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5-cylinder diesel engine

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Engine ID
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
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00 - Technical data
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10 - Removing and installing engine
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20 - Fuel supply system
21 - Turbocharging/supercharging
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23 - Mixture preparation - injection
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26 - Exhaust system
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28 - Glow plug 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 K0058961720

Touareg 2003 ➤
5-cylinder diesel engine - Edition 09.2012
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Safety precautions for when using test and measuring equipment during a road test . . . . 3
2.3 Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Removing engine from scissor-type assembly platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4 Additional information and assembly work for vehicles with air conditioner . . . . . . . . . . . . 16
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1.5 Installing engine olk. s.w.a.ge. . . . . . . . . . . . . G. .do.e.s.no. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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2 Assembly mountings
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2.1 Assembly ut overview - engine mountings . . . . . . . . . . . o.r a. . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.2 Specified
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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1.1 Dismantling and assembling engine, parts I-III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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1.2 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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1.3 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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1.4 Crankshaft bearing cap identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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1.5 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.6 Renewing crankshaft oil seal - engine timing end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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1.7 Renewing alternator shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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2 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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2.2 Separating new conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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2.3 Installation position and allocation of piston to cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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2.4 Checking piston ring gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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2.5 Checking ring-to-groove clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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2.6 Checking cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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2.7 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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1 Overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.2 Renewing pipe connection for coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.3 Removing and installing camshaft drive gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.4 Setting engine to TDC No. 1 cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.5 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.6 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2 Repairing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.2 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Contents i
Touareg 2003 ➤
2.3 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

2.4 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.5 Removing and installing camshaft a. g.e.n.A.G.. V. o.lk.s.w.a.ge. n.A.G. d.o. . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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17 - Lubrication . . . . . . . . . . . r.ise. . . . . . .
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1 Engine oil . . . ............. . . . .a.uth. . . . . . . . . . . . . . . . . . . . . . . . o.r a. . .
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1.1 Oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.2 Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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2 Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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2.1 Assembly overview - oil pump, sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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2.2 Assembly overview - oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
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2.3 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
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2.4 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
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1.1 Parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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1.2 Assembly overview - radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

1.3 Removing and installing fan support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
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1.4 Parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

1.5 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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1.6 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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1.7 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
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1.8 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
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1.9 Checking oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
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20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
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1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
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1.2 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.3 Assembly overview - fuel tank with attachments (► model year 08) . . . . . . . . . . . . . . . . . . 86
1.4 Assembly overview - fuel tank with attachments (model year 08 ►) . . . . . . . . . . . . . . . . . . 88
1.5 Assembly overview - fuel filter with fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.6 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.7 Removing and installing fuel pump unit, fuel gauge sender and suction jet pumps (for vehicles
► model year 08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.8 Removing and installing fuel pump unit, fuel gauge sender and suction jet pumps (for vehicles
model year 08 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.9 Removing and installing fuel tank with attached components . . . . . . . . . . . . . . . . . . . . . . 99
1.10 Checking fuel pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.11 Checking tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.12 Removing and installing tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.13 Assembly overview - accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.2 Turbocharger with attachments for engine codes BAC and BLK . . . . . . . . . . . . . . . . . . . . 110
1.3 Removing and installing turbocharger for engine codes BAC and BLK . . . . . . . . . . . . . . . . 111
1.4 Turbocharger with attachments (engine codes BPD and BPE) . . . . . . . . . . . . . . . . . . . . . . 114
1.5 Removing and installing turbocharger (engine codes BPD and BPE) . . . . . . . . . . . . . . . . 116
1.6 Removing and installing parts of charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.7 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.8 Hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.9 Vacuum hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

ii Contents
Touareg 2003 ➤
1 Repairing diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.3 Removing and installing wiring harness for unit injectors . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.4 Removing and installing unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.5 Assembly overview - unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
1.6 Removing and installing O-rings for unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.7 Assembly overview - intake manifold and fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.8 Repairing intake manifold flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1.9 Dismantling and assembling air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
2.1 Reading and deleting engine control unit event memory . . . . . . . . . . . . . . . . . . . . . . . . . . 140
2.2 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2.3 Removing and installing anti-theft engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . 141
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

1 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
1.1 Assembly overview - front exhaust pipe with catalytic converters . . . . . . . . . . . . . . . . . . . . 145
1.2 Assembly overview - front exhaust pipe with particulate filter . . . . . . . . . . . . . . . . . . . . . . 146
1.3 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1.4 Assembly overview - exhaust manifold (engine codes BPD, BPE) . . . . . . . . . . . . . . . . . . 149
1.5 Removing and installing exhaust manifold (engine codes BPD, BPE) . . . . . . . . . . . . . . . . 151
1.6 Silencer with mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . e.n.A.G.. V. o. lk. s.w.a.ge. n.A.G. . . . . . . . . . . . . . . 155
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2.1 Assembly overview - exhaust gas recirculation V. o.lk.sw . . . . . . . . . . . . . . . . . . .es. n.o.t g. . . . . . . . . 155
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2.2 Checking exhaust gas recirculation valve (mechanical) ris
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28 - Glow plug system . . . . . . . . . . . . . . .ss.a . . ........................... . . . a.c . 161
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1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

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1.1 Characteristics of glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
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1.2 Checking metal glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
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1.3 Removing, installing and checking ceramic glow pin plugs . . . . . . . . . . . . . . . . . . . . . . . . 162
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rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
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ng
t.
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Cop py
t. rig
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Vo
co lksw
by
cted agen
Prote AG.
Contents iii
Touareg 2003 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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.
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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.
iv Contents
Touareg 2003 ➤
00 – Technical data
yV
olksw
agen
AG. Volkswagen AG d
oes
not
g b ua
ed ran
ris tee
1 Technical data tho
or
s au ac
s
(VRL005110; Edition 09.2012)
ce
e
nl
pt
du
an
itte
⇒ “1.1 Engine number”, page 1
y li
erm
ab
ility
⇒ “1.2 Engine data”, page 1
ot p
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, is n
1.1 Engine number
h re
hole
spec
The engine number (“engine code” and “serial number”) can be
es, in part or in w
t to the co
found on the joint between engine and gearbox.
Additionally there is a sticker on the front of the cylinder head with
“Engine code” and “Serial number”.
rrectness of i
The engine code is also included on the vehicle data sticker.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
1.2 Engine data

f
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t.
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op py
Edition 09.2012 Version 22.0 t. C rig
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pyri by
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Engine code by c
BAC BLK BPD BPE
lksw
cted agen
Prote AG.
Manufactured 03.03 ► 08.03 ► 11.05 ► 11.05 ►
Emissions fulfil EU3 standard EU3 standard EU4 standard EU4 standard
Capacity l 2.5 2.5 2.5 2.5
Output kW at rpm 128/3500 120/3500 120/3500 128/3500
Torque Nm at rpm 400/2000… 400/2000… 400/2000 400/2000
2300 2300
Bore ∅ mm 81.0 81.0 81.0 81.0
Stroke mm 95.5 95.5 95.5 95.5
Compression ratio 18.0 18.0 19.5 19.5
Fuel according to DIN EN 590 DIN EN 590 DIN EN 590 DIN EN 590
Firing order 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3
Catalytic converter yes yes yes yes
Exhaust gas recirculation yes yes yes yes
Turbocharging/supercharging yes yes yes yes
Particulate filter no no yes yes
Charge air cooling yes yes yes yes
1. Technical data 1
Touareg 2003 ➤
2 Safety instructions
⇒ “2.1 Safety precautions when working on fuel supply system”,
page 2
⇒ “2.2 Safety precautions for when using test and measuring
equipment during a road test”, page 3
⇒ “2.3 Safety precautions when working on cooling system”, page
3
2.1 Safety precautions when working on

fuel supply system
WARNING
Risk of injury due to highly-pressurised fuel.

♦ For safety reasons, the fuse must be removed from the
fuel pump control unit -J538- before the fuel system is
opened if the battery has not been disconnected. Other‐
wise the fuel pump will be activated by the driver door
contact switch.
♦ Wrap a clean cloth around the connection before opening en AG. Volkswagen AG
the fuel system. Then release pressure by carefully loos‐
olks
wag does
not
ening the connection. d byV gu
ara
e nte
ris
♦ Wear protective gloves. au
tho eo
ra
ss c
♦ Wear eye protection.
ce
e
nl
pt
du
an
Danger of burning from very hot fuel.
itte
y li
erm
ab
♦ In extreme cases, the temperature of the fuel or the fuel
ility
ot p
lines can reach 100 °C after the engine is switched off.
wit
, is n
Allow the fuel to cool down before disconnecting the lines
h re
- danger of scalding.
hole
spec
es, in part or in w
♦ Wear protective gloves.
t to the co
♦ Wear eye protection.
To prevent injuries to persons and destruction of the injection and rrectness of i

l purpos
glow plug system, the following must be noted:

♦ Always switch off the ignition before connecting or discon‐
nf
ercia
necting electrical wiring of injection and glow plug system or

rm
m
connecting/disconnecting tester cables.

atio
om
n in
c
♦ Wash the engine only with the ignition switched off.

or
thi
te
sd
a
♦ Entries have been stored in the event memory of the engine

iv
o
r
rp
cu
control unit if the engine was started after electrical connectors

o
m
f
had been disconnected: Read event memory in vehicle

en
ng
t.
yi Co
self-diagnosis ⇒ Vehicle diagnosis tester . Cop py
ht. rig
rig ht
py by
co Vo
Caution
by lksw
cted agen
Prote AG.
♦ Observe required procedures when disconnecting battery

⇒ Electrical system; Rep. gr. 27 ; battery; Disconnecting
and reconnecting battery.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 .
2 Rep. gr.00 - Technical data

Touareg 2003 ➤
2.2 Safety precautions for when using test

and measuring equipment during a road
test
Note the following if testers and measuring instruments have to en AG. Volkswagen AG
be used during a road test: olks
wag does
no
V t gu
by ara
♦ Test and measuring instruments must always be rsecured
ise
d
to nte
the rear seat and operated by a second personauthfrom
o
this lo‐ eo
ra
cation. ss c
ce
e
nl
♦ If test and measuring instruments are operated from front pas‐
pt
du
an
itte
senger seat and the vehicle is involved in an accident, there
y li
erm
ab
is a possibility that the person sitting in this seat may receive
ility
ot p
serious injuries when the airbag is triggered.
wit
, is n
h re
hole
spec
cooling system
es, in part or in w
t to the co
WARNING
rrectness of i
Hot steam/hot coolant can escape - risk of scalding.
l purpos
♦ The cooling system is under pressure when the engine is

hot.
nf
ercia
or
♦ Cover filler cap on expansion tank with a cloth and open
m
m
atio
carefully to release pressure.
om
n in
or c
Danger of injury; the radiator fans can run at any time.
thi
te
sd
iva
♦ Disconnect electrical connectors before starting work in
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the area of the radiator cowl.
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Cop py
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Caution
c by lksw
cted agen
Prote AG.
Danger of overheating due to incorrectly fitted cap.

♦ Tighten cap of coolant expansion tank until it engages.
2. Safety instructions 3
Touareg 2003 ➤
3 General repair notes

⇒ “3.1 Rules for cleanliness”, page 4
⇒ “3.2 Foreign objects in engine”, page 4
3.1 Rules for cleanliness

When working on fuel supply and injection system, pay careful
attention to the following rules for cleanliness:
♦ Before disconnecting, thoroughly clean all connections and
adjacent areas e.g. with brake cleaner.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
♦ Carefully cover opened components and connections or seal
if repairs cannot be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
♦ When the system is open: Do not work with compressed air.
Do not move vehicle.
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
3.2 Foreign objects in engine
Note
If large quantities of swarf or metal particles (caused, for example,

by partial seizure of the crankshaft or conrod bearings) are found
in the engine oil when performing repairs, clean Athe
G. Vooil passages
lkswagen AG
thoroughly and renew the engine oil cooler lkswain
genorder to prevent does
not
subsequent damage. Vo gu
y
db ar
e an
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utho or
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ss
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un
pt
an
d
itte
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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
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c
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or
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Cop py
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by
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cted agen
Prote AG.
Rep. gr.00 - Technical data
Touareg 2003 ➤
10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 5
⇒ “1.2 Removing engine from scissor-type assembly platform”,
page 13
⇒ “1.3 Securing engine to assembly stand”, page 15
⇒ “1.4 Additional information and assembly work for vehicles with
air conditioner”, page 16
⇒ “1.5 Installing engine”, page 17
⇒ “2.2 Specified torques - Assembly mountings”, page 18
1.1 Removing engine

The engine is removed downwards with gearbox.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e
♦ Scissor-type assembly horis nte
eo
platform -VAS 6131- aut ra
c
ss
♦ Drip tray -V.A.G 1306- or
ce
le
un
pt
drip tray for workshop hoist
an
d
itte
y li
-VAS 6208-
rm
ab
pe
ility
♦ Spring-type clip pliers -VAS
ot
wit
5024 A-
, is n
h re
hole
♦ Torque wrench -V.A.G
spec
1332- (40...200 Nm)
es, in part or in w
t to the co
♦ spring compressor -VW
552-
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Not illustrated:
♦ Basic set for Touareg -VAS 6131/6-
1. Removing and installing engine 5

Touareg 2003 ➤
♦ Engine and gearbox support -T10220- or engine and gearbox

support -T10342-
♦ Engine bracket -T10224-
♦ Container for removed parts -V.A.G 1698-
♦ Cable ties
WARNING
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
♦ All the various lines, e.g. for activated charcoal filter sys‐
tem, electrical wiring as well as
♦ Fuel lines
♦ Hydraulic lines
♦ Coolant and refrigerant lines
♦ Lines for brake fluid
AG. Volkswagen AG d
♦ and vacuum lines agen oes
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♦ must be routed risein their original positions.
d
nte
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♦ Ensure that
ss a there is sufficient clearance to all moving or
u ra
c
hot components.
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e
nl
pt
du
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itte
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erm
ab
– First check whether a coded radio is fitted. If so, obtain anti-

ility
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theft coding.
wit
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hole
spec
Note
es, in part or in w
t to the co
♦ Leave ignition key in ignition lock to prevent steering lock from

engaging.
rrectness of i
♦ It is advisable to remove the front wheels before beginning

engine removal. The vehicle can then be lowered on hoist until
l purpos
the brake disc splash plates are just above the floor. This pro‐
vides a more ergonomic working position regarding accessi‐
nf
ercia
bility of engine compartment components.

orm
m
atio
♦ Some components cannot be removed, or removed only with

om
difficulty, with the engine installed. Therefore, you should de‐

n in
or c
termine all defective components before removing engine and

thi
te
sd
renew them while engine is removed.

iva
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o
♦ To prevent damage to removed components, place them in

m
f
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ng
t.
the container for removed parts -V.A.G 1698- .
yi Co
Cop py
t. rig
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– All cable ties which are opened or cut through when engine is
p by
co Vo
by lksw
removed must be replaced in the same position when engine Prote
cted AG.
agen
is installed.
– Disconnect batteries ⇒ Electrical system; Rep. gr. 27 ; Bat‐
tery; Disconnecting and connecting battery .
Vehicles with manual gearbox
– Remove selector mechanism from centre console ⇒ Rep. gr.
34 ; Selector mechanism; Assembly overview - selector mech‐
anism .
– Then place selector mechanism on gearbox.
6 Rep. gr.10 - Removing and installing engine

Touareg 2003 ➤
Continuation for all vehicles

– Remove engine cover -A- and engine compartment covers
-B-, -C- and -D-, if fitted.
lkswage es n
Vo ot g
– Remove intake hose d -A-.
by ua
ran
ir se tee
o
– Pull vacuum hoses
auth off exhaust gas recirculation valve, intake or a
manifold changeover
ss vacuum actuator and turbocharger. c
ce
le
un
pt
– Remove crankcase breather hose from cylinder head cover.
an
d
itte
y li
erm
– Release clip of air filter connecting hose on engine, then dis‐
ab
ility
connect hose.
ot p
wit
is n
– Extract air conditioning system refrigerant ⇒ Heating, air con‐
h re
ole,
ditioning system; Rep. gr. 87 .
spec
– Unscrew refrigerant lines from air conditioner compressor.
t to the co
– Remove noise insulation: ⇒ General body repairs, exterior;
Rep. gr. 50 ; Body - front; Assembly overview - noise insulation
rrectne
WARNING
ss o
cial p
f i
We recommend removing the »lower connecting bolts« for the

nform
engine/gearbox flange on all Touareg's, including this one, be‐

mer
atio
fore removing the engine/gearbox assembly. If possible, you

om
should also fit the attachment for the torque converter as early
n
c
i
or
as possible. This is valid when removing and reinstalling the

thi
te
gearbox.
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
– Drain off coolant: ⇒ page 72 . t. Cop py
rig
gh ht
pyri by
– Disconnect starter cable -1- and alternator cable -2-, and place
co Vo
by lksw
cted
on engine.
agen
Prote AG.

lkswage es n
Vo ot g
Touareg d 2003 ➤
by ua
ran
ir se
5-cylinder
tho diesel engine - Edition 09.2012 tee
or
au ac
ss
– Pull fuel supply hose -1- and fuel return hose -2- off fuel filter.
ce
e
nl
pt
du
an
– Remove brake servo vacuum supply hose from tandem pump.
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
– Disconnect glow plugs connector -1-.
nform
ercia
– Pull all necessary coolant hoses off engine.

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.
– Clamp off power-assisted steering oil hose -arrow- with hose

clips up to 40 mm Ø -3093- , loosen clip and disconnect hose
from power steering pump.
– Pull engine compartment seal off plenum chamber bulkhead.
– Remove plenum chamber cover.
– Unclip engine control unit from mountings (on right in plenum
chamber) and pull connector off engine control unit.
– Disconnect earth connection -1- from engine control unit wir‐

ing harness.

Touareg 2003 ➤
– Open fuse holder cover in plenum chamber on left and sepa‐

rate connectors -1-, -2- and -3-.
– Remove wiring harness (smaller connection on engine control
unit) from plenum chamber and lay aside on engine.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
s c
– Unclip line for gearbox breather -arrows-. 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
– Secure suspension strut, as shown, with spring compressor -

VW 552- .
nf
ercia
orm
– Remove upper bolts of suspension strut: ⇒ Running gear;

m
atio
m
Rep. gr. 40 ; Front suspension .

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Disconnect engine earth connection -1-.

Touareg 2003 ➤
5-cylinder diesel engine - Edition
agen
AG. Volks09.2012
wagen AG
do
w es n
olks ot g
yV ua
– Pull coolant hoseris-arrow-
ed
b
off continued coolant circulation ran
tee
pump. tho or
au ac
ss
– Remove connecting hose between turbocharger and charge
ce
le
air pipe.
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Pull additional heater coolant hoses -arrows- off and place to
the side so that they are not torn off when removing the engine.
ss
– Remove heat shield -A- (if fitted) from steering box (2 bolts).
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
o Vo
– Unscrew universal joint bolt -B- from steering box, and pull
by c lksw
cted agen
universal joint off steering box.
Prote AG.
– Remove bracket for catalytic converter on underbody.

– Disconnect connectors -A- from gearbox.
– Release exhaust system clip -B- and push to rear.

– Remove propshaft tube ⇒ Transfer box and final drive; Rep.
gr. 39 ; Removing and installing propshaft .

AG. Volkswagen AG d
ksw
agen oes
not
Touareg 2003 ➤
ol
d byV 5-cylinder gdiesel
ua
ran
engine - Edition 09.2012
ise
or tee
th
– Clamp off power steering auoil line to cooler with hose clips up
or
ac
ss
to 40 mm Ø -3093- , loosen clip and pull hose off cooler. Collect
ce
e
escaping oil.
nl
pt
du
an
itte
y li
Vehicles with automatic gearbox
erm
ab
ility
ot p
– Disconnect connectors on gearbox and transfer box ⇒ Auto‐
wit
, is n
matic gearbox 09C; Rep. gr. 37 .
h re
hole
– Remove selector cable from gearbox ⇒ Automatic gearbox
spec
es, in part or in w
09C; Rep. gr. 37 .
t to the co
rrectness of i
l purpos
– Disconnect lines on lower right of radiator -arrow- for gearbox

oil. Collect escaping oil.
nf
ercia
orm
m
atio
– Remove clutch slave cylinder ⇒ Rep. gr. 30 ; Clutch mecha‐
om
nism; Removing and installing clutch slave cylinder .
n in
or c
thi
e

t
sd
iva
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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.
– Remove gearbox transverse support -A-.
– Disconnect brake line at point shown -arrow-. Collect brake

fluid which runs out.
Preparing scissor-type assembly platform -VAS 6131 - for further
procedure:
Note
The vehicle specific mounting set VAS 6131/6 consists of sup‐

ports VAS 6131/6-1 to VAS 6131/6-7. Support 1 (for VAS
6131/6-1) to support 7 (for VAS 6131/6-7) are mentioned to pro‐
vide a better overview of the following procedures.
– Assemble support 1 left and support 2 right (arrows point for‐

wards) on assembly platform -VAS 6131- and secure bolts at
following positions:
Support 1: A 5, B 4 and B 5

Touareg 2003 ➤
Support 2: G 4, H 4 and H 5
– Bolt support 3 and support 4 to scissor-type assembly platform
at following positions:
Support 3: A 6 and B 5
Support 4: F 6 and H 6
– Screw turntables of supports 3 and 4 downwards.
– Place support 5 for subframe and support 6 for gearbox trans‐
verse support in appropriate positions on scissor-type assem‐
bly platform. wage
es ks not
Vol gu
– Fix subframe in position ⇒ Running d bgear, axles, steering; Rep.
y ara
se nte
gr. 40 ; Fixing subframe in position
tho
ri . eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Position horizontal scissor-type assembly platform under en‐
hole
spec
gine/gearbox assembly. The supports -1- and -2- must be
es, in part or in w
guided into corresponding mountings on left and right
t to the co
-arrow-.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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o
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f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– At the same time, guide the supports -6- for the left and right
sides of the gearbox transverse into corresponding hole
-arrow-.
When all 4 supports are located in the mountings without pres‐
sure:
– Screw both turntables of axle supports under wishbones (with
slight pretension), until the spring compressor -VW 552- can
be removed.

AG. Volkswagen AG d
lksw
agen oes
not Touareg 2003 ➤
o
d by
V
5-cylinder gudiesel engine
ara - Edition 09.2012
ise nte
or eo
h
– Guide supports 5 ut respective mountings in subframe
into their
a ra
s c
-arrow-, correcting support height as necessary with knurled s
ce
le
nuts.
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Loosen subframe bolts -1-, -2- and -3- as well as gearbox
ss
transverse support -4-.
o
cial p
f in
Specified torque gearbox carrier -4- to body ⇒ Rep. gr. 34 ; In‐
form
mer
stalling transfer box, gearbox carrier and console
atio
om
n
c
i
or
n thi
e
Note
t
sd
iva
o
pr
cum
r
fo
♦ Engine and gearbox must be guided carefully when lowering
en
ng
t.
to prevent damage to the bodywork.
yi Co
Cop py
t. rig
♦ If the subframe is not fixed on body, after reinstalling it is nec‐
gh ht
yri by
essary to perform wheel alignment on the vehicle.
op Vo
by c lksw
cted agen
Prote AG.
– Now slowly lower engine/gearbox assembly, constantly ob‐

serving the clearance.
1.2 Removing engine from scissor-type assembly platform

Touareg 2003 ➤
Special tools and workshop

equipment required
♦ Hooks -10-222A/2-
♦ Lifting eye -2024A/2-
♦ Lifting tackle -2024 A-
♦ Lifting tackle -3033-
♦ Workshop crane -V.A.G
1202A- or workshop crane
-VAS 6100- with lifting tack‐
le -3033-
drip tray for workshop hoist
-VAS 6208-
♦ Torque wrench -V.A.G
1331- (5...50 Nm)
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Unbolt gearbox from engine: ⇒ Manual gearbox; Rep. gr. 34 ;

l purpos
Removing and installing gearbox .

nf
ercia
or
– Unbolt gearbox from engine: ⇒ Automatic gearbox 09D; Rep.

m
m
atio
gr. 37 ; Removing and installing gearbox .

om
n in
or c

thi
te
sd
iva
– Remove assembly mounting nut/bolt -A- on both sides of en‐

o
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– Fit lifting tackle -2024 A- on cylinder block as shown.
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– Attach lifting tackle -3033- together with hooks -10-222 A/2- to
crane and transportation plates, and lift engine off scissor-type
nform
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assembly platform, as shown.
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1.3 Securing engine to assembly stand

Engine codes BAC and BLK
Before carrying out repair work, secure engine on assembly stand
with engine and gearbox support -T10220- .
Procedure
– Unbolt gearbox from engine ⇒ Manual gearbox; Rep. gr. 34 ;
Removing and installing gearbox ⇒ Automatic gearbox 09C;
Rep. gr. 37 .
– Remove engine bracket from cylinder head.

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Touareg 2003 ➤ ised b ara
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– Fit lifting eye -2024A/2- to cylinder block and tighten to 40 Nm
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– Fit engine and gearbox support -T10220- as shown and tight‐
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– Secure engine to assembly stand with engine and gearbox
is n
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support -T10220- .
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spec
Engine codes BPD and BPE
t to the co
Before carrying out repair work, secure engine on assembly stand
with engine and gearbox support -T10342- .
rrectne
Procedure
– Unbolt gearbox from engine ⇒ Manual gearbox; Rep. gr. 34 ;
ss
Removing and installing gearbox ⇒ Automatic gearbox 09C;
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Rep. gr. 37 .
inform
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– Remove engine bracket from cylinder head.
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– Fit lifting eye -2024A/2- to cylinder block and tighten to 40 Nm
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– Secure engine to assembly stand with engine and gearbox
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support -T10342- .
1.4 Additional information and assembly

work for vehicles with air conditioner
Note
♦ Always observe the notes on installing air conditioner com‐

pressor ⇒ Heating, air conditioning system; Rep. gr. 87 .
♦ To prevent damage to condenser or to refrigerant lines/hoses,
ensure that the lines and hoses are not stretched, kinked or
bent.
– Remove air conditioner compressor ⇒ Heating, air condition‐

ing system; Rep. gr. 87 .

Touareg 2003 ➤
1.5 Installing engine
Note
When moving engine/gearbox into body it is essential to position

the subframe relative to the body with aid of scissor-type assem‐
bly platform. “Pulling up” the subframe with the securing bolts will
damage thread inserts.
Installation is carried out in the reverse order. When installing,

note the following:
Specified torques ⇒ page 18 , assembly mounting.
– Install hydraulic clutch slave cylinder ⇒ 6-speed manual gear‐
box 0A5; Rep. gr. 30 ; Repairing clutch mechanism .
– Install selector mechanism and adjust cables if necessary ⇒
6-speed manual gearbox 0A5; Rep. gr. 34 ; Repairing selector
mechanism; Removing and installing selector cables .
– Install selector lever cable on gearbox ⇒ Rep. gr. 37 ; Selector
mechanism; Assembly overview - selector lever cable .
– Top up ATF level ⇒ Automatic gearbox 09D; Rep. gr. 37 ;
Checking ATF level and topping-up. wagen AG. Volkswagen AG doe
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Continuation for all vehicles ed by ara
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– Electrical connections tho
andaurouting: ⇒ Electrical system; Rep. eo
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gr. 97 . ss c ce
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– Install subframe: ⇒ Running gear, axles, steering; Rep. gr.
an
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40 ; Removing and installing subframe

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– Reconnect air conditioning lines: ⇒ Heating, air conditioning

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system; Rep. gr. 87 ; Repairing components of refrigerant cir‐

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spec
– Replenish coolant ⇒ page 72 .

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

axles, steering; Rep. gr. 48 ; Checking power-assisted steer‐
ing system oil level.
rrectne
– Install noise insulation.

ss
– Carry out a road test and read event memory ⇒ page 140
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Reading and clearing event memory of engine control unit.

inform
mer
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Touareg 2003 ➤
2 Assembly mountings n AG. Volkswagen AG do

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⇒ “2.1 Assembly overview - engine mountings”, page 18 d byV
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⇒ “2.2 Specified torques - Assembly mountings”, page 18 uth o
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2.1 Assembly overview - engine mountings
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Specified torques
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Engine assembly mountings
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A- Bracket for additional 20 Nm
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hole
water pump
spec
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B- Engine bracket to cylin‐ 55 Nm
t to the co
der block
C- Engine mounting 60 Nm
rrectness of i
D- Engine bracket to en‐ 75 Nm
gine mounting
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2.2 Specified torques - Assembly mountings
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Threaded connection Specified torque
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M8 25 Nm
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M12 60 Nm
Specified torques gearbox carrier to body ⇒ Rep. gr. 34 ; Instal‐
ling transfer box, gearbox carrier and console .

Touareg 2003 ➤
13 – Crankshaft group
1 Dismantling and assembling engine
⇒ “1.1 Dismantling and assembling engine, parts I-III”,
page 19
⇒ “1.2 Removing and installing crankshaft”, page 24 AG. Volkswagen AG d
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⇒ “1.3 Removing and installing drive plate”, pagese25 db ara
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⇒ “1.4 Crankshaft bearing cap identification”,a page 26
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⇒ “1.5 Crankshaft dimensions”, page 27
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⇒ “1.6 Renewing crankshaft oil seal - engine timing end”,
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page 27
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⇒ “1.7 Renewing alternator shaft oil seal”, page 28
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1.1 Dismantling and assembling engine,
spec
parts I-III
t to the co
Note
rrectne
♦ If large quantities of swarf or metal particles (caused, for ex‐
ss
ample, by partial seizure of the crankshaft or conrod bearings)
o
cial p
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are found in the engine oil when performing repairs, clean the
nform
oil galleries thoroughly and renew the engine oil cooler in order
mer
to prevent subsequent damage.
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♦ Engine must not be set down on oil sump, as this will damage
i
or
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the oil sump liquid gasket.

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♦ Secure engine to engine and gearbox support -VAS 6095- to
um
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carry out repairs.
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⇒ “1.1.1 Part I”, page 21
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⇒ “1.1.3 Part III”, page 23
1. Dismantling and assembling engine 19

Touareg 2003 ➤
AG. Volkswagen AG d
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20 Rep. gr.13 - Crankshaft group

Touareg 2003 ➤
1.1.1 Part I
1 - Gear train housing cover

❑ Must seat on dowel
sleeves.
❑ Must be removed to al‐
low for removal of sump
and cylinder head.
❑ Insert with sealant ac‐
cording to ⇒ Electronic
parts catalogue (ETKA)
⇒ page 22 .
2 - Rubber sleeve
❑ Renew.
3 - Cylinder block
❑ With gear train.
4 - Cylinder head
❑ Removing and installing n AG. Volkswagen AG do
⇒ page 34 lkswage es n
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5 - Gear wheel o
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❑ For coolant pump. au ac
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❑ Removing and installing
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coolant pump
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⇒ page 77 .
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6 - Oil sump
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❑ Clean sealing surface
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before fitting.
hole
spec
❑ Install with sealant ac‐
es, in part or in w
t to the co
⇒ page 62 .
rrectness of i
7 - 15 Nm
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8 - Plug
❑ Renew if damaged.
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9 - 20 Nm
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10 - Seal
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❑ Do not additionally oil or grease the oil seal sealing lip.

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❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
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❑ Renew. ⇒ page 27 .
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❑ Renew seal if damaged. Prote AG.
12 - 20 Nm

Touareg 2003 ➤
Sealant bead on gear train housing
1.1.2 Part II kswage

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1 - Plug, 20 Nm utho
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❑ Remove to remove ss
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2 - Plug, 20 Nm
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3 - O-ring
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❑ Renew.
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4 - Engine speed sender -G28-
❑ Tighten on cylinder
rrectness of i
block to 10 Nm.
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5 - Oil filter housing

❑ With engine oil cooler.
nf
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❑ Dismantling and assem‐

orm
bling ⇒ page 58 .
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6 - 20 Nm
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7 - Gasket
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9 - Retaining clip
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10 - Noise insulation cted agen
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❑ For oil sump.
11 - Oil sump
❑ Clean sealing surface
before fitting.
❑ Install with sealant ac‐
⇒ page 62 .
12 - Sealing flange
❑ Renew seal if damaged.
13 - Cover
❑ Renew.

Touareg 2003 ➤
14 - 10 Nm
15 - Right engine support
16 - 50 Nm + 90° further
❑ Renew.
1.1.3 Part III
1 - Alternator
❑ The bolts between alter‐ agen
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bracket must not be d b ara
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⇒ Electrical system;
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Rep. gr. 27 ; Alternator;
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Removing and installing
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alternator .
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2 - 20 Nm
, is n
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3 - Balance weight
spec
es, in part or in w
❑ Tighten to 75 Nm.
t to the co
4 - 50 Nm + 90° further
❑ Renew.
rrectness of i
5 - Left engine support
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6 - Engine mounting
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7 - 60 Nm
m
at
8 - Power-assisted steering
om
vane pump ion

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⇒ Running gear, axles,

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steering; Rep. gr. 48 ;

for
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Vane pump, hydraulic

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lines, storage tank with C py
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Prote AG.
9 - 55 Nm
❑ Renew.
10 - Elastic drive coupling
11 - Hexagon bolt
❑ Specified torque ⇒ Heating, air conditioning system; Rep. gr. 87 ; Air conditioning compressor; Re‐
moving and installing air conditioning compressor from and to bracket
12 - Air conditioner compressor
❑ Removing and installing ⇒ Heating, air conditioning system; Rep. gr. 87 ; Air conditioning compressor;
Removing and installing air conditioning compressor from and to bracket
13 - Bracket
❑ For air conditioner compressor.
❑ Note dowel sleeves between bracket/cylinder block and bracket/air conditioner compressor.
14 - Hub
❑ For alternator shaft.

Touareg 2003 ➤
15 - 50 Nm + 90° further
❑ Renew.
1.2 Removing and installing crankshaft

Repairing clutch ⇒ 6-speed manual gearbox 0A5; Rep. gr. 30 ;
Repairing clutch
1 - Tie bolt, 30 Nm
❑ Renew.
❑ If the tie bolts are to be
loosened then the cylin‐
der head bolts must be
removed and the cylin‐
der head removed from
the block first
⇒ page 34 .
2 - Bearing cap
❑ Bearing cap 4 with re‐
cesses for thrust wash‐
ers.
❑ Bearing shell retaining
lugs in cylinder block
and bearing caps must
align.
3 - Thrust washer
❑ For bearing 4.
4 - Bearing shell 4
5 - Crankshaft
❑ If the crankshaft is to be
removed, first remove n AG. Volkswagen AG do
cylinder head bolts and olkswage es n
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cylinder head before byV ua
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loosening crankshaft
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❑ Axial clearance new:
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0.07…0.231 mm, wear

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limit: 0.250 mm.

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❑ Check radial clearance

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0.026…0.040 mm, wear

h re
limit: 0.16 mm
hole
spec
❑ Do not rotate crankshaft

es, in part or in w
t to the co
when checking radial clearance.

❑ Crankshaft dimensions ⇒ page 27 .
rrectness of i
6 - Gear train housing cover

❑ Insert with sealant according to ⇒ Electronic parts catalogue (ETKA) ⇒ page 22 .
l purpos
❑ With seal.
nform
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❑ Use fitting tool -T10122- to pretension seal before installing.

❑ Do not additionally oil or grease the oil seal sealing lip.
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❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
n in
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❑ Renewing seal ⇒ page 27 .

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7 - Flywheel/drive plate
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Engine code: BAC.

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Only vehicles with manual gearbox up to engine number 05984.
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24
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Rep. gr.13 - Crankshaft group
Touareg 2003 ➤
When replacing a defective dual-mass flywheel, the vibration damper ⇒ Item 11 (page 25) must always
be replaced.
❑ When removing and installing flywheel, lock with counterhold -3067- .
❑ Removing and installing drive plate ⇒ page 25 .
8 - 60 Nm + 90° further
❑ Renew.
9 - Cylinder block
10 - 20 Nm + 90° further
❑ Renew.
11 - Vibration damper
❑ To remove, remove conrod bearing cap of cylinder 1. Renew conrod bolts.
❑ When installing, tighten upper bolt to 5 Nm. Then first tighten front and then upper securing bolts to
specified torque.
1.3 Removing and installing drive plate

⇒ “1.3.1 Loosening and tightening drive plate”, page 26
⇒ “1.3.2 Installing drive plate”, page 26
Special tools and workshop equipment required
♦ Clutch counterhold -VW 558-
AG. Volkswagen AG d
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♦ Torque wrench -V.A.G 1332-

es, in part or in w
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♦ Vernier gauge
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♦ Hexagon bolt M8 × 50 with M12 hexagon nuts
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Touareg 2003 ➤
1.3.1 Loosening and tightening drive plate

– Secure clutch counterhold -VW 558- to drive plate with hexa‐
gon bolt M8 x 50. Insert M12 hexagon nuts between counter‐
hold and drive plate.
Installation position of counterhold: -A- when loosening; -B- when
tightening
1.3.2 Installing drive plate

– Position drive plate with shim.
– Fit new bolts and tighten to 30 Nm.
– Use the caliper gauge to check the distance between the drive
plate and gear train cover.
Specification dimension -a-: 18.1 mm…19.7 mm
If specification is not attained:
– Remove drive plate again and place shim between crankshaft
and drive plate. Tighten bolts to 30 Nm again. n AG. Volkswagen AG do
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– Tighten bolts to 60 Nm + turn 90° further (turning further can sed b ua
ran
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1.4 Crankshaft bearing cap identification
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spec
The crankshaft bearing shells are classified during production and
t to the co
cylinder block and crankshaft sender wheel are marked as shown.
When ordering bearing shells, remove oil sump and baffle plate,
read the coloured mark and allocate the bearing shells accord‐
rrectne
ingly.
Identification of crankshaft upper bearing shell - arrow - (next to
first main bearing). ss o
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Touareg 2003 ➤
Identification of crankshaft lower bearing shell - arrow - (on crank‐

shaft sender wheel).
Colour coding
B = Blue
G = gen AG. Volkswagen AYellow
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R Volks = Red not gua
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S ho
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1.5 Crankshaft dimensions
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No further honing dimensions are planned at this time.
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spec
(Dimensions in mm)
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Honing dimension Main journal ∅ Conrod journal ∅
-0.022 -0.022
rrectne
Basic dimension 58.00 50.90
-0.037 -0.042
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1.6 Renewing crankshaft oil seal - engine nform
mer
timing end
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⇒ “1.6.1 Removing”, page 27

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⇒ “1.6.2 Installing”, page 27

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♦ Puller hooks -T20143/2-
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♦ Assembly tool -T10122- co Vo
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1.6.1 Removing
Note
Ensure that sealing surface is not damaged when removing seal.
– Pull old oil seal carefully out of seat using puller hook -
T20143/2- .
1.6.2 Installing
– Remove oil residue from crankshaft journal using clean cloth.

Touareg 2003 ➤
– Pull dry oil seal -A- with outer side 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 stub. AG. Volkswagen n AG do
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– Press oil seal into gear train housing cover to stop using thrust
piece -T10122/3- .
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1.7 Renewing alternator shaft oil seal
co lksw
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Prote AG.

♦ Puller hooks -T20143/1-
♦ Assembly tool -T10208-
♦ Torque wrench -V.A.G 1332- (40 ... 200 Nm)
WARNING
When loosening the threaded connection for the alternator

drive hub, always counterhold at flats (WAF 27 mm) because
otherwise the threaded connection inside the control housing
may be loosened.
1.7.1 Removing
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
nator; Removing and installing alternator .
– Remove hub from alternator shaft. To do this counterhold the
hub with a 27 mm ring spanner.

Touareg 2003 ➤
– Pull old oil seal carefully out of seat using puller hook -
T20143/1- .
1.7.2 Installing
– Remove oil residue from alternator shaft using clean cloth.
– Screw guide sleeve -T10208/1- hand tight onto alternator shaft
and carefully push seal onto stop.
– Now fit press piece -T10208/3- and press seal in onto limit
stop. AG. Volkswagen A
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swa es
– Secure hub
by
Vonto
olk alternator shaft with newnobolts.
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Specified
tho torque: 50 Nm + turn 90° further.
ri e or
au a
– Install
ss alternator ⇒ Electrical system; Rep. gr. 27 ; Alternator;
c
ce
le
Removing and installing alternator .

un
pt
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ility
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wit
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hole
spec
es, in part or in w
t to the co
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l purpos
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mercia
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com
tion in
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Cop py
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rig ht
py by
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by lksw
cted agen
Prote AG.

Touareg 2003 ➤
2 Dismantling and assembling pistons

and conrods
Note
All bearing and running surfaces must be oiled before assembly.
⇒ “2.1 Assembly overview - pistons and conrods”, page 30

⇒ “2.2 Separating new conrods”, page 31
⇒ “2.3 Installation position and allocation of piston to cylinder”,
page 32
⇒ “2.4 Checking piston ring gap”, page 32
⇒ “2.5 Checking ring-to-groove clearance ”, page 32
⇒ “2.6 Checking cylinder bores”, page 33
⇒ “2.7 Piston and cylinder dimensions”, page 33
2.1 Assembly overview - pistons and conrods
1 - Piston rings
❑ Offset gaps by 120°.
❑ Use piston ring pliers to
remove and install.
❑ “TOP” faces towards
piston crown.
❑ Checking ring gap
⇒ page 32 .
❑ Checking ring-to-groove
clearance ⇒ page 32 .
2 - Piston agen
AG. Volkswagen AG d
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❑ With combustion cham‐ by
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❑ Mark installation
aut posi‐ ra
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tion and cylinder
s num‐
ce
le
ber.
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pt
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itte
❑ Installation position and

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allocation of piston to
pe
ility
cylinder ⇒ page 32 .
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wit
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❑ Arrow on piston crown

h re
hole
points towards No. 1 cyl‐

spec
inder end of engine

es, in part or in w
t to the co
block.
❑ Install using piston ring
clamp.
rrectness of i
❑ If piston skirt is cracked,

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renew piston.
❑ Installation position
⇒ page 32 .
nform
ercia
❑ Piston and cylinder di‐

m
mensions ⇒ page 33 .
com
tion in
❑ Checking cylinder bores

r
te o
thi
⇒ page 33 .
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3 - Piston pin
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fo
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❑ If difficult to remove, heat piston to 60 °C.

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Cop py
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30
op Vo
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Rep. gr.13 - Crankshaft group Prote
cted AG.
agen
Touareg 2003 ➤
❑ Remove and install using drift -VW 222 A- .
4 - Circlip
5 - Conrod
❑ Renew as set only.
❑ Mark with cylinder number -A-.
❑ Installation position: Marking -B- faces towards No. 1 cylinder end.
6 - Bearing shell
❑ Note installation position.
❑ Upper bearing shell (towards piston) made of a more wear resistant material.
❑ Do not interchange used bearing shells.
❑ Insert bearing shells centrally.
❑ Check for secure seating.
❑ Axial clearance, wear limit: 0.37 mm
❑ Measure radial clearance with Plastigage: Wear limit: 0.08 mm, do not rotate crankshaft when measuring
radial clearance.
7 - Cylinder block
AG. Volkswagen AG d
❑ Checking cylinder bores
ksw
ag⇒
enpage 33 . oes
not
Vol
❑ Piston and cylinder
ed by dimensions ⇒ page 33 . gu
ara
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or
8 - Conrod bearing
au cap
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❑ Note installation
s
position. ce
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nl
pt
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9 - Oil spray jet

an
itte
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❑ For piston cooling.

ab
ility
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❑ When installing, turn oil spray jet clockwise onto limit stop in cylinder block and tighten in this position.
wit
, is n
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10 - 25 Nm
hole
spec
❑ Insert without sealant.

es, in part or in w
t to the co
11 - Conrod bolt, 30 Nm + turn (90°)

❑ Renew.
rrectness of i
❑ Oil threads and contact surface.

l purpos
❑ First tighten evenly to 5 Nm.

❑ Use old bolt for measuring radial clearance.
nform
mercia
at
om
2.2 Separating new conrods

ion
c
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or
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e
– Mark cylinder allocation of conrod ⇒ Item 5 (page 31)

at
do
priv
– Lightly clamp the conrod in a vice using aluminium vice

um
for
en
g
clamps, as shown in the illustration.

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t.
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Cop py
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Note
op Vo
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cted agen
Prote AG.
♦ To prevent damage to the conrod, only clamp conrod in lightly.
♦ Clamp conrod in below the dashed line.
– Unscrew the two bolts -arrows- approx. 5 turns.
2. Dismantling and assembling pistons and conrods 31

Touareg 2003 ➤
– Using a plastic hammer, carefully knock against conrod bear‐

ing cap in -direction of arrow- until it is loose.
2.3 Installation position and allocation of

piston to cylinder
Installation position and allocation of piston to cylinder
Piston in cylinders 1 and 2:
Larger inlet valve chamber -arrows- towards flywheel.
olksw AG. V agen AG
agen does
Piston in cylinders 3, 4 and 5: Volksw not
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Larger inlet valve chamber oris-arrows-
e
towards No. 1 cylinder end nte
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of block. aut ra
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Note
itte
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♦ New piston allocation to cylinders is shown by a coloured

ot p
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marking on piston crown.

, is n
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hole
♦ Piston for cylinders 1 and 2: marked 1/2

spec
es, in part or in w
♦ Piston for cylinders 3, 4 and 5: Marking 3/4/5

t to the co
2.4 Checking piston ring gap

rrectness of i
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Checking piston ring gap

– Insert ring at right angles from above and push down into cyl‐
nform
ercia
inder approx. 15 mm from bottom end of cylinder.

m
at
om
Piston ring New Wear limit

ion
c
dimensions in mm
in t
or
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ate
1st compression ring 0.25 … 0.40 1.0

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or
2nd compression ring 0.30 … 0.50 1.0

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Oil scraper ring 0.25 … 0.50 1.0
Co
Cop py
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2.5 Checking ring-to-groove clearance
co lksw
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cted agen
Prote AG.
Checking ring-to-groove clearance

Clean annular groove before check.
Piston ring New Wear limit
dimensions in mm
1st compression ring 0.09 … 0.13 0.25
2nd compression ring 0.04 … 0.08 0.25
Oil scraper ring 0.03 … 0.07 0.15

Touareg 2003 ➤
2.6 Checking cylinder bores

Checking cylinder bores
AG. Volkswagen AG d
agen oes
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wit
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es, in part or in w
t to the co
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♦ Internal dial test indicator 50…100 mm

– Take measurements at 3 positions in both lateral direction
nf
ercia
o
-A- and longitudinal direction -B-. Deviation from nominal di‐
rm
m
mension max. 0.08 mm
atio
om
n in
c
2.7 Piston and cylinder dimensions

or
thi
te
sd
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No repairs designated.
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Piston ∅ Cylinder bore ∅
Cop
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py
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Basic dimen‐ mm 80.97 yri
gh 81.01 by
ht
sion cop Vo
by lksw
cted agen
Prote AG.
2. Dismantling and assembling pistons and conrods 33

Touareg 2003 ➤
15 – Cylinder head, valve gear

1 Overview - cylinder head
⇒ “1.1 Assembly overview - cylinder head”, page 34
⇒ “1.2 Renewing pipe connection for coolant”, page 36
⇒ “1.3 Removing and installing camshaft drive gear”, page 37 .
⇒ “1.4 Setting engine to TDC No. 1 cylinder”, page 41
⇒ “1.5 Removing and installing cylinder head”, page 42
⇒ “1.6 Checking compression”, page 44 .
Note agen
AG. Volkswagen AG d
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♦ When installing an exchange cylinder head with fitted
ise cam‐
d ara
r nte
shaft. utho eo
ra
s a c
♦ The contact surfaces between the bucket tappets and the cam
s
ce
e
nl
must be oiled before installing the cylinder head cover.
pt
du
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itte
y li
♦ The plastic packing pieces for protecting the open valves must
erm
ab
not be removed until immediately before fitting cylinder head.
ility
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♦ If the cylinder head is replaced, all the coolant in the system
h re
must also be renewed.
hole
spec
es, in part or in w
t to the co
1.1 Assembly overview - cylinder head
⇒ “1.1.1 Checking cylinder head for distortion”, page 36
rrectness of i
l purpos
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34 Rep. gr.15 - Cylinder head, valve gear

Touareg 2003 ➤
1 - To air filter.
❑ Dismantling and assem‐
bling air filter
⇒ page 139
2 - Crankcase breather valve
3 - Seal
4 - Engine cover
5 - 15 Nm
6 - Cylinder head cover
❑ Before fitting, thorough‐
ly clean sealing surface
of cylinder head with
clean cloth.
7 - Cylinder head bolt
❑ Renew.
❑ Note sequence when
loosening and tighten‐
ing ⇒ page 42 , Re‐
moving and installing wage
es n
cylinder head. yV
olks ot g
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d b ran
8 - 20 Nm ir se tee
tho
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9 - Tandem pump ss
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❑ For fuel and vacuum

un
pt
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supply.
itte
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ab
pe
ility
⇒ page 107
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❑ Checking ⇒ page 104 .
h re
hole
spec
❑ Must not be dismantled.
es, in part or in w
t to the co
10 - 10 Nm
11 - Hall sender -G40-
rrectness of i
❑ For camshaft position.
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12 - O-ring
❑ Renew. nform
ercia
13 - Gasket
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❑ Renew.
com
tion in
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14 - Lifting eye
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❑ With retainer for connector.

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15 - 20 Nm
en
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16 - Bracket C py
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17 - Cylinder head gasket cop Vo
by lksw
cted agen
❑ Renew. Prote AG.
❑ Imprint must be legible.

❑ After renewing, renew entire coolant.
❑ Different thicknesses of cylinder head gasket are fitted depending on the piston projection. When re‐
newing gasket, install new gasket with same identification.
❑ Take note of number of holes next to parts number
1. Overview - cylinder head 35

Touareg 2003 ➤
18 - 20 Nm
19 - Bracket
20 - Coolant temperature sender -G62-
❑ Fitting location is described in guided fault finding in vehicle diagnosis tester.
21 - Seal olkswage es n
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❑ Renew. d b ua
ran
ir se tee
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22 - Plug aut or
ac
ss
23 - Sealing cover
ce
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un
pt
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❑ Renew.
itte
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ab
24 - Cylinder head
pe
ility
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wit
❑ Removing and installing ⇒ page 42
, is n
h re
hole
25 - Pipe connection
spec
es, in part or in w
❑ Drive pipe connection in until stop
t to the co
26 - Lifting eye
rrectness of i
27 - 20 Nm
l purpos
nform
ercia
1.1.1 Checking cylinder head for distortion

m
a
com
ti
Checking cylinder head for distortion

on in
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te o
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Max. permissible distortion: 0.1 mm.

s
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Note
n
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Cop py
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Reworking diesel cylinder heads is not permissible.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.2 Renewing pipe connection for coolant

♦ Thrust piece -T10418-
– Drain coolant ⇒ page 72 .

– Remove coolant line from pipe connection.
– Remove right heat shield from exhaust manifold.
– Remove pipe connection.
– Clean connection hole in cylinder head.

Touareg 2003 ➤
Clean area -arrow- of new pipe connection and apply sealant to

the area as per ⇒ Electronic parts catalogue (ETKA) .
– Drive pipe connection into connection hole in cylinder head as

far as stop -arrows- using thrust piece -T10418- -1-.
Further installation is performed in the reverse sequence.
– Fill coolant system with coolant ⇒ page 72 .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
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pt
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ab
ility
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1.3 Removing and installing camshaft drive
wit
, is n
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gear
hole
spec
es, in part or in w
t to the co
♦ Allen key, long reach -T10198-
rrectness of i
♦ Clamp -T10199-
l purpos
♦ Thrust piece -T10199/1-

♦ Wrench -T10211-
nform
ercia
♦ Insert tool -T10234-

m
at
om
♦ Torque wrench -V.A.G 1331- (5...50 Nm)

on
c
in t
or

his
ate
do
riv
♦ Torque wrench 50-100 Ncm -VAS 6253-

p
cum
for
en
ng
t.
1.3.1 Removing
yi Co
Cop py
ht. rig
rig ht
– Position crankshaft at TDC for cylinder No. 1 ⇒ page 41 . py by
co Vo
by lksw
cted agen
– Remove charge air pipes between charge air cooler and tur‐ Prote AG.
bocharger and between charge air cooler and intake connect‐
ing flange.
– Remove intake manifold support.
– Remove exhaust gas recirculation connecting pipe.
– Remove engine cover and cylinder head cover
⇒ Item 4 (page 35) .
– Remove tandem pump ⇒ page 107 .
– Disconnect central connector for unit injectors.
– Release central connector on cylinder head side. Turn it anti-
clockwise using wrench -T10211-

Touareg 2003 ➤
– Remove outer bearing cap -A-, set clamp -T10199- on cam‐

shaft gear and tighten its bolts to 40 Nm.
– Loosen securing bolt -B- of camshaft gear using socket -
T10198- and remove it along with drive for tandem pump.
– Remove camshaft position Hall sender - G40- -C-.
– Remove the camshaft sprocket and the disc behind it (dia‐
mond-coated) from the camshaft.
– Unbolt sealing cover from eccentric pin.
– Remove securing bolt -D- and pull eccentric pin out.
– Carefully remove camshaft compensating gear together with
adjustment plate.
1.3.2 Installing
– Oil all surfaces of guide sleeve -4- and adjustment plate -1-.
– Place camshaft compensating gear -3- onto guide sleeve.
– Install disc -2- as shown.
Note
The lugs of the disc must engage in the grooves of the guide
sleeve
– Place compensating gear with disc and guide sleeve onto ad‐
justment plate -1-.
AG. Volkswagen AG d
Note agen oes
olksw not
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d b ara
ise
The marks -A- of the guide sleeve and the adjustment plate must
r nte
tho eo
align. s au ra
c
s
ce
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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
– Carefully insert adjustment plate with camshaft compensating

gear from above into respective cavity.
rrectness of i
– Oil all surfaces of eccentric pin -5-.

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

Touareg 2003 ➤
– Install eccentric pin. The marking -B- on the eccentric pin must
be vertical and uppermost.
Note
Marking -C- must align with sealing surface of cylinder head.
– Install outer bearing cap and tighten hand tight.
– Install new securing bolt -6- for eccentric pin and tighten by
hand until approx. one turn before stop.
– Fit insert tool -T10234- with torque wrench -VAS 6253- into
holes of eccentric pin.
– Turn eccentric pin carefully anti-clockwise with 50 Ncm

(0.5 Nm). lkswage es n
ot g
o
byV ua
– Hold eccentric pin in this position and tighten new eccentric
ir se
d ran
tee
securing bolt. utho
or
a ac
ss
Specified torque: 20 Nm + turn (90°) further
ce
e
nl
pt
du
– Remove outer bearing cap again.
an
itte
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erm
ab
– Place central connector of unit injectors carefully into cylinder
ility
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head.
wit
, is n
h re
– Install outer bearing cap with sealant and tighten using new
hole
spec
bolts.
es, in part or in w
t to the co
Specified torque: 8 Nm + turn (90°) further
rrectness of i
Note
l purpos
Seal parting surfaces of outer bearing caps with sealant according

to ⇒ Electronic parts catalogue (ETKA) ⇒ page 50 .
nf
ercia
orm
– Lock central connector of unit injectors on cylinder head side.

m
atio
m
Turn it clockwise onto limit stop using wrench -T10211- .

o
n in
or c
thi
– Tighten eccentric pin sealing cover and Hall sender -G40- .

te
sd
iva
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Specified torque: 10 Nm
rp
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Cop py
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t. rig
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by
♦ Check that the disc (diamond-coated) is seated correctly on cted agen
Prote AG.
the camshaft before installing the camshaft gear wheel.
♦ The teeth of the gear wheel must be oiled completely.

Touareg 2003 ➤
– Seat camshaft gear wheel with new disc (diamond-coated)

onto camshaft so that the marking -arrow- on the sender wheel
aligns with the upper edge of the cylinder head sealing sur‐
face.
– Secure camshaft gear wheel and tandem pump drive using
new bolt and tighten hand-tight. (Camshaft gear wheel can still
turn).
– Fit clamping device -T10199/1- as shown and tighten its
clamping bolts to 70 Nm.
– Insert torque wrench -V.A.G 1332- into square end of clamp,
and push with 80 Nm against direction of engine rotation.
To eliminate gear drive backlash:
AG. Volkswagen AG d
agen oes
– Maintain this force and tighten camshaft gearVol wheel securing
ksw not
gu
bolts to 50 Nm using socket -T10198- s.ed by ara
nte
ri
ho eo
– Remove clamp -T10199/1- . aut ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Fit clamp -T10199- onto camshaft gear wheel.
rrectness of i
l purpos
Note
nf
ercia
Ensure the clamp -T10199- lies flush with the cylinder head.
orm
m
atio
m
– Tighten bolts for clamp - T10199- to 40 Nm.

o
n in
or c
thi
e
– Then secure camshaft gear wheel with clamp -T10198- .

t
sd
iva
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cu
Specified torque: 150 Nm + turn (90°) further.

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t.
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– Remove clamp -T10199- .
Co
Cop py
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– Remove locking devices from camshaft and crankshaft.
gh ht
pyri by
Vo
co lksw
by
– Install tandem pump ⇒ page 107 . cted agen
Prote AG.
– Install cylinder head cover and engine cover

– Turn crankshaft 2 rotations in engine direction of rotation until
crankshaft is set to TDC No. 1 cylinder again.
– Check that the camshaft clamp as well as the crankshaft clamp
can be inserted.
– Install new camshaft sealing cover.
– Install new crankshaft sealing cover.
– Install charge air pipes between charge air cooler and turbo‐
charger and between charge air cooler and intake connecting
flange.
– Install intake manifold support.
– Install exhaust gas recirculation connecting pipe.

Touareg 2003 ➤
1.4 Setting engine to TDC No. 1 cylinder

♦ Camshaft clamp -T10193-
♦ Crankshaft clamp -T10226-
♦ Special wrench -T10225-
♦ Lever -VW 681-
♦ Puller hooks -10-221-
1.4.1 Procedure
With engine installed
– If fitted, remove engine cover -A- and engine compartment
covers -B-, -C- and -D-.
– Remove noise insulation.
Continuation with engine removed or in situ
lkswage es n
o ot g
byV ua
d ran
ir se
– Lever camshaft cover -arrow- tho out using lever -VW 681- . tee
or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove noise insulation from end of engine block.

l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
– Unscrew bolts -arrows- and remove retainer for noise insula‐

tion.
– Lever sealing cover out of sealing flange on end of block using
lever -V.A.G 10-221- .
– Bolt special wrench -T10225- onto crankshaft.
Note
It is only possible to bolt special wrench -T10225- onto crankshaft

in one position. To do this, turn screw into crankshaft through
centre of tool and tighten to 20 Nm.
– Turn the crankshaft in engine direction of rotation until marks

-arrows- on special wrench - T10225- and sealing flange align.
– Unbolt special wrench -T10225- from crankshaft.
– Secure crankshaft with crankshaft clamp -T10226- as shown.

At the same time the crankshaft locking piece must engage in
the cylinder block.
– Bolt crankshaft clamp -T10226- onto crankshaft.
Note
AG. Volkswagen AG d
♦ It is only possible to bolt crankshaft clamp -T10226- onto agen oes
olksw not
crankshaft in one position. ed by
V gu
ara
ris nte
o
♦ If crankshaft clamp -T10226- cannot be bolted to crankshaft,
aut
h eo
ra
crankshaft is at exhaust stroke TDC and not at at ignition
ss TDC. c
ce
le
un
pt
♦ In this case, turn crankshaft in engine direction of rotation until

an
d
itte
marks on special wrench and sealing flange align again.

y li
rm
ab
pe
ility
ot
– Fit camshaft clamp -T10193- .

wit
, is n
h re
– Check position of camshaft gear wheel ⇒ page 37 , Removing

hole
spec
and installing camshaft drive gear.

es, in part or in w
t to the co
1.5 Removing and installing cylinder head

rrectness of i

l purpos

nform
ercia
1.5.1 Removing
m
a
com
tion in
r
te o
thi
Note
s
iva
do
r
rp
cum
fo
The removal and installation of the cylinder head can only be un‐
en
ng
t.
dertaken when the engine is removed due to the cramped con‐
yi Co
op py
ditions. t. C rig
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pyri by
Vo
o
by c lksw
cted agen
Prote
42
AG.
Rep. gr.15 - Cylinder head, valve gear
Touareg 2003 ➤
– Remove engine and gearbox ⇒ page 5 .

– Unscrew turbocharger/exhaust manifold securing bolts
⇒ page 110 .
– Disconnect all necessary coolant and vacuum hoses as well
as electrical connections on cylinder head.
– Position crankshaft at TDC for cylinder No. 1 ⇒ page 41 .
– Remove camshaft gear wheel ⇒ page 37 .
– Unscrew threaded connection for cylinder head control hous‐
wage
ing ⇒ Item 18 (page 36) . Volks es n
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by ua
ed ran
– Maintain sequence when loosening and tightening
ris cylinder tee
head bolts. utho or
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1.5.2 Installing
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nform
ercia
Note
m
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com
t
♦ Different thicknesses of cylinder head gasket are fitted de‐
pending on the piston projection. When renewing gasket, ion in
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install new gasket with same identification.

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♦ Take note of number of holes next to part number.

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♦ Always renew cylinder head bolts.
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♦ In cases of repair carefully remove gasket remains from cyl‐
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inder head and cylinder block. Ensure that no long scores or
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scratches are made on the surfaces. When using abrasive
agen
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paper do not use a grade less than 100.
♦ Carefully remove emery and abrasive remains.
♦ Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
♦ Handle gasket very carefully. Damage to the elastomeric coat‐
ing or the indented area will lead to leaks.
♦ Use new gasket with same identification (index).
– Position crankshaft (turn in engine direction of rotation) at TDC

for No. 1 cylinder and secure with clamp -T101226- .

Touareg 2003 ➤
5-cylinder diesel engine - Edition 09.2012 AG. Volkswagen AG d
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Note ut
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♦ To prevent valves from contacting pistons when installing:
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♦ Always ensure that camshaft is positioned as accurate as
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possible at TDC for No. 1 cylinder.
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– Position cylinder head gasket.
h re
hole
spec
– Fit cylinder head, install cylinder head bolts and tighten hand
es, in part or in w
tight.
t to the co
– Tighten cylinder head in 6 stages in sequence shown as fol‐
lows:
rrectness of i
– Tighten initially with torque wrench:
l purpos
Stage I = 60 Nm
nf
ercia
– Turn further with rigid spanner:
orm
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atio
Stage II = 1/4 turn (90°)
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Stage III = 1/4 turn (90°)
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Stage IV = 1/4 turn (90°)

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Stage V = 1/4 turn (90°)
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– Turning back with rigid spanner: p by
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Stage VI = loosen all cylinder head bolts 1/4 turn (90°).
Prote AG.
– Tighten threaded connection between cylinder head/control

housing ⇒ Item 18 (page 36) to 20 Nm.
– Install camshaft drive gear wheel ⇒ page 37 .
– Install turbocharger ⇒ page 110 .
– Install engine and gearbox ⇒ page 5 .
– Carry out road test and read all event memories
⇒ page 140 .
1.6 Checking compression

Touareg 2003 ➤

equipment required
♦ 10 mm jointed spanner
-3220-
♦ Torque wrench -
V.A.G 1331- (5 ... 50 Nm)
♦ Adapter -V.A.G 1381/12-
♦ Compression tester -
V.A.G 1763-
♦ Removing and installing
valve springs with cylinder
head removed -2037-
AG. Volkswagen AG d
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Test prerequisite
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• Engine oil temperature min. 30 °C.

Test procedure
nform
ercia
– Disconnect central connector on cylinder head for unit injec‐

m
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om
tors.
on
c
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or
– Remove all glow plugs using 10 mm jointed wrench -3220- .

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Prote AG. 1. Overview - cylinder head
Touareg 2003 ➤
– Screw in adapter -V.A.G 1381/12- in place of the glow plugs.

– Check compression using compression tester -V.A.G 1763- .
Note
Using compression tester ⇒ operating instructions .
– Operate starter until tester shows no further pressure in‐

crease.
Compression pressures:
New: 25 ... 31 bar, wear limit: 19 bar
Maximum permissible difference between all cylinders: 5 bar
– Install glow plugs using U/J extension and socket, 10 mm
-3220- . Specified torque: 15 Nm.
– Read event memory ⇒ page 140 .
Note AG. Volkswagen AG d

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Disconnecting the central connector for isunit
ed injectors causes
b ara
nte
faults to be stored. Therefore, read event
hor memory and delete if eo
ut
necessary ⇒ page 140 . ss a ra
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Prote AG.

Touareg 2003 ➤
2 Repairing valve gear
Note
Cylinder heads with cracks between the valve seats may be used
without reducing engine life, provided the cracks are small and
not more than 0.5 mm wide.
lkswage es n
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⇒ “2.1 Assembly overview - valve gear”, page 47 d byV ua
ran
ir se tee
⇒ “2.2 Reworking valve seats”, page 51 utho
or
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ss
⇒ “2.3 Checking valve guides”, page 53
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e
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⇒ “2.4 Renewing valve stem seals”, page 53
itte
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⇒ “2.5 Removing and installing camshaft”, page 55
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2.1 Assembly overview - valve gear
h re
hole
spec
⇒ “2.1.1 Checking camshaft axial clearance”, page 50
es, in part or in w
t to the co
⇒ “2.1.2 Sealing parting surfaces of bearing caps”, page 50
⇒ “2.1.3 Valves”, page 50
rrectness of i
⇒ “2.1.4 Camshaft identification, valve timing”, page 51
l purpos
nform
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Prote AG.
2. Repairing valve gear 47

Touareg 2003 ➤
1 - 8 Nm + 90° further
❑ Renew.
2 - 20 Nm + 90° further
❑ Renew.
❑ Note sequence when
loosening and tighten‐
ing ⇒ page 55 , Re‐
moving and installing
camshaft. agen
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❑ Do not interchange. ut
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4 - Bucket tappet s
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❑ Do not interchange.
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❑ With hydraulic valve
erm
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clearance compensa‐
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tion.
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❑ Set down with contact
hole
spec
surface facing down‐
es, in part or in w
wards.
t to the co
❑ Before installing, check
camshaft axial clear‐
ance ⇒ page 50 .
rrectness of i
❑ Oil running surface.
l purpos
5 - Cotters
nform
ercia
6 - Valve spring plate

m
at
7 - Outer valve spring
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❑ Installing and removing:
in t
or
cylinder head removed:
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with Removing and in‐

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stalling valve springs
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with cylinder head re‐

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head installed:
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⇒ page 53 , Renewing valve stem oil seals co Vo
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8 - Inner valve spring
AG.
❑ Installing and removing: cylinder head removed: with Removing and installing valve springs with cylinder
head removed -2037- . Cylinder head installed: ⇒ page 53 , Renewing valve stem oil seals
9 - Valve stem seal
10 - Washer
❑ For cylinder head bolts.
❑ Insert in cylinder head before installing bearing caps
11 - Valves
❑ Valve dimensions ⇒ page 50
12 - Unit injector
13 - Cylinder head
❑ See note ⇒ page 47 .
❑ Reworking valve seats ⇒ page 51 .
14 - Eccentric pin
❑ Oil when installing.

Touareg 2003 ➤
❑ Note installation position ⇒ page 37 , Removing and installing camshaft drive gear.
15 - 20 Nm + 90° further
❑ Renew.
16 - O-ring
❑ Renew.
17 - 10 Nm
18 - Cap
19 - Washer
20 - Adjustment plate
21 - Compensating gear
❑ For camshaft.
22 - Guide sleeve
❑ Oil when installing.
❑ Note installation position ⇒ page 37 , Removing and installing camshaft drive gear.
23 - 150 Nm + 90° further
❑ Renew.
24 - Tandem pump drive
❑ Removing and installing tandem pump ⇒ page 107 .
25 - Camshaft pulley
❑ With camshaft position sender wheel.
AG. Volkswagen AG d
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❑ Note installation position i⇒
sedpage
b 37 , Removing and installing camshaft
ara
n drive gear.
r tee
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26 - Washer aut or
ac
ss
❑ Renew.
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27 - Bearing shell
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❑ Do not interchange used bearing shells (mark).

ility
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❑ Ensure that retaining lugs are correctly seated in bearing caps and cylinder head
wit
is n
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ole,
28 - Camshaft
spec
❑ Checking axial clearance ⇒ page 50 .

t to the co

❑ Check radial clearance with Plastigage; wear limit: 0.11 mm.
rrectne
❑ Runout: max. 0.01 mm.

❑ Identification and valve timing ⇒ page 51 .
ss o
29 - Bearing cap
cial p
f inform
❑ When installing, seal parting surfaces of outer bearing caps with sealant according to ⇒ Electronic parts
mer
catalogue (ETKA) ⇒ page 50 .

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Prote AG.

Touareg 2003 ➤
2.1.1 Checking camshaft axial clearance

Checking camshaft axial clearance

♦ Universal dial gauge bracket
AG.-VW
Volksw387-
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♦ Dial gauge Volks ot g
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Check with bucketoris tappets removed and with 2, 4 and 6 bearing
tee
th or
caps fitted.
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Wear limit: max. 0.15 mm

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2.1.2 Sealing parting surfaces of bearing caps
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Seal parting surfaces of bearing caps 1 and 7 with sealant.

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nform
ercia

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♦ Sealant as per ⇒ Electronic parts catalogue (ETKA) .

n
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– Apply sealant as per ⇒ Electronic parts catalogue (ETKA)

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thinly and evenly on surfaces.

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2.1.3 Valves
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Valve dimensions rig ht
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Note
Valves must not be reworked. Only lapping-in is permitted.
Dimension Inlet valve Exhaust valve

∅a mm 35.95 31.45
∅b mm 6.980 6.956
c mm 89.95 89.95
α ∠° 45 45

Touareg 2003 ➤
2.1.4 Camshaft identification, valve timing

Camshaft identification, valve timing
Identification
♦ Cam base diameter: a = 52.8 mm ∅.
♦ Identification by stamped numbers and letters on drive-end
face of camshaft.
Drive end -arrow- 070 M
Valve timing at 1 mm valve lift
Inlet opens ATDC 12°
Inlet closes ABDC 21.5°
Exhaust opens BBDC 30°
Exhaust closes BTDC 20.5°
2.2 Reworking valve seats AG. Volkswagen AG d

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Special tools and workshop equipment d by V required gu
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♦ Depth gauge ut
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♦ Valve seat refacing tool s
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pt
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ab
Note
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♦ When repairing engines with leaking valves, it is not sufficient
h re
ole,
to rework or renew valve seats and valves. There is also a
spec
requirement to check the valve guides for wear. This is par‐
ticularly important on high mileage engines.
t to the co
♦ Valve seats are only to be reworked to the extent required to
yield a proper surface appearance. Before beginning to rework rrectne
valve seats, calculate the maximum permissible reworking di‐
mensions. If the reworking dimension is exceeded, the hy‐
draulic valve clearance compensation can no longer be
ss o
guaranteed and the cylinder head must be renewed.

cial p
f inform
mer
The max. permissible reworking dimension is calculated as fol‐

atio
m
lows:
o
n
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or
– Insert valve and press firmly against seat.

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Note
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Cop py
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If the valve is to be renewed as part of a repair, use a new valve rig ht
py by
for the calculation.
co Vo
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Prote AG.

Touareg 2003 ➤
– Measure distance -a- between end of valve stem and upper

edge of cylinder head.
– Calculate maximum permissible reworking dimension from
measured distance -a- and minimum dimension.
Minimum dimension:
Inlet valve 43.4 mm
Exhaust valve 43.2 mm
Measured distance minus minimum dimension = max. permissi‐
ble reworking dimension.
Example:
Measured distance 44.1 mm
- Minimum dimension 43.4 mm
= Max. permissible reworking dimension 0.7 mm
Reworking inlet valve seat.

a = ∅ 35.7 mm
b = 1.6 mm
45° = Valve seat angle
Note
The 30° lower valve seat chamfer is necessary to ensure that the
inlet channel flow characteristics are maintained.
AG. Volkswagen AG d
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Reworking exhaust valve seat. olksw not
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a = ∅ 31.4 mm
rrectness of i
b = 2.7 mm
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45° = Valve seat angle

nform
mercia
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com
tion in
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thi
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Prote AG.

Touareg 2003 ➤
2.3 Checking valve guides

♦ 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.
– Max. rock: 1.3 mm.
– Cylinder head must be renewed if rock exceeds wear limit.
2.4 Renewing valve stem seals

AG. Volkswagen AG d
⇒ “2.4.1 Removing”, page 54 lksw
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⇒ “2.4.2 Installing”, page 55 rised ara
nte
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ility
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es, in part or in w
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rrectness of i
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orm
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Cop py
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rig ht
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co Vo
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53
Prote AG.
2. Repairing valve gear
Touareg 2003 ➤

equipment required
♦ Valve assembly device
-2036-
♦ Puller -3047A-
♦ Fitting tool -3129-
♦ Valve lever -VW 541/1A-
♦ Thrust piece -VW 541/5-
AG. Volkswagen AG d
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spec
es, in part or in w
t to the co
rrectness of i
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nform
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at
om
ion
c
in t
or
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ate
do
priv
cum
for
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t.
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Cop py
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rig ht
by
2.4.1 Removing
copy Vo
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cted agen
Prote AG.
– Remove camshaft ⇒ page 55 .
– Remove bucket tappets and place them with the contact sur‐
face downwards. When doing this, ensure that the tappets are
not interchanged.
– Set piston of respective cylinder to top dead centre (TDC).
– Fit valve assembly tool -2036- and adjust mountings to height
of studs.
– Remove valve springs using valve lever -VW 541/1A- and
press tool - VW 541/5- .
Note
The valves are supported by the piston crown.

Touareg 2003 ➤
– Pull off valve stem seals using tool 3047A.
2.4.2 Installing
– Place the plastic sleeve -A- supplied on the respective valve
stem. This will prevent the new valve stem seal -B- being
damaged.
– Place new valve stem seal in fitting tool -3129- .
– Oil valve stem seal sealing lip and press carefully onto the
valve guide.
2.5 Removing and installing camshaft

AG. Volkswagen n AG do
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⇒ “2.5.1 Removing”, page
y V 55
olks ot g
ua
b
ed ran
⇒ “2.5.2 Installing”,
tho
rispage 56 tee
or
au ac
Special tools and
ss workshop equipment required
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un
pt

an
d
itte
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rm

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ility
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hole
spec
Note
es, in part or in w
t to the co
The removal and installation of the camshaft can only be under‐

taken when the engine is removed due to the cramped conditions.
rrectness of i
l purpos
2.5.1 Removing
– Remove charge air pipes between charge air cooler and tur‐
nform
ercia
bocharger and between charge air cooler and intake connect‐

m
ing flange.
a
com
tion in

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thi
s
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fo

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ng
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Cop py
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by
– Remove camshaft gear wheel ⇒ page 37 . Prote
cted AG.
agen
– Remove rocker arm shafts.

Touareg 2003 ➤
– Loosen bearing caps from outer to inner, loosen bolts of last

two bearing caps alternately and diagonally.
2.5.2 Installing
Note
♦ Ensure that no valve is pressed against a piston during instal‐

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

– Tighten inner 2 bearing caps alternately and diagonally to 8
Nm + turn (90°) further (renew).
– Install remaining bearing caps and also tighten to 8 Nm + turn
(90°) further (renew).
Note
Seal parting surfaces of outer bearing caps with sealant according

to ⇒ Electronic parts catalogue (ETKA) ⇒ page 50 .
– Install rocker arm shafts and tighten securing bolts, first the
inner and then the outer, diagonally and evenly by hand. Then
tighten, in same sequence, to 20 Nm + turn 90° further (re‐
new). wage
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Vol t gu
– Install camshaft drive gear wheel
ed
by ⇒ page 37 . ara
is nte
or eo
– Install tandem pump ⇒aupage
th 107 . ra
ss c
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e
nl
pt

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an
itte
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erm
– Install charge air pipes between charge air cooler and turbo‐
ab
ility
charger and between charge air cooler and intake connecting

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flange.
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hole

spec
es, in part or in w

t to the co
Note
rrectness of i
l purpos
When new bucket tappets have been installed the engine must
not be started for about 30 minutes. Hydraulic compensation el‐
ements must settle (otherwise valves will strike pistons).
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
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co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
17 – Lubrication
1 Engine oil
Note
The oil level must not be above the max. mark! Risk of catalytic
converter damage! Markings ⇒ page 57 .
Engine oil specification ⇒ Maintenance ; Booklet 17.1

⇒ “1.1 Oil capacities”, page 57
⇒ “1.2 Checking engine oil level”, page 57 .
1.1 Oil capacities

With oil filter, 8.9 l
Without oil filter 8.5 l
1.2 Checking engine oil level

Markings on oil dipstick
1 - Max. mark
2 - min. mark
a - Area above hatched field up to max. mark: Do not top up with
engine oil! agen
AG. Volkswagen AG d
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b - Oil level within hatched field: Can be toppedd b up with engine
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c - Area from min. mark up to hatchedss afield: Must be topped up, c
max. 0.5 l of engine oil!
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Prote AG.
1. Engine oil 57
Touareg 2003 ➤
AG. Volkswagen AG d
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2 Parts of lubrication system
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⇒ “2.1 Assembly
aut overview - oil pump, sump ”, page 58 ra
c
ss
⇒ “2.2 Assembly overview - oil filter housing ”, page 59
ce
le
un
pt
an
d
itte
⇒ “2.3 Removing and installing oil sump”, page 62
y li
erm
ab
⇒ “2.4 Checking oil pressure and oil pressure switch”,
ility
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page 64
wit
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ole,
2.1 Assembly overview - oil pump, sump
spec
t to the co
Part II: Dismantling oil filter housing ⇒ page 59
1 - 20 Nm
rrectne
❑ The oil level must not be
above the max. mark!
ss o
cial p
❑ Markings ⇒ page 57 .
f inform
mer
2 - Oil dipstick
atio
m
3 - Guide tube
o
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c
i
or
n thi
e
4 - Cap
t
sd
iva
o
pr
c
5 - Seal
um
r
fo
en
ng
t.
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Cop py
t.
6 - Rubber grommet
rig
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pyri by
Vo
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cted agen
Prote AG.
7 - Oil filler tube
8 - 10 Nm
9 - Seal
10 - Oil spray jet
❑ For piston cooling.
11 - 25 Nm
❑ Insert without sealant.
12 - Dowel sleeves
13 - Oil pump
that both dowel sleeves
for centring oil pump on
cylinder block are fitted.
14 - Gasket
❑ Renew.
15 - Suction line
❑ Clean strainer if soiled.
16 - Oil sump
❑ Clean sealing surface before fitting.
❑ Install with sealant according to ⇒ Electronic parts catalogue (ETKA) ⇒ page 62 .
17 - 15 Nm
18 - Oil drain plug, 30 Nm
❑ Renew.
19 - Seal
❑ Renew.
58 Rep. gr.17 - Lubrication

Touareg 2003 ➤
20 - Oil level and oil temperature sender -G266-

❑ Checking ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.
21 - 15 Nm
22 - Oil filter housing
❑ With engine oil cooler.
❑ Dismantling and assembling ⇒ page 59 .
23 - 20 Nm
24 - Gasket
❑ Renew.
AG. Volkswagen AG d
❑ Note installation position. lksw
agen oes
not
Vo gu
by
25 - Baffle plate rised ara
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ho eo
26 - O-ring aut ra
ss c
❑ Renew.
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ility
2.2 Assembly overview - oil filter housing
ot
wit
, is n
h re
hole
spec
1 - Engine oil cooler
es, in part or in w
t to the co
❑ Checking for leaks
⇒ page 82 .
❑ To remove, the air con‐
rrectness of i
ditioner compressor
must be removed ⇒
l purpos
Rep. gr. 87 .
2 - 10 Nm
nform
ercia
3 - Coolant hose
m
a
com
tion in
4 - Bracket
r
te o
thi
5 - 10 Nm
s
iva
do
r
rp
cum
6 - Screw cap, 25 Nm
fo
en
ng
t.
yi Co
7 - Seal t. Cop py
rig
gh
❑ Renew.
ht
pyri by
Vo
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by c lksw
8 - Oil filter
cted agen
Prote AG.
9 - O-ring
❑ Renew.
10 - 0.9 bar oil pressure switch
-F1- , 25 Nm
❑ If seal is leaking, nip
open and renew.
11 - 20 Nm
12 - Housing
13 - Gasket
❑ Renew.
❑ Note installation posi‐
tion.
14 - Gasket
❑ Renew.
2. Parts of lubrication system 59

Touareg 2003 ➤
. Volkswagen AG
5-cylinder dieselkengine
swa
gen A-GEdition 09.2012 does
n
ol ot g
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2.2.1 Removing and installing oil filter housing
e
ris tee
tho or
au ac
ss
ce
le
un
pt
an
d
equipment required
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erm
ab
♦ Refractometer -T10007-
ility
ot p
wit
is n
♦ Hose clips up to 25 mm Ø
h re
ole,
-3094-
spec
♦ Cooling system tester -
t to the co
V.A.G 1274-
♦ Adapter for cooling system
rrectne
tester -V.A.G 1274/8-
ss
5024 A-
o
cial p
f in
form
mer
drip tray -VAS 6208-
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Disconnecting and reconnecting battery .
Note
If oil filter is to be exchanged during repair, open oil filter cover

now to ventilate oil filter housing. This prevents large amounts of
engine oil to run out when removing housing.
– Remove noise insulation ⇒ General body repairs, exterior;

Rep. gr. 50 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Do not reconnect coolant hose.
– Open thermostat housing. Renew gasket before installing
Hose and thermostat housing need to remain open. Cooling sys‐
tem will therefore not subsequently be damaged when letting
compressed air in.

Touareg 2003 ➤
AG. Volkswagen AG d
agen oes
lksw not
Collect escaping coolant with drip tray -V.A.G 1306- or dripbytray
Vo - gu
ara
VAS 6208- . rised
nte
ho eo
ut
– Remove air intake hose to intake air connection ss a ra
c
⇒ page 122 .
ce
le
un
pt
an
d
– Clean vicinity of oil dipstick guide tube on crankcase to prevent
itte
y li
engine oil contamination.
rm
ab
pe
ility
– Release dipstick guide tube from oil filter housing and crank‐
ot
wit
, is n
case.
h re
hole
spec
Later you will remove dipstick guide tube together with air condi‐
es, in part or in w
tioner compressor.
t to the co
– Remove engine wiring harness bracket from beneath intake
manifold -1- (10 Nm).
rrectness of i
All cable ties which are opened or cut open when engine cable
l purpos
bracket is removed must be replaced in the same position when

engine is installed.
nform
ercia
All connectors which are separated during removal of engine ca‐

ble bracket must be reconnected in the original position when
m
a
installing.
com
tion in
r
te o
Unscrew air conditioner compressor from its console ⇒ Rep. gr.
thi
s
87 .
iva
do
r
rp
cum
Do not open refrigerant circuit. Lay air conditioner compressor to
fo
en
ng
side.
t.
yi Co
Cop py
. rig
– Remove dipstick guide tube.
ht ht
rig by
copy Vo
lksw
– Seal hole.
by
cted agen
Prote AG.
– Remove coolant hose ⇒ Item 3 (page 59) from oil filter housing
and clamp it off using hose clamps, up to Ø 25 mm -3094- .
WARNING
To avoid injury from coolant, wear eye protection.
– Carefully blow coolant residues around coolant connection off

oil filter housing using compressed air and seal with a cloth.
Collect engine oil leaking out of oil filter housing with a cloth, if
necessary.
– Unscrew oil filter housing and disconnect connector for oil
pressure switch. Remove oil filter housing.
Install in reverse order.

Touareg 2003 ➤
lkswage09.2012
5-cylinder diesel engine - Edition es n
o
V o t gu
by ara
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– Renew housing seal. thor is
eo
u ra
– sa
Replenish coolant ⇒ spage 72 . c
ce
le
un
pt
– Check engine oil level, renew if mixed with coolant
an
d
itte
⇒ page 57 .
y li
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ab
pe
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
tion in
r
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thi
2.3 Removing and installing oil sump
s
iva
do
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rp
cum
fo
en
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t.
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op
⇒ “2.3.2 Installing”, page 63 C py
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♦ Hand drill with plastic brush
Prote AG.

♦ Flat scraper
2.3.1 Removing
– Remove noise insulation -A- on engine side.

Touareg 2003 ➤
– Fit lifting tackle -2024A- on cylinder block as shown.
– Fit support bracket -10 - 222 A- .
– Observe mounting points on longitudinal members.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
h
aut ra
ss c
ce
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un
pt
– Remove assembly mounting nut/bolt -A- on both sides of en‐

an
d
itte
gine.
y li
rm
ab
pe
ility

ot
wit
Rep. gr. 50 ; Noise insulation; Assembly overview - noise in‐

, is n
h re
sulation .
hole
spec
– Remove subframe ⇒ Running gear, axles, steering; Rep. gr.

es, in part or in w
t to the co
40 ; Fixing subframe in position .

– Unbolt coolant pipe from sump.
rrectness of i
– Pull connector off oil level and oil temperature sender -G266- .
l purpos

– Drain engine oil.
nform
ercia
– Remove sump.
m
a
com
tio
– Loosen sump with light blows of a rubber headed hammer if

n in
r
necessary.
te o
thi
s
iva
do
r
rp
2.3.2 Installing
um
fo
en
ng
t.
yi Co
op
– Remove sealant residue from cylinder block with a flat scraper.
C py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted
63
agen
Prote AG.
2. Parts of lubrication system
Touareg 2003 ➤
swage es n
– Remove sealant residuebon y V sump, using electric drill with plas‐
olk ot g
ua
tic brush attachmentri(wear
se
d eye protection). ran
tee
tho
or
– Clean sealing surfaces.
ss
au
They must be free of oil and grease. ac
ce
e
nl
pt
du
an
itte
Note
y li
erm
ab
ility
ot p
♦ Observe expiry date of sealing compound.
wit
, is n
h re
♦ The sump must be installed within 5 minutes of applying sili‐
hole
spec
cone sealing compound.
es, in part or in w
t to the co
– Cut off tube nozzle at forward marking (∅ of nozzle approx. 3
rrectness of i
mm).
l purpos
– Apply silicone sealing compound, as shown, to clean sealing

surface on sump. Sealant bead must be:
nform
ercia
♦ 2 ... 3 mm thick.
m
at
♦ Run bead along inner side of bolt holes -arrows-.
om
ion
c
in t
or
his
ate
Note
do
priv
cum
for
en
g
The sealant bead must not be thicker, otherwise excess sealing

n
t.
yi Co
op
compound will enter the oil sump and may block the oil suction C py
t. rig
line strainer.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Apply silicone sealing compound bead as shown to the clean
sealing surface of the sump.
– Install sump immediately and tighten all sump bolts lightly.
Note
The sump must be flush with the cylinder block and the control
housing cover.
– Tighten oil sump bolts to 15 Nm.

– Tighten bolts securing sump to gearbox to 45 Nm.
Note
Allow sealing compound to dry for approx. 30 minutes after in‐

stalling sump. Only then fill with engine oil.
Further assembly is basically the reverse of the dismantling se‐

quence.
2.4 Checking oil pressure and oil pressure switch

Touareg 2003 ➤

equipment required
♦ Oil pressure tester -
V.A.G 1342-
♦ Voltage tester -
V.A.G 1527 B-
♦ Auxiliary measuring set -
V.A.G 1594 A-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Note
l purpos
Functional check and repair of the optical and acoustic oil pres‐
nform
ercia
sure warning: ⇒ Current flow diagrams, Electrical fault finding and

Fitting locations
m
at
om
ion
c
in t
Test prerequisites
or
his
ate
• Engine oil temperature min. 80 °C.

do
priv
cum
or
• Engine oil level OK.

f
en
ng
t.
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op
Test procedure
C py
t. rig
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– Bring lock carrier into service position: ⇒ General body re‐
op Vo
by c lksw
pairs, exterior; Rep. gr. 50 ; Lock carrier; service position .
cted agen
Prote AG.
– Remove air conditioner compressor: ⇒ Heating, air condition‐

ing; Rep. gr. 87 ; Air conditioner compressor; Removing and
installing air conditioner compressor from and to bracket
– Suspend air conditioner compressor so that lines and hoses
are not stretched, kinked or bent. Nor must they enter the ra‐
diator fan.

Touareg 2003 ➤
– Remove oil pressure switch -F1- and screw into tester.

– Screw tester into oil filter housing in place of oil pressure
switch.
– Connect brown wire of tester to earth (-).
– Connect voltage tester -V.A.G 1527 B- to battery positive (+)
and oil pressure switch using cable from auxiliary measuring
set -V.A.G 1594/C- . LED must not light up.
– Install air conditioner compressor: ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor; Removing and in‐
stalling air conditioner compressor from and to bracket .
– Start engine and increase speed slowly. At 0.75 ... 1.05 bar,
the LED must light up; otherwise renew oil pressure switch.
– Increase engine speed further. At 2000 rpm and an oil tem‐
perature of 80°C, the oil pressure should be at least 2.0 bar.
At higher engine speed, oil pressure must not exceed 7.0 bar.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
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 ➤
19 – Cooling
AG. Volkswagen AG d
agen oes
1 Removing and installing parts of cool‐ d by Volksw not
gu
ara
ing system uthorise nte
eo
ra
s a c
s
ce
e
WARNING
nl
pt
du
an
itte
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erm
ab
ility
ment, pay attention to the following due to the cramped condi‐ ot p
wit
tions:
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Fuel lines
♦ Hydraulic lines
rrectness of i
l purpos
nform
ercia
♦ and vacuum lines

m
♦ must be routed in their original positions.
at
om
ion
c
♦ Ensure that there is sufficient clearance to all moving or
in t
or
his
e
hot components.
at
do
priv
c
♦
um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
Note
by lksw
cted agen
Prote AG.
♦ When the engine is warm, the cooling system is under pres‐

sure. If necessary, release pressure before beginning repair
work.
♦ Hoses are secured with spring-type clips. In case of repair,
only use spring-type clips.
♦ Spring-type clip pliers -VAS 5024- are recommended for in‐
stallation of spring-type clips.
♦ When installing coolant hoses, route stress-free so that they
do not come into contact with other components (observe
markings on coolant connection and hose).
Test for leaks in cooling system using cooling system tester -

V.A.G 1274- and adapters -V.A.G 1274/8- and -V.A.G 1274/9- .
1. Removing and installing parts of cooling system 67

Touareg 2003 ➤
⇒ “1.1 Parts of cooling system, body side”, page 68 .

⇒ “1.2 Assembly overview - radiator fan ”, page 69 .
⇒ “1.3 Removing and installing fan support”, page 69
⇒ “1.4 Parts of cooling system, engine side”, page 70 .
⇒ “1.5 Coolant hose schematic diagram”, page 72 .
⇒ “1.6 Draining and filling coolant”, page 72 .
⇒ “1.7 Removing and installing radiator”, page 75 .
⇒ “1.8 Removing and installing coolant pump”, page 77 . n AG. Volkswagen AG do
lkswage es n
o ot g
⇒ “1.9 Checking oil cooler for leaks”, page 82 d byV ua
ran
ir se tee
o
1.1 Parts of cooling system, body side auth or
ac
ss
ce
le
un
pt
an
Note d
itte
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ab
pe
ility
Coolant hose schematic diagram ⇒ page 72 .
ot
wit
, is n
h re
hole
spec
es, in part or in w
1 - Radiator/cooler
t to the co
⇒ page 75
rrectness of i
❑ After renewing, renew
entire coolant.
l purpos
❑ Coolant hose schematic

diagram ⇒ page 72 .
nform
ercia
2 - Retaining clip
m
a
❑ Check for secure seat‐
com
tion in
ing.
r
te o
thi
3 - Condenser
s
iva
do
r
rp
cum
4 - Gearbox oil cooler
fo
en
ng
t.
yi
❑ For gear oil
Co
Cop py
t. rig
❑ Only vehicles with an yri
gh by
ht
automatic gearbox. cop Vo
by lksw
cted agen
Prote
5 - Oil cooler
AG.
❑ For power-assisted
steering
6 - Lock carrier
7 - 10 Nm
8 - Rubber bush
❑ For lock carrier
9 - Rubber bush
❑ For bottom of radiator
68 Rep. gr.19 - Cooling

Touareg 2003 ➤
1.2 Assembly overview - radiator fan
1 - Radiator fan control unit -

J293-
AG. Volkswagen AG d
agen oes
2 - Radiator fan -V7- olksw not
byV gu
ara
ed
3 - Fan support horis nte
eo
ut ra
❑ Removing and installing ss a c
⇒ page 69
ce
le
un
pt
an
d
4 - 10 Nm
itte
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rm
ab
5 - Charge air pipe
pe
ility
ot
wit
6 - Radiator fan 2 -V177- , is n
h re
hole
spec
7 - Radiator fan control unit -
es, in part or in w
J671-
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.
1.3 Removing and installing fan support

Removing
– Pull off upper coolant hose on radiator.
– 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 charge air pipe from fan support.
– Detach the connectors of the two fans.

Touareg 2003 ➤
– Release securing devices -arrows- and remove fans with fan

support.
Installing
note the following:
– Fan support must engage in its intended fastenings.
– Install charge air pipe and tighten to 10 Nm.
– Fill coolant system with coolant ⇒ page 72 . n AG. Volkswagen AG doe
wage ks s no
Vol t gu
d by ara
e nte
ris
utho eo
ra
a
1.4 Parts of cooling system, engine side ss c
ce
le
un
pt
an
d
itte
y li
1 - 10 Nm
erm
ab
ility
ot p
2 - Coolant pipe
wit
is n
h re
ole,
spec
t to the co
3 - Seal
❑ Renew.
rrectne
4 - Seal
❑ Renew.
ss
5 - Connection
o
cial p
f in
form
mer
atio
om
6 - 10 Nm n
c
i
or
n thi
e
7 - Gasket
t
sd
iva
o
r
❑ Renew.
p
cum
r
fo
en
ng

t.
yi Co
tion. Cop py
t. rig
gh ht
yri
8 - Thermostat
p by
co Vo
by lksw
cted
agen
Prote AG.
tion.
❑ Checking: heat thermo‐
stat in water.
❑ Opening begins at ap‐
prox. 87 °C.
❑ Ends at approx. 102 °C.
❑ Opening stroke at least
8 mm.
9 - Thermostat housing
10 - Connecting hose
11 - Seal
❑ Renew.
12 - Coolant drain plug, 20 Nm
❑ Remove to remove coolant pump.
❑ On vehicles with particulate filter the front exhaust pipe must be removed with particulate filter
⇒ page 146 .

Touareg 2003 ➤
13 - Coolant pump
14 - 20 Nm
15 - Cover AG. Volkswagen AG d
agen oes
ksw
❑ For coolant pump. by
Vol not
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ara
ed
❑ Renew. horis nte
eo
ut
❑ Lightly coat gasket with oil when installing.
ss a ra
c
ce
e
16 - 84 Nm
nl
pt
du
an
itte
y li
17 - Gear wheel
erm
ab
ility
❑ For coolant pump.
ot p
wit
, is n
❑ Check for damage.
h re
hole
spec
es, in part or in w
18 - 20 Nm + 90° further
t to the co
❑ Renew.
19 - Exhaust gas recirculation cooler
rrectness of i
❑ Vehicles with automatic gearbox and exhaust gas recirculation changeover valve.
l purpos

❑ Coolant hose schematic diagram ⇒ page 72 .
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
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by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
1.5 Coolant hose schematic diagram n AG. Volkswagen AG do

lkswage es n
o ot g
byV ua
d ran
1 - Expansion tank ir se tee
tho
u or
❑ Renew seal if damaged. ss
a ac
❑ Check cooling system
ce
e
nl
pt
du
for leaks with cooling
an
itte
y li
system tester -V.A.G
erm
ab
1274- and adapter -
ility
ot p
V.A.G 1274/8- .
wit
, is n
h re
❑ Check cap using cooling
hole
system tester -V.A.G
spec
es, in part or in w
1274- and adapter -
t to the co
V.A.G 1274/9- .
❑ Test pressure 1.4 ... 1.6
bar.
rrectness of i
2 - Cylinder head/cylinder
l purpos
block
3 - Engine oil cooler
nform
ercia
4 - Heat exchanger for heater

m
at
om
unit
ion
c
in t
or
5 - Fuel cooler
his
ate
do
riv
6 - Change-over valve
p
cum
for
❑ For coolant circuits
en
ng
t.
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op py
7 - Radiator/cooler t. C rig
gh ht
pyri by
8 - Fuel cooling pump -V166-
co Vo
by lksw
cted agen
Prote AG.
9 - Radiator/cooler
❑ For exhaust gas recircu‐
lation.
10 - Change-over flap
lation.
❑ Only vehicles with an
automatic gearbox.
The connection diagram for vehicles with an auxiliary heater/pre‐

heater is located in ⇒ Rep. gr. 82 ; Auxiliary heater/preheater .
The coolant run-on pump ( circulation pump -V55- ) is located in
⇒ Rep. gr. 80 ; Heater .
1.6 Draining and filling coolant

⇒ “1.6.1 Draining”, page 73
⇒ “1.6.2 Filling”, page 74
⇒ “1.6.3 Procedure”, page 75

Touareg 2003 ➤

equipment required
♦ Drip tray -V.A.G 1306-
♦ Torque wrench (5 ... 50
Nm) -V.A.G 1331-
5024 A-
♦ Cooling system charge unit
-VAS 6096-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
1.6.1 Draining
orm
m
atio
m
– Open filler cap on coolant expansion tank.

o
n in
or c
thi
te
sd
iva
WARNING
o
r
rp
cu
o
m
f
en
ng
Hot steam may escape when expansion tank is opened. Place

t.
yi Co
op
cloth over cap and open with caution.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
AG.

Touareg 2003 ➤
– To drain coolant, pull coolant hose -arrow- off fuel cooling

pump -V166- .
Note
Follow disposal regulations for coolant!
1.6.2 Filling
Note
The amount of water used in the coolant mixture has a great in‐
fluence on its effectiveness. Because the water quality differs
from country to country and even region to region, Volkswagen
has decided to define the quality of the water to be used in the
coolant system. Distilled water fulfils all requirements. It is there‐
fore recommended that distilled water be mixed with the coolant
whenever an older model's coolant AG. Vis
olkreplenished
swagen AG or replaced. For
newer models (model oyear agen
ksw 2010 ►) the use of distilled
not water is
does
l
absolutely essential
ed
byand compulsory.
V gu
ara
ris nte
ho eo
aut ra
ss c
Caution
ce
le
un
pt
an
d
itte
Only distilled water may be used for mixing with coolant addi‐
y li
rm
ab
tives. The use of distilled water ensures optimum protection

pe
ility
against corrosion.
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.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
Note
♦ Use only coolant additive G 12 plus-plus in accordance with

G. Volkswage
TL VW 774 G. wage
nA n AG d
oes
Volks not
g
y
♦ Coolant additives marked ed “in
b
accordance with TL VW 774 G”uarant
ris
prevent lime accretion,
ut
h frost damage and corrosion. Moreover,
o ee
or
the boiling temperature
ss
a is raised. Therefore, the cooling sys‐ ac
tem must be filled all year round with coolant additive.
ce
e
nl
pt
du
an
♦ Because of its higher boiling point, the coolant improves en‐
itte
y li
gine reliability under heavy loads, particularly in countries with
erm
ab
tropical climates.
ility
ot p
wit
, is n
♦ The frost protection must be guaranteed to approx. -25 °C. (In
h re
countries with an arctic climate, down to approx. -35 °C).
hole
spec
es, in part or in w
♦ The coolant concentration must not be reduced by adding wa‐
t to the co
ter even in warmer seasons and in warmer countries. The
coolant additive concentration must be at least 40%.
rrectness of i
♦ If a stronger anti-freeze mixture is necessary due to harsher
weather conditions, the coolant additive content can be in‐
l purpos
creased. However, this is only permitted to 60% (antifreeze

protection to about -40°C). Since the frost protection will oth‐
erwise be reduced again and also the cooling effect will be
nf
ercia
o
worsened.
rm
m
atio
m
♦ The Refractometer -T10007- is recommended for determining

o
n in
c
the current anti-freeze density.

or
thi
te
sd
a
♦ Do not reuse old coolant.

iv
o
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rp
cu
o
m
f
en
ng
Recommended mixture ratios:

t.
yi Co
Cop py
t. rig
Frost protection Amount of anti- G 12 Water
gh ht
pyri by
to freeze plus-
co Vo
by lksw
cted agen
Prote
plus 1)
AG.
-25 °C 40 % 4.0 l 5.0 l

-35 °C 50 % 4.5 l 4.5 l
1) The quantity of coolant can vary depending upon vehicle equipment.
1.6.3 Procedure
– Push lower coolant hose onto radiator union and secure.
– Screw adapter -V.A.G 1274/8- onto expansion tank.
– Fill coolant circuit with cooling system charge unit -VAS 6096- .
⇒ Operating instructions for cooling system charge unit
VAS 6096 .
1.7 Removing and installing radiator


Touareg 2003 ➤

equipment required
♦ Torque wrench -
V.A.G 1331- (5 ... 50 Nm)
♦ Spring-type clip pliers -
VAS 5024-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
e
1.7.1 Removing
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Pull all coolant hoses off radiator.

wit
, is n
h re
– Remove front bumper ⇒ General body repairs, exterior; Rep.

hole
spec

es, in part or in w
t to the co

sition .
rrectness of i
– Remove fans together with fan support ⇒ page 69 .

l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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

– Remove upper securing bolts for radiator and remove radiator
upwards.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
ho eo
1.7.2 Installing ut ra
s a c
s
ce
le

un
pt
an
d
note the following:

itte
y li
rm
ab
pe
ility
ot
wit
, is n
– Electrical connections and routing ⇒ Current flow diagrams,
h re
Electrical fault finding and Fitting locations.
hole
spec
es, in part or in w
– Bolt lock carrier in position ⇒ General body repairs, exterior;
t to the co
Rep. gr. 50 ; Body - front; Lock carrier service position.
– Install front bumper: ⇒ General body repairs, exterior; Rep.
rrectness of i
l purpos
– Check headlight adjustment and correct if necessary ⇒ Main‐

tenance ; Booklet 17.1 .
nform
ercia
1.8 Removing and installing coolant pump

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

Touareg 2003 ➤

equipment required
♦ Torque wrench -
V.A.G 1331- (5 ... 50 Nm)
♦ Spring-type clip pliers -
VAS 5024-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Puller -T10221A-
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
♦ Puller -T10222A-
♦ Special wrench -T10225-
♦ Puller hooks -10-221-
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
1.8.1 Removing
y li
erm
ab
ility
ot p
wit
, is n
WARNING
h re
hole
spec
Risk of scalding.
es, in part or in w
t to the co
The cooling system is under pressure, when the engine is

warm the coolant temperature can be above 100 °C.
rrectness of i
Before carrying out repairs, release pressure and allow tem‐

perature to drop as necessary.
l purpos
nf
ercia
Vehicles with engine codes BAC and BLK

orm
m
atio
– Loosen exhaust pipe and starter catalytic converter from tur‐

om
bocharger and gearbox. It is not necessary to remove the

n in
or c
catalytic converter.
thi
te
sd
iva
Vehicles with engine codes BPD and BPE

o
r
rp
cu
o
m
f
en
ng
– Remove exhaust gas recirculation cooler ⇒ page 158 .

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
79
by lksw
cted agen
Prote 1. Removing and installing parts of cooling system
AG.
Touareg 2003 ➤
– Remove particulate filter ⇒ page 148 .

For all engine codes
– Remove coolant drain plugs ⇒ Item 12 (page 70) .
– Remove coolant pump cover ⇒ Item 15 (page 71) .
– Remove noise insulation -A- from No. 1 cylinder end of engine
block.
– Remove bolts -arrows- and remove bracket for noise insula‐

tion.
– Lever sealing cover out of sealing flange on No. 1 cylinder end
of block using lever -10-221- .
Note
Renew sealing cover after removing.
– Bolt special wrench -T10225- onto crankshaft. To do this, turn

screw into crankshaft through centre of tool and tighten to 20 en AG. Volkswagen AG
Nm. olks
wag does
no
yV t gu
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rise nte
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au ra
Note ss c
ce
le
un
pt
an
d
♦ It is only possible to bolt special wrench -T10225- onto crank‐

itte
y li
shaft in one position.

rm
ab
pe
ility
♦ To remove the coolant pump, the engine must not be at TDC.

ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Counterhold special wrench -T10225- using suitable tool, and

l purpos
loosen coolant pump securing nut -1-.

nform
ercia
Note
m
a
com
tion in
For engines manufactured in the first batch, puller -T10221- can‐

r
te o
thi
not be fitted due to lack of clearance behind coolant pump gear.

s
iva
In this case release coolant pump gear by tapping lightly on its

do
r
rp
sides with a hammer and copper drift.

um
fo
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
y V gu
d b ara
orise nte
eo
Touareg 2003 ➤
h
aut
5-cylinder diesel engine r a- Edition 09.2012
c
ss
ce
le
un
– Fit puller -T10221A- as shown and turn hexagon clockwise
pt
an
d
until the gear wheel can be removed from the pump.
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
– Unscrew coolant pump securing bolts -arrows-.
nform
ercia
– Prior to fitting, screw puller -T10222A- in and out to adjust, until

m
a
com
ti
spindle hexagon is flush with tool surface shown in grey.
on 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.
Adjusting T 10222 A
– Fit adjusted puller -T10222A- , turn its bolt clockwise until the
puller first contacts the cylinder block as shown and subse‐
quently pulls the coolant pump out.
1.8.2 Installing
note the following:
– Wet new O-rings with coolant; do not use any other lubricants.

Touareg 2003 ➤ . Volkswagen AG
gen AG does
5-cylinder diesel engine - Edition
ol swa
k09.2012 not
V g y ua
db ran
rise tee
tho or
au ac
Note ss
ce
le
un
pt
an
d
Ensure the seals on the coolant pump are correctly seated.
itte
y li
erm
ab
ility
ot p
– Fit coolant pump.
wit
is n
h re
– Tighten new coolant pump securing bolts.
ole,
spec
Torque settings ⇒ Item 18 (page 71)
t to the co
– Fit gear wheel and tighten securing nut.
rrectnes
Note
s o
cial p
f inform
♦ Tighten securing nut from underside of vehicle using a uni‐
mer
versal joint and extension, if necessary.
atio
om
n
♦ The angle of the universal joint must not exceed max. 20°.
c
i
or
n thi
te
sd
va
– Install drain plugs with new seal and tighten.

i
o
pr
cum
r
fo
en
ng

t.
yi Co
op py
– Lightly coat sealing lip of coolant pump cover with oil.
t. C rig
gh ht
pyri by
Vo
– Install coolant pump cover .
co lksw
by
cted agen
Prote AG.
Further assembly is carried out in the reverse order of removal.
1.9 Checking oil cooler for leaks

Touareg 2003 ➤
AG. Volkswagen AG d
Special tools and workshop agen oes
olksw not
V
equipment required d by gu
ara
rise nte
o
♦ Refractometer -T10007- auth eo
ra
ss c
♦ Hose clips up to 25 mm Ø
ce
le
un
pt
-3094-
an
d
itte
y li
♦ Cooling system tester -
rm
ab
pe
ility
V.A.G 1274-
ot
wit
, is n
♦ Adapter for cooling system
h re
hole
tester -V.A.G 1274/8-
spec
es, in part or in w
t to the co
5024 A-
rrectness of i
drip tray -VAS 6208- 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 ➤

Not illustrated
♦ Expansion tank -1K0 121 407 A- or expansion tank -1J0 121
407 B-
♦ Plug -191 211 343-
♦ Cap -1J0 121 324-
♦ Coolant hose -251 265 056-
Prerequisites:
• Engine cold
Test procedure
– Remove noise insulation. ⇒ General body repairs, exterior;
Rep. gr. 50 ; Body - front; Assembly overview - noise insula‐
tion .
– Drain coolant ⇒ page 72
AG. Volkswagen AG d
– Drain engine oil ⇒ page 57 . agen oes
olksw not
V gu
d by ara
– Loosen hose clips using spring-type
orise clip pliers -VAS 5024- . nte
h eo
ut ra
– Remove oil cooler with
ss a housing ⇒ page 59 c
ce
le
un
pt
an
d
itte
Note
y li
erm
ab
ility
ot p
♦ Collect escaping coolant with drip tray -V.A.G 1306- or drip

wit
is n
tray -VAS 6208- .

h re
ole,
♦ Collect leaking engine oil with a cleaning cloth, if necessary. spec

t to the co
Checking when removed

rrectne
– Clamp housing with old seal on a suitable, level clean surface.

– Secure sealing plug -2- to breather connection of expansion
ss
tank -1-.
o
cial p
f inform
– Secure coolant hose -3- to engine oil cooler and expansion

mer
tank.
atio
om
– Fill expansion tank up to “Max” marking.

c
i
or
n thi
te
– Attach cooling system tester -V.A.G 1274- with cooling system

sd
iva
o
r
tester adapter -V.A.G 1274/8- to expansion tank.

p
cum
r
fo
en
ng
– Use hand pump on tester to create a pressure of about 1.6 bar.

t.
yi Co
Cop py
t.
– Watch pressure drop on pressure gauge. A pressure drop
rig
gh ht
yri by
within 10 minutes is not permitted. op Vo
by c lksw
cted agen
Prote
If pressure drops:
AG.
– Renew engine oil cooler ⇒ page 59 .

note the following:
– Renew seal for housing.
– Check coolant level, replenish coolant if necessary
⇒ page 72 .
– Check engine oil level, if necessary replenish oil ⇒ page 57

Touareg 2003 ➤
20 – Fuel supply system

1 Removing and installing parts of fuel
supply system
Note
♦ Hose connections are secured with quick-release couplings,

spring-type or clamp-type clips.
♦ 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.
♦ Assembly tool -VAS 5024A- or pliers -V.A.G 1921- are rec‐
ommended for fitting spring-type clips. AG. Volkswagen AG d
agen oes
olksw not
yV gu
⇒ “1.1 Rules for cleanliness”, page 85 . ised b ara
nte
or eo
th
⇒ “1.2 Safety precautions when workingauon fuel supply system”, ra
c
s
page 86 . s
ce
le
un
pt
⇒ “1.3 Assembly overview - fuel tank with attachments (► model
an
d
itte
y li
year 08)”, page 86
rm
ab
pe
ility
⇒ “1.4 Assembly overview - fuel tank with attachments (model
ot
wit
year 08 ►) ”, page 88
, is n
h re
hole
⇒ “1.5 Assembly overview - fuel filter with fuel cooler”,
spec
page 90 .
es, in part or in w
t to the co
⇒ “1.6 Emptying fuel tank”, page 91
⇒ “1.7 Removing and installing fuel pump unit, fuel gauge sender
rrectness of i
and suction jet pumps (for vehicles ► model year 08)”,
page 95
l purpos
⇒ “1.8 Removing and installing fuel pump unit, fuel gauge sender
and suction jet pumps (for vehicles model year 08 ►)”,
nform
ercia
page 97
m
a
com
ti
⇒ “1.9 Removing and installing fuel tank with attached compo‐

on in
nents”, page 99
r
te o
thi
s
iva
⇒ “1.10 Checking fuel pumps”, page 102

do
r
rp
cum
fo
⇒ “1.11 Checking tandem pump”, page 104

en
ng
t.
yi Co
op
⇒ “1.12 Removing and installing tandem pump”, page 107
C py
ht. rig
rig ht
py by
⇒ “1.13 Assembly overview - accelerator mechanism”, co Vo
by lksw
page 109 .
cted agen
Prote AG.

When working on the fuel supply and injection system, pay careful
attention to the following “6 rules” for cleanliness:
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
lint-free cloths.
♦ Carefully cover opened components or seal if repairs cannot
be carried out immediately.
1. Removing and installing parts of fuel supply system 85

AG. Volkswagen AG d
Touareg 2003 ➤ agen oes
olksw not
V
5-cylinder diesel engine - Edition 09.2012 d by gu
ara
rise nte
tho eo
use parts that have not been stored in theirss apacking (e.g. in
u ra
c
tool boxes etc.).
ce
e
nl
pt
du
an
♦ When system is open: do not work with compressed air if this
itte
y li
can be avoided. Do not move vehicle unless absolutely nec‐
erm
ab
essary.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
fuel supply system
rrectness of i
l purpos
WARNING
nf
ercia
o
rm
m
atio
tions:
om
n in
c
or
thi
e

t
sd
iva
o
r
rp
cu
♦ Fuel lines
o
m
f
en
ng
t.
yi
♦ Hydraulic lines
Co
Cop py
t. rig
gh
ht
pyri by
Vo
co lksw
by
cted
agen
Prote AG.

hot components.
When removing and installing the fuel pump and fuel gauge send‐
er from a full or partly filled fuel tank the following must be
observed:
♦ Even before work commences, the extraction hose of an ac‐
tivated fume extraction system has to be placed in the vicinity
of the assembly opening of the fuel tank to extract any escap‐
ing fumes. If no exhaust gas extraction system is available, a
radial fan with a displacement greater than 15 m3/h can be
used providing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
1.3 Assembly overview - fuel tank with attachments (► model year 08)
86 Rep. gr.20 - Fuel supply system

Touareg 2003 ➤
1 - Fuel tank filler neck

2 - Fuel tank
❑ When removing, sup‐
port using engine and
gearbox jack -
V.A.G 1383 A- .
❑ Drain fuel tank using
fuel extractor -
VAS 5190- ⇒ page 91
⇒ page 99
3 - Flange
❑ Left side.
tion on fuel tank
⇒ page 88 .
4 - Locking ring, 145 Nm
❑ Remove and install us‐
ing wrench -T10202- .
ing.
5 - Fuel delivery unit
❑ Left side. AG. Volkswagen AG d
agen oes
ksw
6 - Fuel gauge sender 3 - by Vol not
gu
ara
G237- rise
d
nte
ho eo
❑ Left side. aut ra
c
ss
❑ Clipped into bottom of
ce
e
nl
tank.
pt
du
an
itte
y li
7 - Float for fuel gauge sender
erm
ab
3 -G237-
ility
ot p
wit
, is n
❑ On fuel delivery unit.
h re
hole
8 - Protective cover
spec
es, in part or in w
❑ For bottom of fuel tank.
t to the co
9 - Securing strap
rrectness of i
l purpos
10 - 20 Nm + 90° turn
nf
ercia
orm
❑ For top of fuel tank

m
atio
om
n in
12 - Suction-jet pump
or c
thi
e
❑ Left side.
t
sd
iva
o
r
rp
cu
❑ Clipped into bottom of tank.

o
m
f
en
ng
t.
yi Co
Cop py
❑ Right side.
t. rig
gh ht
pyri by
Vo
o
14 - Fuel delivery unit
c by lksw
cted agen
Prote AG.
❑ Right side.
15 - Fuel gauge sender -G-
❑ Right side.

Touareg 2003 ➤
16 - Flange
❑ Right side.
❑ Note installation position on fuel tank ⇒ page 88 .
Fitting position of sender flange on fuel tank

– Insert sender flange with marking in direction of travel
-arrow-.
1.4 Assembly overview - fuel tank with attachments (model year 08 ►)

AG. Volkswagen AG d
agen oes
1 - Fuel tank filler neck olksw not
y V gu
d b ara
2 - Fuel tank rise nte
tho eo
u ra
❑ When removing, sup‐ ss a c
port using engine and
ce
le
un
pt
gearbox jack -
an
d
itte
V.A.G 1383 A- .
y li
erm
ab
❑ Drain fuel tank using
ility
ot p
fuel extractor -
wit
is n
VAS 5190-
h re
ole,
spec
❑ Removing and instal‐
ling.
t to the co
3 - Flange
❑ Left side.
rrectne
tion on fuel tank
ss
⇒ page 89 .
o
cial p
f in
4 - Locking ring, 145 Nm

form
mer

atio
m
ing wrench -T10202- .

o
n
c
i
or

thi
te
sd
ing.
iva
o
pr
cum
r
5 - Fuel gauge sender 3 -

fo
en
ng
G237-
t.
yi Co
Cop py
❑ Left side.
t. rig
gh ht
yri by
❑ Clipped into bottom of cop Vo
by lksw
cted
tank.
agen
Prote AG.
❑ Clipped into bottom of
tank.
❑ For bottom of fuel tank.
8 - Securing strap

Touareg 2003 ➤
9 - 20 Nm + 90° turn
❑ Front left side
12 - Fuel delivery unit AG. Volkswagen AG d
agen
❑ Right side. Volksw
oes
not
gu
by ara
d
13 - Fuel gauge sender -G- orise nte
eo
th
❑ Right side. ss au ra
c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
15 - Flange
h re
ole,
❑ Right side.
spec
❑ Note installation position on fuel tank.
t to the co
Installation position of left sender flange (fuel tank)
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
1.5 Assembly overview - fuel filter with fuel cooler
1 - Securing clip
2 - Return line
❑ To fuel cooler
❑ Blue or with blue mark‐
ing.
❑ Union with marking -
RT-.
ing.
❑ To pull off, press release
button on connection.
3 - Supply
❑ From fuel tank.
❑ Black
❑ Union with marking -
VF-.
ing.
4 - 10 Nm
5 - Fuel cooler
6 - Coolant hose
❑ Coolant hose schematic AG. Volkswagen AG d
diagram ⇒ page 72 . agen oes
olksw not
byV gu
ara
7 - Return line rised
nte
ho eo
❑ To fuel tank. s aut ra
c
s
❑ Check for secure seat‐ ce
e
nl
pt
ing.
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
8 - Bracket
h re
hole
❑ For fuel filter.

spec
es, in part or in w
9 - Fuel filter
t to the co
❑ Observe change intervals.

rrectness of i
10 - Seal
l purpos
❑ Renew.
❑ If fitted.
nf
ercia
orm
11 - Water drainage connection, 5 Nm

m
atio
m
❑ If fitted.
o
n in
or c
❑ Unscrew to drain water and extract approx. 100 cm3 using diesel extractor -VAS 5226- .
thi
te
sd
iva
o
r
12 - Supply line
rp
cu
o
m
f
en
ng
❑ To tandem pump.
t.
yi Co
op py
❑ Union with marking -VM-. . C rig
ht ht
rig by
❑ Check for secure seating. copy Vo
by lksw
cted agen
❑ To pull off, press release button on connection. Prote AG.

Touareg 2003 ➤
13 - Return line
❑ From fuel rail.
❑ Union with marking -RF-.
❑ To pull off, press release button on connection.
1.6 Emptying fuel tank

⇒ “1.6.1 Emptying fuel tank when fuel pump is intact”,
page 94
♦ Fuel extractor -VAS 5190-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
♦ Wrench -T10202-
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
e
♦ Not illustrated:
t
sd
iva
o
r
rp
cu
♦ Assembly tool -T10118-

o
m
f
en
ng
t.
yi
Procedure
Co
Cop py
t. rig
gh
– Note safety precautions before beginning work ⇒ page 86 .
ht
pyri by
Vo
co lksw
by
cted
– Open fuel tank filler flap.
agen
Prote AG.

Touareg 2003 ➤ n AG. Volkswagen AG do
wage
5-cylinder diesel
Volksengine - Edition 09.2012es not g
y ua
db ran
rise tee
– Push suction thohose -arrow- of fuel extractor -VAS 5190- ap‐or
au 180 cm into fuel tank filler neck and
prox. 170ss… extract fuel.
ac
ce
le
un
pt
an
d
itte
Note
y li
rm
ab
pe
ility
ot
♦ When no more fuel is extracted, the fuel tank is emptied just
wit
, is n
enough for the sender flanges to be opened without danger.
h re
hole
The tank may be removed while containing remaining fuel.
spec
es, in part or in w
♦ If work must be performed on fuel pumps or fuel tank senders,
t to the co
proceed as follows:
rrectness of i
Vehicles up to week 47/06
l purpos
Vehicles from week 48/06 ⇒ page 92

– Fold rear bench seat forwards.
nform
ercia
– Cut carpet open from point -A- to point -B- in the pre-cut area
m
a
com
t
-arrows-.
ion in
r
te o
Right side of vehicle
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.
– Remove nuts -1- from cover. If necessary, unscrew backrest

mounting -2- or support mounting ⇒ General body repairs,
interior; Rep. gr. 72 ; Rear seats .
Left side of vehicle
– Remove bolts -1-.
– Then remove nuts -2-, to do this for one nut push mounting
bracket slightly upwards.
Vehicles from week 48/06
– Remove rear bench seat ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing bench seat /
individual seats .

AG. Volkswagen AG d
lksw
agen oes
not Touareg 2003 ➤
o
d by
V
gu
ara - Edition 09.2012
e nte
ris
tho eo
Continuation for all vehicles s au ra
c
s
ce
le
– Pull off connectors for fuel pump and fuel gauge sender -4-.
un
pt
an
d
itte
– Pull return line -1-, supply line -2- and, if necessary, the return
y li
rm
ab
line for auxiliary heater -3- off right sender flange.
pe
ility
ot
wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co
Release connection by pressing button on line coupling.
rrectness of i
l purpos
– Now remove locking ring from sender flange using wrench -

T10202- .
nform
ercia
– Carefully lever out sender flange and raise it slightly.

m
a
– Insert suction hose of fuel extractor -VAS 5190- as deeply as
com
tion in
possible into right or left side of fuel tank and extract fuel.
r
te o
thi
– For work on left side of fuel tank, proceed as described above.
s
iva
do
r
rp
cum
– When breather lines are pulled off, buttons of hose couplings
fo
en
g
sometimes cannot be pressed in. Use assembly tool -T10118-

n
t.
yi Co
op
for this. C py
t. rig
gh ht
yri by
For further work on inside of fuel tank, sender flanges may remain op Vo
by c lksw
removed. cted agen
Prote AG.
If fuel tank needed only to be emptied, install sender flanges

again.
– First check that sender flange seals are properly seated.
Note
Renew seals if the fuel has caused them to swell.
– Insert sender flange with locating tab in direction of travel

-arrow-.
– Tighten locking rings on left and right using wrench -T10202-
to 145 Nm.

Touareg 2003 ➤
Note
♦ Do not interchange supply and return lines (return line -1- blue,
supply line -2- black).
♦ Ensure that fuel hose connections are tight.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
1.6.1 Emptying fuel tank when fuel pump is
h
aut ra
ss c
intact
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
♦ Vehicle diagnosis tester
ot
wit
, is n
h re
hole
spec
♦ Adapter for fuel extraction -VAS 5190 /3 -
es, in part or in w
t to the co
WARNING
rrectness of i
Fuel supply line is pressurised. Wear eye protection and pro‐
tective clothing to avoid possible injury and skin contact. Before
l purpos
loosening hose connections, wrap a cloth around the connec‐

tion. Then release pressure by carefully pulling hose off con‐
nform
ercia
nection.
m
a
com
tion in
r
te o
thi
Note
s
iva
do
r
rp
cum
fo
Press in securing ring to release fuel lines. en

ng
t.
yi Co
Cop py
ht. rig
– Pull off supply line -1- and catch escaping fuel with a cloth. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
– Connect fuel extractor -VAS 5190- with adapter for fuel ex‐
tractor -VAS 5190 /3 - to fuel supply line.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
– Connect a diagnosis tester.
h re
hole
spec
es, in part or in w
t to the co
Note
The fuel pump is being activated when engine is not running.
rrectness of i
l purpos
– Switch on ignition.
– Remove filler cap from fuel tank filler neck.
nf
ercia
o
– Perform the function “Bleeding fuel system” in “guided func‐
rm
m
atio
tions”.
om
n in
c
If the fuel tank is emptied, »stop« the function to prevent the fuel
or
thi
e
pump from running »dry«.

t
sd
iva
o
r
rp
cu
– Operate shut-off tap on fuel extractor -VAS 5190- , until the
o
m
f
en
ng
fuel tank is emptied.

t.
yi Co
op py
Bleeding fuel system
. C rig
ht ht
rig by
opy Vo
2) Low-pressure section by c lksw
cted agen
Prote AG.
• Fuel tank filled.
– Connect a diagnosis tester.
– Perform the function “Bleeding fuel system” in “guided func‐
tions”.
1.7 Removing and installing fuel pump unit,

fuel gauge sender and suction jet pumps
(for vehicles ► model year 08)
♦ Wrench -T10202-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
Touareg 2003 ➤ rised
nte
o eo
aut - Edition 09.2012
h
ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Prerequisites
m
• Fuel tank must be emptied ⇒ page 91 , Emptying fuel tank.
at
om
ion
c
• Connectors and wires for left and right-hand sender flanges
in t
or
his
e
have been removed.

at
do
priv
c
• Locking rings for left and right sender flanges have been re‐
um
for
en
moved.
ng
t.
yi Co
op py
. C rig
ht ht
rig by
py Vo
Procedure
co lksw
by
cted agen
Prote AG.
– Pull off connectors -1- and -2- as well as hose couplings -3-,
-4- and -5- below right sender flange.
– Remove sender flange.
– Unclip black filler hose -arrow- from fuel pump unit housing on
left and right sides of fuel tank.

Touareg 2003 ➤
– Pull fuel supply line, to suction-jet pumps, off fuel delivery unit
-arrow- on left and right sides of fuel tank.
– Disconnect fuel supply and return lines between the two fuel
pump units on the left side of the fuel tank.
– Unscrew fuel delivery unit in bottom of fuel tank by turning ap‐
prox. 90° to left.
AG. Volkswagen AG d
agen oes
ksw
Note byV
ol not
gu
ara
ed
ris nte
o eo
The fuel pump housing is filled
aut
h
with fuel. Fuel may run out if hous‐ ra
ing is tipped or canted.
ss c
ce
e
nl
pt
du
an
– Now unclip fuel gauge senders on each side of fuel tank and
itte
y li
erm
pull them out.
ab
ility
ot p
– Now unclip suction-jet pumps from bottom on each side and
wit
, is n
remove with a slight turn.
h re
hole
spec
– Pull out hose ends through left and right sender openings.
es, in part or in w
t to the co
1.8 Removing and installing fuel pump unit,
fuel gauge sender and suction jet pumps
rrectness of i
(for vehicles model year 08 ►)
l purpos
nform
ercia
♦ Wrench -T10202-
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Prerequisites
• Fuel tank must be drained.
• Locking rings for left and right sender flanges have been re‐
moved.
• Connectors and wires for left and right-hand sender flanges
have been removed.

Touareg 2003 ➤
– Observe safety precautions before beginning work.

Procedure for right side.
– Pull off connectors -1- and -2- as well as hose connections
-3- and -4- below right sender flange.
– Unclip hose coupling (heater supply) -arrow- from fuel pump
unit.
– Remove sender flange.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unclip black filler hose connection -arrow- (from suction jet
rrectness of i
pumps) from fuel pump unit housing.
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
– Disconnect fuel supply line at fuel pump unit -arrow- (to suction
ht
pyri by
Vo
jet pumps on left side of fuel tank).
co lksw
by
cted agen
Prote AG.
Note
The fuel pump housing is filled with fuel. Fuel may run out if hous‐
ing is tipped or canted.
– Unscrew fuel delivery unit in bottom of fuel tank by turning ap‐

prox. 90° to left ⇒ Item 12 (page 89) .
3) Fuel pump unit remains in fuel tank to exchange fuel gauge sender.

n AG. Volkswagen AG do Touareg 2003 ➤
lkswage es n
byV
o
ot g
uara Edition 09.2012
-
ed nte
oris eo
– Now unclip fuel gauge sender on rightuthside -arrow- of fuel tank ra
a c
and remove upwards. ss
ce
le
un
pt
– Install in reverse order.
an
d
itte
y li
erm
ab
Procedure for left side.
ility
ot p
– Unclip and remove fuel gauge sender on left side of fuel tank.
wit
is n
h re
ole,
spec
t to the co
rrectne
– On left side of fuel tank, now unclip bracket for suction jet pump
ss
-arrow- ⇒ Item 6 (page 88) .
o
cial p
f in
Pull suction-jet pumps together with supply/filler hoses and fuel
form
mer
lines for suction-jet pumps out of left opening of fuel tank.
atio
om
– Install in reverse order.
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.
1.9 Removing and installing fuel tank with attached components

Touareg 2003 ➤

equipment required
♦ Wrench -T10202-
Nm) -V.A.G 1331-
Nm) -V.A.G 1332-
♦ Engine and gearbox jack -
V.A.G 1383/A-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Prerequisites
rrectne
Fuel tank must be empty ⇒ “1.6 Emptying fuel tank”, page 91 .
1.9.1 Removing
ss o
cial p
f i

nform
mer
– Observe rules for cleanliness ⇒ page 85 .

atio
om
– Remove Silencer with mountings.

c
i
or
n thi
te
– Remove rear propshaft ⇒ Transfer box and final drive; Rep.

sd
iva
o
r
gr. 39 ; Removing and installing propshaft .

p
cum
r
fo
en
ng
– Remove rear axle ⇒ Running gear, axles, steering; Rep. gr.

t.
yi Co
op
42 ; Repairing rear axle . C py
t. rig
gh ht
yri by
– Open fuel flap and remove fuel tank cap. cop Vo
by lksw
cted agen
Prote
– Pull rubber gasket off fuel tank filler neck.
AG.

Touareg 2003 ➤
– Remove securing bolts -1- on filler neck and pull off earth wire
-2-.
– Remove rear rightgwheel
en AG. Vhousing
olkswagenliner
AG do⇒ General body re‐
pairs, exterior;
ol swa gr. 66 ; Wheel housing
kRep. es n liner; Removing
ot g
V
and installing
ed by wheel housing liner . ua
ran
ris tee
utho or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Unbolt cover plate -arrows-.
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
– Unclip fuel tank breather lines attached to longitudinal mem‐

rp
cum
fo
ber.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove securing bolt for filler neck -arrow- in wheel housing.

Touareg 2003 ➤
5-cylinder diesel engine - Edition 09.2012 AG. Volkswagen AG d
agen oes
olksw not
y V gu
– Disconnect connector to fuel pump on left d bnext to fuel tank. ara
rise nte
ho eo
– Now remove securing straps to leftaand right with cover below
ut ra
c
fuel tank. ss
ce
e
nl
pt
du
– Support fuel tank using engine and gearbox jack -
an
itte
y li
V.A.G 1383 A- and remove securing strap in middle of fuel
erm
ab
tank.
ility
ot p
wit
– Carefully lower fuel tank about 30 cm.
, is n
h re
hole
– Reach between fuel tank and vehicle underbody and pull fuel
spec
line off sender flange, while holding a cloth around supply line.
es, in part or in w
t to the co
Note
rrectness of i
This step saves cutting carpet in vehicle interior in vicinity of
l purpos
sender flange.
nf
ercia
– Lower fuel tank.
orm
m
atio
om
1.9.2 Installing
n in
or c
thi
te
sd
a

iv
o
r
rp
cu
note the following:
o
m
f
en
ng
t.
yi
♦ Do not interchange supply and return hose (return line -1- blue
Co
op py
or blue markings, supply line -2- black). t. C rig
gh ht
pyri by
♦ Connections for breather and fuel lines must engage audibly
co Vo
by lksw
cted
when joined.
agen
Prote AG.
♦ Clip fuel lines onto fuel tank.

♦ Install breather and fuel hoses free of kinks.
♦ Ensure that fuel hose connections are tight.
1.10 Checking fuel pumps

♦ Voltage tester -V.A.G 1527 B-

Touareg 2003 ➤
♦ Hand multimeter -V.A.G 1526 C- or multimeter -V.A.G 1715-
Not illustrated:
♦ Auxiliary measuring set -V.A.G 1594 C-
Test prerequisites
• Fuses must be OK
• The battery voltage mustGbe
. Voat least
lkswagen 11.5 V nA AG do
wage e
• All electrical consumers,
Vol
ks e.g. lights and rear window
s no
t gu heating,
by
are switched
ise
d off. ara
nt
r ee
tho
Checking
s a function and voltage supply
u or
ac
s
ce
– Fold rear bench seat forwards.

e
nl
pt
du
an
itte
– Briefly operate starter. Fuel pumps must be heard to start run‐

y li
erm
ab
ning.
ility
ot p
wit
– Switch off ignition.

, is n
h re
hole
If the fuel pump does not start:

spec
es, in part or in w
Vehicles up to week 47/06

t to the co
Vehicles from week 48, 2006 ⇒ page 104

rrectness of i
– Cut carpet open from point -A- to point -B- in the pre-cut area
-arrows-.
l purpos
Right side of vehicle

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
– Unscrew nuts -1- from cover. If necessary, unscrew backrest
co Vo
by lksw
cted
mounting -2- or support mounting: ⇒ General body repairs,
agen
Prote AG.
interior; Rep. gr. 72 ; Rear seats; Removing and installing
bench seat / individual seats .
Left side of vehicle
– Remove bolts -1-.

Touareg 2003 ➤
– Then remove nuts -2-, to do this for one nut push mounting
bracket slightly upwards.
Vehicles from week 48, 2006
– Remove rear bench seat ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing bench seat /
individual seats .
Check voltage supply of each fuel pump separately as follows:
– Pull connector off right flange of fuel delivery unit.
– Connect voltage tester -V.A.G 1527 B- to outer contacts of

connector using auxiliary cables from auxiliary measuring set
-V.A.G 1594 C- .
– Switch on ignition; LED must light up for approx. 2 seconds.
If LED does not light up
– Check activation of fuel pump relay and wiring for open circuit
and short circuit ⇒ Vehicle diagnostic tester.
LED lights up (voltage supply OK): n AG. Volkswagen AG do
kswage es n
– Remove right-hand fuel delivery unit ⇒ page by V 95 .
ol ot g
ua
d ran
ir se
– Check that electrical wiring between
th flange and fuel pump is
o tee
or
connected and has continuity. ss au ac
ce
le
If no open circuit can be found:

un
pt
an
d
itte
y li
– Right-hand fuel pump is defective, renew fuel delivery unit
rm
ab
⇒ page 95 .
pe
ility
ot
wit
, is n
– Repeat check on left fuel pump unit.

h re
hole
Checking current draw of fuel pumps

spec
es, in part or in w
t to the co
– Check current draw of each fuel pump separately as follows:
– Connect current pick-up of multimeter -V.A.G 1715- to line of

rrectness of i
contact 1 -arrow- of 4-pin connector of wiring harness to right

fuel pump unit.
l purpos
– Start engine and run at idling speed.

nform
ercia
– Measure current draw of fuel pump. Specification: max. 8 Am‐

peres.
m
a
com
tio
If current draw is exceeded:

n in
r
te o
thi
– Right-hand fuel pump is defective, renew fuel delivery unit

s
iva
do
⇒ page 95 .
r
rp
cum
fo
en
g
– Repeat check on left fuel pump unit.

n
t.
yi Co
Cop py
t. rig
gh ht
1.11 Checking tandem pump pyri by
Vo
co lksw
by
cted agen
Prote
⇒ “1.11.1 Checking delivery pressure ”, page 104
AG.
⇒ “1.11.2 Checking for internal leaks”, page 106
1.11.1 Checking delivery pressure


Touareg 2003 ➤
lkswage es n
o ot g
byV ua
♦ Tandem pump tester -VAS 5187- ir se
d ran
tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Vehicle diagnosis, testing and information system -VAS
l purpos
5051B-
♦ Diagnosis cable -VAS 5051/1- or -VAS 5051/3-
nform
ercia
Test prerequisites
m
a
com
tio
• Coolant temperature must be at least 85 °C.
n in
r
te o
thi
• Unit injectors OK.
s
iva
do
r
rp
c
• Intact fuel pump unit
um
fo
en
ng
t.
• Fuel filter and fuel lines must not be blocked.
yi Co
Cop py
t. rig
Procedure
gh ht
pyri by
Vo
co lksw
by
– Disconnect supply line -arrow- from tandem pump. Prote
cted AG.
agen

. Volkswagen AG
gen AG does
swa
Touareg 2003 ➤ yV
olk not
gu
b ara
5-cylinder diesel engineris- Edition 09.2012
ed
nte
ho eo
aut ra
– Connect tandem pump tester
ss -VAS 5187- as shown. c
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
wit
Two versions of tandem pump tester -VAS 5187- are in use. In
, is n
h re
older version adapter -VAS 5187/6-3- must be used as shown.
hole
spec
es, in part or in w
t to the co
– Connect vehicle diagnosis, testing and information system -
VAS 5051B- and select operating mode “vehicle self-diagno‐
rrectness of i
sis”. Then select engine electronics control unit with the
Address word “01”.
l purpos
– Press diagnosis function “08-Read measured value block”.
nf
ercia
– Enter display group “1” using number block (key pad) and
orm
confirm entry with Q button.
m
atio
om
n in
c
– Read off engine idling speed in display zone 1.

or
thi
te
sd
– Increase engine speed to 1500 rpm.
iva
o
r
rp
cu
o
– Observe pressure indicated on pressure gauge. Specification:
m
f
en
ng
t.
min. 7.5 bar. Cop
yi Co
py
ht. rig
– Press button ← . rig ht
py by
co Vo
by lksw
– Select “06-End output” function. cted agen
Prote AG.
If the specification is not attained:

– Renew tandem pump ⇒ page 107 , Removing and installing
tandem pump.
Note
After removing pressure tester, tighten supply line to 27 Nm.
1.11.2 Checking for internal leaks
Note
The tandem pump must be checked for internal leaks between

fuel side and oil side after reinstalling a used tandem pump, e.g.
after renewing or repairing a cylinder head and/or when installing
a "short" engine. When leaking it is possible for the fuel to mix
with the oil which may cause damage to the engine.

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

Touareg 2003 ➤
Procedure
– Pull fuel supply hose (white marking) and fuel return hose
(blue marking) off tandem pump.
– Seal fuel return union on tandem pump with a plug. Secure
sealing plug with a spring-type clip.
Prepare charge air system tester -V.A.G 1687- as follows:
– Turn pressure regulating valve -2- anti-clockwise onto stop.
– Close valves -3- and -4-.
– Connect test connection -5- to fuel supply union of tandem
pump using a commercially available compressed air connec‐
tion and a section of fuel hose. Use a spring-type clip to secure.
Note
To turn the pressure regulating valve -2- the knob must be pulled
upwards.
– Connect compressed air hose -1- (compressed air source) to

charge air system tester -V.A.G 1687- .
Note
If there is water in the sight glass, drain at water drain screw -6-.
– Open valve -3-.

wage es n
– Adjust pressure to 1.0 bar with pressure regulating
yV
olks
valve -2-. ot g
ua
d b ran
ir se tee
ho
Caution aut or
ac
ss ce
le
un
The maximum test pressure is 1.3 bar and this must not be
pt
an
d
exceeded.
itte
y li
erm
ab
ility
ot p
wit
is n
– Open valve -4- and wait until the test circuit is filled. If neces‐
h re
ole,
sary readjust pressure to 1.0 bar.

spec
– Close valve -3- to retain pressure and observe the pressure

t to the co
drop over a period of 1 minute.

If the pressure does not drop the tandem pump can be reused, if
rrectne
the pressure drops the tandem pump must be renewed.

s
1.12 Removing and installing tandem pump

s o
cial p
f in

form
mer
atio

om
n
c
i
or
n thi
e
DANGER!
t
sd
iva
o
pr
cum
r
fo
The tandem pump may, under no circumstances, be disman‐

en
ng
t.
yi
tled as the vacuum part could otherwise malfunction. This
Co
op py
would result in the failure of the brake servo. t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
♦ Spring-type clip pliers -VAS 5024-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
is nte
1.12.1 Removing aut
hor eo
ra
ss c
ce
e
nl
pt
du
Note
an
itte
y li
erm
ab
The removal and installation of the tandem pump can only be un‐
ility
ot p
dertaken when the engine is removed due to the cramped con‐

wit
, is n
ditions.
h re
hole
spec
es, in part or in w
– Remove engine and gearbox ⇒ page 5 .

t to the co
– Pull vacuum line -1- from brake servo off tandem pump -4-.
– Pull fuel line -2- off tandem pump -4-.
rrectness of i
– Disconnect fuel line -3- from tandem pump -4-.

l purpos
– Remove securing bolts -arrows-.

nform
ercia
– Remove tandem pump -4- from cylinder head.

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op py
1.12.2 Installing
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote
note the following:
AG.
Note
♦ Ensure proper seating of tandem pump coupling in the shaft.

♦ Always renew tandem pump seals.

Touareg 2003 ➤
– Install tandem pump and tighten securing bolts -arrows-.

Specified torque M 6: 8 Nm, M 8: 20 Nm
– Attach fuel hose -2- and vacuum hose -1- to tandem pump.
– Connect fuel line -3- to tandem pump -4- and tighten fuel line
to to 27 Nm.
– Install engine and gearbox ⇒ page 5 .
– Carry out a road test and read event memory ⇒ page 140
Reading and clearing event memory of engine control unit.
1.13 Assembly overview - accelerator mechanism
1 - Bearing bracket
2 - Connector
❑ Black, 6-pin.
3 - 10 Nm
4 - Accelerator position sender
-G79-
❑ Not adjustable. AG. Volkswagen AG d
agen oes
❑ The accelerator position Volksw not
gu
sender passes the posi‐ ed by ara
nte
is
tion of the accelerator hor eo
on to the engine control aut ra
s c
unit. s
ce
le
un
pt
❑ Remove footwell cover
an
d
itte
to remove sender.
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
21 – Turbocharging/supercharging
1 Charge air system with turbocharger
⇒ “1.2 Turbocharger with attachments for engine codes BAC and
BLK”, page 110
AG. Volkswagen AG d
⇒ “1.3 Removing and installing turbocharger for engine
wage
n
codes oes
olks not
BAC and BLK”, page 111 d by V gu
ara
e nte
ris
⇒ “1.4 Turbocharger with attachmentsut (engine codes
ho BPD and eo
ra
BPE)”, page 114 ss
a c
ce
e
nl
⇒ “1.5 Removing and installing turbocharger (engine codes BPD
pt
du
an
and BPE)”, page 116
itte
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erm
ab
⇒ “1.6 Removing and installing parts of charge air cooling”, page
ility
ot p
119 .
wit
, is n
h re
⇒ “1.7 Checking charge air system for leaks”, page 120 .
hole
spec
es, in part or in w
⇒ “1.8 Hose connections”, page 122
t to the co
⇒ “1.9 Vacuum hose schematic diagram”, page 123
rrectness of i
l purpos
When working on the turbocharger, pay careful attention to the

following “5 rules” for cleanliness:
nform
ercia

connecting.
m
at
om
io
n
c
in t
or
lint-free cloths.
his
ate
do
riv

p
cum
or

f
en
ng
t.
yi Co
♦ Install clean components only. Do not remove replacement Cop py
. rig
t
gh ht
yri by
use parts that have not been stored in their packing (e.g. in cop Vo
by lksw
tool boxes etc.).
cted agen
Prote AG.
1.2 Turbocharger with attachments for engine codes BAC and BLK
Observe rules for cleanliness ⇒ page 110 .
Note
♦ All hose connections are secured with clamps or retaining clips.

♦ Charge air system must be free of leaks.
♦ Renew self-locking nuts.
♦ After installing turbocharger run engine for approx. 1 minute at idling speed, do not rev engine. This ensures
that the turbocharger/compressor is adequately lubricated.
110 Rep. gr.21 - Turbocharging/supercharging

Touareg 2003 ➤
1 - Connecting pipe
lation.
2 - 10 Nm
AG . Volkswagen AG
3 - Connecting clamp,
ksw
agen8 Nm does
not
ol
yV gu
4 - Bracket/lifting
edb eye ara
nte
ris
ho eo
5 - Gasket
aut ra
c
ss
❑ Renew.
ce
e
nl
pt
du
an
itte
y li
tion.
erm
ab
ility
ot p
6 - 25 Nm
wit
, is n
h re
7 - Exhaust manifold
hole
spec
❑ To remove, remove ex‐
es, in part or in w
haust gas recirculation
t to the co
cooler
⇒ Item 20 (page 111)
and unscrew securing
rrectness of i
bolts securing turbo‐
l purpos
charger to exhaust
manifold
⇒ Item 6 (page 111) .
nform
ercia
8 - Connecting hose
m
at
om
❑ From air filter.

ion
c
in t
or
9 - Vacuum line
his
ate
do
riv
10 - Cylinder block
p
cum
for
en
g
11 - 40 Nm
n
t.
yi Co
Cop py
.
12 - Gasket
ht rig
rig ht
py by
Vo
❑ Renew.
co lksw
by
cted agen
Prote AG.
13 - Turbocharger
14 - Bracket
15 - 40 Nm
16 - Connecting clamp, 8 Nm
❑ For front exhaust pipe
❑ Renew.
17 - Front exhaust pipe
18 - Washer
❑ Renew.
19 - 25 Nm
❑ Vehicles with automatic gearbox and exhaust gas recirculation changeover valve.
1.3 Removing and installing turbocharger

for engine codes BAC and BLK
1. Charge air system with turbocharger 111

Touareg 2003 ➤
♦ Support bracket -10-222A-
Not illustrated
♦ Lifting tackle -2024 A/02-
♦ Adapter -10-222A/03-
♦ Adapter -10-222A/18-
♦ Adapter -10-222A/19- AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
Caution thor eo
au ra
ss c
When a mechanical fault is found on the turbocharger, e.g. a
ce
e
nl
pt
destroyed compressor impeller, it is not only sufficient to renew
du
an
itte
the turbocharger. To avoid subsequent damage, the following

y li
erm
ab
work must be carried out:
ility
ot p
♦ Check air filter housing, air filter element and intake hoses wit
, is n
h re
for soiling.
hole
spec
♦ Check complete charged air routing and charge air cooler

es, in part or in w
t to the co
for foreign objects.

If foreign objects are found in the charge air system, the charg‐
ed air routing must be cleaned and the charge air cooler must
rrectness of i
be renewed, if necessary.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
Removing
Rep. gr. 50 ; Assembly overview - noise insulation .
– Remove air filter housing ⇒ page 139 .
– Loosen charge air pipe and vacuum line from turbocharger.
– Loosen exhaust pipe and starter catalytic converter from tur‐
bocharger and gearbox ⇒ page 145 .
– Remove noise insulation -A-.
– Fit lifting tackle -2024A/2- on cylinder block as shown.

– Support bonnet with suitable workshop equipment.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Fit support bracket -10-222A- .

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤

– Remove right assembly mounting from engine ⇒ page 18 .
– Unscrew bolts -3- from turbocharger.
– Unscrew bolts -1- and remove bracket -2-.
AG. Volkswagen AG d
agen oes
– Remove bolts -arrows- from turbocharger. olksw not
byV gu
ara
d
– Remove turbocharger. orise nte
eo
h
ut ra
Installing ss a c
ce
e
nl
– Installation is performed in the reverse sequence.
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.4 Turbocharger with attachments (engine codes BPD and BPE)
rrectness of i

l purpos
nf
ercia
Note
orm
m
atio
m

o
n in
or c
♦ Charge air system must be free of leaks.

thi
te
sd
iva
o
r

rp
cu
o
m
f
en
ng
♦ After installing turbocharger run engine for approx. 1 minute at idling speed, do not rev engine. This ensures
t.
yi Co
op
that the turbocharger/compressor is adequately lubricated. C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
AG. Volkswagen AG d
agen 5-cylinder diesel oeengine - Edition 09.2012
olksw s no
t gu
byV a
ed ran
1 - Bracket ris tee
tho or
u
2 - Exhaust gas recirculation ss
a ac
cooler
ce
e
nl
pt
du
an
itte
y li
⇒ page 158 .
erm
ab
ility
ot p
3 - Gasket
wit
, is n
h re
❑ Renew.
hole
spec
4 - Exhaust gas temperature es, in part or in w
sender 1 -G235-
t to the co
❑ 45 Nm
❑ Lubricate thread of
rrectness of i
sender using high-tem‐
perature paste -G 052
l purpos
112 A3- .
5 - 40 Nm + turn 90° further
nform
ercia
❑ Renew.
m
at
om
io
❑ Qty. 3
n
c
in t
or
❑ Do not grease
his
ate
do
riv
6 - Washers
p
cum
for
en
g
❑ Qty. 3
n
t.
yi Co
op py
7 - Gasket
. C rig
ht ht
rig by
py
❑ Renew. co Vo
by lksw
cted agen
❑ Note installation posi‐ Prote AG.
tion.
❑ To remove, remove ex‐
cooler and remove tur‐
bocharger to exhaust
manifold securing bolts
⇒ Item 5 (page 115) .
9 - 25 Nm
❑ Renew.
10 - Flange upper part
❑ Renew.
11 - Gasket
❑ Renew.
13 - Clip
14 - Vacuum line
17 - Turbocharger
18 - Gasket
❑ Renew.

Touareg 2003 ➤
19 - Clamp, 7 Nm
❑ Renew.
20 - Particulate filter agen
AG. Volkswagen AG d
oes
olksw not
V gu
21 - Gasket ed by ara
nte
ris
❑ Renew. ut
ho eo
ra
a c
❑ Note installation position. ss
ce
e
nl
pt
du
22 - Flange lower part
an
itte
y li
❑ Renew.
erm
ab
ility
ot p
23 - Gasket
wit
, is n
h re
❑ Renew.
hole
spec
es, in part or in w
t to the co
24 - Bracket upper part
25 - 8 Nm
rrectness of i
26 - Vacuum actuator
l purpos
❑ For bypass flap.

❑ Renew only together with exhaust gas recirculation cooler
nform
ercia
27 - 8 Nm
m
at
om
i
28 - 15 Nm
on
c
in t
or
his
ate
do
priv
c
1.5 Removing and installing turbocharger
um
for
en
ng
t.
(engine codes BPD and BPE)
yi Co
Cop py
t. rig
gh ht
Observe rules for cleanliness ⇒ page 110 . yri
p by
o Vo
by c lksw
cted
agen
Prote AG.
♦ Allen key, long reach -VAS 3410-
♦ Torque wrench -V.A.G 1331/-

Touareg 2003 ➤
♦ Support bracket -10-222A-
Not illustrated
AG. Volkswagen AG d
agen oes
♦ Lifting tackle -2024 A/02- yV
olksw not
gu
d b ara
e
♦ Adapter -10-222A/03- horis nte
eo
aut ra
♦ Adapter -10-222A/18- ss c
ce
le
un
pt
♦ Adapter -10-222A/19-
an
d
itte
y li
rm
ab
pe
ility
Caution
ot
wit
, is n
h re
When a mechanical fault is found on the turbocharger, e.g. a

hole
spec
destroyed compressor impeller, it is not only sufficient to renew

es, in part or in w
the turbocharger. To avoid subsequent damage, the following

t to the co
work must be carried out:

♦ Check air filter housing, air filter element and intake hoses
rrectness of i
for soiling.
l purpos
♦ Check complete charged air routing and charge air cooler

for foreign objects.
nform
ercia
If foreign objects are found in the charge air system, the charg‐
ed air routing must be cleaned and the charge air cooler must
m
be renewed, if necessary.
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 ➤
Removing
Rep. gr. 50 ; Assembly overview - noise insulation .
– Remove air filter housing ⇒ page 139 .
– Loosen charge air pipe and vacuum line from turbocharger.
– Removing exhaust manifold ⇒ page 149 .
– Remove front exhaust pipe together with diesel particulate fil‐
ter ⇒ page 148 .
– Remove noise insulation -A-.
– Fit lifting tackle -2024A/2- on cylinder block as shown.

– Support bonnet with suitable workshop equipment.
– Unclip lower bonnet dampers. n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
– Fit support bracket -10-222A- .

spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤

– Remove right engine mounting and right engine bracket
⇒ page 18 .
– Unscrew bolt -1- and nuts -2-.

– Remove turbocharger.
Installing
Installing the turbocharger is carried out in reverse order of re‐
moval.
– Guide turbocharger onto studs on cylinder block.
Caution
If the assembly sequence is not followed, the seal may be

damaged and exhaust emissions may escape.
– Tighten bolt -1- ⇒ Item 16 (page 115) .
. Volkswagen AG
gen AG does
swa
– Tighten nuts -2- ⇒ Item 15 (page
by
115)
Volk . not
gu
d ara
ise nte
– Install exhaust manifold with
thor sealing set ⇒ page 149 . eo
au ra
c
– Install exhaust gas recirculation cooler ⇒ page 158 .
ss
ce
le
un
pt
– Remove front exhaust pipe together with diesel particulate fil‐

an
d
itte
y li
ter ⇒ page 148 .

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
1.6 Removing and installing parts of charge

n
c
i
or
n thi
e
air cooling
t
sd
iva
o
pr
cum
r
Assembly of hose connections

fo
en
ng
⇒ “1.8 Hose connections”, page 122

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

Touareg 2003 ➤
AG. Volkswagen AG d
1 - Air duct agen oes
olksw not
byV gu
ara
2 - 8 Nm rised
nte
ho eo
ut
3 - Shim ss a ra
c
ce
e
4 - Charge air cooler

nl
pt
du
an
itte
❑ To remove bumper cov‐
y li
erm
ab
er ⇒ General body re‐
ility
ot p
pairs, exterior; Rep. gr.
wit
63 ; Body - front; Re‐
, is n
h re
moving and installing
hole
spec
bumper cover. .
es, in part or in w
t to the co
5 - Seal
❑ If renewed, observe fit‐
rrectness of i
ting instructions
l purpos
⇒ page 122
6 - 3 Nm
nform
ercia
7 - Charge air pressure sender

m
at
-G31- with intake air tempera‐
om
io
ture sender -G42-
n
c
in t
or
his
e
8 - Charge air pipe/connecting

at
do
riv
hose
p
cum
for
en
g
9 - To intake connecting pipe.

n
t.
yi Co
Cop py
10 - Retaining clip ht. rig
rig ht
py by
❑ Check for secure seat‐ co Vo
by lksw
cted
ing.
agen
Prote AG.
11 - From turbocharger
12 - 8 Nm
1.7 Checking charge air system for leaks

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

Touareg 2003 ➤
– Remove intake hose -1- from air filter.

– Insert adapter -V.A.G 1687/10- in intake hose -1- and secure
with clip.
– Detach hose from valve for crankcase breather system.
– Seal hose using adapter -V.A.G 1687/4- and secure with
clamp.
Prepare charge air system tester -V.A.G 1687- as follows:
AG. Volkswagen AG d
agen oes
o lksw not
byV gu
ara
d
– Turn pressure
orise regulating valve -2- anti-clockwise nteonto stop.
h eo
ut ra
– Close
ss a valves -3- and -4-. c
ce
e
nl
pt
du
an
itte
Note
y li
erm
ab
ility
ot p
To turn the pressure regulating valve -2- the knob must be pulled
wit
, is n
upwards.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Connect charge air system tester -V.A.G 1687- to adapter

-1687/10- as shown.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
– Connect compressed air hose -1- (compressed air source) to

charge air system tester -V.A.G 1687- .
lkswage es n
Note byV
o ot g
ua
d ran
ir se tee
o
If there is water in the sight glass, drainu at water drain screw -6-.
th or
a ac
ss
ce
e
nl
pt
– Open valve -3-. du
an
itte
y li
– Adjust pressure to 0.5 bar with pressure regulating valve -2-.
erm
ab
ility
ot p
wit
, is n
Caution
h re
hole
spec
The pressure must not exceed 0.5 bar! If the pressure is too
es, in part or in w
t to the co
high this can cause damage to the engine.
rrectness of i
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary readjust pressure to 0.5 bar.
l purpos
– Check charge air system via:
nform
ercia
♦ listening
m
at
♦ feeling
om
ion
c
in t
r
♦ with leak detector spray

o
his
ate
do
riv
– or with ultrasonic tester -V.A.G 1842- for leaks.

p
cum
for
en
ng
t.
yi Co
op
Note C py
t. rig
gh ht
pyri by
Vo
o
♦ Slight leaks on the intake side of turbocharger are permissible,
c by lksw
cted agen
as the intake hoses are not designed for high-pressure.
Prote AG.
♦ A small amount of air escapes through the valves and enters

the engine. Therefore a holding pressure test is not possible.
♦ How to use the ultrasonic tester -V.A.G 1842- ⇒ operating
instructions
♦ If leaks occur, when doing any repair work observe notes for
charge air system ⇒ page 119 .
♦ Before removing the adapter, depressurise the test circuit by
pulling coupling off adapter -1687/1- .
1.8 Hose connections

⇒ “1.8.1 Fitting hose connections with plug-in connectors”,
page 122
⇒ “1.8.2 Hose connections with spring band ring”, page 123
1.8.1 Fitting hose connections with plug-in

connectors
Caution
The seal in the plug-in connector can be damaged if the se‐

curing clip is in the locked position when fitting the connector.
This can cause leakage. Observe installation instructions.

Touareg 2003 ➤
Removing
– Release plug-in connector by pulling out retaining clip
-arrow-. Separate hose/pipe without tools.
Installing
– If renewed, place oil seal in. Vgroove
AG olkswageof
n Acharge air hose. Ensure
agen G do
the seal is correctly
Volksw seated in the groove. es not
g
y ua
db ran
– Lubricate
or sealing surface and seal with oil.
ise tee
h
ut or
– Bring
ss retaining clip to release position -1-.
a ac
ce
le
un
– Push charge air hose into coupling to stop.
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
– Bring securing clip to locking position -2- and then push charge
h re
ole,
air hose again.
spec
– Check if connector coupling seats correctly and is properly
t to the co
engaged by pulling hose.
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
n thi
te
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fo
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ng
t.
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Cop py
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rig ht
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by lksw
cted agen
Prote AG.
1.8.2 Hose connections with spring band ring
Note
There is a danger of a “hose detaching” whilst driving after re‐

moving and reinstalling charge air lines with spring-type clips. For
this reason, spring band rings are used; these must only be
opened if a defect requires the charge air line to be opened. In
cases of repair, the charge air pipe must be removed if necessary,
the spring band ring must be destroyed using a suitable tool (e.g.
angle grinder) and must be renewed by a replacement part ac‐
cording to ⇒ Electronic parts catalogue (ETKA) .
1.9 Vacuum hose schematic diagram

⇒ “1.9.1 Vacuum hose schematic diagram for engine codes BAC
and BLK”, page 123
⇒ “1.9.2 Vacuum hose schematic diagram for engine codes BPD
and BPE”, page 125
1.9.1 Vacuum hose schematic diagram for engine codes BAC and BLK

Touareg 2003 ➤
1 - Charge pressure control

solenoid valve -N75-
2 - Exhaust gas recirculation
cooler changeover valve -
N345-
lation cooler.
automatic gearbox.
3 - Brake servo line
valve
❑ Part of intake connect‐
ing pipe
❑ Can only be renewed to‐
gether with intake con‐
necting pipe
valve -N18- (electro-pneumat‐ AG. Volkswagen AG d
ic) agen oes
olksw not
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b ara
6 - Variable intake manifold rise
d
nte
flap changeover valve -N239- utho eo
ra
s a c
s
7 - Vacuum reservoir
ce
e
nl
pt
du
an
8 - Non-return valve
itte
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erm
ab
ility
ot p
tion.
wit
, is n
h re
9 - Intake manifold flap
hole
spec
es, in part or in w
t to the co
lation cooler.
rrectness of i
automatic gearbox.
l purpos
11 - Turbocharger
nf
ercia
orm
m
atio
om
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te
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t.
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Cop py
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pyri by
Vo
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by
cted agen
Prote AG.

Touareg 2003 ➤
1.9.2 Vacuum hose schematic diagram for engine codes BPD and BPE
1 - Brake servo line

2 - Non-return valve
tion.
3 - Charge pressure control
solenoid valve -N75-
4 - Exhaust gas recirculation AG. Volkswagen AG d
cooler changeover agen
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oes
ol not
N345- ed byV gu
ara
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❑ uFor th exhaust gas recircu‐
or eo
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pt
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rm
ab
lation cooler.
pe
ility
ot
wit
6 - Turbocharger
, is n
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hole
7 - Vacuum reservoir
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
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thi
s
iva
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Cop py
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rig ht
py by
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by lksw
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Prote AG.

wage es n
Touareg 2003 ➤y Vo lks ot g
b ua
5-cylinder diesel
ir se engine - Edition 09.2012
d ran
tee
tho
u or
a ac
ss
23 – Mixture preparation - injection
ce
le
un
pt
an
d
itte
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erm
ab
1 Repairing diesel direct injection sys‐
ility
ot p
wit
is n
tem
h re
ole,
spec
The diesel direct injection system control unit is equipped with an

event memory. Read event memory before and after making re‐
t to the co
pairs or adjustments ⇒ Vehicle diagnosis tester .
⇒ “1.1 Safety precautions”, page 126
rrectne
ss
⇒ “1.3 Removing and installing wiring harness for unit injectors”,
o
cial p
f
page 127
inform
mer
⇒ “1.4 Removing and installing unit injector”, page 130
atio
om
⇒ “1.5 Assembly overview - unit injector”, page 133
n
c
i
or
n thi
e
⇒ “1.6 Removing and installing O-rings for unit injector”,

t
sd
va
page 134
i
o
pr
cum
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fo
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ng
⇒ “1.7 Assembly overview - intake manifold and fuel rail”,

t.
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page 135 Cop py
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⇒ “1.8 Repairing intake manifold flap”, page 137 p by
co Vo
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⇒ “1.9 Dismantling and assembling air filter”, page 139 Prote AG.
1.1 Safety precautions
WARNING

tions:
♦ Fuel lines
♦ Hydraulic lines
hot components.
Note the following if testers and measuring instruments have to

be used during a road test:
♦ Test and measuring instruments must always be secured to
rear seat and operated by a second person from this location.
If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there is a
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
126 Rep. gr.23 - Mixture preparation - injection

Touareg 2003 ➤
WARNING
Secure fault reader to rear seat and operate from this position.
To prevent injuries to persons and/or destruction of the injection

and glow plug system, the following must be noted:
♦ The ignition must be switched off wbefore
agen connectingAor
AG. Volkswagen G ddis‐
oe
connecting glow plug systemy Vand
olks injection system lines ors not g
tester cables. ise
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ho
♦ If the engine is to bes auturned
t
at starter speed, without starting, or
ac
e.g. when checking compressions, disconnect unit injector
s
ce
le
connector on cylinder head.

un
pt
an
d
itte
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♦ Before disconnecting battery, obtain radio code for radios with
rm
ab
anti-theft coding.
pe
ility
ot
wit
, is n
♦ Disconnecting and connecting the battery must only be done
h re
with the ignition switched off, as otherwise the control unit for
hole
spec
diesel direction injection system could become damaged.
es, in part or in w
t to the co
When working on the fuel supply and injection system, pay careful
rrectness of i
attention to the following “6 rules” for cleanliness:
l purpos

connecting.
nform
ercia

lint-free cloths.
m
a
com
tion in
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use parts that have not been stored in their packing (e.g. in
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tool boxes etc.). t. C rig
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♦ When system is open: do not work with compressed air if this
co Vo
by lksw
cted
can be avoided. Do not move vehicle unless absolutely nec‐
agen
Prote AG.
essary.
1.3 Removing and installing wiring harness

for unit injectors
♦ Wrench -T10211-
1. Repairing diesel direct injection system 127

. Volkswagen AG
Touareg 2003 ➤ wage
n AG does
olks not
d b - Edition 09.2012
y V gu
ara
e nte
ris
ho eo
♦ Puller -T10312- au
t ra
c
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing
nf
ercia
o
rm
m
atio
sition .
om
n in
c

or
thi
e

t
sd
iva
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rp
cu
– Remove intake manifold ⇒ page 135 .
o
m
f
en
ng
t.
yi
– Remove cylinder head cover ⇒ Item 6 (page 35) .
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Unplug electric multiway connector for unit injectors. To do so,

pull release pin -arrow 1- and loosen knurled nut -arrow 2-.
Note
Only puller -T10312- must be used to unplug electrical connectors

on piezo unit injectors.

Touareg 2003 ➤
– Prise off connector from unit injector using screwdriver

-arrow-. To avoid canting, support opposite side of connector
with light finger pressure.
– Locate special wrench -T10211- on adapter ring and loosen

by turning anticlockwise through 90° -arrow-.
Caution
Removal and installation of the pre-wired wiring harness may

only be undertaken by unscrewing the clips. Releasing the ca‐
ble channel at the clips bends the clips which may break the
cables due the excessive play. This also applies when chang‐
ing the unit injectors and all work which does not require the
central connector to be completely removed.
– Unscrew securing bolts of pre-wired wiring harness.

G. Volkswagen
– Unplug connector from cylinder head andlksw
remove
agen
A
entire pre‐AG does n
wiring. by
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Installing tho or
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ss
Further installation steps are carried out in the reverse order; note
ce
e
the following:
nl
pt
du
an
itte
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– Fit prewiring and tighten securing bolts to 10 Nm.

erm
ab
ility
ot p
– Route central connector through opening in frame of mount‐

wit
, is n
ing. Ensure it is seated correctly.

h re
hole
spec
– Tighten adapter ring with special wrench -T10211- by turning

es, in part or in w
90° in clockwise direction..

t to the co
Note
rrectness of i
When adapter ring is installed correctly the colour marked "short‐

l purpos
er" stud faces 12 o'clock)

nf
ercia
• Long green line faces upwards.

rm
m
atio
m
– Tighten central connector on cylinder head and lock in place.

o
n in
or c
– Install cylinder head cover ⇒ Item 6 (page 35) .

thi
te
sd
iva
o
r
– Install intake manifold ⇒ page 135 .

rp
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ng
Specified torque
t.
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Cop py
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Component Nm
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Electrical wiring harness to cylinder head Prote
cted 10 AG.
agen

Touareg 2003 ➤
1.4 Removing and installing unit injector


equipment required
♦ Universal dial gauge brack‐
et -VW 387-
♦ Allen key, long reach
-3410- . Volkswagen AG
gen AG does
swa
♦ Allen key, long reach - y Volk not
gu
T10054- risedb ara
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♦ Puller -T10055- aut ra
s s c
ce
le
♦ Torque wrench -
un
pt
V.A.G 1331- (5 ... 50 Nm)
an
d
itte
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erm
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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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
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by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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aut ra
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un
pt
an
d
itte
1.4.1 Removing
y li
erm
ab
ility
ot p
– Remove cylinder head cover.
wit
is n
h re
– Turn crankshaft until the cam pair point evenly upwards for the
ole,
spec
unit injector which is to be removed.
t to the co
– Loosen lock nut of adjuster screws -1- and screw adjuster
screws out until the relevant rocker arm lies against the plung‐
er spring of the unit injector.
rrectne
– Remove rocker arm securing bolts -2- (from outwards to in‐

wards) with socket XZN 10 -3410- and remove rocker arm
s
shaft.
s o
cial p
f in
– Remove tensioning block securing bolt -3- with special

form
mer
wrench, long reach -T10054- and remove the block.

atio
m
– Lever connector off unit injector using a screwdriver. Support

o
n
c
i
or
opposite side of connector with light finger pressure to prevent

thi
e
canting.
t
sd
iva
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pr
cum
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fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
– Seat the puller into the slot on the side of the unit injector in‐
stead of the tensioning block.
– Pull unit injector out of cylinder head seat by gently tapping
wage
upwards. Volks es n
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by ua
ed ran
oris tee
th or
au ac
ss
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nl
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
1.4.2 Installing
nf
ercia
orm
m
atio
m
Note
o
n in
or c
thi
te
♦ If a new unit injector is installed, the appropriate adjustment
sd
iva
o
screw in the rocker arm must also be renewed.
r
rp
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f
en
ng
♦ Each time work is performed which requires adjustment of the

t.
yi Co
op
unit injector, the adjustment screw in the rocker arm and also C py
t. rig
the unit injector ball stud must be renewed.
gh ht
pyri by
Vo
co lksw
by
♦ New unit injectors are supplied with O-rings and heat shield cted agen
Prote AG.
seal.
– Heat insulating seal and O-rings must be renewed if old unit

injector is reused ⇒ page 134 .
– Check that the 3 O-rings and the heat shield seal along with
securing clip are seated correctly before installing unit injector.
Note
The seals must not be twisted.
– Oil the seals and fit the unit injector into the seat in cylinder
head with great care.
– Push the unit injector evenly into the cylinder head onto its limit
stop.
– Insert tensioning block in slot on side of unit injector.
Note
If the unit injector is not at right angles to the tensioning block the
securing bolt may loosen and this can damage the unit injector or
the cylinder head.
– Therefore align the unit injector as follows.

– Screw new securing bolt into clamping block, but do not tighten
(it must still be possible to turn the unit injector slightly).

Touareg 2003 ➤
– Position gauge -T10210- between mounting bracket and unit

injector as shown.
– Turn unit injector by hand against gauge.
– If necessary, adjust the unit injector and tighten the securing
bolt as follows:
12 Nm and + 270° (3/4 turn) further.
(Turning further can be carried out in several stages)
– Fit rocker arm shaft and tighten new securing bolts as follows.
– Tighten inner and then both outer bolts hand-tight. Then using
same sequence, tighten to 20 Nm and turn 90° (1/4 turn) fur‐
ther. gen AG
. Volkswagen AG
a does
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y Vol gu
– Fit dial gauge onto adjustment screwrisofed unit injector as shown.
b ara
nte
tho eo
– Turn crankshaft in direction of engine
au rotation until roller of ra
c
ss
rocker arm is located at tip of drive cam.
ce
e
nl
pt
du
Roller side -arrow A- is at highest point. Adjuster screw of unit
an
itte
y li
injector -arrow B- is at lowest pump.
erm
ab
ility
ot p
– Remove dial gauge.
wit
, is n
h re
– Now turn adjuster screw into rocker arm against spring pres‐
hole
spec
sure of unit injector until firm resistance is felt (unit injector
es, in part or in w
positioned at stop).
t to the co
rrectness of i
– Turn adjustment screw 180° back off stop.
l purpos
– Hold adjuster screw in this position and tighten lock nut to 30

Nm.
nf
ercia
– Reconnect unit injector connector and install cylinder head
orm
cover.
m
atio
om
n in
or c
thi
te
sd
iva
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en
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t.
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Cop py
t. rig
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co lksw
1.5 Assembly overview - unit injector
by
cted agen
Prote AG.
♦ Observe rules for cleanliness ⇒ page 127 .

♦ Always renew seals and O-rings

Touareg 2003 ➤
1 - 20 Nm + 90° further
❑ Renew.
2 - Lock nut
3 - Adjuster screw
❑ Renew each time it is
separated from ball pin
4 - Rocker arm shaft
❑ With rocker arms
⇒ page 130 , removing
and installing unit injec‐
tor
❑ Check ball pin for signs
of wear, replace if nec‐
essary
⇒ page 130
5 - Tensioning block
6 - 12 Nm + 270° further
❑ Renew. AG. Volkswagen AG d
agen oes
olksw not
7 - Unit injector d byV gu
ara
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❑ Removing and hoinstalling
r eo
ut
⇒ page 130 ss a ra
c
ce
le
8 - O-ring
un
pt
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d
itte

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ab
pe
9 - Heat shield seal

ility
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wit
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❑ Renew.
h re
hole
10 - Circlip
spec
es, in part or in w
t to the co
rrectness of i
1.6 Removing and installing O-rings for unit

l purpos
injector
nform
ercia
♦ Assembly sleeves -T10056-

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing
– Lever old O-rings very carefully out of unit injector.
– Pay particular attention to ensure that seat of O-ring is not
damaged by burrs.

Touareg 2003 ➤
Installing
Note
♦ Always use the assembly sleeves to fit the O-rings. There is a

danger of damaging the O-rings if the sleeves are not used.
♦ Gradual introduction of O-rings without different coloured
markings. Note the correct allocation of O-rings to grooves:
the thickness of the rings reduces towards injector nozzle.
n AG. Volkswagen AG ge does
swa
♦ Prevent O-rings from rolling when sliding
by them on. The O-rings
Vol
k not
gu
must not be twisted in their seatsriin
se unit injector.
d ara
nte
tho eo
s au ra
c
– Pull heat shield seal off together
s with securing clip.
ce
e
nl
pt
du
– Clean seating surfaces for O-rings on unit injector very care‐
an
itte
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fully.
erm
ab
ility
ot p
– Place assembly sleeve -T10056/1- onto stop on unit injector.
wit
, is n
h re
– Push the upper, thicker O-ring carefully onto assembly sleeve
hole
and into seat on unit injector.
spec
es, in part or in w
– Remove assembly sleeve.
t to the co
rrectness of i
l purpos
nform
mercia
at
om
io
n
c
in t
or
his
e
– Slide the middle, thinner O-ring carefully onto assembly sleeve

at
do
riv
and into seat on unit injector.

p
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for
en
g

n
t.
yi Co
Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

– Push the lower O-ring carefully onto the assembly sleeve and
into the seat of the unit injector.
– Fit new heat shield seal together with securing clip.
1.7 Assembly overview - intake manifold and fuel rail

AG. Volkswagen AG d
Touareg 2003 ➤ lksw
agen oes
not
o
5-cylinder diesel engine - Edition 09.2012 d by
V gu
ara
ise nte
or eo
h
1 - Cylinder head aut ra
ss c
ce
e
nl
pt
⇒ page 42
du
an
itte
y li
erm
2 - Intake manifold support
ab
ility
ot p
3 - 10 Nm
wit
, is n
h re
4 - Intake manifold
hole
spec
es, in part or in w
5 - 20 Nm
t to the co
6 - Fuel rail
7 - 8 Nm + 90° further
rrectness of i
❑ Renew. l purpos
8 - Connection
❑ Long.
nf
ercia
orm
❑ For supply flow
m
atio
om
9 - Connection
n in
or c
thi
e
❑ Short.
t
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❑ For return flow

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10 - Seal
t.
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op py
❑ Renew.
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Vo
11 - Glow plug
o
by c lksw
cted agen
Prote
❑ 15 Nm
AG.

12 - Gasket
❑ Renew.

Touareg 2003 ➤
1.8 Repairing intake manifold flap

⇒ “1.8.1 Repairing intake manifold flap for engine codes BAC and
BLK”, page 137 .
⇒ “1.8.2 Repairing intake manifold flap for engine codes BPD and
BPE”, page 138 .
1.8.1 Repairing intake manifold flap for engine codes BAC and BLK
The intake manifold flap is closed for approx. 3 seconds when
stopping engine and then opens again. This reduces the stop jolt.
1 - Intake manifold
2 - O-ring
❑ Renew.
3 - Gasket
❑ Renew.
4 - Connecting pipe
lation.
AG. Volkswagen AG d
5 - 20 Nm lksw
agen oes
not
Vo gu
y
6 - 10 Nm rise
d b ara
nte
tho eo
7 - From charge air cooler s au ra
c
s
ce
e
8 - Intake connecting pipe

nl
pt
du
an
❑ With mechanical ex‐
itte
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erm
ab
ility
valve and intake mani‐
ot p
wit
fold flap
, is n
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hole
9 - 10 Nm
spec
es, in part or in w
t to the co
11 - Vacuum supply
rrectness of i
12 - Variable intake manifold
flap changeover valve
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
1.8.2 Repairing intake manifold flap for engine codes BPD and BPE
1 - Intake manifold
2 - Seal
❑ Renew.
3 - Gasket
❑ Renew.
4 - Connecting pipe
lation cooler.
❑ Assembly overview - ex‐
cooler ⇒ page 158
5 - 22 Nm
6 - 10 Nm
7 - Intake manifold flap motor -
V157-
❑ The intake manifold flap
is closed for approx. 3
seconds when stopping
engine and then opens
again. This reduces the
stop jolt.
8 - 10 Nm
9 - Seal
❑ Renew.
valve -N18- with exhaust gas agen
AG. Volkswagen AG d
oes
recirculation potentiometer - olksw not
yV gu
G212- ised b ara
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or
❑ Assembly overview - ex‐ aut
h eo
ra
haust gas recirculation ss c
⇒ page 158
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
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om
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or c
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by lksw
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Prote AG.

Touareg 2003 ➤
1.9 Dismantling and assembling air filter
1 - Air filter lower part

2 - Filter element
3 - Air filter upper part
4 - Securing pins
⇒ page 139
5 - O-ring
6 - Intake manifold
7 - Air mass meter -G70-
8 - 6 Nm
9 - Clip
ing spring-type clip pli‐
ers -VAS 5024A- .
10 - Adapter
11 - To turbocharger.
AG. Volkswagen AG d
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nl
pt
du
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Removing and installing securing pins

, is n
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hole
Removing
spec
es, in part or in w
– Turn securing pins using appropriate bit until markings -A- on

t to the co
pins and -B- on housing align.

Installing
rrectness of i
– Press pins into bores to stop, rotate by 180°.

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nf
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Prote AG.

Touareg 2003 ➤
2 Engine control unit

⇒ “2.1 Reading and deleting engine control unit event memory”,
page 140 .
⇒ “2.2 Removing and installing engine control unit J623 ”,
page 141 .
⇒ “2.3 Removing and installing anti-theft engine control unit J623
”, page 141 .
2.1 Reading and deleting engine control unit

event memory
♦ Vehicle diagnosis, testing and information system -VAS
AG. Volkswagen AG d
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Procedure
rrectness of i
– Connect Vehicle diagnosis, testing and information system -

VAS 5051B- as follows:
l purpos
– Push diagnostic cable connector onto diagnostic connector.

nform
ercia

m
Only when engine does not start:

a
com
tion in
– Switch on ignition.
r
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Selecting operating mode:

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fo
– Press button on display for “Vehicle self-diagnosis”.

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Selecting vehicle system:
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– Press button “01 - Engine electronics” on display to read con‐
co Vo
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The display indicates the control unit identification and the coding
of the engine control unit.
Select diagnostic function:
– Press button “02 - Read event memory” on display.
– If no fault is stored in engine control unit “0 faults detected” is
displayed.
– If faults are stored in the engine control unit, these are shown
one below the other on the display.
– Press button ← .
– Press button “05 - event memory” on display.
– Press function “06-End output”.

Touareg 2003 ➤
2.2 Removing and installing engine control

unit -J623-
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.
AG. Volkswagen AG d
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Removing d byV gu
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ut
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s
– Remove wiper arms, ⇒ Electrical system; Rep. gr. 92 ; Wind‐
ce
le
un
screen wiper system; Removing and installing wiper arms.
pt
an
d
itte
y li
– Remove plenum chamber cover ⇒ General body repairs, ex‐
rm
ab
pe
terior; Rep. gr. 64 ; Removing and installing plenum chamber
ility
ot
cover.
wit
, is n
h re
– Slide connector locking devices -1- on engine control unit out‐
hole
spec
wards and pull off both connectors.
es, in part or in w
t to the co
– Press securing clips aside and remove engine control unit.
Installing
rrectness of i
– Insert engine control unit into retaining frame in plenum cham‐
l purpos
ber.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
– Fit connectors to engine control unit and slide locking devices

do
r
rp
-1- inwards.
um
fo
en
ng
t.
yi
– Install plenum chamber cover ⇒ General body repairs, exte‐
Co
op py
rior; Rep. gr. 64 ; Removing and installing plenum chamber
. C rig
ht ht
rig
cover. py by
co Vo
by lksw
cted agen
– Install wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
Prote AG.
screen wiper system; Removing and installing wiper arms .
2.3 Removing and installing anti-theft en‐

gine control unit -J623-
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.
2. Engine control unit 141

Touareg 2003 ➤
♦ Hot air blower from wiring harness repair set -VAS 1978-
AG. Volkswagen AG d
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spec
♦ Nozzle attachment from wiring harness repair set -VAS 1978-
t to the co
Removing
rrectne
– Remove wiper arms, ⇒ Electrical system; Rep. gr. 92 ; Wind‐
ss
– Remove plenum chamber cover ⇒ General body repairs, ex‐
o
cial p
f
terior; Rep. gr. 64 ; Removing and installing plenum chamber
inform
cover.
mer
atio
om
n
c
i
or
n
Note
thi
te
sd
iva
o
pr
c
The shear-head bolt threads are coated with locking compound.
um
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fo
Heating the shear-head bolt with a hot air blower releases the
en
ng
t.
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locking effect of the locking compound. t. Cop py
rig
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pyri by
Vo
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cted
Caution
agen
Prote AG.
Cover lines, connections and control units in the vicinity of the

engine control unit to prevent damage through heat.
Perform settings on hot air blower -4- as shown:

– Turn temperature setting potentiometer -2- to maximum heat
output (600°C).
– Set two-stage switch for volume of air -3- to position 3.
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.

Touareg 2003 ➤
– Switch on hot air blower and warm bolt heads -arrows- for ap‐
proximately 20 to 25 seconds.
– Unscrew shear-head bolt using mole grips/pliers on bolt head.
The procedure for the second shear-head bolt is identical.
AG. Volkswagen AG d
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– Remove cover -1- from control unit.
ce
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nl
pt
du
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itte
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erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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– Slide connector locking devices -1- on engine control unit out‐
nform
ercia
wards and pull off both connectors.

m
at
– Remove engine control unit.
om
ion
c
in t
Installing
or
his
ate
do
riv
– Insert engine control unit into retaining frame in plenum cham‐

p
cum
ber.
for
en
ng
t.
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Cop py
t. rig
gh ht
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Vo
co lksw
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cted agen
Prote AG.
– Fit connectors to engine control unit and slide locking devices

-1- inwards.
2. Engine control unit 143

Touareg 2003 ➤
– Place cover -1- over engine control unit and fit new shear-head
bolts -arrows- by hand. AG. Volkswagen n AG do
ks wage es n
– Then tighten new shear-head bolts evenlyVol until heads shear ot g
by ua
off. ris
ed ran
tee
tho or
– Install plenum chamber covers a⇒
u General body repairs, exte‐ ac
rior; Rep. gr. 64 ; Removings and installing plenum chamber
ce
e
nl
cover.
pt
du
an
itte
y li
– Install wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
26 – Exhaust system
1 Exhaust system
Note
♦ After working on the exhaust system, ensure that the system

is not under stress and that there is sufficient clearance to the
bodywork. If necessary, loosen double and single clamps and
align silencer and exhaust pipe so that sufficient clearance is
maintained to the bodywork and the support rings are evenly
loaded.
⇒ “1.1 Assembly overview - front exhaust pipe with catalytic con‐

verters”, page 145
⇒ “1.2 Assembly overview - front exhaust pipe with particulate
filter”, page 146
⇒ “1.3 Removing and installing particulate filter”, page 148
Volkswa AG. gen AG
agen does
⇒ “1.4 Assembly overview - exhaust manifold
yV
olks (engine codes BPD,
w not
gu
BPE)”, page 149 ise
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⇒ “1.5 Removing and installingau exhaust manifold (engine
t
codes ra
c
BPD, BPE)”, page 151 ss
ce
e
nl
pt
du
⇒ “1.6 Silencer with mountings”, page 153
an
itte
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erm
ab
1.1 Assembly overview - front exhaust pipe with catalytic converters
ility
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spec
es, in part or in w
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nf
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1. Exhaust system 145

Touareg 2003 ➤
1 - From turbocharger
2 - Gasket
❑ Renew.
tion.
❑ Renew.
4 - Front exhaust pipe with
starter catalytic converter
5 - Bracket
❑ Bolted to gearbox.
6 - 25 Nm
7 - Gasket
❑ Renew.
AG. Volkswagen AG d
8 - Front exhaust pipe with cat‐
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9 - To rear silencer
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10 - Mounting s
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1.2 Assembly overview - front exhaust pipe

m
atio
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with particulate filter

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Note
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If the particulate filter or the exhaust gas pressure sensor 1 - C py
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G450- is changed, the exhaust gas pressure sensor 1 -G450-
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must always be adapted using diagnosis tester : Guided
co Vo
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functions; adapting exhaust pressure sensor 1 -G450- . Prote AG.
146 Rep. gr.26 - Exhaust system

Touareg 2003 ➤
1 - Turbocharger
2 - Gasket
❑ Renew.
❑ Note installation posi‐ AG. Volkswagen AG d
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3 - Clamp, 7 Nm orise nte
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❑ Renew. ss a ra
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4 - Exhaust gas pressure sen‐
un
pt
an
sor 1 -G450-
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❑ Guided functions; pe
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Adapting exhaust gas
ot
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pressure sensor 1 -
, is n
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G450- .
hole
spec
5 - Bracket
es, in part or in w
t to the co
❑ For control line
6 - 10 Nm
rrectness of i
7 - Control line, 45 Nm
l purpos
8 - Temperature sender after

particulate filter -G527- , 45
nform
ercia
Nm
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on in
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112 A3-
s
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9 - 25 Nm
um
fo
en
ng
t.
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10 - Rear support
Co
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11 - 40 Nm
rig ht
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12 - Particulate filter
agen
Prote AG.
❑ Guided functions;
Adapting exhaust gas
pressure sensor 1 -
G450- .
13 - Front exhaust pipe
14 - Mounting
15 - Gasket
❑ Renew.
16 - 25 Nm
17 - Exhaust gas temperature sender 2 for bank 1 -G448-
❑ 45 Nm
❑ Lubricate thread of sender using high-temperature paste -G 052 112 A3-
18 - 40 Nm
19 - Lambda probe -G39-
❑ Grease only threads with high-temperature paste -G 052 112 A3- ; high-temperature paste -G 052 112
A3- must not get into the slots of probe body.
20 - Front support

Touareg 2003 ➤
AG. Volkswagen AG d
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agen oes
n ol ot g
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db ran
1.3 Removing and installing particulate filter
e
ris tee
tho or
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ss
ce
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un
pt
Note
an
d
itte
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erm
ab
If the particulate filter or the exhaust gas pressure sensor 1 -
ility
G450- is changed, the exhaust gas pressure sensor 1 -G450- ot p
wit
is n
must always be adapted using diagnosis tester : Guided
h re
ole,
functions; adapting exhaust pressure sensor 1 -G450- .
spec
t to the co
Removing
– Loosen cooler for exhaust gas recirculation and remove brack‐
et.
rrectne
– Separate connectors to Lambda probe -G39- , to bank 1 ex‐
s
haust gas temperature sender 2 -G448- , exhaust gas tem‐
s o
perature sender 1 -G235- and temperature sender after
cial p
f in
particulate filter -G527- .
form
mer
atio
Separate cable ties.
om
n
c
i
– Unscrew exhaust gas pressure sensor 1 -G450- from bracket.
or
n thi
te
sd
va
The exhaust gas pressure sensor 1 -G450- and the control lines
i
o
pr
cum
remain connected on the particulate filter.
r
fo
en
ng
t.
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– Remove front exhaust pipe.
Co
Cop py
ht. rig
– Loosen clamp.
rig ht
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co Vo
by lksw
cted
– Remove front support -1- and rear support -2- from particulate
agen
Prote AG.
filter.
– Take particulate filter out upwards.
Installing
– Insert particulate filter.

Touareg 2003 ➤
– Tighten rear support -2- on gearbox.

– Tighten hexagon nut of front support hand-tight.
– Fit clamp and new seal on particulate filter.
– Fit particulate filter to turbocharger and, simultaneously, tight‐
en hexagon nut hand-tight.
n AG to 7 Nm. . Volkswage
– Align particulate filter and tighten bolt
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geclamp n AG d
oes
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– Tighten hexagon bolt. edb ran
ris tee
tho
Specified torque: 40 Nm. s au
or
ac
s
– Tighten hexagon nut on thread of front support -1- and tighten
ce
le
un
pt
hexagon nut on engine support.
an
d
itte
y li
erm
ab
ility
ot p
wit
– Join connectors to Lambda probe -G39- , to bank 1 exhaust
is n
h re
gas temperature sender 2 -G448- , exhaust gas temperature
ole,
sender 1 -G235- and temperature sender after particulate filter
spec
-G527- and connect lines at the marked points using cable
t to the co
ties.
– Install front exhaust pipe.
rrectne
1.4 Assembly overview - exhaust manifold (engine codes BPD, BPE)
ss o
⇒ page 110 .
cial p
f inform
mer
atio
m
Note
o
n
c
i
or
n thi
e

t
sd
iva
o
pr
c
um
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
1 - Bracket
cooler
⇒ page 158 .
3 - Gasket
❑ Renew.
4 - Exhaust gas temperature
sender 1 -G235-
❑ 45 Nm
sender using high-tem‐ AG. Volkswagen AG d
agen oes
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perature paste -G 052 by Vol not
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ara
112 A3- rise
d
nte
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5 - 40 Nm + 90° turn ss au ra
c
❑ Renew.
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❑ Qty. 3
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ab
❑ Do not grease
pe
ility
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6 - Washers
, is n
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❑ Qty. 3
hole
spec
es, in part or in w
7 - Gasket
t to the co
❑ Renew.
rrectness of i
tion.
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❑ To remove: remove ex‐
nform
ercia
cooler and remove se‐

m
curing bolts securing
a
com
tio
turbocharger to exhaust
n in
r
manifold
te o
thi
⇒ Item 5 (page 150) .
s
iva
do
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cum
9 - 25 Nm
fo
en
ng
t.
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❑ Renew.
Co
Cop py
t. rig
gh
10 - Flange upper part
ht
pyri by
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❑ Renew.
by
cted agen
Prote AG.
11 - Seal
❑ Renew.
13 - Clip
14 - Vacuum line
15 - 40 Nm + 90° turn
16 - 40 Nm + 90° turn
17 - Turbocharger
18 - Gasket
❑ Renew.

Touareg 2003 ➤
19 - Clamp, 7 Nm AG. Volkswagen AG d

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❑ Renew. ed by
V gu
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20 - Particulate filter aut
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21 - Gasket
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pt
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❑ Renew.
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ility
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22 - Flange lower part
wit
, is n
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❑ Renew.
hole
spec
23 - Gasket
es, in part or in w
t to the co
❑ Renew.
rrectness of i
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25 - 10 Nm
nform
ercia

m
at
om
❑ Renew only together with exhaust gas recirculation cooler
ion
c
in t
or
27 - 10 Nm
his
ate
do
riv
28 - 15 Nm
p
cum
for
en
ng
t.
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Cop py
t. rig
1.5 Removing and installing exhaust mani‐
gh ht
pyri by
Vo
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fold (engine codes BPD, BPE)
lksw
cted agen
Prote AG.

♦ Allen key, long reach -VAS 3410-
♦ Gauge -10348-

AG. Volkswagen AG d
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Touareg 2003 ➤ ut
ho eo
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a
5-cylinder diesel engine - Edition 09.2012 ss c
ce
le
un
pt
an
♦ Torque wrench -V.A.G 1331/-
d
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
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nform
ercia
Removing exhaust manifold (engine codes BPD, BPE)
m
a
com
tio
n in
r
te o
thi
– Removing bracket ⇒ Item 1 (page 150) .
s
iva
do
r
rp
c
– Remove exhaust temperature sender 1 -G235-
um
fo
⇒ Item 4 (page 150) .
en
ng
t.
yi Co
op py
– Unscrew exhaust manifold securing nut ⇒ Item 9 (page 150) . t. C rig
gh ht
pyri by
– Unscrew bolts to turbocharger ⇒ Item 5 (page 150) .
o Vo
by c lksw
cted agen
Prote AG.
– Remove exhaust manifold.
Installing exhaust manifold (engine codes BPD, BPE)
• Renew all seals and gaskets.
• Specified torque ⇒ page 149 .
• Install in reverse order.
• In the process, note the following:
♦ In the case of a used exhaust manifold:
– Clean exhaust manifold connection using abrasive paper.
Note
The abrasive paper grade must not be less than 100.
– Fit new gasket onto turbocharger ⇒ Item 23 (page 116) .

– Fit sealing set onto exhaust manifold.
• The sealing set consists of:
♦ Flange upper part ⇒ Item 10 (page 115)
♦ Gasket ⇒ Item 23 (page 151)
♦ Flange lower part ⇒ Item 22 (page 116)

Touareg 2003 ➤
– Fix a new sealing set to exhaust manifold, e.g. using cable ties.
– Install exhaust manifold with sealing set on cylinder head
⇒ Item 8 (page 150) .
– Remove cable tie from sealing set.
– Start bolts on turbocharger. ⇒ Item 5 (page 150)
– Insert gauge -T10348- -1- in direction of arrow -A- and turn

gauge -T10348- in direction of arrow -B-.
1
AG. Volkswagen AG d
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un
pt
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erm
ab
ility
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wit
is n
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ole,
– Gauge -T10348- must be located between flange upper and

flange lower parts. spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
va
– Tighten bolts -1-, -2- and -3- to 5 Nm.

i
o
pr
cum
r
fo
– Loosen bolts by turning 180°.

en
ng
t.
yi Co
op
– Remove gauge from turbocharger.
C py
t. rig
gh ht
yri by
– Tighten bolts one by one to 30 Nm in 90° steps.
op Vo
by c lksw
cted agen
Prote AG.
– Then turn all bolts 180° further.
1.6 Silencer with mountings

Touareg 2003 ➤
1 - From front exhaust pipe

2 - Double clamp
AG. Volkswagen AG d
3 - Exhaust pipe with rear si‐ agen oes
olksw not
lencer d by V gu
ara
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4 - 25 Nm utho eo
ra
s a c
s
5 - Mounting
ce
le
un
pt
an
d
itte
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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.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
2 Exhaust gas recirculation system

⇒ “2.1 Assembly overview - exhaust gas recirculation”,
page 155 AG. Volkswagen AG d
agen oes
lksw not
⇒ “2.2 Checking exhaust gas recirculation valve (mechanical)”,
d byV
o gu
ara
page 159 orise nte
h eo
aut ra
ss c
ce
le
Note
un
pt
an
d
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♦ The exhaust gas recirculation system is actuated by the en‐
erm
ab
ility
gine control unit via the exhaust gas recirculation valve -N18-
(electropneumatic) to the exhaust gas recirculation valve ot p
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(mechanical).
ole,
spec
♦ The cone-shaped plunger in the mechanical exhaust gas re‐
t to the co
circulation valve ensures that various opening cross-sections
are possible at different valve lifts.
rrectne
2.1 Assembly overview - exhaust gas recir‐
ss o
culation
cial p
f inform
mer
⇒ “2.1.1 Assembly overview - exhaust gas recirculation (engine
atio
m
codes BAC and BLK)”, page 155

o
n
c
i
or
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⇒ “2.1.2 Assembly overview - exhaust gas recirculation, intake
thi
te
sd
a
manifold side (engine codes BPD and BPE)”, page 157

iv
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⇒ “2.1.3 Assembly overview - exhaust gas recirculation, exhaust
en
ng
t.
gas side (engine codes BPD and BPE)”, page 158
yi Co
Cop py
ht. rig
⇒ “2.1.4 Removing and installing exhaust gas recirculation cooler rig ht
py by
(engine codes BPD and BPE)”, page 158
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2.1.1 Assembly overview - exhaust gas recirculation (engine codes BAC and
BLK)
2. Exhaust gas recirculation system 155

Touareg 2003 ➤
1 - 10 Nm
2 - From charge air cooler
3 - Intake connecting pipe
❑ With mechanical ex‐
valve and intake mani‐
fold flap
❑ Can only be renewed in
its entirety, together with
exhaust gas recircula‐ AG. Volkswagen AG d
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manifold flap. byV gu
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❑ Perform mechanical in‐ ut
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spection of exhaust gas ss a c
recirculation valve
ce
le
un
pt
⇒ page 159 .
an
d
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4 - O-ring
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ab
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❑ Renew.
wit
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5 - Intake manifold
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spec
6 - Coolant hose
t to the co
diagram
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7 - 10 Nm
ss
cooler
o
cial p
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❑ Vehicles with automatic
nform
gearbox and exhaust
mer
gas recirculation
atio
m
changeover valve.
o
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or
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diagram
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11 - 25 Nm co Vo
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❑ Renew. Prote AG.
12 - 25 Nm
13 - Connecting pipe
14 - Gasket
❑ Renew.

Touareg 2003 ➤
2.1.2 Assembly overview - exhaust gas recirculation, intake manifold side (engine
codes BPD and BPE)
1 - 10 Nm
2 - Intake manifold flap motor -
V157-
❑ The intake manifold flap
is closed for approx. 3
seconds when stopping
engine and then opens
again. This reduces the
stop jolt.
3 - 10 Nm
valve -N18- with exhaust gas
recirculation potentiometer -
G212-
sealing surface on in‐
take manifold for soiling
and clean if necessary
❑ If the exhaust gas recir‐
culation valve -N18-
with exhaust gas recir‐
culation potentiometer -
G212- is renewed the
ignition must be switch‐ AG. Volkswagen AG d
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ed on and off again. by
Vol not
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Then wait one minute rised
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for the control unit to run ut
ho eo
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down (valve learns, ss a c
main relay must click)
ce
le
un
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an
❑ Start engine and run at
d
itte
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idling speed for one mi‐
rm
ab
pe
nute.
ility
ot
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❑ Then read engine con‐
, is n
h re
trol unit event memory;
hole
spec
event memory must not
es, in part or in w
contain any fault
t to the co
⇒ page 140 .
5 - Intake manifold
6 - Connecting pipe rrectness of i
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❑ To exhaust gas recirculation cooler.

7 - 22 Nm
nform
ercia
8 - Gasket
m
a
com
ti
❑ Renew.
on in
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Touareg 2003 ➤
2.1.3 Assembly overview - exhaust gas recirculation, exhaust gas side (engine
codes BPD and BPE)
1 - 8 Nm
3 - Bracket
4 - 15 Nm
5 - 8 Nm
6 - Coolant hoses
❑ To remove: clamp off
exhaust gas recircula‐
tion cooler using hose
clamps, up to 25 mm
-3094- .
7 - 25 Nm
8 - Gasket
❑ Renew.
Volkswagen AG
9 - Exhaust gas temperature agen
AG. does
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sender 1 -G235- by
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❑ 45 Nm ho
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❑ Lubricate threadss aof ra
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ce
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pt
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112 A3-
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h re
hole
cooler changeover valve -

spec
N345-
es, in part or in w
t to the co
13 - 10 Nm
rrectness of i
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❑ Renew only together
nf
ercia
with exhaust gas recirculation cooler

orm
m
atio

om
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or c
16 - Gasket
thi
te
sd
a
❑ Renew.
iv
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rp
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17 - Connecting pipe
f
en
ng
t.
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18 - 22 Nm C py
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rig ht
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19 - 10 Nm copy Vo
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2.1.4 Removing and installing exhaust gas re‐

circulation cooler (engine codes BPD
and BPE)

Touareg 2003 ➤
♦ Hose clamps up to 25 mm -3094-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
Removing
ce
le
un
pt
an
d
– Remove connecting pipe ⇒ Item 17 (page 158) . itte
y li
rm
ab
pe
ility
– Disconnect and remove coolant hoses ⇒ Item 6 (page 158) .
ot
wit
, is n
– Use a cloth to collect residual coolant.
h re
hole
spec
– Disconnect connecting hose from vacuum unit
es, in part or in w
⇒ Item 14 (page 158) .
t to the co
– Remove upper part bracket ⇒ Item 2 (page 158) .
rrectness of i
– Unbolt connection to exhaust manifold ⇒ Item 7 (page 158) .
– Carefully remove exhaust gas recirculation cooler. Dispose of
l purpos
residual coolant.
nform
ercia
Installing
m
• Install in reverse order.
a
com
tion in
• Specified torque ⇒ page 158 .
r
te o
thi
s
iva
• Replenish coolant ⇒ page 74 .
do
r
rp
cum
fo
2.2 Checking exhaust gas recirculation
en
ng
t.
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valve (mechanical) Cop py
t. rig
gh ht
pyri by
Only for engine codes BAC and BLK
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♦ Hand vacuum pump -V.A.G 1390-
Vacuum hose schematic diagram for engine codes BAC and BLK
⇒ page 123
Test procedure
– Remove charge air pipe / intake connecting pipe connecting
hose.
– Disconnect vacuum hose from mechanical exhaust gas recir‐
culation valve.

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

– Operate hand vacuum pump -V.A.G 1390- and observe dia‐
phragm rod.
• The diaphragm rod must move in -direction of arrow-.
– Remove hose of hand vacuum pump -V.A.G 1390- from me‐

chanical exhaust gas recirculation valve.
• The diaphragm rod must move back to its original position
counter to the direction of the arrow
AG. Volkswagen AG d
agen oes
olksw not
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tho eo
au ra
ss c
ce
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un
pt
an
d
itte
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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
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pr
cum
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fo
en
ng
t.
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Cop py
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gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
28 – Glow plug system

1 Glow plug system
⇒ “1.1 Characteristics of glow plugs”, page 161
⇒ “1.2 Checking metal glow plugs”, page 161 .
⇒ “1.3 Removing, installing and checking ceramic glow pin plugs”,
AG. Volkswagen AG d
page 162 . lksw
agen oes
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1.1 Characteristics of glow plugs
ho
ris
ed ran
tee
t or
au ac
ss
Caution
ce
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un
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an
d
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Ceramic glow plugs are sensitive to knocks and bending.
erm
ab
ility
ot p
For this reason a glow plug which has dropped from even a
wit
is n
small height (approx. 2 cm) must not be used, even if there is
h re
ole,
no obvious damage.
spec
It is absolutely essential to follow the installation instructions,
t to the co
otherwise the heater pin of the glow plug can break and cause
engine damage.
rrectne
Optical characteristics of glow plugs
ss
A - Ceramic glow plugs, phase step on top (see enlargement),
o
cial p
f i
colour-coded white -arrow-.
nform
mer
B - Metal glow plugs, colour-coded green -arrow-.
atio
om
n
c
Removing, installing and checking ceramic glow plugs
i
or
n thi
⇒ page 162 .
te
sd
iva
o
pr
Checking metal glow plugs ⇒ page 161 .
cum
r
fo
en
ng
t.
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Cop py
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1.2 Checking metal glow plugs
♦ Auxiliary measuring set -V.A.G 1594C-
1. Glow plug system 161

Touareg 2003 ➤ n AG. Volkswagen AG do
wage e
5-cylinder diesel
yV
o engine - Edition 09.2012 s not g
lks
b ua
ed ran
ris tee
♦ 10 mm jointedth spanner
o -3220- or
au ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Voltage tester -V.A.G 1527B-
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
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f
en
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t.
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Cop py
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Test prerequisites
• Battery voltage at least 11.5 V
• Ignition switched off
Test procedure
– Pull glow plug connectors off glow plugs.
– Connect voltage tester line to battery positive terminal using
auxiliary clamps from auxiliary measuring set -V.A.G 1594C- .
– Place test probe of voltage tester on each glow plug one after
the other. Diode lights up: glow plug OK., diode does not light
up: renew glow plug.
– Remove and install glow plugs with U/J extension and socket,
10 mm -3220- .
1.3 Removing, installing and checking ceramic glow pin plugs
162 Rep. gr.28 - Glow plug system

Touareg 2003 ➤

equipment required AG. Volkswagen AG d
agen oes
lksw not
♦ 10 mm jointed spanner d by Vo gu
ara
-3220- orise nte
th eo
u ra
♦ Torque wrench -V.A.Gss a c
1331-
ce
e
nl
pt
du
an
♦ Hand-held multimeter -
itte
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V.A.G 1526A-
erm
ab
ility
ot p
♦ Auxiliary measuring set -
wit
, is n
V.A.G 1594C-
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
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cum
for
en
ng
t.
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Cop py
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pyri by
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co lksw
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cted agen
Prote AG.
Not illustrated:
♦ Flat-headed pliers -VAS 6275-
Caution
Ceramic glow plugs are sensitive to knocks and bending.

For this reason a glow plug which has dropped from even a
small height (approx. 2 cm) must not be used, even if there is
no obvious damage.
It is absolutely essential to follow the installation instructions,
otherwise the heater pin of the glow plug can break and cause
engine damage.
Test prerequisites
♦ Engine is cold
♦ Ignition switched off
1. Glow plug system 163

Touareg 2003 ➤
Procedure
Note
Do not cant ceramic glow plugs when removing and installing.

Remove any components hindering assembly.

– Pull connectors off ceramic glow plugs using flat headed pliers
-VAS 6275- .
– Remove ceramic glow plugs using U/J extension and socket,
10 mm -3220- .
Installation is carried out in the reverse order; note the following:
– Before installing, bore in cylinder head and threads must be
completely cleaned of all deposits.gen AG. Volkswagen AG d
a oes
ksw not
y Vol gu
b ara
ed nte
Note oris eo
th
au ra
c
ss
Do not oil or grease thread of cylinder head bore or of ceramic
ce
e
nl
pt
glow pin plugs.
du
an
itte
y li
erm
ab
– Turn ceramic glow plugs into cylinder head by hand using U/
ility
ot p
J extension and socket, 10 mm -3220- .

wit
, is n
h re
– Then tighten the ceramic glow plugs.
hole
spec
es, in part or in w
Specified torque: t to the co
• WAF 8 = 12 Nm
• WAF 10 = 15 Nm
rrectness of i
l purpos
Caution
nform
ercia
After installing and before the engine is started, perform a re‐

sistance test on all ceramic glow plugs when engine is cold.
m
at
om
io
• Specification: max. 1.0 Ω

n
c
in t
or
his
ate
do
priv
– If the specification is exceeded, renew the defective ceramic

um
for
en
g
glow plug.
n
t.
yi Co
Cop py
t. rig
gh ht
yri by
Note cop Vo
by lksw
cted agen
Prote AG.
If the defective ceramic glow plug is broken, remove all fragments
from the engine, otherwise these can cause damage to the en‐
gine.
164 Rep. gr.28 - Glow plug system

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Service

5-cylinder diesel engine

Service Department. Technical Information

All rights reserved.

Copyright © 2015 Volkswagen AG, Wolfsburg K0058961720

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.1 Dismantling and assembling engine, parts I-III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.2 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.3 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1.4 Crankshaft bearing cap identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.5 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.7 Renewing alternator shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.2 Separating new conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2.3 Installation position and allocation of piston to cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.4 Checking piston ring gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 Checking ring-to-groove clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.6 Checking cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2.7 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2.3 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

2.2 Assembly overview - oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

1.2 Assembly overview - radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

1.4 Parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

1.7 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

1.8 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

1 Repairing diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

1.1 Characteristics of glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

⇒ “1.1 Engine number”, page 1

1.1 Engine number

1.2 Engine data

2.1 Safety precautions when working on

Risk of injury due to highly-pressurised fuel.

lines can reach 100 °C after the engine is switched off.

Allow the fuel to cool down before disconnecting the lines

♦ Wear protective gloves.

To prevent injuries to persons and destruction of the injection and rrectness of i

glow plug system, the following must be noted:

necting electrical wiring of injection and glow plug system or

connecting/disconnecting tester cables.

♦ Wash the engine only with the ignition switched off.

♦ Entries have been stored in the event memory of the engine

control unit if the engine was started after electrical connectors

had been disconnected: Read event memory in vehicle

♦ Observe required procedures when disconnecting battery

– Disconnect battery ⇒ Electrical system; Rep. gr. 27 .

2 Rep. gr.00 - Technical data

2.2 Safety precautions for when using test

♦ The cooling system is under pressure when the engine is

Danger of injury; the radiator fans can run at any time.

♦ Disconnect electrical connectors before starting work in

Danger of overheating due to incorrectly fitted cap.

3 General repair notes

3.1 Rules for cleanliness

3.2 Foreign objects in engine

If large quantities of swarf or metal particles (caused, for example,