n
h re
hole
spec
es, in part or in w
1 - 10 Nm
t to the co
2 - Protective cap
rrectness of i
3 - Breather valve
❑ For checking fuel pres‐
l purpos
sure
❑ For bleeding fuel sys‐
nform
ercia
tem
m
at
4 - Injector, cylinder 6 -N84-
om
ion
c
in t
or
his
ate
do
riv
5 - Seal
p
cum
or
❑ Renew.
f
en
ng
t.
yi Co
op
6 - Retaining clip C py
t. rig
gh ht
❑ Check for secure seat‐ yri
p by
o Vo
ing.
c by lksw
cted agen
Prote AG.
7 - Connection, supply line
8 - Fuel rail
9 - Connector
❑ Black, 2-pin.
ing.
10 - Wiring harness
❑ With connectors for in‐
jectors
❑ Clipped into wiring
channel
1.3 Assembly overview - air filter

Separating connecting line to air suspension compressor
⇒ Item 13 (page 163) ⇒ page 164

Touareg 2003 ➤
1 - Air duct
❑ Secured to lock carrier.
2 - Protective grommet
3 - Air filter lower part
❑ To remove lower part of
air filter, remove bracket
⇒ page 163
4 - 10 Nm
5 - Filter element
6 - Air filter upper part
7 - Seal
8 - Air mass meter -G70- with
intake air temperature sender -
G42-
❑ Gold-plated contacts on
sensor and connector.
9 - 6 Nm
10 - Spring-type clip
❑ Check for secure seat‐ n AG. Volkswagen AG do
ing. olkswage es n
ot g
byV ua
11 - Intake hose ir se
d ran
te
tho eo
12 - To throttle valvess amodule
u
- ra
c
J338- .
ce
le
un
pt
an
13 - To compressor for air sus‐

d
itte
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pension
erm
ab
ility
ot p
❑ Separating connection
wit
line ⇒ page 164 .

is n
h re
ole,
❑ Depending on equip‐
spec
ment, connection may be sealed with a blanking plug

t to the co
14 - Heat shield
❑ For upper part of air filter.
rrectne
15 - 6 Nm
16 - To secondary air pump motor -V101-
ss o
cial p
f inform
mer
Removing bracket for engine cover

atio
om
– Press in lug -1- from below and pull bracket out in

c
i
or
n thi
-direction of arrow-.
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.
1. Repairing injection system 163

AG. Volkswagen AG d
agen o
Touareg 2003Vo➤ lksw es n
ot g
by ua
6-cylinder
riseinjection
d engine - Edition 02.2012 ran
t ee
tho or
au ac
1.3.1 sDisconnecting connecting line to air sus‐
s
ce
le
pension compressor
un
pt
an
d
itte
y li
rm
ab
– Separate line at air filter -arrow- as follows:
pe
ility
ot
– Carefully lever off green securing ring -1- using a screwdriver.
wit
, is n
h re
Then press clamping ring -2- in direction of -arrow-.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
– Now pull loosened line -B- off connection -A- on air filter.
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 ➤
1.4 Safety precautions

♦ For safety reasons, fuse nos. -13- and -14- -arrows- must be
removed from the fuse holder before opening the fuel system.
Otherwise, the fuel pumps could be activated by the driver's
door contact switch.
♦ Fuse nos. -13- and -14- are located in the E-box fuse holder
in the left plenum chamber.
WARNING
AG. Volkswagen AG d
agen oes
lksw n
Fuel supply lines are under y V pressure! Before opening fuelotsys‐
o gu
d b ara
tem, connect diesel orisuction
se pump -VAS 5226- and release nte
eo
pressure. auth
ra
c
ss
ce
le
un
pt
an
d
To prevent injuries to persons and/or damage to the injection and

itte
y li
ignition system, the following must be observed:
erm
ab
ility
ot p
♦ Switch off ignition before connecting or disconnecting injection
wit
is n
and ignition system wiring as well as test instrument cables.
h re
ole,
spec
♦ Do not touch or disconnect ignition cables when the engine is
running or being turned at starter speed.
t to the co
Note the following if testers and measuring instruments have to
be used during a road test:
rrectne
♦ Test and measuring instruments must always be secured to
rear seat and operated by a second person from this location.
ss o
cial p
If test and measuring instruments are operated from front pas‐

f in
senger seat and the vehicle is involved in an accident, there is a form
mer
possibility that the person sitting in this seat may receive serious
atio
m
injuries when the airbag is triggered.

o
n
c
i
or
♦ If the engine is to be turned at starter speed without starting:

thi
te
sd
iva
– Pull connectors off ignition coils 1…6.

pr
cum
r
fo
en
ng
t.
yi Co
– Apply assembly tool -T10118- to locking mechanism button Cop py
-arrow- and carefully pull connector off.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.5 Rules for cleanliness

When working on the fuel supply and injection system, pay careful
attention to the following „five rules“ for cleanliness:
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
♦ Carefully cover opened components or seal if repairs cannot
be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
1. Repairing injection system 165

Touareg 2003 ➤
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
♦ When system is open: do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely nec‐
essary.
wage
1.6 Technical data lks es n
o ot g
byV ua
d ran
ir se tee
Engine code AZZ uth BAA
o
BKJ BMV BMX
or BRJ
a ac
ss
Idling check
ce
le
un
pt
Idling rpm 650...750 650...750 650...750 650...750 650...750 650...750
an
d
itte
speed7)
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erm
ab
ility
Engine control
ot p
unit
wit
is n
h re
System Motronic Motronic Motronic Motronic Motronic Motronic
ole,
spec
designa‐ ME7.1.1 ME7.1.1 ME7.1.1 ME7.1.1 ME7.1.1 ME7.1.1
tion
t to the co
Part num‐ ⇒ EKTA ⇒ EKTA ⇒ EKTA ⇒ EKTA ⇒ EKTA ⇒ EKTA
ber (electronic (electronic (electronic (electronic (electronic (electronic
parts cata‐ parts cata‐ parts cata‐ parts cata‐ parts cata‐ parts cata‐
rrectne
logue) logue) logue) logue) logue) logue)
Governed rpm from approx. from approx. from approx. from approx. from approx. from approx.
ss o
speed 6500 6500 6500 6500 6500 6500
cial p
f inform
mer
atio
om
7) Not adjustable.
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 ➤
2 Checking components
2.1 Checking injectors

Checking for leaks ⇒ page 167 .
Checking injection rate ⇒ page 168 .

equipment required
1348 -V.A.G 1348/3A-
1348/3-2-
♦ Adapter cable, 121-pin -
V.A.G 1598/31-
♦ Injection rate tester -V.A.G
1602-
1348/3-3-
♦ Auxiliary measuring set -
V.A.G 1594C-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Test prerequisite
rrectness of i
• The fuel pressure must be OK, checking ⇒ page 169 , check‐

l purpos
ing fuel pressure regulator and holding pressure.

Test procedure
nform
ercia
– Remove intake manifold ⇒ page 63 , Removing and installing

m
a
com
cylinder head cover.

ion in
r
te o
thi
– Then remove complete fuel rail (fuel pressurisation line re‐

s
iva
mains connected) ⇒ page 162 , Dismantling and assembling

do
r
rp
fuel rail.
um
fo
en
ng
t.
yi
2.1.1 Checking for leaks
Co
Cop py
t. rig
gh ht
yri
– Remove fuse holder cover.
p by
o Vo
by c lksw
cted agen
Prote AG.
2. Checking components 167

Touareg 2003 ➤
– Pull fuel pump relays -1- and -2- from their sockets.
– Connect remote control for V.A.G 1348 -V.A.G 1348/3A- with gen AG. Volkswagen AG d
adapter cable -V.A.G 1348/3-3- -arrow- to connection ofVofuel
lksw
a oes
not
pump relay for right fuel delivery unit. ed by gu
ara
ris nte
utho eo
ra
a 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
– Now connect second connection of adapter cable -
V.A.G 1348/3-3- to connector connection -arrow- for fuel pump
rrectness of i
relay for left fuel delivery unit.
l purpos
– Operate remote control.

Fuel pumps running:
nf
ercia
o
– Check injectors for leaks (visual check). No more than 1 to 2
rm
m
drops per minute may escape from each valve when fuel
atio
m
pumps are running.

o
n in
or c
thi
e
If the fuel loss is greater:

t
sd
iva
o
r
rp
cu
– Renew defective injector ⇒ Item 4 (page 162) .
o
m
f
en
ng
t.
yi
Install injectors in reverse order. In the process, note the follow‐
Co
op py
ing: t. C rig
gh ht
pyri by
♦ Renew O-rings on all injectors and lightly moisten with clean
co Vo
by lksw
cted agen
engine oil. Prote AG.
♦ Insert injectors vertically and in the correct position into the fuel
rail and secure with retaining clips.
♦ Fit fuel rail with secured injectors on cylinder head and press
in evenly.
2.1.2 Checking quantity injected

Test prerequisite
• Fuel pump relays and fuses 13 and 14 are fitted in their sock‐
ets.

Touareg 2003 ➤
Test procedure
– Connect adapter cable, 121-pin -V.A.G 1598/31- and bridge
test box sockets 1 and 65 using cables from auxiliary test set
-V.A.G 1594C- .
– Insert injector to be checked into measuring glass from injec‐
tion rate tester -V.A.G 1602- .
– Connect a contact of injector to be tested to engine earth using

auxiliary cables from auxiliary measuring set -V.A.G 1594/C- .
– Connect second injector contact with auxiliary cable to remote
control for V.A.G 1348 -V.A.G 1348/3A- using adapter cable -
V.A.G 1348/3-2- . agen
AG. Volkswagen AG d
o w es n
olks ot g
– Connect crocodile clip to positive battery
d b pole in engine com‐
yV ua
ran
partment. rise tee
ho t or
au ac
– Operate remote control for 30ssseconds.
ce
le
un
pt
– Repeat check on other injectors. Use new measuring beakers.
an
d
itte
y li
– After all injectors have been activated, place measuring beak‐
rm
ab
pe
ility
ers on a level surface and compare the quantity injected.
ot
Specification: 128 ... 140 ml per injector
wit
, is n
h re
hole
If the measured values of one or more injectors are above or be‐
spec
low the prescribed specifications:
es, in part or in w
t to the co
– Renew defective injector ⇒ Item 4 (page 162) .
Install injectors in reverse order. In the process, note the follow‐
rrectness of i
ing:
l purpos
♦ Renew O-rings on all injectors and lightly moisten with clean

engine oil.
nform
ercia
♦ Insert injectors vertically and in the correct position into the fuel
rail and secure with retaining clips.
m
a
com
tio
♦ Fit fuel rail with secured injectors on cylinder head and press
n in
r
te o
in evenly.
thi
s
iva
do
r
rp
cum
2.2 Checking fuel pressure regulator and

fo
en
ng
t.
yi
holding pressure
Co
Cop py
t. rig
gh ht
yri
The fuel pressure regulator maintains the fuel pressure at a con‐
p by
co Vo
by lksw
stant 4.0 bar. Prote
cted AG.
agen

Touareg 2003 ➤

equipment required
♦ Pressure tester -
V.A.G 1318-
♦ Multimeter -V.A.G 1715-
♦ Spring-type clip pliers -
VAS 5024 A-
♦ Diesel extractor -
VAS 5226-
♦ Adapter -V.A.G 1318/20-1-
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
ercia
Test prerequisite
m
at
om
ion
• Fuel pump delivery rate OK, checking: ⇒ page 135 , Checking

c
in t
or
fuel pumps.
his
ate
do
riv
Test procedure
p
cum
for
en
g
– Unscrew adapter -V.A.G 1318/20-1- from adapter -

n
t.
yi Co
op
V.A.G 1318/20- . C py
t. rig
gh ht
yri by
– Now turn valve on T-piece of adapter -V.A.G 1318/20- anti- cop Vo
by lksw
clockwise until it is entirely open. cted agen
Prote AG.

Touareg 2003 ➤
– Then connect pressure tester -V.A.G 1318- to bleed valve

-1- with adapters -V.A.G 1318/20- , -V.A.G 1318/20-1- , -
V.A.G 1318/9- and diesel extractor -VAS 5226- as shown.
– Shut-off tap -arrow- of pressure tester must be closed.

– Screw valve on T-piece of adapter -V.A.G 1318/20- clockwise
into bleed valve to stop.
– Open shut-off tap of pressure tester briefly and close it gagain
AG. Volkswagen AG d
a en
to bleed line to pressure tester. Volksw
oes
not
y gu
db ara
– Measure fuel pressure. Specification: approx.
or 4.0 bar.
ise nte
eo
th
If the specification is not attained: s au ra
c
s
ce
le
– Check fuel pump delivery rate ⇒ page 135 Checking fuel

un
pt
an
d
pumps.
itte
y li
erm
ab
ility
ot p
– Renew fuel pressure regulator -2-, if necessary.
wit
is n
h re
If specification is attained:
ole,
spec
– Switch off ignition.
t to the co
– Now check for leaks and holding pressure. Do this by observ‐
ing pressure drop on gauge. After 10 minutes, there must be
a residual pressure of at least 3.0 bar.
rrectne
If the holding pressure drops below 3 bar:

ss
– Check pressure tester for leaks.

o
cial p
f inform
– Check non-return valves of fuel pumps ⇒ page 135 .

mer
atio
When the pressure tester is removed after the test has been
om
completed:
c
i
or
n thi
te

sd
iva
o
pr
cum
r
– Open shut-off tap of pressure tester to release fuel pressure.

fo
en
ng
t.
yi Co
– Remove pressure tester with adapters. Cop py
t. rig
gh ht
yri
– Wrap a cloth around the joint to collect fuel which flows out. p by
o Vo
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
3 Engine control unit

Removing and installing engine control unit ⇒ page 172 .
Removing and installing anti-theft engine control unit
⇒ page 172 .
n AG. Volkswagen A
3.1 Removing and installing Volks engine control
wage
G do
es n
ot g
unit by ua
ed ran
is te
or h eo
ut
If you wish to replace the engine
ss control unit, connect the vehicle
a ra
c
diagnosis, testing and information system -VAS 5051B- and carry
ce
le
un
out the guided function „Renew control unit“.
pt
an
d
itte
y li
Removing
erm
ab
ility
ot p
wit
is n
h re
– Remove windscreen wiper motor on right side: ⇒ Electrical
ole,
spec
system; Rep. gr. 92 ; Removing and installing windscreen
wiper system .
t to the co
– Release both connectors from control unit and pull off.
– Control unit can now be removed.
rrectne
Installing
ss o
– Place control unit into retaining frame.
cial p
f inform
– Fit connector and lock in position.
mer
atio
m
– Install windscreen wiper motor on right side: ⇒ Electrical sys‐

o
n
c
tem; Rep. gr. 92 ; Windscreen wiper system .
i
or
n thi
te
sd
a
– Install plenum chamber cover.

iv
o
pr
cum
r
fo
– Adapt new engine control unit: ⇒ Vehicle diagnostic tester;

en
ng
t.
„Guided functions“ .
yi Co
Cop py
ht. rig
3.2 Removing and installing anti-theft en‐
rig ht
py by
co Vo
gine control unit

by lksw
cted agen
Prote AG.
Note
If the engine control unit is to be renewed, connect Vehicle diag‐

nosis, testing and information system -VAS 5051B- and perform
„Renewing engine control unit“ in guided functions.

♦ Hot air blower from wiring harness repair set -VAS 1978-
♦ Nozzle attachment from wiring harness repair set -VAS 1978-

Touareg 2003 ➤
agen
AG. Volkswagen AG d
oes 6-cylinder injection engine - Edition 02.2012
olksw not
y V gua
b
Removing ris
ed ran
tee
tho
or
– Switch offssignition.
au ac
ce
– Remove wiper arms, ⇒ Electrical system; Rep. gr. 92 ; Wind‐ le
un
pt
an
screen wiper system; Removing and installing wiper arms.
d
itte
y li
erm
ab
– Remove plenum chamber cover ⇒ General body repairs, ex‐
ility
ot p
terior; Rep. gr. 64 ; Removing and installing plenum chamber
wit
is n
cover.
h re
ole,
spec
Note
t to the co
The shear-head bolt threads are coated with locking compound.
rrectne
Heating the shear-head bolt with a hot air blower releases the
locking effect of the locking compound.
ss o
cial p
f in
Caution
form
mer
atio
m
Cover lines, connections and control units in the vicinity of the

o
n
c
engine control unit to prevent damage through heat (scorching/
i
or
n thi
melting of plastics etc.).
te
sd
iva
o
pr
cum
r
fo
en
ng
Perform settings on hot air blower -4- as shown:

t.
yi Co
Cop py
t. rig
– Turn temperature setting potentiometer -2- to maximum heat yri
gh by
ht
output (600°C).
op Vo
by c lksw
cted agen
Prote
– Set two-stage switch for volume of air -3- to position 3.
AG.
WARNING
When shear-head bolts are heated up, parts of the protective

housing will be subjected to a large amount of heat. Wear pro‐
tective gloves to avoid possible injury.
– Place nozzle of hot air blower close to shear-head bolt.

– Switch on hot air blower and heat head of bolt for about 20 to
25 seconds.
– Unscrew shear-head bolt -2- using pliers on bolt head.
The procedure for the second shear-head bolt is exactly the
same.
– Remove cover -1- from control unit.
3. Engine control unit 173

Touareg 2003 ➤
– Slide connector locking devices -1- on engine control unit out‐

wards and pull off both connectors.
AG. Volkswagen AG d
– Remove engine control unit. agen oes
olksw not
y V gu
b ara
Installing rise
d
nte
tho eo
u
– Insert engine control
ss aunit into retaining frame in plenum cham‐ ra
c
ber.
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
– Fit connector to engine control unit and slide locking devices
t to the co
-1- inwards.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
– Place cover -1- over engine control unit and fit new shear-head
f
en
ng
t.
yi
bolts -arrows- by hand.
Co
Cop py
t. rig
– Tighten new shear-head bolts evenly until head shears off.
gh ht
pyri by
Vo
co lksw
by
– Install plenum chamber cover ⇒ General body repairs, exte‐ cted agen
Prote AG.
rior; Rep. gr. 64 ; Removing and installing plenum chamber
cover.
– Install wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing wiper arms.

Touareg 2003 ➤
26 – Exhaust system
1 Removing and installing parts of ex‐
haust system
Assembly overview - exhaust manifold with starter catalytic con‐
verters and attachments ⇒ page 176
Silencer with mountings ⇒ page 178
Removing and installing exhaust manifolds and exhaust pipes
with starter catalytic converters ⇒ page 179
Note
After working on the exhaust system, ensure that the system has . Volkswagen AG
sufficient clearance to the bodywork. If necessary, loosen flanges lkswagen AG does
on catalytic converter and realign silencers and exhaust pipes o not
byV gu
ara
⇒ page 179 orised
nte
th eo
au ra
c
ss
ce
e
nl
pt
du
an
equipment required
itte
y li
erm
ab
♦ Lambda probe open ring
ility
ot p
spanner set -3337-
wit
, is n
h re
hole
spec
-V.A.G 1331-
es, in part or in w
t to the co
Nm) -V.A.G 1332-
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.
1. Removing and installing parts of exhaust system 175

Touareg 2003 ➤
1.1 Assembly overview - exhaust manifold

with starter catalytic converters and at‐
tachments
Note
♦ Disconnect batteries before removing front exhaust pipes with

catalytic converters ⇒ Electrical system; Rep. gr. 27 ; Dis‐
connecting and reconnecting batteries.
♦ When installing exhaust pipes, ensure that the flange connec‐
tion after the catalytic converter seals tightly. Leaks in this area
cause pulsation in exhaust. This allows ambient air to reach
the Lambda probe after the catalytic converter, thereby dis‐
turbing Lambda regulation.
♦ Renew self-locking nuts.
1 - Cylinder head
2 - Gasket
❑ Renew.
AG. Volkswagen AG d
agen
3 - Securing nut olksw
oes
not
byV gu
ara
❑ M8: 25 Nm. rised
nte
ho eo
❑ M10: 40 Nm. aut ra
c
ss
4 - Exhaust manifold
ce
e
nl
pt
du
an
itte
5 - Gasket
y li
erm
ab
❑ Locating tabs point
ility
ot p
downwards
wit
, is n
h re
❑ Renew.
hole
6 - Starter catalytic converter spec

es, in part or in w
t to the co
❑ Installed in exhaust gas
stream of cylinders 1, 2
and 3
rrectness of i
7 - Starter catalytic converter

l purpos

nform
ercia
and 6
m
8 - Lambda probe -G39- , 50

at
om
io
Nm
n
c
in t
or

his
ate
do
priv
and 3
um
for
en
ng
❑ Grease only thread with

t.
yi Co
op
-G 052 112 A3- . -G 052 C py
ht. rig
112 A3- must not get in‐ rig ht
py by
to slots in probe body.
co Vo
by lksw
cted agen
Prote
❑ Remove and install with
AG.
Lambda probe open

ring spanner set -3337- .
9 - Lambda probe 2 -G108- , 50
Nm
❑ Installed in exhaust gas stream of cylinders 4, 5 and 6
❑ Grease only thread with -G 052 112 A3- . -G 052 112 A3- must not get into slots in probe body.
❑ Remove and install with Lambda probe open ring spanner set -3337- .
176 Rep. gr.26 - Exhaust system

AG. Volkswagen AG d
agen oes
Volksw not
gu
Touareg 2003 ➤
y
rise
d b ara
nte 6-cylinder injection engine - Edition 02.2012
tho eo
au ra
10 -ss Catalytic converter c
ce
e
nl
11 - 25 Nm
pt
du
an
itte
y li
12 - Lambda probe after catalytic converter -G130- , 50 Nm
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
13 - Lambda probe 2 after catalytic converter -G131- , 50 Nm
rrectness of i
l purpos
14 - Heat shield
❑ With intake manifold support.
nform
mercia
15 - 23 Nm
at
om
ion
c
16 - 20 Nm
in t
or
his
ate
17 - Bracket
do
priv
cum
or
18 - 23 Nm
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
1.2 Silencer with mountings
1 - Double clamp, 40 Nm
2 - Centre silencer
3 - Securing bolt, 25 Nm
4 - Mounting
❑ Installation position
⇒ page 179 .
5 - Separating point
❑ For repair cases
❑ Marked by impressions
on exhaust pipe.
❑ Centre and rear silenc‐
ers are installed as a
single component dur‐
ing production. In cases
of repair, the centre and
rear silencers are sup‐
plied separately, with a
double repair clamp for
connecting.
❑ Cut through separating
point on connecting pipe
at right angles using
body saw -V.A.G
1523A- for example.
❑ The indentations to the
left and right of the sep‐
AG. Volkswagen AG d
arating points must be ksw
agen oes
not
l
visible following the in‐ byV
o gu
ara
stallation of the double rised
nte
clamp. aut
ho eo
ra
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6 - Rear silencer
ce
e
nl
pt
du
❑ Align rear silencer free

an
itte
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of stress.
erm
ab
ility
ot p
7 - Mounting
wit
, is n

h re
hole
spec
es, in part or in w
t to the co
8 - Double clamp
❑ Must be slid to its mid-point on forward exhaust pipe.
rrectness of i
9 - Mounting
l purpos

nform
mercia
10 - Double clamp
at
om
io
❑ Must be slid to its mid-point on forward exhaust pipe.

n
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.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
ut
ho eo
ra Touareg 2003 ➤
a
ss 6-cylinder
c injection engine - Edition 02.2012
ce
e
nl
pt
du
an
Installation position, double repair clamp in direction of travel
itte
y li
erm
ab
1 - The end of the bolt must not project beyond lower edge of
ility
ot p
clamp.
wit
, is n
h re
2 - Angle between 10° and 5°
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Aligning exhaust system

m
at
Prerequisite
om
ion
c
in t
r
• Exhaust system cold

o
his
ate
do
riv
Procedure
p
cum
for
en
g
– Push exhaust system in direction of travel -1- and tighten dou‐

n
t.
yi Co
ble clamps until dimension -a- is attained at the mountings. Cop py
t. rig
gh ht
yri
Centre silencer: dimension -a- = 10 mm p by
o Vo
by c lksw
cted agen
Rear silencer: dimension -a- = 15 mm Prote AG.
1.3 Removing and installing exhaust mani‐

folds and exhaust pipes with starter cat‐
alytic converters
Removing
– Disconnect batteries ⇒ Electrical system; Rep. gr. 27 ; Dis‐
connecting and reconnecting batteries .
Note
The procedure must be strictly followed!


Touareg 2003 ➤
– Detach pressure hose -arrow- from secondary air pump.

– Remove air filter housing completely.
– Remove intake manifold ⇒ page 63 , Removing and installing
cylinder head cover.
– Then unscrew heat shield with intake manifold support from
cylinder head.
– Detach connectors -1…4- for Lambda probes and unclip ca‐

bles from cable routing.
– Now unscrew Lambda probes from catalytic converters using
Lambda probe open ring spanner set -3337- .
– Raise vehicle. AG. Volkswagen AG d
agen oes
lksw not
– Now unscrew securing nuts on flange to main catalytic
d by con‐
Vo gu
ara
verter. orise nte
eo
h
ut ra
– Unbolt support to gearbox. ss a c
ce
e
nl
– Unbolt flange to exhaust manifold.
pt
du
an
itte
y li
– Now remove exhaust manifold.
erm
ab
ility
ot p
– Then carefully remove exhaust pipe with catalytic converters.
wit
, is n
h re
Installing
hole
spec
es, in part or in w
t to the co
Note
♦ When installing exhaust pipes, ensure that the flange connec‐
rrectness of i
tion after the catalytic converter seals tightly. Leaks in this area
cause pulsation in exhaust. This allows ambient air to reach
l purpos
the Lambda probe after the catalytic converter, thereby dis‐

turbing Lambda regulation.
nform
ercia
♦ Align exhaust system so that there is sufficient clearance to

m
at
gearbox and subframe.
om
ion
c
in t
or
his
e

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

Touareg 2003 ➤
2 Secondary air system

Assembly overview - parts of secondary air system ⇒ page 181
Function
Air is blown from the secondary air system behind the exhaust
valves for 65 seconds during a cold start (+15 °C…+35 °C coolant
temperature). This produces an oxygen-rich exhaust gas, caus‐
ing afterburning and reducing the heat-up phase of the catalytic
converter. Actuation is by the Motronic control unit -J220- via the
secondary air pump relay -J299- to the secondary air inlet valve
-N112- , (changeover valve) and combination valve. Additionally,
after each subsequent engine start (up to max. 85 C engine tem‐
perature), the secondary air system will, after a 20 second delay,
switch in for 5 seconds during idling and will be checked by the
self-diagnosis.
2.1 Assembly overview - parts of secondary

air system
Checking combination valve ⇒ page 183
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
Note orise nte
eo
th
au ra
s c
Secondary air pump relay -J299- ⇒ page 183 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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Secondary air system 181

Touareg 2003 ➤
1 - Combination valve
3 - Gasket
❑ Renew.
4 - Connection
5 - 10 Nm
6 - Pressure pipe
7 - Bracket
8 - Stud, 8 Nm
❑ Screwed in to intake
manifold
9 - To intake manifold.
10 - To combination valve
11 - To vacuum positioning el‐
ement
❑ For intake manifold
change-over.
12 - Non-return valve agen
AG. Volkswagen AG d
oes
lksw not
❑ Note installation posi‐ d by Vo gu
ara
tion. orise nte
th eo
❑ White connection points s au ra
c
to vacuum reservoir s
ce
le
un
pt
13 - Variable intake manifold
an
d
itte
y li
changeover valve -N156-
erm
ab
ility
ot p
14 - 8 Nm
wit
is n
h re
15 - Secondary air inlet valve -
ole,
spec
N112-
t to the co
16 - Vacuum reservoir
17 - Pressure hose
rrectne
❑ Press together at front to release.
ss
18 - Secondary air pump motor -V101-
o
cial p
f inform
19 - 10 Nm
mer
atio
20 - Bracket
om
n
c
❑ For secondary air pump motor -V101-

or
n thi
te
sd
va
21 - Intake hose
i
o
pr
cum
r
fo
❑ From upper part of air filter

en
ng
t.
yi Co
❑ Check for secure seating. t. Cop py
rig
❑ Press together at front to release.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
Secondary air pump relay -J299-
Note
♦ The secondary air pump relay -J299- -1- is in socket A4.

♦ If tools are required to remove relays or control units from the
relay plate, disconnect the battery's earthing strip first: ⇒ Elec‐
trical system; Rep. gr. 27 ; Disconnecting and reconnecting
batteries
2.2 Checking combination valve

♦ Hand vacuum pump -V.A.G 1390-
Test prerequisites
• Vacuum pipes and hose connections free of leaks. AG. Volkswagen AG d
agen oes
lksw not
• Vacuum pipes not blocked or kinked. d by Vo gu
ara
rise nte
Test procedure utho eo
ra
s a c
– Detach vacuum hose from secondary air inlet valve -N112- s
ce
e
nl
from combination valve -arrow-. pt

du
an
itte
y li
erm
ab
ility
Note
ot p
wit
, is n
h re
Do not use compressed air during the following check!

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.
2. Secondary air system 183

Touareg 2003 ➤
– Connect hand vacuum pump -V.A.G 1390- to vacuum con‐

nection on combination valve -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
– Detach pressure hose to combination byV valve from coupling gu
ara
ed
-arrow-, connect auxiliary those
horis
to end of pipe and blow gently nte
eo
into it. Combination valve
s au must be closed. ra
c
s
ce
– Operate hand vacuum pump. Combination valve must open.
le
un
pt
an
d
itte
If combination valve does not open:
y li
rm
ab
pe
ility
Renew combination valve ⇒ Item 1 (page 182) .
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
28 – Ignition system
1 Repairing ignition system
Safety precautions ⇒ page 187 .
Spark plug test data ⇒ page 187 .
Assembly overview - parts of ignition system ⇒ page 185
Removing and installing ignition coils with output stages
⇒ page 188 . wage
e s no ks
Vol
t gu
General notes onedignition
by system ara
ris nte
o
♦ Only theaucomponents
th which specifically relate to the ignition
eo
ra
systems are dealt with here. For other components of the in‐
s c
jection and ignition system, ⇒ page 160 .
ce
le
un
pt
an
d
itte
♦ For trouble-free operation of electrical components, a voltage
y li
erm
ab
of at least 11.5 V is necessary.
ility
ot p
wit
♦ Certain tests may lead to a fault being detected by the control
is n
h re
unit and stored. Therefore, after completing all checks and re‐
ole,
pairs, read the fault memory and clear if necessary ⇒ Vehicle
spec
diagnostic tester; „Guided functions“ .
t to the co
♦ If, after fault finding, repairs or component tests, the engine
starts, runs for a short period and then stops, then the fault
may be that the immobilizer is blocking the engine control unit.
In this case, the control unit must be adapted ⇒ Vehicle diag‐ rrectne
nostic tester „guided functions“.
ss o
cial p
1.1 Assembly overview - parts of ignition

f inform
system
mer
atio
om
n
c
i
or
n thi
Note
te
sd
iva
o
pr
cum
r
The engine speed sender -G28- can be found on the cylinder

fo
en
ng
block ⇒ Item 16 (page 20) .

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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1. Repairing ignition system 185

Touareg 2003 ➤
1 - Ignition coil with output

stage -N70, N127, N291,
N292, N323, N324-
❑ Remove and install with
puller -T10095 A- .
2 - Connector
❑ Black, 4-pin.
❑ Use assembly tool -
T10118- to pull off.
3 - Bracket n AG. Volkswagen AG do
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❑ For connector for knock yV
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sensor 1 -G61- is.ed b ran
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4 - 10 Nm aut or
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5 - Connector
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❑ Black, 3-pin.
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❑ Gold-plated contacts on
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sensor and connector.
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spec
❑ Fitting location: be‐
tween cylinder 1 and
t to the co
cylinder 3.
7 - 20 Nm
rrectne
❑ The specified torque in‐
fluences the function of ss
the knock sensor.
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form
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❑ With sender wheel for

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Hall sender 2 -G163-

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❑ Gold-plated contacts on sensor and connector.
12 - 10 Nm
13 - Connector
❑ Black, 3-pin.
❑ Mark connector before removing.
❑ Fitting location: between cylinder 4 and cylinder 6.
16 - Connector
❑ Black, 2-pin.
186 Rep. gr.28 - Ignition system

Touareg 2003 ➤
❑ With sender wheel for Hall sender -G40-
18 - Spark plug, 20 Nm
❑ Remove and install with spark pluggesocket
n AG. Voand
lkswaextension
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swa does
❑ Type and electrode gap ⇒ page
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19 - Valve timing housing thoris tee
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camshaft adjuster valves ⇒ page 80 ac
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❑ Removing and installing ⇒ page 73 Removing and installing camshafts.

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1.2 Safety precautions
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To prevent injuries to persons and/or damage to the injection and
spec
ignition system, the following must be observed:
es, in part or in w
t to the co
♦ Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as test instrument cables.
rrectness of i
♦ Do not touch or disconnect ignition cables when the engine is
running or being turned at starter speed.
l purpos
Note the following if testers and measuring instruments have to

be used during a road test:
nform
ercia
♦ Test and measuring instruments must always be secured to

m
at
rear seat and operated by a second person from this location.
om
ion
c
in t
or
If test and measuring instruments are operated from front pas‐ his
te
senger seat and the vehicle is involved in an accident, there is a

a
do
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possibility that the person sitting in this seat may receive serious
p
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or
injuries when the airbag is triggered.

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If the engine is to be turned at starter speed without starting, de‐
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tach the connectors from ignition coils 1...6 as follows:
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– Apply assembly tool -T10118- to locking mechanism button
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-arrow- and carefully pull connector off each ignition coil with
output stage .
1.3 Test data, spark plugs

Engine code AZZ / BAA / BKJ BMV / BMX BRJ8)
Firing order 1-5-3-6-2-4 1-5-3-6-2-4
Spark plugs9)
VW/Audi 101 905 606 A 101 905 6248)
Manufacturer's designation IZKR 7B ZKR 7AP-Q
Electrode gap max. 1.1 mm max. 1.1 mm
Specified torque 20 Nm 20 Nm

Touareg 2003 ➤
8) Only used in China

9) Remove and install spark plugs with spark plug socket and extension -3122B- .
1.4 Removing and installing ignition coils

with output stage
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rrectness of i
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Removing
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– Apply assembly tool -T10118- to locking mechanism button
om
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-arrow- and carefully pull connector off.

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188 Rep. gr.28 - Ignition system

Touareg 2003 ➤
– Push puller -T10095 A- on from flat side of connector in

-direction of arrow- and pull out ignition
gen A coil
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– To install, insert ignition coil with output stage into respective
spark plug hole so that the flat sides of connectors fit with each
other -arrows-.
rrectness of i
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– Push puller -T10095 A- on from flat side of connector in
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-direction of arrow- and push ignition coil with output stage
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K0058961320 6 Cylinder Injection Engine

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Service

AZZ BAA BKJ BMV BMX BRJ

Service Department. Technical Information

15 - Cylinder head, valve gear

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Copyright © 2015 Volkswagen AG, Wolfsburg K0058961320

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

1.3 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

1.6 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1.8 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

2.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

2.2 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

2.3 Removing and installing camshaft control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

2.4 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

2.5 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

2.6 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

1.4 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

1.1 Assembly overview - fuel tank with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

1.2 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

1.4 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 123

1.11 Checking fuel pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

3.1 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

4.1 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

4.2 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

1.3 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

The engine code is also included on the vehicle data sticker.

sors sors sors sors sors sors

Self-diagnosis EOBD OBD II yes yes yes yes

Catalytic convert‐ yes yes yes yes yes yes

Secondary air yes yes yes yes yes yes

Electronic power yes yes yes yes yes yes

Variable intake yes yes yes yes yes yes

Camshaft timing yes3) yes3) yes3) yes3) yes3) yes3)

Leakage diagno‐ no yes no no yes no

2 Rep. gr.00 - Technical data

10 – Removing and installing engine

port -VAS 6095-

1. Removing and installing engine 3

♦ Engine and gearbox jack -

♦ Grease (vehicles with manual gearbox) -G 000 1000-

1.1 Removing engine

The engine is removed downwards with gearbox.

hose connections, wrap a cloth around the connection. Then

release pressure by carefully pulling hose off connection.

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

– Read the fault memories of all control units before removing

– Screw adapter -V.A.G 1318/20-1- onto adapter -

tem, connect diesel suction pump -VAS 5226- and release

1. Removing and installing engine 5

– Separate fuel supply line -arrow-.

removed must be replaced in the same position when engine

– In engine compartment, disconnect breather line -arrow- to

6 Rep. gr.10 - Removing and installing engine

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

– Pull vacuum hoses -1…3- off intake manifold.

– Detach pressure hose -arrow- from secondary air pump.

1. Removing and installing engine 7

– Detach connectors -1…4- for Lambda probes and lay con‐

– Separate line/wiring to air suspension compressor at air filter

– Now remove upper part of air filter upwards ⇒ page 162 .