GB 5-Cylinder Diesel Engine

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Service Department. Technical Information

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Repair GroupsList 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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13 - Crankshaft group
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15 - Cylinder head, valve gear
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17 - Lubrication
19 - Cooling
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20 - Fuel supply system
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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 © 2011 Volkswagen AG, Wolfsburg K0058961720

Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
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Contents
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00 - Technical data . . . a.uth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . e.e .or a. . . . . ............ 1
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1 Technical data s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. 1
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1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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2.2 Safety precautions for when using test and measuring equipment during a road test . . . . 3
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2.3 Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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3 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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1.2 Removing engine from scissor-type assembly platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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1.3 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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1.4 Additional information and assembly work for vehicles with air conditioner . . . . . . . . . . . . 16
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1.5 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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2.1 Assembly overview - engine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.2 Specified torques - Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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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
1.6 Renewing crankshaft oil seal - engine timing end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.7 Renewing alternator shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.1 Assembly overview - 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.5 Checking ring-to-groove clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.6 Checking cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.7 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1 Overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2 Repairing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.2 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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2.3 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

2.4 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.5 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.1 Oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.2 Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2 Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.1 Assembly overview - oil pump, sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.2 Assembly overview - oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.3 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.4 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.1 Parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.2 Assembly overview - radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.3 Removing and installing fan support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.4 Parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.5 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.6 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.7 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.8 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.9 Checking oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ge. n. A. G. ..V.ol.ks. w. a.g.en. A. G
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1.3 Assembly overview - fuel tank with attachments (►rismodel ed year 08) . . . . . . . . . . . . . . . . .ra.nte 87
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1.4 Assembly overview - fuel tank with attachments ut (model year 08 ►) . . . . . . . . . . . . . . . . . . 88
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1.5 Assembly overview - fuel filter with fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
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1.6 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
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1.7 Removing and installing fuel pump unit, fuel gauge sender and suction jet pumps (for vehicles
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► model year 08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
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1.8 Removing and installing fuel pump unit, fuel gauge sender and suction jet pumps (for vehicles
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1.9 Removing and installing fuel tank with attached components . . . . . . . . . . . . . . . . . . . . . . 100 spec
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1.10 Checking fuel pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

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1.11 Checking tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

1.12 Removing and installing tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
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1.13 Assembly overview - accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

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21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
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1.2 Turbocharger with attachments for engine codes BAC and BLK . . . . . . . . . . . . . . . . . . . . 110
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1.3 Removing and installing turbocharger for engine codes BAC and BLK . . . . . . . . . . . . . . . . 112
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1.4 Turbocharger with attachments (engine codes BPD and BPE) . . . . . . . . . . . . . . . . . . . . . . 114
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1.5 Removing and installing turbocharger (engine codes BPD and BPE) . . . . . . . . . . . . . . . . 116
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1.6 Removing and installing parts of charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

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1.7 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t. Cop
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1.8 Hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
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1.9 Vacuum hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
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23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

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Touareg 2003 ➤
1 Repairing diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.3 Removing and installing unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.4 Assembly overview - unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
1.5 Removing and installing O-rings for unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
1.6 Assembly overview - intake manifold and fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.7 Repairing intake manifold flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.8 Dismantling and assembling air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2.1 Reading and deleting engine control unit event memory . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2.2 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
2.3 Removing and installing anti-theft engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . 140
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

1 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.4 Assembly overview - exhaust manifold (engine codes BPD, BPE) . . . . . . . . . . . . . . . . . . 148
1.5 Removing and installing exhaust manifold (engine codes BPD, BPE) . . . . . . . . . . . . . . . . 150
1.6 Silencer with mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2.1 Assembly overview - exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
2.2 Checking exhaust gas recirculation valve (mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
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Characteristics of glow plugs . . . . . . . . . . o.r a.c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
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1.2 Checking metal glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
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1.3 Removing, installing and checking ceramic glow pin plugs . . . . . . . . . . . . . . . . . . . . . . . . 162
an
d
itte
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ab
pe
ility
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spec
es, in part or in w
t to the co
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Cop py
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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
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
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or
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ate
do
priv
cum
for
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Cop py
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cted agen
Prote AG.
iv Contents
Touareg 2003 ➤
00 – Technical wdata
agen
AG. Volkswagen AG d
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olks s no
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1 Technical data tho
ris
e nte
eo
au ra
⇒ „1.1 Engine number“,
ss page 1 c
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un
pt
⇒ „1.2 Engine data“, page 1
an
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1.1 Engine number
ab
ility
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The engine number („engine code“ and „serial number“) can be
h re
found on the joint between engine and gearbox.
ole,
spec
urposes, in part or in wh
Additionally there is a sticker on the front of the cylinder head with
t to the co
„Engine code“ and „Serial number“.
The engine code is also included on the vehicle data sticker.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n
1.2 Engine data
thi
te
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Edition 11.20011 Version 21.0
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Engine code ht. Cop
BAC BLK py
rig BPD BPE
rig ht
Manufactured 03.03 ► 08.03 ► 11.05 ► 11.05 ►
py by
co Vo
by lksw
Emissions fulfil cted EU3 standard EU3 standard EU4 standard EU4 standard
agen
Prote AG.
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
the fuel system. Then release pressure by carefully loos‐
ening the connection.
♦ Wear protective gloves.
♦ Wear eye protection.
Danger of burning from very hot fuel.
♦ In extreme cases, the temperature of the fuel or the fuel
lines can reach 100 °C after the engine is switched off.
Allow the fuel to cool down before disconnecting the lines
- danger of scalding. en AG. V
olkswagen AG
g does
swa
♦ Wear protective gloves.
by
Vol
k not
gu
ara
d
ise nte
♦ Wear eye protection.
tho
r eo
au ra
c
ss
ce
e
nl
pt
To prevent injuries to persons and destruction of the injection and

du
an
itte
glow plug system, the following must be noted:

y li
erm
ab
ility
♦ Always switch off the ignition before connecting or discon‐

ot p
wit
necting electrical wiring of injection and glow plug system or

, is n
h re
connecting/disconnecting tester cables.

hole
spec
♦ Wash the engine only with the ignition switched off.

es, in part or in w
t to the co
♦ 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
rrectness of i
self-diagnosis ⇒ Vehicle diagnosis tester .

l purpos
Caution
nf
ercia
orm
♦ Observe required procedures when disconnecting battery

m
atio
m
⇒ Electrical system; Rep. gr. 27 ; battery; Disconnecting

o
n in
c
and reconnecting battery.

or
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te
sd
iva
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o
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 .

f
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
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
be used during a road test:
♦ Test and measuring instruments must always be secured to
the rear seat and operated by a second person from this lo‐
cation.
♦ 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.

cooling system
WARNING
Hot steam/hot coolant can escape - risk of scalding.

♦ The cooling system is under pressure when the engine is
hot.
♦ Cover filler cap on expansion tank with a cloth and open
carefully to release pressure. AG. Volkswagen AG d
agen oes
Danger of injury; the radiator fans can run at any time. olksw not
y V gu
d b ara
♦ Disconnect electrical connectors before starting work rise in nte
tho eo
the area of the radiator cowl. s au ra
c
s
ce
e
nl
pt
du
an
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erm
Caution
ab
ility
ot p
wit
, is n
Danger of overheating due to incorrectly fitted cap.
h re
hole
spec
♦ Tighten cap of coolant expansion tank until it engages.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
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 n AG. Volkswagen AG do

lkswage es n
When working on fuel supply and injection system, d by Vpay careful
o ot g
ua
attention to the following rules for cleanliness: o
ir se
ran
tee
th or
u
♦ Before disconnecting, thoroughly clean ss all connections and
a ac
adjacent areas e.g. with brake cleaner.
ce
e
nl
pt
du
an
♦ Place removed parts on a clean surface and cover. Use only
itte
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lint-free cloths.
erm
ab
ility
ot p
♦ Carefully cover opened components and connections or seal
wit
, is n
if repairs cannot be carried out immediately.
h re
hole
spec
♦ Install clean components only. Do not remove replacement
es, in part or in w
parts from packing until immediately before installing. Do not
t to the co
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
rrectness of i
♦ When the system is open: Do not work with compressed air.
Do not move vehicle.
l purpos
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
nform
ercia
immediately. Damaged hoses must be renewed.

m
at
om
3.2 Foreign objects in engine
ion
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in t
or
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ate
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Note
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If large quantities of swarf or metal particles (caused, for example, Cop py
by partial seizure of the crankshaft or conrod bearings) are found
t. rig
gh ht
yri by
in the engine oil when performing repairs, clean the oil passages cop Vo
by lksw
thoroughly and renew the engine oil cooler in order to prevent cted agen
Prote AG.
subsequent damage.
4 Rep. gr.00 - Technical data

Touareg 2003 ➤
n AG. Volkswage
5-cylinder
n AG d
oes diesel engine - Edition 11.2011
lkswage not
Vo gu
by ara
ed
ris nte
10 – Removing and installing engine tho eo

au ra
ss c
ce
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un
pt
1 Removing and installing engine
an
d
itte
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erm
ab
ility
⇒ „1.1 Removing engine“, page 5
ot p
wit
is n
⇒ „1.2 Removing engine from scissor-type assembly platform“,
h re
ole,
page 14
spec
⇒ „1.3 Securing engine to assembly stand“, page 15
t to the co
⇒ „1.4 Additional information and assembly work for vehicles with
air conditioner“, page 16
rrectne
⇒ „1.5 Installing engine“, page 17
s
⇒ „2.2 Specified torques - Assembly mountings“, page 18
s o
cial p
f in
1.1 Removing engine
form
mer
atio
The engine is removed downwards with gearbox.
om
n
c
i
or
n thi
te
sd
iva
o
r
♦ Scissor-type assembly
p
cum
r
fo
platform -VAS 6131-
en
ng
t.
yi Co
op
♦ Drip tray -V.A.G 1306- or C py
t. rig
drip tray for workshop hoist
gh ht
pyri by
-VAS 6208-
co Vo
by lksw
cted agen
Prote AG.
♦ Spring-type clip pliers -VAS
5024 A-
♦ Torque wrench -V.A.G
1332- (40...200 Nm)
♦ spring compressor -VW
552-
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‐olksw
tem, electrical wiring as well as swa
gen AG
.V agen AG
does
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Vol gu
♦ Fuel lines ed by ara
nte
ris
♦ Hydraulic lines utho eo
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a c
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♦ Coolant and refrigerant lines
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nl
pt
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an
♦ Lines for brake fluid
itte
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ab
♦ and vacuum lines
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♦ must be routed in their original positions.
h re
hole
spec
♦ Ensure that there is sufficient clearance to all moving or
es, in part or in w
hot components.
t to the co
– First check whether a coded radio is fitted. If so, obtain anti-
rrectness of i
theft coding.
l purpos
Note
nf
ercia
orm
m
♦ Leave ignition key in ignition lock to prevent steering lock from atio
m
engaging.
o
n in
or c
thi
♦ It is advisable to remove the front wheels before beginning

te
sd
iva
engine removal. The vehicle can then be lowered on hoist until

o
r
rp
cu
the brake disc splash plates are just above the floor. This pro‐
o
m
f
en
ng
vides a more ergonomic working position regarding accessi‐

t.
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bility of engine compartment components. Cop py
t. rig
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♦ Some components cannot be removed, or removed only with
p by
co Vo
by lksw
difficulty, with the engine installed. Therefore, you should de‐ Prote
cted AG.
agen
termine all defective components before removing engine and
renew them while engine is removed.
♦ To prevent damage to removed components, place them in
the container for removed parts -V.A.G 1698- .
– All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
– 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

AG. Volkswagen AG d
agen
Volksw
oes
not Touareg 2003 ➤
by gu
ised ara
nte 5-cylinder diesel engine - Edition 11.2011
or eo
h
ut ra
Continuation
ss a
for all vehicles c
ce
le
un
– Remove engine cover -A- and engine compartment covers
pt
an
d
-B-, -C- and -D-, if fitted.

itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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– Remove intake hose -A-.
nform
ercia
– Pull vacuum hoses off exhaust gas recirculation valve, intake

m
a
com
t
manifold changeover vacuum actuator and turbocharger.
ion in
r
te o
– Remove crankcase breather hose from cylinder head cover.
thi
s
iva
do
r
– Release clip of air filter connecting hose on engine, then dis‐

rp
cum
fo
connect hose. en
ng
t.
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op
– Extract air conditioning system refrigerant ⇒ Heating, air con‐
C py
t. rig
ditioning system; Rep. gr. 87 .
gh ht
pyri by
Vo
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by c lksw
– Unscrew refrigerant lines from air conditioner compressor.
cted agen
Prote AG.
– Remove noise insulation: ⇒ General body repairs, exterior;

Rep. gr. 50 ; Body - front; Assembly overview - noise insulation
WARNING
We recommend removing the »lower connecting bolts« for the

engine/gearbox flange on all Touareg's, including this one, be‐
fore removing the engine/gearbox assembly. If possible, you
should also fit the attachment for the torque converter as early
as possible. This is valid when removing and reinstalling the
gearbox.
– Drain off coolant: ⇒ page 72 .
– Disconnect starter cable -1- and alternator cable -2-, and place
on engine.

Touareg 2003 ➤
– Pull fuel supply hose -1- and fuel return hose -2- off fuel filter.
– Remove brake servo vacuum supply hose from tandem pump.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
– Disconnect glow plugs connector -1-.
ot p
wit
is n
– Pull all necessary coolant hoses off engine.
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m
– Clamp off power-assisted steering oil hose -arrow- with hose

o
n
c
clips up to 40 mm Ø -3093- , loosen clip and disconnect hose

or
n thi
e
from power steering pump.

t
sd
iva
o
pr
– Pull engine compartment seal off plenum chamber bulkhead.

um
r
fo
en
ng
t.
yi
– Remove plenum chamber cover.
Co
Cop py
t. rig
gh
– Unclip engine control unit from mountings (on right in plenum
ht
pyri by
Vo
o
chamber) and pull connector off engine control unit.
c by lksw
cted agen
Prote AG.
– 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.
– Unclip line for gearbox breather -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
s c
– Secure suspension strut, as shown, with spring compressor - s
ce
le
VW 552- .
un
pt
an
d
itte
– Remove upper bolts of suspension strut: ⇒ Running gear; y li

erm
ab
Rep. gr. 40 ; Front suspension . ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness
– Disconnect engine earth connection -1-.

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 ➤
– Pull coolant hose -arrow- off continued coolant circulation

pump.
– Remove connecting hose between turbocharger and charge
air pipe.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
– Pull additional heater coolant hoses -arrows- off and place to
pe
ility
the side so that they are not torn off when removing the engine.
ot
wit
, is n
h re
– Remove heat shield -A- (if fitted) from steering box (2 bolts).
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
– Unscrew universal joint bolt -B- from steering box, and pull
com
tion in
universal joint off steering box.
r
te o
thi
s
– Remove bracket for catalytic converter on underbody.
iva
do
r
rp
cum
– Disconnect connectors -A- from gearbox.

fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Release exhaust system clip -B- and push to rear.

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

Touareg 2003 ➤
– Clamp off power steering oil line to cooler with hose clips up
to 40 mm Ø -3093- , loosen clip and pull hose off cooler. Collect
escaping oil.
Vehicles with automatic gearbox
– Disconnect connectors on gearbox and transfer box ⇒ Auto‐
matic gearbox 09C; Rep. gr. 37 .
– Remove selector cable from gearbox ⇒ Automatic gearbox
09C; Rep. gr. 37 . wage
e
olks s no
yV t gu
edb ara
ris nte
tho eo
au ra
c
ss
ce
le
– Disconnect lines on lower right of radiator -arrow- for gearbox

un
pt
an
d
oil. Collect escaping oil.

itte
y li
erm
ab
ility
ot p
wit
is n
– Remove clutch slave cylinder ⇒ Rep. gr. 30 ; Clutch mecha‐
h re
ole,
nism; Removing and installing clutch slave cylinder .
spec
Continuation for all vehicles
t to the co
rrectness o
cial p
f
– Remove gearbox transverse support -A-.
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– 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
. Volkswagen AG
a gen AG d
– Bolt support 3 and support Vol 4 to scissor-type assembly platform
ksw
oes
not
gu
at following positions:
ed by ara
n is tee
or
Support 3: A 6 and
au B 5
th or
ac
ss
Support 4: F 6 and H 6
ce
e
nl
pt
du
an
– Screw turntables of supports 3 and 4 downwards.
itte
y li
erm
ab
– Place support 5 for subframe and support 6 for gearbox trans‐
ility
ot p
verse support in appropriate positions on scissor-type assem‐
wit
, is n
bly platform.
h re
hole
spec
– Fix subframe in position ⇒ Running gear, axles, steering; Rep.
es, in part or in w
gr. 40 ; Fixing subframe in position .
t to the co
rrectness of i
l purpos
nform
ercia
– Position horizontal scissor-type assembly platform under en‐

m
gine/gearbox assembly. The supports -1- and -2- must be
at
om
io
guided into corresponding mountings on left and right
n
c
in t
r
-arrow-.
o
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
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.

Touareg 2003 ➤
– Guide supports 5 into their respective mountings in subframe

-arrow-, correcting support height as necessary with knurled
nuts.
– Loosen subframe bolts -1-, -2- and -3- as well as gearbox

transverse support -4-.
Specified torque gearbox carrier -4- to body ⇒ Rep. gr. 34 ; In‐
stalling transfer box, gearbox carrier and console gen AG
. Volkswagen AG
d wa oes
olks not
byV gu
ara
ed nte
Note ris
tho eo
au ra
c
ss
♦ Engine and gearbox must be guided carefully when lowering
ce
e
nl
pt
to prevent damage to the bodywork.
du
an
itte
y li
erm
♦ If the subframe is not fixed on body, after reinstalling it is nec‐
ab
ility
essary to perform wheel alignment on the vehicle.
ot p
wit
, is n
h re
– Now slowly lower engine/gearbox assembly, constantly ob‐
hole
spec
serving the clearance.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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o
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f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

lkswage es n
o ot g
byV ua
d ran
Touareg 2003 ➤ ho
ir se tee
t or
5-cylinder diesel engine - Edition 11.2011au ac
ss
ce
e
nl
pt
1.2 Removing engine from scissor-type assembly platform
du
an
itte
y li
erm
ab
ility
ot p
Special tools and workshop
wit
, is n
equipment required
h re
hole
spec
♦ Hooks -10-222A/2-
es, in part or in w
t to the co
♦ Lifting eye -2024A/2-
♦ Lifting tackle -2024 A-
rrectness of i
♦ Lifting tackle -3033- l purpos
♦ Workshop crane -V.A.G

1202A- or workshop crane
-VAS 6100- with lifting tack‐
nf
ercia
o
le -3033-
rm
m
atio
m
♦ Drip tray -V.A.G 1306- or

o
n in
c
drip tray for workshop hoist

or
thi
e
-VAS 6208-
t
sd
iva
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cu
o
m
f
en
ng
1331- (5...50 Nm)

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– Unbolt gearbox from engine: ⇒ Manual gearbox; Rep. gr. 34 ;

Removing and installing gearbox .
– Unbolt gearbox from engine: ⇒ Automatic gearbox 09D; Rep.
gr. 37 ; Removing and installing gearbox .
– Remove assembly mounting nut/bolt -A- on both sides of en‐
gine.

Touareg 2003 ➤
– Fit lifting tackle -2024 A- on cylinder block as shown.
– Attach lifting tackle -3033- together with hooks -10-222 A/2- to

crane and transportation plates, and lift engine off scissor-type
assembly platform, swa
as
geshown.
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1.3 Securing engine to assembly stand

nform
mercia
Engine codes BAC and BLK

com
tion in
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Before carrying out repair work, secure engine on assembly stand

te o
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with engine and gearbox support -T10220- .

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– Unbolt gearbox from engine ⇒ Manual gearbox; Rep. gr. 34 ;
Cop py
Removing and installing gearbox ⇒ Automatic gearbox 09C;
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– Remove engine bracket from cylinder head.
AG.

Touareg 2003 ➤
– Fit lifting eye -2024A/2- to cylinder block and tighten to 40 Nm

– Fit engine and gearbox support -T10220- as shown and tight‐
en to 40 Nm.
– Secure engine to assembly stand with engine and gearbox
support -T10220- .
Engine codes BPD and BPE
Before carrying out repair work, secure engine on assembly stand
with engine and gearbox support -T10342- .
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.
– Fit lifting eye -2024A/2- to cylinder block and tighten to 40 Nm

– Fit engine and gearbox support -T10342- as shown and tight‐
en to 40 Nm.
– Secure engine to assembly stand with engine and gearbox
support -T10342- .
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1.4 Additional information and assembly

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work for vehicles with air conditioner

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Note
spec
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t to the co
♦ Always observe the notes on installing air conditioner com‐

pressor ⇒ Heating, air conditioning system; Rep. gr. 87 .
rrectness of i
♦ To prevent damage to condenser or to refrigerant lines/hoses,

ensure that the lines and hoses are not stretched, kinked or
l purpos
bent.
nform
ercia
– Remove air conditioner compressor ⇒ Heating, air condition‐

ing system; Rep. gr. 87 .
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Prote AG.
Rep. gr.10 - Removing and installing engine
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 agenmechanism . AG do
AG. Volkswagen
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– Install selector mechanism and d b adjust cables if necessary ⇒
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6-speed manual gearboxh0A5;rise Rep. gr. 34 ; Repairing selector tee
t o
mechanism; Removingauand installing selector cables . or
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– Install selector lever cable on gearbox ⇒ Rep. gr. 37 ; Selector
y li
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mechanism; Assembly overview - selector lever cable .
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– Top up ATF level ⇒ Automatic gearbox 09D; Rep. gr. 37 ;
wit
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Checking ATF level and topping-up.
hole
spec
es, in part or in w
t to the co
– Electrical connections and routing: ⇒ Electrical system; Rep.
gr. 97 .
rrectness of i
– Install subframe: ⇒ Running gear, axles, steering; Rep. gr.
40 ; Removing and installing subframe
l purpos
– Reconnect air conditioning lines: ⇒ Heating, air conditioning

system; Rep. gr. 87 ; Repairing components of refrigerant cir‐
nf
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cuit .
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– Replenish coolant ⇒ page 72 .

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– Replenish oil in power-assisted steering: ⇒ Running gear,

thi
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sd
axles, steering; Rep. gr. 48 ; Checking power-assisted steer‐

iva
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ing system oil level.

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– Install noise insulation.

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– Carry out a road test and read event memory ⇒ page 139 yri
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Reading and clearing event memory of engine control unit. cop Vo
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Touareg 2003 ➤
AG. Volkswagen AG d
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2 Assembly mountings
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⇒ „2.1 Assembly overview - engine mountings“, page 18
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⇒ „2.2 Specified torques - Assembly mountings“, page 18
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2.1 Assembly overview - engine mountings
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Specified torques
spec
Engine assembly mountings
t to the co
A- Bracket for additional 20 Nm
water pump
rrectne
B- Engine bracket to cylin‐ 55 Nm
der block
ss
C- Engine mounting 60 Nm
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D- Engine bracket to en‐ 75 Nm
form
mer
gine mounting
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2.2 Specified torques - Assembly mountings
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Threaded connection opSpecified torque
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Bolts, nuts M6 10 Nm
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M7 15 Nm
M8 25 Nm
M10 40 Nm
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
agen
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⇒ „1.1 Dismantling
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⇒ „1.2 Removing
ss
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and installing crankshaft“, page 24 ac
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⇒ „1.3 Removing and installing drive plate“, page 25
pt
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⇒ „1.4 Crankshaft bearing cap identification“, 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“,
hole
spec
page 27
es, in part or in w
t to the co
⇒ „1.7 Renewing alternator shaft oil seal“, page 28
1.1 Dismantling and assembling engine,
rrectness of i
parts I-III
l purpos
Note
nform
mercia
♦ If large quantities of swarf or metal particles (caused, for ex‐

at
om
ample, by partial seizure of the crankshaft or conrod bearings) ion

c
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are found in the engine oil when performing repairs, clean the
o
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oil galleries thoroughly and renew the engine oil cooler in order
a
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to prevent subsequent damage.

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♦ Engine must not be set down on oil sump, as this will damage
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♦ Secure engine to engine and gearbox support -VAS 6095- to
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⇒ „1.1.1 Part I“, page 21

⇒ „1.1.2 Part II“, page 22
⇒ „1.1.3 Part III“, page 23
1. Dismantling and assembling engine 19

Touareg 2003 ➤
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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
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⇒ page 34 d byV ua
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5 - Gear wheel utho or
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❑ For coolant
ss pump.
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coolant pump y li
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⇒ page 77 . ility
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6 - Oil sump
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❑ Clean sealing surface

hole
spec
before fitting.
es, in part or in w
t to the co
❑ Install with sealant ac‐

⇒ page 62 .
rrectness of i
7 - 15 Nm
l purpos
8 - Plug
nf
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❑ 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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❑ For coolant pump.
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❑ Renew seal if damaged.
12 - 20 Nm

Touareg 2003 ➤
5-cylinder diesel engine - Edition G. Volkswagen AG d
gen A11.2011
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Sealant bead on gear trainorihousing
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1.1.2 Part II
ss o
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1 - Plug, 20 Nm
inform
mer
❑ Remove to remove
atio
coolant pump.
om
n
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2 - Plug, 20 Nm
thi
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❑ Remove to remove
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coolant pump.
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3 - O-ring
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❑ Renew. gh ht
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4 - Engine speed sender -G28- Prote
cted AG.
agen
❑ Tighten on cylinder
block to 10 Nm.
5 - Oil filter housing
❑ With engine oil cooler.
❑ Dismantling and assem‐
bling ⇒ page 58 .
6 - 20 Nm
7 - Gasket
❑ Renew.
8 - 15 Nm
9 - Retaining clip
10 - Noise insulation
❑ For oil sump.
11 - Oil sump
❑ Clean sealing surface
before fitting.
❑ Install with sealant ac‐
⇒ page 62 .
12 - Sealing flange
13 - Cover
❑ Renew.

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15 - Right engine support
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16 - 50 Nm + 90° further
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❑ Renew.
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1.1.3 Part III
es, in part or in w
t to the co
1 - Alternator
rrectness of i
❑ The bolts between alter‐
nator and alternator
l purpos
bracket must not be

loosened.
nf
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⇒ Electrical system;
atio
m
Rep. gr. 27 ; Alternator;

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c
Removing and installing

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alternator .
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2 - 20 Nm
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3 - Balance weight
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❑ Tighten to 75 Nm.
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4 - 50 Nm + 90° further Prote
cted AG.
agen
❑ Renew.
5 - Left engine support
6 - Engine mounting
7 - 60 Nm
8 - Power-assisted steering
vane pump
⇒ Running gear, axles,
steering; Rep. gr. 48 ;
Vane pump, hydraulic
lines, storage tank with
suction hoses; Remov‐
ing and installing vane
pump .
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 agen AG. Volkswagen AG do
removed, first removeVolksw es n
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cylinder head bolts ed and
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cylinder head tbefore tee
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loosening crankshaft
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bearings.
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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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using Plastigage:
hole
0.026…0.040 mm, wear

spec
limit: 0.16 mm
es, in part or in w
t to the co
❑ Do not rotate crankshaft

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

l purpos
❑ Insert with sealant according to ⇒ Electronic parts catalogue (ETKA) ⇒ page 22 .

nform
ercia
❑ With seal.
❑ Use fitting tool -T10122- to pretension seal before installing.
m
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❑ Do not additionally oil or grease the oil seal sealing lip.

n in
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❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
s
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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.
Prote
cted AG.
agen

Touareg 2003 ➤
When replacing a defective dual-mass flywheel, the vibration damper ⇒ Item 11 (page 25) must always
be replaced.
n AG . Volkswage
❑ When removing and installing flywheel,wage lock with counterhold
n AG d
oes -3067- .
Volks not
❑ Removing and installing drive
ed bplate
y ⇒ page 25 . gu
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8 - 60 Nm + 90° further utho eo
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❑ Renew.
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9 - Cylinder block
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10 - 20 Nm + 90° further
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❑ Renew.
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11 - Vibration damper
hole
spec
❑ To remove, remove conrod bearing cap of cylinder 1. Renew conrod bolts.
es, in part or in w
t to the co
❑ When installing, tighten upper bolt to 5 Nm. Then first tighten front and then upper securing bolts to
specified torque.
rrectness of i
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1.3 Removing and installing drive plate

⇒ „1.3.1 Loosening and tightening drive plate“, page 26
nform
mercia
⇒ „1.3.2 Installing drive plate“, page 26
a
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tion in
Special tools and workshop equipment required
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♦ Clutch counterhold -VW 558-
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♦ Torque wrench -V.A.G 1332-
♦ Vernier gauge
♦ Hexagon bolt M8 × 50 with M12 hexagon nuts

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
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1.3.2 Installing drive plate itte
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– Position drive plate with shim.
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– Fit new bolts and tighten to 30 Nm.
ole,
spec
– Use the caliper gauge to check the distance between the drive
t to the co
plate and gear train cover.
Specification dimension -a-: 18.1 mm…19.7 mm
rrectne
If specification is not attained:
– Remove drive plate again and place shim between crankshaft
ss
and drive plate. Tighten bolts to 30 Nm again.
o
cial p
f inform
– Tighten bolts to 60 Nm + turn 90° further (turning further can
mer
be carried out in several stages).
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1.4 Crankshaft bearing cap identification
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The crankshaft bearing shells are classified during production and
agen
Prote AG.
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‐
ingly.
Identification of crankshaft upper bearing shell - arrow - (next to
first main bearing).

Touareg 2003 ➤
Identification of crankshaft lower bearing shell - arrow - (on crank‐

shaft sender wheel).
Colour coding
B = Blue
G = Yellow
R = Red
S = Black
1.5 Crankshaft dimensions

No further honing dimensions are planned at this time.
(Dimensions in mm)
Honing dimension Main journal ∅ Conrod journal ∅
-0.022 -0.022
Basic dimension 58.00 50.90
-0.037 -0.042
1.6 Renewing crankshaft oil seal - engine

timing end agen
AG. Volkswagen AG d
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⇒ „1.6.1 Removing“, page 27 ed
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⇒ „1.6.2 Installing“, page 27 tho eo
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♦ Puller hooks -T20143/2- an

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♦ Assembly tool -T10122- ab

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1.6.1 Removing
h re
hole
spec
es, in part or in w
t to the co
Note
Ensure that sealing surface is not damaged when removing seal.

rrectness of i
l purpos
– Pull old oil seal carefully out of seat using puller hook -
T20143/2- .
nform
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at
om
ion
c
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do
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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. gen AG
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es, in part or in w
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rrectness of i
– Press oil seal into gear train housing cover to stop using thrust
piece -T10122/3- .
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at
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1.7 Renewing alternator shaft oil seal
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Prote AG.
⇒ „1.7.1 Removing“, page 28

⇒ „1.7.2 Installing“, page 29
♦ 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 agen

AG. Volkswagen AG d
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– Remove oil residue from alternator shaft using cleanedcloth.
by
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– Screw guide sleeve -T10208/1- hand tight onto alternator
aut
h shaft eo
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and carefully push seal onto stop. ss c
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– Now fit press piece -T10208/3- and press seal in onto limit
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stop.
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– Secure hub onto alternator shaft with new bolts.
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Specified torque: 50 Nm + turn 90° further.
h re
hole
spec
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Alternator;
es, in part or in w
Removing and installing alternator .
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Touareg 2003 ➤ autho eo
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5-cylinder diesel engine - Edition 11.2011 ss c
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2 Dismantling and assembling pistons
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and conrods
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Note
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All bearing and running surfaces must be oiled before assembly.
rrectness of i
⇒ „2.1 Assembly overview - pistons and conrods“, page 30
l purpos
⇒ „2.2 Separating new conrods“, page 31

⇒ „2.3 Installation position and allocation of piston to cylinder“,
nform
ercia
page 32
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⇒ „2.4 Checking piston ring gap“, page 32
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⇒ „2.5 Checking ring-to-groove clearance “, page 32
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⇒ „2.6 Checking cylinder bores“, page 33

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⇒ „2.7 Piston and cylinder dimensions“, page 33

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2.1 Assembly overview - pistons and conrods
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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
❑ With combustion cham‐
ber.
❑ Mark installation posi‐
tion and cylinder num‐
ber.
❑ Installation position and
allocation of piston to
cylinder ⇒ page 32 .
❑ Arrow on piston crown
points towards No. 1 cyl‐
inder end of engine
block.
❑ Install using piston ring
clamp.
❑ If piston skirt is cracked,
renew piston.
❑ Installation position
⇒ page 32 .
❑ Piston and cylinder di‐
mensions ⇒ page 33 .
❑ Checking cylinder bores
⇒ page 33 .
3 - Piston pin
❑ If difficult to remove, heat piston to 60 °C.

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
❑ Checking cylinder bores ⇒ page 33 .
❑ Piston and cylinder dimensions ⇒ page 33 .
8 - Conrod bearing cap
9 - Oil spray jet
❑ For piston cooling.
❑ When installing, turn oil spray jet clockwise onto limit stop in cylinder block and tighten in this position.
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❑ Insert withoutorsealant.
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11 - Conrod bolt,
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❑ Renew.
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❑ Oil threads and contact surface.

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❑ First tighten evenly to 5 Nm.

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2.2 Separating new conrods

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– Mark cylinder allocation of conrod ⇒ Item 5 (page 31)

rrectness of i
– Lightly clamp the conrod in a vice using aluminium vice

clamps, as shown in the illustration.
l purpos
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Note
orm
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♦ To prevent damage to the conrod, only clamp conrod in lightly.

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♦ Clamp conrod in below the dashed line.

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– Unscrew the two bolts -arrows- approx. 5 turns.

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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.
Piston in cylinders 3, 4 and 5:
Larger inlet valve chamber -arrows- towards No. 1 cylinder end
of block.
Note
♦ New piston allocation to cylinders is shown by a coloured

marking on piston crown.
♦ Piston for cylinders 1 and 2: marked 1/2
♦ Piston for cylinders 3, 4 and 5: Marking 3/4/5
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2.4 Checking piston ring gap utho tee
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Checking piston ring gap ss
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– Insert ring at right angles from above and push down into cyl‐ an
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inder approx. 15 mm from bottom end of cylinder.
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Piston ring New Wear limit

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dimensions in mm
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1st compression ring 0.25 … 0.40 1.0

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2nd compression ring 0.30 … 0.50 1.0

Oil scraper ring 0.25 … 0.50 1.0
rrectness of i
2.5 Checking ring-to-groove clearance

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Checking ring-to-groove clearance

nform
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Clean annular groove before check.

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Piston ring New Wear limit

on in
dimensions in mm
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1st compression ring 0.09 … 0.13 0.25

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2nd compression ring 0.04 … 0.08 0.25

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Oil scraper ring 0.03 … 0.07 0.15
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Touareg 2003 ➤
2.6 Checking cylinder bores

Checking cylinder bores
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♦ Internal dial test indicator 50…100 mm
– Take measurements at 3 positions in both lateral direction
rrectness of i
-A- and longitudinal direction -B-. Deviation from nominal di‐
mension max. 0.08 mm
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2.7 Piston and cylinder dimensions
nform
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No repairs designated.
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Piston ∅ Cylinder bore ∅
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Basic dimen‐ mm 80.97 81.01
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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 45 .
Note
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♦ The contact surfaces between
ss the bucket tappets and the cam
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must be oiled before installing the cylinder head cover.
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♦ The plastic packing pieces for protecting the open valves must
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♦ If the cylinder head is replaced, all the coolant in the system
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1.1 Assembly overview - cylinder head
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⇒ „1.1.1 Checking cylinder head for distortion“, page 36
rrectness of i
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34 Rep. gr.15 - Cylinder head, valve gear

Touareg 2003 ➤
1 - To air filter. AG. Volkswagen AG d

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⇒ page
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2 - Crankcase breather valve
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3 - Seal
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4 - Engine cover
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5 - 15 Nm
spec
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6 - Cylinder head cover
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❑ Before fitting, thorough‐
ly clean sealing surface
of cylinder head with
rrectness of i
clean cloth.
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7 - Cylinder head bolt

❑ Renew.
nform
ercia
❑ Note sequence when

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loosening and tighten‐
com
tio
ing ⇒ page 42 , Re‐
n in
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moving and installing
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⇒ page 107
❑ Checking ⇒ page 104 .
❑ Must not be dismantled.
10 - 10 Nm
11 - Hall sender -G40-
❑ For camshaft position.
12 - O-ring
❑ Renew.
13 - Gasket
❑ Renew.
14 - Lifting eye
❑ With retainer for connector.
15 - 20 Nm
16 - Bracket
17 - Cylinder head gasket
❑ Renew.
❑ 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
❑ Renew.
22 - Plug
23 - Sealing cover
❑ Renew.
24 - Cylinder head
❑ Removing and installing ⇒ page 42
25 - Pipe connection
❑ Drive pipe connection in until stop
26 - Lifting eye agen
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1.1.1 Checking cylinder head for distortion
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Checking cylinder head for distortion
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Reworking diesel cylinder heads is not permissible.
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1.2 Renewing pipe connection for coolant
cial p
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mer

atio
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♦ Thrust piece -T10418-

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– 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.

AG. Volkswagen AG d
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Clean area -arrow- of new pipe connection and apply sealant to
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– Drive pipe connection into connection hole in cylinder head as
form
mer
far as stop -arrows- using thrust piece -T10418- -1-.
atio
om
Further installation is performed in the reverse sequence.
n
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– Fill coolant system with coolant ⇒ page 72 .
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1.3 Removing and installing camshaft drive

gear
♦ Allen key, long reach -T10198-
♦ Clamp -T10199-
♦ Thrust piece -T10199/1-
♦ Wrench -T10211-
♦ Insert tool -T10234-
♦ Torque wrench -V.A.G 1331- (5...50 Nm)
♦ Torque wrench 50-100 Ncm -VAS 6253-
1.3.1 Removing
– Position crankshaft at TDC for cylinder No. 1 ⇒ page 41 .
– Remove charge air pipes between charge air cooler and tur‐
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-.
Note
The marks -A- of the guide sleeve and the adjustment plate must
align. AG. Volkswagen AG d
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– Carefully insert adjustment plate with camshaft compensating

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gear from above into respective cavity.

h re
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– Oil all surfaces of eccentric pin -5-.

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Rep. gr.15 - Cylinder head, valve gear Prote
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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.
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– Turn eccentric pin carefully anti-clockwise
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– Hold eccentric pin in this position
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Specified torque: 20 Nm + turn (90°) further

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– Remove outer bearing cap again.
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– Place central connector of unit injectors carefully into cylinder

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head.
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– Install outer bearing cap with sealant and tighten using new
es, in part or in w
bolts.
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Specified torque: 8 Nm + turn (90°) further

rrectness of i
Note
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Seal parting surfaces of outer bearing caps with sealant according

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to ⇒ Electronic parts catalogue (ETKA) ⇒ page 50 .

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– Lock central connector of unit injectors on cylinder head side.

on in
Turn it clockwise onto limit stop using wrench -T10211- .

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– Tighten eccentric pin sealing cover and Hall sender -G40- .

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♦ Check that the disc (diamond-coated) is seated correctly on
the camshaft before installing the camshaft gear wheel.
♦ The teeth of the gear wheel must be oiled completely.

Touareg 2003 ➤ agen
AG. Volkswagen AG d
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– Seat camshaft
aut
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ra
onto camshaft
ss so that the marking -arrow- on the sender wheel c
aligns with the upper edge of the cylinder head sealing sur‐
ce
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nl
pt
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– Secure camshaft gear wheel and tandem pump drive using
ility
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new bolt and tighten hand-tight. (Camshaft gear wheel can still
wit
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h re
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– Fit clamping device -T10199/1- as shown and tighten its
spec
es, in part or in w
clamping bolts to 70 Nm.
t to the co
– Insert torque wrench -V.A.G 1332- into square end of clamp,
and push with 80 Nm against direction of engine rotation.
rrectness of i
To eliminate gear drive backlash:
l purpos
– Maintain this force and tighten camshaft gear wheel securing

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

– Then secure camshaft gear wheel with clamp -T10198- .
Specified torque: 150 Nm + turn (90°) further.
– Remove clamp -T10199- .
– Remove locking devices from camshaft and crankshaft.
– Install tandem pump ⇒ page 107 .
– 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
– Lever camshaft cover -arrow- out using lever -VW 681- .
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– Remove noise insulation from end of engine block.

es, in part or in w
t to the co
rrectness of i
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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
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♦ If crankshaft clamp -T10226- cannot be bolted to crankshaft, aut
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crankshaft is at exhaust stroke TDC and not at at ignitionsTDC.
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♦ In this case, turn crankshaft in engine direction of rotation until pt

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marks on special wrench and sealing flange align again. y li

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– Fit camshaft clamp -T10193- .

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– 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

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1.5.1 Removing
m
at
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Note
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The removal and installation of the cylinder head can only be un‐
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dertaken when the engine is removed due to the cramped con‐
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42
AG.
Rep. gr.15 - Cylinder head, valve gear
n AG. Volkswagen AG do Touareg 2003 ➤
lkswage es n
ua 5-cylinder diesel engine - Edition 11.2011
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– Remove engine
aut and gearbox ⇒ page 5 . or
ac
ss
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un
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– Unscrew turbocharger/exhaust manifold securing bolts
t to the co
⇒ page 110 .
– Disconnect all necessary coolant and vacuum hoses as well
rrectness of i
as electrical connections on cylinder head.
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– Position crankshaft at TDC for cylinder No. 1 ⇒ page 41 .

– Remove camshaft gear wheel ⇒ page 37 .
nform
ercia
– Unscrew threaded connection for cylinder head control hous‐

m
a
ing ⇒ Item 18 (page 35) .
com
tion in
– Maintain sequence when loosening and tightening cylinder
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head bolts.
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1.5.2 Installing
Note
♦ Different thicknesses of cylinder head gasket are fitted de‐

pending on the piston projection. When renewing gasket,
install new gasket with same identification.
♦ Take note of number of holes next to part number.
♦ Always renew cylinder head bolts.
♦ In cases of repair carefully remove gasket remains from cyl‐
inder head and cylinder block. Ensure that no long scores or
scratches are made on the surfaces. When using abrasive
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 11.2011 AG. Volkswagen AG d
agen oes
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Note auth eo
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♦ To prevent valves from contacting pistons when installing:
un
pt
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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.
ole,
spec
– Fit cylinder head, install cylinder head bolts and tighten hand
tight.
t to the co
– Tighten cylinder head in 6 stages in sequence shown as fol‐
lows:
rrectne
– Tighten initially with torque wrench:
ss
Stage I = 60 Nm
o
cial p
f in
– Turn further with rigid spanner:
form
mer
atio
Stage II = 1/4 turn (90°)
om
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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°) Cop py
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– Turning back with rigid spanner: cop Vo
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Stage VI = loosen all cylinder head bolts 1/4 turn (90°).
AG.
– Tighten threaded connection between cylinder head/control

housing ⇒ Item 18 (page 35) 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 139 .

Touareg 2003 ➤
1.6 Checking compression

equipment required AG. Volkswagen AG d
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♦ 10 mm jointed spanner d byV
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♦ Torque wrench - ss a c
V.A.G 1331- (5 ... 50 Nm)
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♦ Adapter -V.A.G 1381/12- itte
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♦ Compression tester -
ility
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V.A.G 1763-
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♦ Removing and installing
hole
spec
valve springs with cylinder
es, in part or in w
head removed -2037-
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Test prerequisite
• Engine oil temperature min. 30 °C.
Test procedure
– Disconnect central connector on cylinder head for unit injec‐
tors.
– Remove all glow plugs using 10 mm jointed wrench -3220- .

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- .
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Using compression tester
ss ⇒ operating instructions .
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– Operate starter until tester shows no further pressure in‐

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Compression pressures:
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New: 25 ... 31 bar, wear limit: 19 bar
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spec
Maximum permissible difference between all cylinders: 5 bar
t to the co
– Install glow plugs using U/J extension and socket, 10 mm
-3220- . Specified torque: 15 Nm.
rrectne
– Read event memory ⇒ page 139 .
ss o
cial p
f
Note
inform
mer
Disconnecting the central connector for unit injectors causes
atio
m
faults to be stored. Therefore, read event memory and delete if

o
n
c
i
necessary ⇒ page 139 .
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Touareg 2003 ➤
2 Repairing valve gear

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Note ir se
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Cylinder heads with cracks between the valvess seats may be used
a ac
without reducing engine life, provided the cracks are small and
ce
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un
pt
not more than 0.5 mm wide.
an
d
itte
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⇒ „2.1 Assembly overview - valve gear“, page 47
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⇒ „2.2 Reworking valve seats“, page 51
h re
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spec
⇒ „2.3 Checking valve guides“, page 53
t to the co
⇒ „2.4 Renewing valve stem seals“, page 53
⇒ „2.5 Removing and installing camshaft“, page 55
rrectne
2.1 Assembly overview - valve gear
ss
⇒ „2.1.1 Checking camshaft axial clearance“, page 50
o
cial p
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⇒ „2.1.2 Sealing parting surfaces of bearing caps“, page 50
form
mer
⇒ „2.1.3 Valves“, page 50
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⇒ „2.1.4 Camshaft identification, valve timing“, page 51
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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‐
camshaft.
3 - Rocker arm shaft
❑ Do not interchange. agen
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❑ Do not interchange.
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❑ With hydraulic
s s valve c
clearance compensa‐
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tion.
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❑ Set down with contact
rm
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surface facing down‐
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wards.
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❑ Before installing, check
hole
spec
camshaft axial clear‐
es, in part or in w
ance ⇒ page 50 .
t to the co
❑ Oil running surface.
5 - Cotters
rrectness of i
6 - Valve spring plate
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7 - Outer valve spring

nform
ercia
❑ Installing and removing:

cylinder head removed:
m
with Removing and in‐

com
tion in
stalling valve springs

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with cylinder head re‐

thi
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moved -2037- . Cylinder

do
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rp
head installed:
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⇒ page 53 , Renewing valve stem oil seals

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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
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.
26 - Washer
❑ Renew.
27 - Bearing shell AG. Volkswagen AG d
agen oes
❑ Do not interchange used bearing shells (mark). Volksw not
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❑ Ensure that retaining lugs are correctly seated
ris in bearing caps and cylinder head
ed
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28 - Camshaft ss
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❑ Checking axial clearance ⇒ page 50 .
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❑ Check radial clearance with Plastigage; wear limit: 0.11 mm.

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❑ Runout: max. 0.01 mm.

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❑ Identification and valve timing ⇒ page 51 .

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spec
29 - Bearing cap
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❑ When installing, seal parting surfaces of outer bearing caps with sealant according to ⇒ Electronic parts
catalogue (ETKA) ⇒ page 50 .
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49
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Prote AG.
2. Repairing valve gear
Touareg 2003 ➤
2.1.1 Checking camshaft axial clearance

Checking camshaft axial clearance

♦ Universal dial gauge bracket -VW 387-
♦ Dial gauge
Check with bucket tappets removed and with 2, 4 and 6 bearing
caps fitted.
Wear limit: max. 0.15 mm
2.1.2 Sealing parting surfaces of bearinggcaps

en AG. V
olkswagen AG
d a oes
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Seal parting surfaces of bearing caps 1 and 7 with
db
ysealant.
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♦ Sealant as per ⇒ Electronic parts catalogue (ETKA) . rrectness of i
– Apply sealant as per ⇒ Electronic parts catalogue (ETKA)

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thinly and evenly on surfaces.
2.1.3 Valves
nf
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Valve dimensions
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Valves must not be reworked. Only lapping-in is permitted.

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Dimension Inlet valve Exhaust valve
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∅a mm 35.95 31.45
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∅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

♦ Depth gauge
AG. Volkswagen AG d
♦ Valve seat refacing tool olksw
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Note aut ra
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♦ When repairing engines with leaking valves, it is not sufficient

un
pt
an
d
to rework or renew valve seats and valves. There is also a

itte
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erm
requirement to check the valve guides for wear. This is par‐
ab
ility
ticularly important on high mileage engines.
ot p
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♦ Valve seats are only to be reworked to the extent required to

h re
ole,
yield a proper surface appearance. Before beginning to rework

spec
valve seats, calculate the maximum permissible reworking di‐

mensions. If the reworking dimension is exceeded, the hy‐ t to the co
draulic valve clearance compensation can no longer be
guaranteed and the cylinder head must be renewed.
rrectne
The max. permissible reworking dimension is calculated as fol‐

lows:
ss o
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– Insert valve and press firmly against seat.

inform
mer
atio
om
Note
n
c
i
or
n thi
te
sd
a
If the valve is to be renewed as part of a repair, use a new valve

iv
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pr
for the calculation.

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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
n AG. Volkswagen A
The 30° lower valve seat chamferolis necessary
ksw
age to ensureGthat
does the
not
inlet channel flow characteristics
db
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Reworking exhaust valve seat.
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a = ∅ 31.4 mm
nform
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b = 2.7 mm
m
at
45° = Valve seat angle

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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 inen AG. Volkswagen AG
exhaust guide. olks
wag does
not
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– Max. rock: 1.3 mm. ir se nte
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– Cylinder head must be renewed if rock exceeds
ss
a wear limit. c
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pt
du
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itte
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ab
ility
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hole
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2.4 Renewing valve stem seals
es, in part or in w
t to the co
rrectness of i
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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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2.4.1 Removing
un
pt
an
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itte
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rm
– Remove camshaft ⇒ page 55 .

ab
pe
ility
ot
– Remove bucket tappets and place them with the contact sur‐
wit
, is n
face downwards. When doing this, ensure that the tappets are
h re
hole
not interchanged.
spec
es, in part or in w
– Set piston of respective cylinder to top dead centre (TDC).

t to the co
– Fit valve assembly tool -2036- and adjust mountings to height

of studs.
rrectness of i
– Remove valve springs using valve lever -VW 541/1A- and

l purpos
press tool - VW 541/5- .

nform
ercia
Note
m
a
com
tion in
The valves are supported by the piston crown.

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Prote AG.

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

⇒ „2.5.1 Removing“, page 55 . Volkswagen AG
gen AG does
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⇒ „2.5.2 Installing“, page 56 y Volk not
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Special tools and workshop equipment horis
required eo
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♦ Torque wrench -V.A.G 1331- s(5 ... 50 Nm)
s c
ce
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nl
pt

du
an
itte
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erm
♦ Sealant as per ⇒ Electronic parts catalogue (ETKA) .

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

t to the co
taken when the engine is removed due to the cramped conditions.

rrectness of i
2.5.1 Removing
l purpos
– Remove charge air pipes between charge air cooler and tur‐
bocharger and between charge air cooler and intake connect‐
ing flange.
nf
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orm
m

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c

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

Touareg 2003 ➤
5-cylinder dieselwengine
agen
AG. -Vo
Edition 11.2011
lkswagen AG
doe
ks s no
Vol t gu
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– Loosen bearingrised
caps from outer to inner, loosen bolts nof
tee last
two bearing
aut caps alternately and diagonally.
ho
or
ac
ss
2.5.2 Installing
ce
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nl
pt
du
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Note
ility
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♦ Ensure that no valve is pressed against a piston during instal‐
hole
spec
lation of the camshaft. Position pistons as uniformly as possi‐
es, in part or in w
ble below TDC.
t to the co
♦ Do not interchange used bearing shells (mark).
♦ When installing the camshaft, ensure proper seating of retain‐
rrectness of i
ing lugs in bearing caps and cylinder head.
l purpos
♦ Before installing bearing caps, ensure that cylinder head bolt

washers are inserted in the cylinder head.
nform
ercia
– Oil running surfaces of shell bearings.

m
at
om
ion
– Tighten inner 2 bearing caps alternately and diagonally to 8
c
in t
or
Nm + turn (90°) further (renew).
his
ate
do
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– Install remaining bearing caps and also tighten to 8 Nm + turn

p
cum
or
(90°) further (renew).

f
en
ng
t.
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Cop py
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Note p by
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by lksw
cted agen
Prote AG.
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).
– Install camshaft drive gear wheel ⇒ page 37 .
– Install tandem pump ⇒ page 107 .
– Install charge air pipes between charge air cooler and turbo‐
charger and between charge air cooler and intake connecting
flange.
Note
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).

AG. Volkswagen AG d
agen oes
olksw not Touareg 2003 ➤
byV gu
ara
rised
nte 5-cylinder diesel engine - Edition 11.2011
ho eo
aut ra
ss c
17 – Lubrication
ce
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nl
pt
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ab
1 Engine oil
ility
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hole
spec
Note
es, in part or in w
t to the co
The oil level must not be above the max. mark! Risk of catalytic
converter damage! Markings ⇒ page 57 .
rrectness of i
Engine oil specification ⇒ Maintenance ; Booklet 17.1
l purpos
⇒ „1.1 Oil capacities“, page 57
nf
ercia
⇒ „1.2 Checking engine oil level“, page 57 .
orm
m
atio
1.1 Oil capacities
om
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thi
With oil filter, 8.9 l
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Without oil filter 8.5 l
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1.2 Checking engine oil level
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Markings on oil dipstick py by
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1 - Max. mark Prote AG.
2 - min. mark
a - Area above hatched field up to max. mark: Do not top up with
engine oil!
b - Oil level within hatched field: Can be topped up with engine
oil.
c - Area from min. mark up to hatched field: Must be topped up,
max. 0.5 l of engine oil!
1. Engine oil 57
Touareg 2003 ➤
2 Parts of lubrication system

⇒ „2.1 Assembly overview - oil pump, sump “, page 58
⇒ „2.2 Assembly overview - oil filter housing “, page 59
⇒ „2.3 Removing and installing oil sump“, page 62
⇒ „2.4 Checking oil pressure and oil pressure switch“,
page 65
2.1 Assembly overview - oil pump, sump

Part II: Dismantling oil filter housing ⇒ page 59
1 - 20 Nm AG. Volkswagen AG d
agen oes
ksw
❑ The oil level must not be by Vol not
gu
ara
above the max. mark!
rise
d
nte
ho eo
❑ Markings ⇒ page a 57 .
ut ra
css
2 - Oil dipstick
ce
e
nl
pt
du
an
itte
3 - Guide tube
y li
erm
ab
4 - Cap
ility
ot p
wit
, is n
5 - Seal
h re
hole
spec
es, in part or in w
t to the co
6 - Rubber grommet
rrectness of i
7 - Oil filler tube
l purpos
8 - 10 Nm
9 - Seal
nf
ercia
10 - Oil spray jet

rm
m
atio
❑ For piston cooling.

om
n in
or c
11 - 25 Nm
thi
te
sd
a
❑ Insert without sealant.

iv
o
r
rp
cu
o
12 - Dowel sleeves
f
en
ng
t.
yi Co
op
13 - Oil pump
C py
t. rig
gh ht
yri
❑ Before installing, check p by
co Vo
lksw
that both dowel sleeves
by
cted agen
Prote
for centring oil pump on
AG.
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

lkswage es n Touareg 2003 ➤
o ot g
byV 5-cylinder diesel engine ua - Edition 11.2011
ed ra
ris nte
utho eo
20 - Oil level and oil temperature sender
ss -G266-
a ra
c
❑ Checking ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.
ce
le
un
pt
an
d
itte
21 - 15 Nm
y li
rm
ab
pe
ility
22 - Oil filter housing
ot
wit
, is n
❑ With engine oil cooler.
h re
hole
❑ Dismantling and assembling ⇒ page 59 .
spec
23 - 20 Nm es, in part or in w
t to the co
24 - Gasket
❑ Renew.
rrectness of i
l purpos
25 - Baffle plate
nform
ercia
26 - O-ring
m
❑ Renew.
a
com
tion in
r
te o
thi
s
iva
2.2 Assembly overview - oil filter housing
do
r
rp
cum
fo
en
ng
t.
yi Co
op
1 - Engine oil cooler
C py
t. rig
gh ht
yri
❑ Checking for leaks p by
co Vo
lksw
⇒ page 83 .
by
cted agen
Prote AG.
❑ To remove, the air con‐
ditioner compressor
must be removed ⇒
Rep. gr. 87 .
2 - 10 Nm
3 - Coolant hose
4 - Bracket
5 - 10 Nm
6 - Screw cap, 25 Nm
7 - Seal
❑ Renew.
8 - Oil filter
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 ➤ AG. Volkswagen AG d
agen oes
5-cylinder diesel engine - Edition 11.2011 Volksw not
gu
by ara
d
rise nte
2.2.1 Removing and installing oil filter housing tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
equipment required
erm
ab
ility
ot p
♦ Refractometer -T10007-
wit
, is n
h re
♦ Hose clips up to 25 mm Ø
hole
spec
-3094-
es, in part or in w
t to the co
♦ Cooling system tester -
V.A.G 1274-
♦ Adapter for cooling system
rrectness of i
tester -V.A.G 1274/8- l purpos

5024 A-
nform
ercia

m
drip tray -VAS 6208-
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.
– 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 ➤
Collect escaping coolant with drip tray -V.A.G 1306- or drip tray -
VAS 6208- . Volkswa gen AG AG.
does agen
– Remove air intake hose to intake air Vconnection
olks
w not
gu
y
⇒ page 123 . se
d b ara
nte
ri
ho eo
– Clean vicinity of oil dipstick guide
aut tube on crankcase to prevent ra
c
engine oil contamination. ss
ce
le
un
pt
– Release dipstick guide tube from oil filter housing and crank‐
an
d
itte
y li
case.
rm
ab
pe
ility
Later you will remove dipstick guide tube together with air condi‐
ot
wit
tioner compressor.
, is n
h re
hole
– Remove engine wiring harness bracket from beneath intake
spec
manifold -1- (10 Nm).
es, in part or in w
t to the co
All cable ties which are opened or cut open when engine cable
bracket is removed must be replaced in the same position when
engine is installed.
rrectness of i
All connectors which are separated during removal of engine ca‐
l purpos
ble bracket must be reconnected in the original position when

installing.
nform
ercia
Unscrew air conditioner compressor from its console ⇒ Rep. gr.

m
87 .
a
com
tion in
Do not open refrigerant circuit. Lay air conditioner compressor to
r
te o
thi
side.
s
iva
do
r
rp
c
– Remove dipstick guide tube.
um
fo
en
ng
t.
yi
– Seal hole.
Co
Cop py
t. rig
gh
– Remove coolant hose ⇒ Item 3 (page 59) from oil filter housing
ht
pyri by
Vo
and clamp it off using hose clamps, up to Ø 25 mm -3094- .
o
by c lksw
cted agen
Prote AG.
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 ➤
– Renew housing seal.

– Check engine oil level, renew if mixed with coolant
⇒ page 57 .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
d
2.3 Removing and installing oil sump ise nte
or eo
h
aut ra
c
⇒ „2.3.1 Removing“, page 62 ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
♦ Hand drill with plastic brush
wit
, is n
h re
hole
♦ Sealant as per ⇒ Electronic parts catalogue (ETKA) .
spec
es, in part or in w
♦ Flat scraper
t to the co
2.3.1 Removing
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
– Remove noise insulation -A- on engine side.
by lksw
cted agen
Prote AG.

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
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
– Remove assembly mounting nut/bolt -A- on both sides of en‐
ce
le
un
pt
gine.
an
d
itte
y li
rm
ab

pe
ility
Rep. gr. 50 ; Noise insulation; Assembly overview - noise in‐

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

spec
40 ; Fixing subframe in position .

es, in part or in w
t to the co
– Unbolt coolant pipe from sump.

– Pull connector off oil level and oil temperature sender -G266- .
rrectness of i

l purpos
– Drain engine oil.

nform
ercia
– Remove sump.
m
– Loosen sump with light blows of a rubber headed hammer if

com
tio
necessary.
n in
r
te o
thi
s
iva
do
2.3.2 Installing
r
rp
cum
fo
en
g
– Remove sealant residue from cylinder block with a flat scraper.

n
t.
yi Co
Cop py
ht. rig
rig ht
py by
63
co Vo
by lksw
cted
2. Parts of lubrication system
agen
Prote AG.
Touareg 2003 ➤
– Remove sealant residue on sump, using electric drill with plas‐

tic brush attachment (wear eye protection).
– Clean sealing surfaces. They must be free of oil and grease.
Note
♦ Observe expiry date of sealing compound.

♦ The sump must be installed within 5 minutes of applying sili‐
cone sealing compound.
– Cut off tube nozzle at forward marking (∅ of nozzle approx. 3

mm).
– Apply silicone sealing compound, as shown, to clean sealing
surface on sump. Sealant bead must be:
AG. Volkswagen AG d
agen oes
♦ 2 ... 3 mm thick. Volksw not
gu
y b ar
ed
♦ Run bead along
oris inner side of bolt holes -arrows-. antee
th or
au ac
ss
ce
le
Note
un
pt
an
d
itte
y li
erm
The sealant bead must not be thicker, otherwise excess sealing

ab
ility
compound will enter the oil sump and may block the oil suction
ot p
wit
line strainer.
is n
h re
ole,
spec
– Apply silicone sealing compound bead as shown to the clean

t to the co
sealing surface of the sump.

– Install sump immediately and tighten all sump bolts lightly.
rrectne
Note
ss o
cial p
f in
The sump must be flush with the cylinder block and the control
form
mer
housing cover.
atio
om
n
c
– Tighten oil sump bolts to 15 Nm.

or
n thi
te
sd
a
– Tighten bolts securing sump to gearbox to 45 Nm.

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
op
Note C py
t. rig
gh ht
pyri by
Vo
Allow sealing compound to dry for approx. 30 minutes after in‐
o
by c lksw
cted agen
stalling sump. Only then fill with engine oil. Prote AG.
Further assembly is basically the reverse of the dismantling se‐

quence.

Touareg 2003 ➤
2.4 Checking oil pressure and oil pressure switch

olks
wage es n
ot g
equipment requiredd by V ua
ran
e
ris tee
♦ Oil pressure thotester - or
au
V.A.G 1342-
ss ac
ce
e
nl
♦ Voltage tester -
pt
du
an
V.A.G 1527 B-
itte
y li
erm
ab
♦ Auxiliary measuring set -
ility
ot p
V.A.G 1594 A-
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Functional check and repair of the optical and acoustic oil pres‐
sure warning: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
Test prerequisites
• Engine oil temperature min. 80 °C.
• Engine oil level OK.
Test procedure
– Bring lock carrier into service position: ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Lock carrier; service position .
– Remove air conditioner compressor: ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Air conditioner compressor; Removing and
installing air conditioner compressor from and to bracket

Touareg 2003 ➤
– Suspend air conditioner compressor so that lines and hoses

are not stretched, kinked or bent. Nor must they enter the ra‐
diator fan.
– Remove oil pressure switch -F1- and screw into tester.
– Screw tester into oil filter housing in place of oil pressure AG. Volkswagen AG d
switch. agen oes
olksw not
byV gu
ara
– Connect brown wire of tester to earth (-). rised
nte
ho eo
ut
– Connect voltage tester -V.A.G 1527 B- to battery positive
ss a (+) ra
c
and oil pressure switch using cable from auxiliary measuring
ce
e
nl
set -V.A.G 1594/C- . LED must not light up.
pt
du
an
itte
y li
– Install air conditioner compressor: ⇒ Heating, air conditioning;
erm
ab
Rep. gr. 87 ; Air conditioner compressor; Removing and in‐
ility
ot p
stalling air conditioner compressor from and to bracket .
wit
, is n
h re
– Start engine and increase speed slowly. At 0.75 ... 1.05 bar,
hole
spec
the LED must light up; otherwise renew oil pressure switch.
es, in part or in w
t to the co
– 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.
rrectness of i
At higher engine speed, oil pressure must not exceed 7.0 bar.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
19 – Cooling
1 Removing and installing parts of cool‐
ing system
WARNING

tions:
♦ All the various lines, e.g. for activated charcoal filter sys‐
tem, electrical wiring as well as
♦ Fuel lines
♦ Hydraulic lines
hot components.
♦
Note
♦ When the engine is warm, the cooling system is under pres‐

sure. If necessary, release pressure before beginning repair
work. olks
wage es n
o V t gu
by
♦ Hoses are secured with spring-type
ris
ed clips. In case of repair, ara
nte
only use spring-type clips.
ut
ho eo
ra
sa c
♦ Spring-type clip plierss -VAS 5024- are recommended for in‐
ce
le
stallation of spring-type clips.

un
pt
an
d
itte
y li
♦ When installing coolant hoses, route stress-free so that they

erm
ab
do not come into contact with other components (observe

ility
ot p
markings on coolant connection and hose).

wit
is n
h re
ole,
spec
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- .

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
67
cted agen
Prote
1. Removing and installing parts of cooling system
AG.
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 .
⇒ „1.9 Checking oil cooler for leaks“, page 83
1.1 Parts of cooling system, body side

AG. Volkswagen AG d
agen oes
lksw not
Note d byV
o gu
ara
ise nte
or eo
h
Coolant hose schematic
s aut diagram ⇒ page 72 . ra
c
s
ce
e
nl
pt
du
an
itte
y li
1 - Radiator/cooler
erm
ab
ility
ot p
⇒ page 75
wit
, is n
h re
❑ After renewing, renew
hole
spec
entire coolant.
es, in part or in w
❑ Coolant hose schematic t to the co

diagram ⇒ page 72 .
2 - Retaining clip
rrectness of i
❑ Check for secure seat‐

l purpos
ing.
3 - Condenser
nform
ercia
4 - Gearbox oil cooler

m
at
om
❑ For gear oil

ion
c
in t
r
❑ Only vehicles with an

o
his
te
automatic gearbox.
a
do
priv
cum
or
5 - Oil cooler
f
en
ng
t.
yi
❑ For power-assisted
Co
op py
steering
. C rig
ht ht
rig by
py Vo
6 - Lock carrier
co lksw
by
cted agen
Prote AG.
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-
2 - Radiator fan -V7- olkswage es n
ot g
byV ua
3 - Fan support ir se
d ran
tee
ho
❑ Removing and installing aut or
ac
⇒ page 69 ss
ce
e
nl
pt
du
4 - 10 Nm
an
itte
y li
erm
ab
5 - Charge air pipe
ility
ot p
6 - Radiator fan 2 -V177-
wit
, is n
h re
hole
7 - Radiator fan control unit -
spec
J671-
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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.
1. Removing and installing parts of cooling system 69

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 .
1.4 Parts of cooling system, engine side
1 - 10 Nm
2 - Coolant pipe
❑ Coolant hose schematic
3 - Seal
❑ Renew.
4 - Seal
❑ Renew.
5 - Connection
6 - 10 Nm
7 - Gasket n AG. Volkswagen AG do
wage es n
❑ Renew. yV
olks ot g
ua
d b ran
❑ Note installation
o
ir se posi‐ tee
tion. au
th or
a
ss c
8 - Thermostat
ce
e
nl
pt
du

an
itte
y li
tion.
erm
ab
ility
❑ Checking: heat thermo‐

ot p
wit
stat in water.
, is n
h re
❑ Opening begins at ap‐

hole
spec
prox. 87 °C.
es, in part or in w
t to the co
❑ Ends at approx. 102 °C.

❑ Opening stroke at least
8 mm.
rrectness of i
9 - Thermostat housing
l purpos
10 - Connecting hose
nf

ercia
rm
m
atio
m
11 - Seal
o
n in
or c
❑ Renew.
thi
te
sd
iva
12 - Coolant drain plug, 20 Nm

r
rp
cu
o
m
f
❑ Remove to remove coolant pump.

en
ng
t.
yi Co
op
❑ On vehicles with particulate filter the front exhaust pipe must be removed with particulate filter
C py
t. rig
⇒ page 146 .
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
13 - Coolant pump
14 - 20 Nm
15 - Cover
❑ Renew.
❑ Lightly coat gasket with oil when installing.
16 - 84 Nm
17 - Gear wheel
❑ Check for damage.
. Volkswagen AG
gen AG
❑ Removing and installing ⇒ page
olkswa77 does
no
V t gu
by ara
18 - 20 Nm + 90° further rised nte
ho eo
❑ Renew. s aut ra
c
s
19 - Exhaust gas recirculation cooler
ce
e
nl
pt
du
an
❑ Vehicles with automatic gearbox and exhaust gas recirculation changeover valve.
itte
y li
erm
ab
ility
ot p
❑ Coolant hose schematic diagram ⇒ page 72 .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
1.5 Coolant hose schematic diagram
1 - Expansion tank
❑ Check cooling system
for leaks with cooling
system tester -V.A.G
1274- and adapter -
V.A.G 1274/8- .
❑ Check cap using cooling
system tester -V.A.G
1274- and adapter -
V.A.G 1274/9- .
❑ Test pressure 1.4 ... 1.6
bar.
2 - Cylinder head/cylinder AG. Volkswagen AG d
block agen oes
olksw not
V gu
d by ara
3 - Engine oil cooler orise nte
h eo
ut ra
4 - Heat exchanger for heater
ss a c
unit
ce
le
un
pt
an
d
5 - Fuel cooler
itte
y li
rm
ab
6 - Change-over valve
pe
ility
ot
wit
❑ For coolant circuits
, is n
h re
hole
7 - Radiator/cooler
spec
es, in part or in w
8 - Fuel cooling pump -V166-
t to the co
9 - Radiator/cooler
❑ For exhaust gas recircu‐ rrectness of i
lation.
l purpos
10 - Change-over flap
❑ For exhaust gas recircu‐
nform
ercia
lation.
m

com
tio
automatic gearbox.
n in
r
te o
thi
s
iva
do
r
rp
cum
The connection diagram for vehicles with an auxiliary heater/pre‐

fo
en
g
heater is located in ⇒ Rep. gr. 82 ; Auxiliary heater/preheater .

n
t.
yi Co
Cop py
t.
The coolant run-on pump ( circulation pump -V55- ) is located in
rig
gh ht
yri by
⇒ Rep. gr. 80 ; Heater . op Vo
by c lksw
cted agen
Prote
1.6 Draining and filling coolant
AG.
⇒ „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- agen
AG. Volkswagen AG d
oes
olksw not
V
♦ Spring-type clip pliers -VASed by gu
ara
5024 A- horis nte
eo
aut ra
♦ Adapter -V.A.G 1274/8-
ss c
ce
le
un
pt
♦ Cooling system charge unit
an
d
itte
-VAS 6096-
y li
rm
ab
pe
ility
ot
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
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tion in
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te o
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Cop py
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rig ht
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Prote AG.
1.6.1 Draining
– Open filler cap on coolant expansion tank.
WARNING
Hot steam may escape when expansion tank is opened. Place

cloth over cap and open with caution.

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

pump -V166- .
Note
Follow disposal regulations for coolant!
1.6.2 Filling
lkswage es n
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Note o
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s
The amount of water used in the coolant mixture has a great in‐
s
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le
fluence on its effectiveness. Because the water quality differs

un
pt
an
d
from country to country and even region to region, Volkswagen

itte
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has decided to define the quality of the water to be used in the
erm
ab
coolant system. Distilled water fulfils all requirements. It is there‐
ility
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fore recommended that distilled water be mixed with the coolant
wit
is n
h re
whenever an older model's coolant is replenished or replaced. For
ole,
newer models (model year 2010 ►) the use of distilled water is
spec
absolutely essential and compulsory.
t to the co
Caution
rrectne
Only distilled water may be mixed with G12 plus-plus. The use
s
of distilled water ensures optimum protection against corro‐
s o
cial p
sion. f inform
mer
atio
om
n
c
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or
n thi
te
sd
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pr
cum
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

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

TL VW 774 G.
♦ It is recommended to use distilled water only for mixing.
♦ Coolant additives marked „in accordance with TL VWag774
en AGG“
. Volkswagen AG
do
prevent lime accretion, frost damage and corrosion.yV
olksMoreover,
w es n
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the boiling temperature is raised. Therefore, e the cooling sys‐
d b ua
ran
ris additive.
tem must be filled all year round with coolant tee
tho or
au ac
♦ Because of its higher boiling point, the
ss coolant improves en‐
ce
e
gine reliability under heavy loads, particularly in countries with
nl
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du
tropical climates.
an
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♦ The frost protection must be guaranteed to approx. -25 °C. (In
ility
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countries with an arctic climate, down to approx. -35 °C).
wit
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♦ The coolant concentration must not be reduced by adding wa‐
hole
spec
ter even in warmer seasons and in warmer countries. The
es, in part or in w
coolant additive concentration must be at least 40%.
t to the co
♦ If a stronger anti-freeze mixture is necessary due to harsher
weather conditions, the coolant additive content can be in‐
rrectness of i
creased. However, this is only permitted to 60% (antifreeze
protection to about -40°C). Since the frost protection will oth‐
l purpos
erwise be reduced again and also the cooling effect will be

worsened.
nf
ercia
♦ The Refractometer -T10007- is recommended for determining
orm
the current anti-freeze density.
m
atio
om
n in
♦ Do not reuse old coolant.
or c
thi
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Recommended mixture ratios:
o
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Frost protection Amount of anti- G 12 Water

t.
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to freeze plus1)
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gh
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plus-
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plus1)
Prote 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
AG. Volkswagen AG d
♦ Drip tray -V.A.G 1306- agen oes
olksw not
y V gu
d b ara
♦ Torque wrench - orise nte
V.A.G 1331- (5 ... 50 Nm) auth eo
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ss c
♦ Spring-type clip pliers -
ce
le
un
pt
VAS 5024-
an
d
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rm
ab
pe
ility
ot
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.7.1 Removing
– Pull all coolant hoses off radiator.
– Remove front bumper ⇒ General body repairs, exterior; Rep.
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front; Lock carrier - service po‐
sition .
– Remove fans together with fan support ⇒ page 69 .

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
1.7.2 ised byV Installing gu
ara
nte
or eo
h
Installation
s aut is carried out in the reverse order. When installing,
ra
c
notes the following:
ce
e
nl
pt
du
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erm
ab
– Electrical connections and routing ⇒ Current flow diagrams,
ility
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Electrical fault finding and Fitting locations.
wit
, is n
h re
– Bolt lock carrier in position ⇒ General body repairs, exterior;
hole
Rep. gr. 50 ; Body - front; Lock carrier service position.

spec
es, in part or in w
– Install front bumper: ⇒ General body repairs, exterior; Rep. t to the co

– Check headlight adjustment and correct if necessary ⇒ Main‐
rrectness of i
tenance ; Booklet 17.1 .

l purpos
1.8 Removing and installing coolant pump

nform
ercia

m

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

Touareg 2003 ➤
AG. Volkswagen AG d
agen oes
Special tools and workshop olksw not
V gu
equipment required d by ara
ise nte
or eo
h
♦ Refractometer -T10007- s aut ra
c
s
♦ Drip tray -V.A.G 1306-
ce
le
un
pt
an
d
itte
♦ Torque wrench -
y li
erm
ab
V.A.G 1331- (5 ... 50 Nm)
ility
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wit
♦ Spring-type clip pliers -
is n
h re
VAS 5024-
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
o
by c lksw
cted agen
Prote AG.
♦ Puller -T10221A-

Touareg 2003 ➤
♦ Puller -T10222A-
♦ Special wrench -T10225-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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aut ra
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ce
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nl
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ility
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wit
, is n
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hole
spec
♦ Puller hooks -10-221-
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
or
1.8.1 Removing
f
en
ng
t.
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Cop py
ht. rig
rig ht
WARNING py by
co Vo
by lksw
cted agen
Prote AG.
Risk of scalding.
The cooling system is under pressure, when the engine is
warm the coolant temperature can be above 100 °C.
Before carrying out repairs, release pressure and allow tem‐
perature to drop as necessary.
Vehicles with engine codes BAC and BLK

– Loosen exhaust pipe and starter catalytic converter from tur‐
bocharger and gearbox. It is not necessary to remove the
catalytic converter.
Vehicles with engine codes BPD and BPE
– Remove exhaust gas recirculation cooler ⇒ page 157 .

Touareg 2003 ➤
– Remove particulate filter ⇒ page 147 .

n AG. Volkswagen A ge G do
swa es n
For all engine codes
by
Vol
k ot g
ua
d ran
se
– Drain coolant
tho ⇒ page 72 .
ri tee
or
au ac
– Remove
ss coolant drain plugs ⇒ Item 12 (page 70) .
ce
e
nl
pt
du
– Remove coolant pump cover ⇒ Item 15 (page 71) .
an
itte
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erm
ab
– Remove noise insulation -A- from No. 1 cylinder end of engine
ility
ot p
block.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
– Remove bolts -arrows- and remove bracket for noise insula‐
om
tion.
n in
or c
thi
e
– Lever sealing cover out of sealing flange on No. 1 cylinder end

t
sd
iva
of block using lever -10-221- .

o
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rp
cu
o
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f
en
ng
t.
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op
Note
C py
t. rig
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pyri by
Vo
co
Renew sealing cover after removing.
by lksw
cted agen
Prote AG.
– Bolt special wrench -T10225- onto crankshaft. To do this, turn

screw into crankshaft through centre of tool and tighten to 20
Nm.
Note
♦ It is only possible to bolt special wrench -T10225- onto crank‐

shaft in one position.
♦ To remove the coolant pump, the engine must not be at TDC.
– Counterhold special wrench -T10225- using suitable tool, and

loosen coolant pump securing nut -1-.
Note
For engines manufactured in the first batch, puller -T10221- can‐

not be fitted due to lack of clearance behind coolant pump gear.
In this case release coolant pump gear by tapping lightly on its
sides with a hammer and copper drift.

Touareg 2003 ➤
– Fit puller -T10221A- as shown and turn hexagon clockwise

until the gear wheel can be removed from the pump.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
– Unscrew
aut coolant pump securing bolts -arrows-. ra
c
ss
– Prior to fitting, screw puller -T10222A- in and out to adjust, until
ce
le
un
pt
spindle hexagon is flush with tool surface shown in grey.
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Adjusting T 10222 A
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
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.
– 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 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
Note thor eo
au ra
ss c
Ensure the seals on the coolant pump are correctly seated.
ce
le
un
pt
an
d
itte
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– Fit coolant pump.
rm
ab
pe
ility
– Tighten new coolant pump securing bolts.
ot
wit
, is n
h re
Torque settings ⇒ Item 18 (page 71) hole
spec
– Fit gear wheel and tighten securing nut.
es, in part or in w
t to the co
Torque settings ⇒ Item 16 (page 71)
rrectness of i
Note
l purpos
♦ Tighten securing nut from underside of vehicle using a uni‐

versal joint and extension, if necessary.
nform
ercia
♦ The angle of the universal joint must not exceed max. 20°.
m
a
com
tion in
r
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– Install drain plugs with new seal and tighten.
thi
s
iva
do
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cum
fo
en
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– Lightly coat sealing lip of coolant pump cover with oil.

n
t.
yi Co
Cop py
– Install coolant pump cover .
t. rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
Further assembly is carried out in the reverse order of removal.

Touareg 2003 ➤
1.9 Checking oil cooler for leaks

equipment required
♦ Hose clips up to 25 mm Ø
-3094-
♦ Cooling system tester -
V.A.G 1274-
♦ Adapter for cooling system
tester -V.A.G 1274/8-
5024 A-
drip tray -VAS 6208-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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- AG. Volkswagen AG d
agen oes
olksw not
yV gu
♦ Cap -1J0 121 324- ed b ara
nte
ris
ho eo
♦ Coolant hose -251 265 056- aut ra
c
ss
Prerequisites:
ce
le
un
pt
an
d
itte
• Engine cold
y li
rm
ab
pe
Test procedure
ility
ot
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, is n
– Remove noise insulation. ⇒ General body repairs, exterior;
h re
hole
Rep. gr. 50 ; Body - front; Assembly overview - noise insula‐
spec
tion .
es, in part or in w
t to the co
– Drain coolant ⇒ page 72
– Drain engine oil ⇒ page 57 .
rrectness of i
– Loosen hose clips using spring-type clip pliers -VAS 5024- .
l purpos
– Remove oil cooler with housing ⇒ page 59
nform
ercia
Note
m
a
com
tion in
♦ Collect escaping coolant with drip tray -V.A.G 1306- or drip
r
te o
thi
tray -VAS 6208- .
s
iva
do
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rp
c
♦ Collect leaking engine oil with a cleaning cloth, if necessary.
um
fo
en
ng
t.
yi Co
Cop py
ht. rig
Checking when removed rig ht
py by
co Vo
by lksw
– Clamp housing with old seal on a suitable, level clean surface. Prote
cted AG.
agen
– Secure sealing plug -2- to breather connection of expansion

tank -1-.
– Secure coolant hose -3- to engine oil cooler and expansion
tank.
– Fill expansion tank up to „Max“ marking.
– Attach cooling system tester -V.A.G 1274- with cooling system
tester adapter -V.A.G 1274/8- to expansion tank.
– Use hand pump on tester to create a pressure of about 1.6 bar.
– Watch pressure drop on pressure gauge. A pressure drop
within 10 minutes is not permitted.
If pressure drops:
– 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

AG. Volkswagen AG d
agen oes
olksw not
yV gu
ed b ara
nte
Touareg 2003 ➤
ris
ut
ho 5-cylinder
eo
ra
diesel engine - Edition 11.2011
s a c
s
ce
le
un
20 – Fuel supply system
pt
an
d
itte
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rm
ab
pe
ility
1 Removing and installing parts of fuel
ot
wit
, is n
h re
supply system
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ Hose connections are secured with quick-release couplings,
spring-type or clamp-type clips.
l purpos
♦ Renew clamp-type clips with spring-type clips.
nform
ercia
♦ Fuel hoses on engine must be secured with spring-type clips

only. The use of clamp or screw-type clips is not permissible.
m
a
com
tion in
♦ Assembly tool -VAS 5024A- or pliers -V.A.G 1921- are rec‐
r
te o
ommended for fitting spring-type clips.
thi
s
iva
do
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rp
cum
⇒ „1.1 Rules for cleanliness“, page 85 .
fo
en
ng
t.
yi Co
⇒ „1.2 Safety precautions when working on fuel supply system“, . Cop py
page 86 .
ht rig
rig ht
py by
co Vo
⇒ „1.3 Assembly overview - fuel tank with attachments (► model
by lksw
cted agen
Prote
year 08)“, page 87
AG.
⇒ „1.4 Assembly overview - fuel tank with attachments (model

year 08 ►) “, page 88
⇒ „1.5 Assembly overview - fuel filter with fuel cooler“,
page 90 .
⇒ „1.6 Emptying fuel tank“, page 91
⇒ „1.7 Removing and installing fuel pump unit, fuel gauge sender
and suction jet pumps (for vehicles ► model year 08)“,
page 95
⇒ „1.8 Removing and installing fuel pump unit, fuel gauge sender
and suction jet pumps (for vehicles model year 08 ►)“,
page 97
⇒ „1.9 Removing and installing fuel tank with attached compo‐
nents“, page 100
⇒ „1.10 Checking fuel pumps“, page 102
⇒ „1.11 Checking tandem pump“, page 104
⇒ „1.12 Removing and installing tandem pump“, page 107
⇒ „1.13 Assembly overview - accelerator mechanism“,
page 109 .
1.1 Rules for cleanliness

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.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
1. Removing and installing parts of fuel supply system 85

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
Touareg 2003 ➤ tho ris
eo
u
5-cylinder dieselss engine - Edition 11.2011
a ra
c
ce
le
un
pt
use parts that have not been stored in their packing (e.g. in
an
d
itte
tool boxes etc.).
y li
erm
ab
ility
♦ When system is open: do not work with compressed air if this ot p
wit
can be avoided. Do not move vehicle unless absolutely nec‐
is n
h re
essary.
ole,
spec
t to the co
rrectne
fuel supply system
ss o
cial p
f in
WARNING
form
mer
atio
om
n
c
i
or
n thi
tions:
te
sd
iva
o
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p
cum
r
fo
en
ng
t.
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op
♦ Fuel lines
C py
t. rig
gh ht
yri by
♦ Hydraulic lines
op Vo
by c lksw
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!
86 Rep. gr.20 - Fuel supply system

Touareg 2003 ➤
1.3 Assembly overview - fuel tank with attachments (► model year 08)
1 - Fuel tank filler neck

2 - Fuel tank
❑ When removing, sup‐
port using engine and
gearbox jack - AG. Volkswagen AG d
agen oes
ksw
V.A.G 1383 A- . by V ol not
gu
ara
ed
❑ Drain fuel tank horis using nte
eo
fuel extractor
aut - ra
c
VAS 5190-ss
⇒ page 91
ce
e
nl
pt
du
an
itte
⇒ page 100
y li
erm
ab
3 - Flange
ility
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wit
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❑ Left side.
h re
hole
spec
tion on fuel tank
es, in part or in w
t to the co
⇒ page 88 .
4 - Locking ring, 145 Nm
rrectness of i
❑ Remove and install us‐
ing wrench -T10202- .
l purpos

ing.
nf
ercia
o
5 - Fuel delivery unit
rm
m
❑ Left side. atio

om
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or c
6 - Fuel gauge sender 3 -

thi
te
G237-
sd
iva
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cu
❑ Left side.
o
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f
en
ng
❑ Clipped into bottom of

t.
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op
tank.
C py
ht. rig
rig ht
py by
7 - Float for fuel gauge sender co Vo
by lksw
3 -G237-
cted agen
Prote AG.
❑ On fuel delivery unit.
8 - Protective cover
❑ For bottom of fuel tank.
9 - Securing strap
10 - 20 Nm + 90° turn
❑ For top of fuel tank
12 - Suction-jet pump
❑ Left side.
❑ Clipped into bottom of tank.
❑ Right side.
❑ Right side.
15 - Fuel gauge sender -G-
❑ Right side.

Touareg 2003 ➤
❑ Clipped into bottom of tank.
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-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
1.4 Assembly overview - fuel tank with attachments (model year 08 ►)
an
d
itte
y li
rm
ab
pe
ility
ot
1 - Fuel tank filler neck
wit
, is n
h re
hole
2 - Fuel tank
spec
es, in part or in w
❑ When removing, sup‐
t to the co
port using engine and
gearbox jack -
V.A.G 1383 A- .
rrectness of i
❑ Drain fuel tank using
fuel extractor -
l purpos
VAS 5190-
❑ Removing and instal‐
nform
ercia
ling.
m
a
com
t
3 - Flange
ion in
r
❑ Left side.
te o
thi
s
iva
❑ Note installation posi‐ do

r
rp
tion on fuel tank

um
fo
⇒ page 89 .
en
ng
t.
yi Co
op py
4 - Locking ring, 145 Nm t. C rig
gh ht
yri by
❑ Remove and install us‐ cop Vo
by lksw
ing wrench -T10202- . cted agen
Prote AG.
ing.
5 - Fuel gauge sender 3 -
G237-
❑ Left side.
tank.
tank.
❑ For bottom of fuel tank.
8 - Securing strap

n AG. Volkswagen AG
Touareg 2003 ➤
lkswage does
not
by5-cylinder
Vo diesel engine - Edition g11.2011
uara
ed nte
ris
❑ Check for secure seating. autho eo
ra
ss c
9 - 20 Nm + 90° turn
ce
e
nl
pt
du
an
itte
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erm
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ility
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❑ Front left side
hole
spec
es, in part or in w
t to the co
❑ Right side.
13 - Fuel gauge sender -G-
rrectness of i
❑ Right side.
❑ Clipped into bottom of tank. l purpos
nf
ercia
o
rm
m
atio
m
15 - Flange
o
n in
or c
❑ Right side.
thi
te
sd
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❑ Note installation position on fuel tank.
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Installation position of left sender flange (fuel tank)
t. rig
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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 - AG. Volkswagen AG d
VF-. agen oes
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❑ Check for secure seat‐ rised b ara
nte
ing. ut
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❑ To pull off, press release ss c
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an
itte
4 - 10 Nm
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ility
5 - Fuel cooler
ot p
wit
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6 - Coolant hose
h re
hole
spec
es, in part or in w
t to the co
7 - Return line
❑ To fuel tank.
rrectness of i
l purpos
ing.
❑ To pull off, press release
nf
ercia
orm
m
8 - Bracket
atio
om
❑ For fuel filter.

n in
or c
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e
9 - Fuel filter
t
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❑ Observe change intervals.

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.
10 - Seal
ht rig
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❑ Renew.
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❑ If fitted.
AG.
11 - Water drainage connection, 5 Nm

❑ If fitted.
❑ Unscrew to drain water and extract approx. 100 cm3 using diesel extractor -VAS 5226- .
12 - Supply line
❑ To tandem pump.
❑ Union with marking -VM-.
❑ To pull off, press release button on connection.

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
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ility
♦ Wrench -T10202-
ot p
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
♦ Not illustrated:
in t
or
his
ate
♦ Assembly tool -T10118-

do
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or
Procedure
f
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ng
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op
– Note safety precautions before beginning work ⇒ page 86 . C py
t. rig
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– Open fuel tank filler flap.
p by
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cted agen
Prote AG.

Touareg 2003 ➤
– Push suction hose -arrow- of fuel extractor -VAS 5190- ap‐

prox. 170 … 180 cm into fuel tank filler neck and extract fuel.
Note
♦ When no more fuel is extracted, the fuel tank is emptied just

enough for the sender flanges to be opened without danger.
The tank may be removed while containing remaining fuel.
♦ If work must be performed on fuel pumps or fuel tank senders,
proceed as follows:
Vehicles up to week 47/06

Vehicles from week 48/06 ⇒ page 92
– Fold rear bench seat forwards.
– Cut carpet open from point -A- to point -B- in the pre-cut area
-arrows-.
Right side of vehicle
lkswage es n
o ot g
byV ua
– Remove nuts -1- from cover. If necessary, unscrew ir se backrest
d ran
tee
mounting -2- or support mounting ⇒ General bodyutho repairs, or
interior; Rep. gr. 72 ; Rear seats . ss
a ac
ce
e
nl
Left side of vehicle

pt
du
an
itte
y li
– Remove bolts -1-.
erm
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ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Then remove nuts -2-, to do this for one nut push mounting
bracket slightly upwards.
l purpos
Vehicles from week 48/06

nform
ercia
– Remove rear bench seat ⇒ General body repairs, interior;

Rep. gr. 72 ; Rear seats; Removing and installing bench seat /
m
at
om
individual seats .
on
c
in t
or
his
ate
do
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cum
for
en
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t.
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t. rig
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Prote AG.

Touareg 2003 ➤

– Pull off connectors for fuel pump and fuel gauge sender -4-.
– Pull return line -1-, supply line -2- and, if necessary, the return
line for auxiliary heater -3- off right sender flange.
Note
Release connection by pressing button on line coupling.
– Now remove locking ring from sender flange using wrench

agen
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T10202- . Volksw es n
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– Carefully lever out sender flange and raisehitorisslightly.
e
tee
t or
au ac
– Insert suction hose of fuel extractor -VAS ss 5190- as deeply as
possible into right or left side of fuel tank and extract fuel.
ce
le
un
pt
an
d
itte
– For work on left side of fuel tank, proceed as described above.
y li
erm
ab
– When breather lines are pulled off, buttons of hose couplings
ility
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sometimes cannot be pressed in. Use assembly tool -T10118-
wit
is n
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for this.
ole,
spec
For further work on inside of fuel tank, sender flanges may remain
removed.
t to the co
If fuel tank needed only to be emptied, install sender flanges
again.
rrectne
– First check that sender flange seals are properly seated.
ss o
cial p
f in
Note
form
mer
atio
Renew seals if the fuel has caused them to swell.
om
n
c
i
or
n thi
te
sd
a
– Insert sender flange with locating tab in direction of travel

iv
o
pr
c
-arrow-.
um
r
fo
en
ng
t.
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– Tighten locking rings on left and right using wrench -T10202-
Co
Cop py
to 145 Nm.
t. rig
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pyri by
Vo
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cted agen
Prote AG.

Touareg 2003 ➤
en AG. V
olkswagen AG
ag does
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ris
Note tho eo
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ss
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♦ Do not interchange supply and return lines (return line -1- blue,
nl
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supply line -2- black).
an
itte
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erm
ab
♦ Ensure that fuel hose connections are tight.
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
1.6.1 Emptying fuel tank when fuel pump is
intact
l purpos
nform
ercia
♦ Vehicle diagnosis tester

m
at
om
io
n
c
in t
or
his
e
♦ Adapter for fuel extraction -VAS 5190 /3 -

at
do
priv
cum
for
en
WARNING
ng
t.
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Cop py
t. rig
Fuel supply line is pressurised. Wear eye protection and pro‐
gh ht
yri by
tective clothing to avoid possible injury and skin contact. Before
op Vo
by c lksw
cted
loosening hose connections, wrap a cloth around the connec‐
agen
Prote AG.
tion. Then release pressure by carefully pulling hose off con‐
nection.
Note
Press in securing ring to release fuel lines.
– Pull off supply line -1- and catch escaping fuel with a cloth.

Touareg 2003 ➤
– Connect fuel extractor -VAS 5190- with adapter for fuel ex‐
tractor -VAS 5190 /3 - to fuel supply line.
– Connect a diagnosis tester.
Note
The fuel pump is being activated when engine is not running.
– Switch on ignition.
– Remove filler cap from fuel tank filler neck.
– Perform the function „Bleeding fuel system“ in „guided func‐
tions“.
olksw
If the fuel tank is emptied,sw»stop«
agen
AG.the
V
function
agen AG
to
doprevent
es n the fuel
pump from running b»dry«.
y Volk ot g
u
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– Operate shut-off
tho
ri tap on fuel extractor -VAS 5190- , untiltethe
eo
fuel tanksis emptied.
au ra
c
s
ce
le
Bleeding fuel system

un
pt
an
d
itte
y li
2) Low-pressure section
rm
ab
pe
ility
• Fuel tank filled.

ot
wit
, is n
– Connect a diagnosis tester.

h re
hole
spec
– Perform the function „Bleeding fuel system“ in „guided func‐

es, in part or in w
tions“.
t to the co
1.7 Removing and installing fuel pump unit,

rrectness of i
fuel gauge sender and suction jet pumps

l purpos
(for vehicles ► model year 08)

nform
ercia
♦ Wrench -T10202-
m
a
com
tion in
r
te o
thi
s
iva
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fo
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
Prerequisites
• Fuel tank must be emptied ⇒ page 91 , Emptying fuel tank.
• Connectors and wires for left and right-hand sender flanges
have been removed. AG. Volkswagen AG d
agen oes
ksw n ol ot g
yV
• Locking rings for left and right sender flangesed have been re‐
b ua
ran
ris
moved. tho tee
or
u ac
sa
– Note safety precautions before beginning
s work ⇒ page 86 .
ce
e
nl
pt
du
Procedure
an
itte
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erm
ab
– Pull off connectors -1- and -2- as well as hose couplings -3-,
ility
ot p
-4- and -5- below right sender flange.
wit
, is n
h re
– Remove sender flange.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
– Unclip black filler hose -arrow- from fuel pump unit housing on
om
io
left and right sides of fuel tank.

n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

lk swage es n Touareg 2003 ➤
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byV ua 5-cylinder diesel engine - Edition 11.2011
d ran
ir se tee
tho
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– Pull fuel supply
ss
a line, to suction-jet pumps, off fuel delivery unitr ac
-arrow- on left and right sides of fuel tank.
ce
e
nl
pt
du
an
– Disconnect fuel supply and return lines between the two fuel
itte
y li
pump units on the left side of the fuel tank.
erm
ab
ility
ot p
– Unscrew fuel delivery unit in bottom of fuel tank by turning ap‐
wit
, is n
prox. 90° to left.
h re
hole
spec
es, in part or in w
t to the co
Note
The fuel pump housing is filled with fuel. Fuel may run out if hous‐
rrectness of i
ing is tipped or canted.
l purpos
– Now unclip fuel gauge senders on each side of fuel tank and
pull them out.
nform
ercia
– Now unclip suction-jet pumps from bottom on each side and

m
at
remove with a slight turn.
om
ion
c
in t
– Pull out hose ends through left and right sender openings.
or
his
ate
do
priv
c
1.8 Removing and installing fuel pump unit,
um
for
en
ng
fuel gauge sender and suction jet pumps

t.
yi Co
Cop py
(for vehicles model year 08 ►)
t. rig
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pyri by
Vo
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by
Special tools and workshop equipment required cted agen
Prote AG.
♦ Wrench -T10202-
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
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ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Unclip black filler hose connection -arrow- (from suction jet

pumps) from fuel pump unit housing.
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
– Disconnect fuel supply line at fuel pump unit -arrow- (to suction
r
fo
en
ng
jet pumps on left side of fuel tank).

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

Touareg 2003 ➤
– Now unclip fuel gauge sender on right side n-arrow-

AG. Volkof
swafuel tank
gen A
and remove upwards. olkswage G do
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– Install in reverse order. db ara
rise nte
tho eo
Procedure for left side. ss au ra
c
ce
le
– Unclip and remove fuel gauge sender on left side of fuel tank.
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– On left side of fuel tank, now unclip bracket for suction jet pump
-arrow- ⇒ Item 6 (page 88) .
rrectne
Pull suction-jet pumps together with supply/filler hoses and fuel
lines for suction-jet pumps out of left opening of fuel tank.
ss
– Install in reverse order.
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
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
AG. Volkswagen AG d
agen oes
lksw not
1.9 Removing and installing fuel tank with attached components Vo gu
d by ara
ise nte
or eo
h
aut ra
s c
Special tools and workshop s
ce
le
equipment required
un
pt
an
d
itte
y li
rm
ab
pe
ility
♦ Wrench -T10202-
ot
wit
, is n
h re
hole
spec
Nm) -V.A.G 1331-
es, in part or in w
t to the co
Nm) -V.A.G 1332-
♦ Engine and gearbox jack -
rrectness of i
V.A.G 1383/A-
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
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.
Prerequisites
Fuel tank must be empty ⇒ „1.6 Emptying fuel tank“, page 91 .
1.9.1 Removing
– Note safety precautions before beginning work ⇒ page 86 .
– Observe rules for cleanliness ⇒ page 85 .
– Remove Silencer with mountings.
– Remove rear propshaft ⇒ Transfer box and final drive; Rep.
gr. 39 ; Removing and installing propshaft .
– Remove rear axle ⇒ Running gear, axles, steering; Rep. gr.
42 ; Repairing rear axle .
– Open fuel flap and remove fuel tank cap.
– Pull rubber gasket off fuel tank filler neck.

Touareg 2003 ➤
– Remove securing bolts -1- on filler neck and pull off earth wire
-2-.
– Remove rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Removing
and installing wheel housing liner .
– Unbolt cover plate -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
– Unclip fuel tank breather lines attached to longitudinal mem‐
spec
ber.
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
– Remove securing bolt for filler neck -arrow- in wheel housing.

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 ➤
– Disconnect connector to fuel pump on left next to fuel tank.

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

sender flange.
– Lower fuel tank.
1.9.2 Installing
note the following:
♦ Do not interchange supply and return hose (return line -1- blue
or blue markings, supply line -2- black).
♦ Connections for breather and fuel lines must engage audibly
when joined.
♦ Clip fuel lines onto fuel tank.
♦ Install breather and fuel hoses free of kinks.
♦ Ensure that fuel hose connections are tight. agen
AG. Volkswagen AG d
oes
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ara
ed
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un
1.10 Checking fuel pumps

pt
an
d
itte
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rm
ab

pe
ility
ot
♦ Voltage tester -V.A.G 1527 B-

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

Touareg 2003 ➤
♦ 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 must be at least 11.5 V
• All electrical consumers, e.g. lights and rear window heating,
are switched off.
Checking function and voltage supply
– Fold rear bench seat forwards.
AG. Volkswagen AG d
agen o
– Briefly operateVstarter.
olks
w Fuel pumps must be
esheard
not
gu
to start run‐
ning. sed by ara
n
i tee
or
– Switch
au off ignition.
th or
ac
ss
If the fuel pump does not start:
ce
e
nl
pt
du
an
Vehicles up to week 47/06

itte
y li
erm
ab
Vehicles from week 48, 2006 ⇒ page 104

ility
ot p
wit
, is n
– Cut carpet open from point -A- to point -B- in the pre-cut area
h re
-arrows-.
hole
spec
es, in part or in w
Right side of vehicle

t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
– Unscrew nuts -1- from cover. If necessary, unscrew backrest

te
sd
a
mounting -2- or support mounting: ⇒ General body repairs,

iv
o
r
rp
cu
interior; Rep. gr. 72 ; Rear seats; Removing and installing

o
m
f
en
ng
bench seat / individual seats .

t.
yi Co
op py
Left side of vehicle
. C rig
ht ht
rig by
py Vo
– Remove bolts -1-.
co lksw
by
cted agen
Prote AG.

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):
. Volkswagen AG
gen AG does
– Remove right-hand fuel delivery unit ⇒ page 95V.olkswa not
y gu
db ara
– Check that electrical wiring between flange ris and fuel
e pump is nte
connected and has continuity. utho eo
ra
a c
ss
If no open circuit can be found:
ce
le
un
pt
an
d
– Right-hand fuel pump is defective, renew fuel delivery unit

itte
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rm
⇒ page 95 .
ab
pe
ility
ot
– Repeat check on left fuel pump unit.
wit
, is n
h re
Checking current draw of fuel pumps
hole
spec
es, in part or in w
– Check current draw of each fuel pump separately as follows:

t to the co
– Connect current pick-up of multimeter -V.A.G 1715- to line of
contact 1 -arrow- of 4-pin connector of wiring harness to right
rrectness of i
fuel pump unit.

l purpos
– Start engine and run at idling speed.

– Measure current draw of fuel pump. Specification: max. 8 Am‐
nform
ercia
peres.
m
a
com
ti
If current draw is exceeded:

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

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

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


Touareg 2003 ➤
♦ Tandem pump tester -VAS 5187-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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♦ Vehicle diagnosis, testing and information system -VAS
erm
ab
5051B-
ility
ot p
wit
♦ Diagnosis cable -VAS 5051/1- or -VAS 5051/3-
, is n
h re
hole
Test prerequisites
spec
es, in part or in w
• Coolant temperature must be at least 85 °C.
t to the co
• Unit injectors OK.
• Intact fuel pump unit rrectness of i
l purpos
• Fuel filter and fuel lines must not be blocked.

Procedure
nform
ercia
– Disconnect supply line -arrow- from tandem pump.

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

Touareg 2003 ➤
– Connect tandem pump tester -VAS 5187- as shown.
Note
Two versions of tandem pump tester -VAS 5187- are in use. In

older version adapter -VAS 5187/6-3- must be used as shown.

– Connect vehicle diagnosis, testing and information system -
VAS 5051B- and select operating mode „vehicle self-diagno‐
sis“. Then select engine electronics control unit with the
Address word „01“.
AG. Volkswagen AG d
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– Press diagnosis function „08-Read measured valuey Vblock“.
olks
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– Enter display group „1“ using number block (keyoris pad) and nte
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confirm entry with Q button. au ra
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ss
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– Read off engine idling speed in display zone 1.
le
un
pt
an
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– Increase engine speed to 1500 rpm.
y li
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ility
– Observe pressure indicated on pressure gauge. Specification:
ot p
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min. 7.5 bar.
is n
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ole,
– Press button ← .
spec
– Select „06-End output“ function.
t to the co
If the specification is not attained:
rrectne
– Renew tandem pump ⇒ page 107 , Removing and installing
tandem pump.
ss o
cial p
f i
Note
nform
mer
atio
After removing pressure tester, tighten supply line to 27 Nm.
om
n
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1.11.2 Checking for internal leaks

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Note
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The tandem pump must be checked for internal leaks between Prote
cted AG.
agen
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 ➤
5-cylinderAdiesel
G . Volksengine
wagen A Edition 11.2011
-
n G do
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Volks ot g
Procedure ed
by ua
ran
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– Pull fuel supply hose (white marking) and fuel return
au
th hose or
ac
(blue marking) off tandem pump. ss
ce
le
un
pt
– Seal fuel return union on tandem pump with a plug. Secure
an
d
itte
sealing plug with a spring-type clip.
y li
erm
ab
ility
Prepare charge air system tester -V.A.G 1687- as follows:
ot p
wit
is n
– Turn pressure regulating valve -2- anti-clockwise onto stop.
h re
ole,
spec
– Close valves -3- and -4-.
t to the co
– 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.
rrectnes
Note
s o
cial p
f in
To turn the pressure regulating valve -2- the knob must be pulled
form
mer
upwards.
atio
om
n
c
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or
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– Connect compressed air hose -1- (compressed air source) to

t
sd
va
charge air system tester -V.A.G 1687- .

i
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rig ht
py by
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If there is water in the sight glass, drain at water drain screw -6-.
by c lksw
cted agen
Prote AG.
– Open valve -3-.

– Adjust pressure to 1.0 bar with pressure regulating valve -2-.
Caution
The maximum test pressure is 1.3 bar and this must not be
exceeded.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary readjust pressure to 1.0 bar.
– Close valve -3- to retain pressure and observe the pressure
drop over a period of 1 minute.
If the pressure does not drop the tandem pump can be reused, if
the pressure drops the tandem pump must be renewed.
1.12 Removing and installing tandem pump

DANGER!
The tandem pump may, under no circumstances, be disman‐

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

Touareg 2003 ➤
♦ Spring-type clip pliers -VAS 5024-
swage es n
1.12.1 Removing olk ot g
byV ua
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tho
u or
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Note ss
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nl
pt
du
an
The removal and installation of the tandem pump can only be un‐
itte
y li
erm
ab
dertaken when the engine is removed due to the cramped con‐
ility
ot p
ditions.
wit
, is n
h re
hole
– Remove engine and gearbox ⇒ page 5 . spec

es, in part or in w
– Pull vacuum line -1- from brake servo off tandem pump -4-.
t to the co
– Pull fuel line -2- off tandem pump -4-.

– Disconnect fuel line -3- from tandem pump -4-.
rrectness of i
– Remove securing bolts -arrows-.

l purpos
– Remove tandem pump -4- from cylinder head.

nf
ercia
orm
m
atio
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n in
or c
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1.12.2 Installing
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note the following: cop Vo
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Prote 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 139
Reading and clearing event memory of engine control unit. AG. Volkswagen AG d
agen oes
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1.13 Assembly overview - accelerator mechanism s
ce
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un
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an
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itte
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erm
ab
1 - Bearing bracket
ility
ot p
2 - Connector
wit
is n
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❑ Black, 6-pin.
ole,
spec
3 - 10 Nm
t to the co
4 - Accelerator position sender
-G79-
rrectne
❑ Not adjustable.
❑ The accelerator position
s
sender passes the posi‐
s o
cial p
f
tion of the accelerator
in
on to the engine control
form
mer
unit.
atio
m
❑ Remove footwell cover

o
n
c
i
or
n
to remove sender.
thi
te
sd
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t.
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
21 – Turbocharging/supercharging
1 Charge air system with turbocharger
⇒ „1.1 Rules for cleanliness“, page 110
⇒ „1.2 Turbocharger with attachments for engine codes BAC and
BLK“, page 110
⇒ „1.3 Removing and installing turbocharger for engine codes
BAC and BLK“, page 112
⇒ „1.4 Turbocharger with attachments (engine codes BPD and
BPE)“, page 114
⇒ „1.5 Removing and installing turbocharger (engine codes BPD
and BPE)“, page 116
⇒ „1.6 Removing and installing parts of charge air cooling“, page
120 .
⇒ „1.7 Checking charge air system for leaks“, page 121 .
⇒ „1.8 Hose connections“, page 123
⇒ „1.9 Vacuum hose schematic diagram“, page 125

When working on the turbocharger, pay careful attention to the
following „5 rules“ for cleanliness:
connecting.
lint-free cloths.
AG. Volkswagen AG d
♦ Install clean components only. Do not remove replacement ksw
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parts from packing until immediately before installing.
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use parts that have not been stored in their packing (e.g. in nte
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tool boxes etc.). au
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1.2 Turbocharger with attachments for engine codes BAC and BLK
ce
e
nl
pt
du
an
itte
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Observe rules for cleanliness ⇒ page 110 .

erm
ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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or c
thi
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110
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Rep. gr.21 - Turbocharging/supercharging Prote AG.
Touareg 2003 ➤
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.
AG. Volkswagen AG d
1 - Connecting pipe lksw
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❑ For exhaust gas recircu‐ byV gu
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lation. horis nte
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2 - 10 Nm ss c
ce
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un
pt
3 - Connecting clamp, 8 Nm
an
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4 - Bracket/lifting eye
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ab
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5 - Gasket
wit
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❑ Renew.
hole
spec
es, in part or in w
tion.
t to the co
6 - 25 Nm
rrectness of i
7 - Exhaust manifold
❑ To remove, remove ex‐
l purpos
haust gas recirculation

cooler
nform
ercia
⇒ Item 20 (page 111)

and unscrew securing
m
a
bolts securing turbo‐
com
tion in
charger to exhaust
r
te o
manifold
thi
s
iva
⇒ Item 6 (page 111) .
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8 - Connecting hose en
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❑ From air filter. ht. Cop py
rig
rig ht
9 - Vacuum line py by
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10 - Cylinder block Prote AG.
11 - 40 Nm
12 - Gasket
❑ Renew.
13 - Turbocharger
14 - Bracket
15 - 40 Nm
❑ For front exhaust pipe
❑ Renew.
17 - Front exhaust pipe
18 - Washer
❑ Renew.
19 - 25 Nm
1. Charge air system with turbocharger 111

Touareg 2003 ➤

❑ Vehicles with automatic gearbox and exhaust gas recirculation
agen
AG. Volchangeover
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1.3 Removing and installing ssturbocharger
t or
au ac
for engine codes BAC and BLK
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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spec
t to the co
rrectness o
cial p
f inform
mer
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c
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sd
a
♦ Support bracket -10-222A-

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t.
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Cop py
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rig ht
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by lksw
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Prote AG.
Not illustrated
♦ Lifting tackle -2024 A/02-
♦ Adapter -10-222A/03-
♦ Adapter -10-222A/18-
♦ Adapter -10-222A/19-
Caution
When a mechanical fault is found on the turbocharger, e.g. a

destroyed compressor impeller, it is not only sufficient to renew
the turbocharger. To avoid subsequent damage, the following
work must be carried out:
♦ Check air filter housing, air filter element and intake hoses
for soiling.
♦ Check complete charged air routing and charge air cooler
for foreign objects.
If foreign objects are found in the charge air system, the charg‐
ed air routing must be cleaned and the charge air cooler must
be renewed, if necessary.
112 Rep. gr.21 - Turbocharging/supercharging

Touareg 2003 ➤
Removing
Rep. gr. 50 ; Assembly overview - noise insulation .
– Remove air filter housing ⇒ page 138 .
– Loosen charge air pipe and vacuum line from turbocharger.
– Loosen exhaust pipe and starter catalytic converter from tur‐
bocharger and gearbox ⇒ page 145 .
lkswage es n
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byV ua
d ran
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– Remove noise insulation -A-. tho tee
or
au ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Fit lifting tackle -2024A/2- on cylinder block as shown.
l purpos
– Support bonnet with suitable workshop equipment.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
– Fit support bracket -10-222A- . Prote AG.

AG. Volkswagen AG d
agen oes
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Touareg 2003 ➤ thor eo
u ra
ss a - Edition 11.2011 c
ce
le
un
pt
an
d
itte
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erm
ab
– Remove right assembly mounting from engine ⇒ page 18 .
ility
ot p
– Unscrew bolts -3- from turbocharger.
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f in
– Unscrew bolts -1- and remove bracket -2-.
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove bolts -arrows- from turbocharger.

– Remove turbocharger.
Installing
– Installation is performed in the reverse sequence.
1.4 Turbocharger with attachments (engine codes BPD and BPE)


Touareg 2003 ➤
Note

♦ Charge air system must be free of leaks.
♦ 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.
1 - Bracket
2 - Exhaust gas recirculation
cooler
⇒ page 157 .
3 - Gasket
❑ Renew. agen
AG. Volkswagen AG d
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4 - Exhaust gas temperature d by
V gu
ara
sender 1 -G235- orise nte
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h
ut
❑ 45 Nm ss a ra
c
❑ Lubricate thread of
ce
le
un
pt
sender using high-tem‐
an
d
itte
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perature paste -G 052
rm
ab
112 A3- .
pe
ility
ot
wit
5 - 40 Nm + turn 90° further
, is n
h re
hole
❑ Renew.
spec
es, in part or in w
❑ Qty. 3
t to the co
❑ Do not grease
6 - Washers
❑ Qty. 3 rrectness of i
l purpos
7 - Gasket
❑ Renew.
nform
ercia

m
tion.
a
com
tion in
r
te o
thi
s
❑ To remove, remove ex‐

iva
do
r

rp
cum
fo
cooler and remove tur‐

en
ng
t.
yi
bocharger to exhaust
Co
op py
manifold securing bolts
t. C rig
gh ht
yri
⇒ Item 5 (page 115) . p by
o Vo
by c lksw
cted agen
9 - 25 Nm Prote AG.
❑ Renew.
10 - Flange upper part
❑ Renew.
11 - Gasket
❑ Renew.
❑ From air filter.

Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011 n AG. Volkswagen AG do
lkswage es n
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13 - Clip ir se
d b ran
o tee
h
14 - Vacuum line aut or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
17 - Turbocharger
ot p
wit
, is n
h re
hole
spec
18 - Gasket
es, in part or in w
❑ Renew.
t to the co
19 - Clamp, 7 Nm
rrectness of i
❑ Renew.
l purpos
20 - Particulate filter
nf
ercia
21 - Gasket
orm
m
❑ Renew.
atio
om
n in
or c
thi
e
22 - Flange lower part

t
sd
iva
o
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cu
❑ Renew.
o
m
f
en
ng
t.
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23 - Gasket
Co
Cop py
.
❑ Renew.
t rig
gh ht
pyri by
Vo
co lksw
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Prote AG.
24 - Bracket upper part
25 - 8 Nm
26 - Vacuum actuator
❑ For bypass flap.
❑ Renew only together with exhaust gas recirculation cooler
27 - 8 Nm
28 - 15 Nm
1.5 Removing and installing turbocharger

(engine codes BPD and BPE)
♦ Allen key, long reach -VAS 3410-

Touareg 2003 ➤
♦ Torque wrench -V.A.G 1331/-
lkswage es n
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un
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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
♦ Support bracket -10-222A-
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Not illustrated
♦ Lifting tackle -2024 A/02-
♦ Adapter -10-222A/03-
♦ Adapter -10-222A/18-
♦ Adapter -10-222A/19-

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

destroyed compressor impeller, it is not only sufficient to renew
the turbocharger. To avoidswsubsequent
agen
AG. Volksdamage,
wagen AG
dothe
es n following
work must be carriedbyout:
Vol
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♦ Check air filter
tho housing, air filter element and intake hosese or
ri te
for soiling.
s au ac
s
ce
le
♦ Check complete charged air routing and charge air cooler

un
pt
for foreign objects.
an
d
itte
y li
erm
ab
If foreign objects are found in the charge air system, the charg‐
ility
ot p
ed air routing must be cleaned and the charge air cooler must
wit
is n
be renewed, if necessary.
h re
ole,
spec
t to the co
Removing
rrectne
Rep. gr. 50 ; Assembly overview - noise insulation .
ss o
cial p
f
– Remove air filter housing ⇒ page 138 .
inform
mer
– Loosen charge air pipe and vacuum line from turbocharger.

atio
om

n
c
i
or
n thi
e
– Removing exhaust manifold ⇒ page 148 .

t
sd
iva
o
pr
cum
– Remove front exhaust pipe together with diesel particulate fil‐

r
fo
en
ng
ter ⇒ page 147 .

t.
yi Co
Cop py
ht. rig
ht
– Remove noise insulation -A-.
rig by
copy Vo
by lksw
cted agen
Prote AG.
– Fit lifting tackle -2024A/2- on cylinder block as shown.

– Support bonnet with suitable workshop equipment.
– Unclip lower bonnet dampers.

Touareg 2003 ➤
– Fit support bracket -10-222A- .

– Remove right engine mounting and right engine bracket
⇒ page 18 .
AG. Volkswagen AG d
agen oes
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au ra
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
– Unscrew bolt -1- and nuts -2-.
is n
h re
ole,
– Remove turbocharger.
spec
Installing
t to the co
Installing the turbocharger is carried out in reverse order of re‐

moval.
rrectne
– Guide turbocharger onto studs on cylinder block.

ss o
cial p
Caution
inform
mer
If the assembly sequence is not followed, the seal may be

atio
m
damaged and exhaust emissions may escape.

o
n
c
i
or
n thi
te
sd
iva
o
r
– Tighten bolt -1- ⇒ Item 16 (page 116) .

p
cum
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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 ➤
– Tighten nuts -2- ⇒ Item 15 (page 116) .

– Install exhaust manifold with sealing set ⇒ page 148 .
– Install exhaust gas recirculation cooler ⇒ page 157 .
– Remove front exhaust pipe together with diesel particulate fil‐
ter ⇒ page 147 .
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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h
aut ra
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1.6 Removing and installing parts of charge

un
pt
an
d
itte
air cooling
y li
erm
ab
ility
ot p
Assembly of hose connections
wit
is n
⇒ „1.8 Hose connections“, page 123
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
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
1 - Air duct
2 - 8 Nm
3 - Shim
4 - Charge air cooler
❑ To remove bumper cov‐
er ⇒ General body re‐
pairs, exterior; Rep. gr.
63 ; Body - front; Re‐
bumper cover. .
5 - Seal
❑ If renewed, observe fit‐
ting instructions
⇒ page 123
6 - 3 Nm
7 - Charge air pressure sender
-G31- with intake air tempera‐
ture sender -G42-
8 - Charge air pipe/connecting
hose
9 - To intake connecting pipe.
10 - Retaining clip
ing.
11 - From turbocharger
12 - 8 Nm
lkswage es n
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1.7 Checking charge air system for leaks au ac
ss
ce
e
nl
pt

du
an
itte
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♦ Charge air system tester -V.A.G 1687-

erm
ab
ility
ot p

wit
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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
121
cted agen
Prote AG.
1. Charge air system with turbocharger
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:
– Turn pressure regulating valve -2- anti-clockwise onto stop.

– Close valves -3- and -4-.
Note
To turn the pressure regulating valve -2- the knob must be pulled
upwards.
. Volkswagen AG
– Connect charge air system tester -V.A.G 1687- to adapter
ksw
agen
AG does
-1687/10- as shown. by
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es, in part or in w
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tion in
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Touareg 2003 ➤
– Connect compressed air hose -1- (compressed air source) to

charge air system tester -V.A.G 1687- .
Note
wage e
If there is water in the bsight
yV
olksglass, drain at water drain screw
s no
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– Open valve a-3-.
ut
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ac
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– Adjust pressure to 0.5 bar with pressure regulating valve -2-.
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The pressure must not exceed 0.5 bar! If the pressure is too
h re
high this can cause damage to the engine.
ole,
spec
t to the co
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary readjust pressure to 0.5 bar.
rrectne
– Check charge air system via:
♦ listening
ss o
cial p
f
♦ feeling
inform
mer
♦ with leak detector spray
atio
om
– or with ultrasonic tester -V.A.G 1842- for leaks.

n
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the engine. Therefore a holding pressure test is not possible.
AG.
♦ 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 120 .
♦ 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 123
⇒ „1.8.2 Hose connections with spring band ring“, page 124
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 groove of charge air hose. Ensure
the seal is correctly seated in the groove.
– Lubricate sealing surface and seal with oil.
– Bring retaining clip to release position -1-.
– Push charge air hose into coupling to stop.
– Bring securing clip to locking position -2- and then push charge
air hose again.
– Check if connector coupling seats correctly and is properly
engaged by pulling hose.
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1.8.2 Hose connections with spring band ring
rrectness of i
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Note
There is a danger of a „hose detaching“ whilst driving after re‐
nf
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moving and reinstalling charge air lines with spring-type clips. For
orm
this reason, spring band rings are used; these must only be
m
atio
m
opened if a defect requires the charge air line to be opened. In

o
n in
c
cases of repair, the charge air pipe must be removed if necessary,

or
thi
e
the spring band ring must be destroyed using a suitable tool (e.g.
t
sd
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angle grinder) and must be renewed by a replacement part ac‐

o
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cording to ⇒ Electronic parts catalogue (ETKA) .

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Touareg 2003 ➤
1.9 Vacuum hose schematic diagram

⇒ „1.9.1 Vacuum hose schematic diagram for engine codes BAC
and BLK“, page 125
⇒ „1.9.2 Vacuum hose schematic diagram for engine codes BPD
and BPE“, page 126
1.9.1 Vacuum hose schematic diagram for engine codes BAC and BLK
1 - Charge pressure control

solenoid valve -N75-
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‐ wagen AG. Volkswagen AG does
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6 - Variable intake manifold
tho
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flap changeover valve
s a -N239-
u ac
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7 - Vacuum reservoir
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8 - Non-return valve
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9 - Intake manifold flap

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spec
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lation cooler.
rrectness of i

automatic gearbox.
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11 - Turbocharger
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Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011 AG. Volkswagen AG d
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1.9.2 Vacuum hose schematic diagram for engine codes BPD and BPE b gu
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1 - Brake servo line
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2 - Non-return valve
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3 - Charge pressure control
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solenoid valve -N75-
t to the co
N345-
rrectne
lation cooler.
ss
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form
mer
lation cooler.
atio
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6 - Turbocharger
o
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7 - Vacuum reservoir
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Prote AG.

Touareg 2003 ➤
23 – Mixture preparation - injection

1 Repairing diesel direct injection sys‐
tem
The diesel direct injection system control unit is equipped with an
event memory. Read event memory before and after making re‐
pairs or adjustments ⇒ Vehicle diagnosis tester .
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⇒ „1.1 Safety precautions“, kpage
swa 127 ol
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⇒ „1.2 Rules for cleanliness“,
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⇒ „1.3 Removings autand installing unit injector“, page 128 ra
c
s
⇒ „1.4 Assembly overview - unit injector“, page 132
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⇒ „1.5 Removing and installing O-rings for unit injector“,
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page 133
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⇒ „1.6 Assembly overview - intake manifold and fuel rail“,
, is n
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page 135
hole
spec
⇒ „1.7 Repairing intake manifold flap“, page 136
es, in part or in w
t to the co
⇒ „1.8 Dismantling and assembling air filter“, page 138
1.1 Safety precautions
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WARNING
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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.
WARNING
Secure fault reader to rear seat and operate from this position.
1. Repairing diesel direct injection system 127

Touareg 2003 ➤
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 before connecting or dis‐
connecting glow plug system and injection system lines or
tester cables.
♦ If the engine is to be turned at starter speed, without starting,
e.g. when checking compressions, disconnect unit injector
connector on cylinder head.
♦ Before disconnecting battery, obtain radio code for radios with
anti-theft coding.
♦ Disconnecting and connecting the battery must only be done
with the ignition switched off, as otherwise the control unit for
diesel direction injection system could become damaged.

When working on the fuel supply and injection system, pay careful
attention to the following „6 rules“ for cleanliness:
connecting.
lint-free cloths.
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♦ Install clean components only. Do not remove replacement Vol
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parts from packing until immediately before installing.
ed
by Do not ara
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use parts that have not been stored in their packing
tho
ris (e.g. in eo
tool boxes etc.). sa
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♦ When system is open: do not work with compressed air if this

nl
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can be avoided. Do not move vehicle unless absolutely nec‐
an
itte
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essary.
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1.3 Removing and installing unit injector

t to the co
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128 Rep. gr.23 - Mixture preparation - injection

Touareg 2003 ➤

equipment required
♦ Universal dial gauge brack‐
et -VW 387-
♦ Allen key, long reach
-3410-
♦ Allen key, long reach -
T10054-
♦ Puller -T10055-
♦ Torque wrench -
V.A.G 1331- (5 ... 50 Nm)
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Touareg 2003 ➤ olks
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5-cylinder diesel engine - Edition
ise
d 11.2011
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♦ Gauge -T10-210-
1.3.1 Removing
– Remove cylinder head cover.
– Turn crankshaft until the cam pair point evenly upwards for the
unit injector which is to be removed.
– 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.
– Remove rocker arm securing bolts -2- (from outwards to in‐
wards) with socket XZN 10 -3410- and remove rocker arm
shaft.
– Remove tensioning block securing bolt -3- with special
wrench, long reach -T10054- and remove the block.
– Lever connector off unit injector using a screwdriver. Support
opposite side of connector with light finger pressure to prevent
canting.

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
upwards.
1.3.2 Installing
Note
AG. Volkswagen AG d
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If a new unit injector is installed, the appropriate adjustment
o
♦ d byV gu
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screw in the rocker arm oris must also be renewed.
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♦ Each time work sis performed which requires adjustment of the
s a c
unit injector, the adjustment screw in the rocker arm and also
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pt
the unit injector ball stud must be renewed.

du
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♦ New unit injectors are supplied with O-rings and heat shield
ab
ility
seal.
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– Heat insulating seal and O-rings must be renewed if old unit

hole
spec
injector is reused ⇒ page 133 .

es, in part or in w
t to the co
– Check that the 3 O-rings and the heat shield seal along with
securing clip are seated correctly before installing unit injector.
rrectness of i
Note
l purpos
The seals must not be twisted.

nf
ercia
orm
m
– Oil the seals and fit the unit injector into the seat in cylinder
atio
om
head with great care.

n in
or c
thi
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– Push the unit injector evenly into the cylinder head onto its limit
t
sd
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stop.
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– Insert tensioning block in slot on side of unit injector.

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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.
– Fit dial gauge onto adjustment screw of unit injector as shown.

– Turn crankshaft in direction of engine rotation until roller of
rocker arm is located at tip of drive cam.
Roller side -arrow A- is at highest point. Adjuster screw of unit
injector -arrow B- is at lowest pump.
– Remove dial gauge.
– Now turn adjuster screw into rocker arm against spring pres‐
sure of unit injector until firm resistance is felt (unit injector
positioned at stop).
– Turn adjustment screw 180° back off stop.

olkswagen AG
en AG. V
– Hold adjuster screw in this position
ksw and tighten lock nut eto
ag do s 30
not
Vol
Nm. db
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– Reconnect unit injector
au
tho connector and install cylinder head eo
ra
cover. ss c
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1.4 Assembly overview - unit injector

♦ Observe rules for cleanliness ⇒ page 128 .
rrectness of i
♦ Always renew seals and O-rings

l purpos
nf
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orm
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Prote AG.

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 128 , removing
and installing unit injec‐
tor
❑ Check ball pin for signs
of wear, replace if nec‐
essary
⇒ page 128 n AG. Volkswagen AG do
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5 - Tensioning block d byV
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ran
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6 - 12 Nm + 270° further
utho
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❑ Renew. ss
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7 - Unit injector
du
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⇒ page 128
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8 - O-ring
h re
hole
❑ Renew. ⇒ page 133 . spec

es, in part or in w
9 - Heat shield seal

t to the co
❑ Renew.
10 - Circlip
rrectness of i
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1.5 Removing and installing O-rings for unit

m
at
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injector
ion
c
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at
do
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♦ Assembly sleeves -T10056-

um
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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.
♦ Prevent O-rings from rolling when sliding them on. The O-rings
must not be twisted in their seats in unit injector.
– Pull heat shield seal off together with securing clip.

– Clean seating surfaces for O-rings on unit injector very care‐
fully.
– Place assembly sleeve -T10056/1- onto stop on unit injector.
– Push the upper, thicker O-ring carefully onto assembly sleeve
and into seat on unit injector.
– Remove assembly sleeve.
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– Slide the middle, thinner O-ring carefully onto assembly sleeve ility
ot
and into seat on unit injector. wit

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spec
es, in part or in w
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– Push the lower O-ring carefully onto the assembly sleeve and
n in
r
into the seat of the unit injector.

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– Fit new heat shield seal together with securing clip.

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Touareg 2003 ➤
1.6 Assembly overview - intake manifold and fuel rail
1 - Cylinder head
⇒ page 42
2 - Intake manifold support
3 - 10 Nm
4 - Intake manifold AG. Volkswagen AG d
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5 - 20 Nm by Vo gu
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6 - Fuel rail uthor eo
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7 - 8 Nm + 90° further s
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❑ Renew.
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8 - Connection
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❑ Long.
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❑ For supply flow
h re
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spec
9 - Connection
es, in part or in w
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❑ Short.
❑ For return flow
rrectness of i
10 - Seal
❑ Renew.
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11 - Glow plug
nf
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❑ 15 Nm
orm
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atio
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12 - Gasket
or
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❑ Renew.
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Prote AG.

Touareg 2003 ➤
1.7 Repairing intake manifold flap

⇒ „1.7.1 Repairing intake manifold flap for engine codes BAC and
BLK“, page 136 .
⇒ „1.7.2 Repairing intake manifold flap for engine codes BPD and
BPE“, page 137 .
1.7.1 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.
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4 - Connecting pipe ksw
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❑ For exhaust gas edrecircu‐
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5 - 20 Nm
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6 - 10 Nm
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7 - From charge air cooler

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8 - Intake connecting pipe

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❑ With mechanical ex‐

hole
spec

es, in part or in w
valve and intake mani‐

t to the co
fold flap
9 - 10 Nm
rrectness of i
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11 - Vacuum supply
nf
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12 - Variable intake manifold

or
flap changeover valve

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Touareg 2003 ➤
1.7.2 Repairing intake manifold flap for engine codes BPD and BPE
1 - Intake manifold
2 - Seal
❑ Renew. AG. Volkswagen AG d
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olksw not
3 - Gasket d byV gu
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❑ Renew. hor eo
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4 - Connecting pipe ss
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d
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lation cooler.
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❑ Assembly overview - ex‐
pe
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cooler ⇒ page 157
h re
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spec
5 - 22 Nm
es, in part or in w
t to the co
6 - 10 Nm
7 - Intake manifold flap motor -
V157-
rrectness of i
❑ The intake manifold flap
l purpos
is closed for approx. 3

seconds when stopping
engine and then opens
nform
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again. This reduces the

m
a
stop jolt.
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tion in
8 - 10 Nm
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9 - Seal
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10 - Exhaust gas recirculation C py
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valve -N18- with exhaust gas rig ht
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Prote AG.
❑ Assembly overview - ex‐

⇒ page 157

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

2 - Filter element
3 - Air filter upper part
4 - Securing pins
⇒ page 138
5 - O-ring
6 - Intake manifold
7 - Air mass meter -G70-
8 - 6 Nm
9 - Clip
❑ Remove and install us‐
ing spring-type clip pli‐
ers -VAS 5024A- .
10 - Adapter
11 - To turbocharger. lkswage es n
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Removing and installing securing pins

nf
ercia
Removing
orm
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– Turn securing pins using appropriate bit until markings -A- on

atio
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pins and -B- on housing align.

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

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Prote AG.

Touareg 2003 ➤
2 Engine control unit

⇒ „2.1 Reading and deleting engine control unit event memory“,
page 139 .
⇒ „2.2 Removing and installing engine control unit J623 “,
page 140 .
⇒ „2.3 Removing and installing anti-theft engine control unit J623
“, page 140 .
2.1 Reading and deleting engine control unit

event memory
♦ Vehicle diagnosis, testing and information system -VAS
5051B- n AG. Volkswagen A G do
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Procedure
– Connect Vehicle diagnosis, testing and information system -
rrectne
VAS 5051B- as follows:
– Push diagnostic cable connector onto diagnostic connector.
ss o

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Only when engine does not start:

mer
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– Switch on ignition.
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Selecting operating mode:

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– 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‐ gh ht
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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“.
2. Engine control unit 139

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.
Removing
– Switch off ignition.
– Remove wiper arms, ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing wiper arms.
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 64 ; Removing and installing plenum chamber
cover.
– Slide connector locking devices -1- on engine control unit out‐
wards and pull off both connectors.
– Press securing clips aside and removeagengine
en AG. V control
olkswagenunit.
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– Insert engine control unituinto
tho retaining frame in plenum cham‐ eo
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ber. ss a c
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– Fit connectors to engine control unit and slide locking devices

es, in part or in w
-1- inwards.
t to the co
– Install plenum chamber cover ⇒ General body repairs, exte‐

rior; Rep. gr. 64 ; Removing and installing plenum chamber
rrectness of i
cover.
l purpos
– Install wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐

screen wiper system; Removing and installing wiper arms .
nf
ercia
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2.3 Removing and installing anti-theft en‐

o
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f
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gine control unit -J623-

t.
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Note cted agen
Prote AG.
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.

agen
AG. Volkswagen AG d
oes Touareg 2003 ➤
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y Vol 5-cylinder diesel engine not
-guEdition 11.2011
db ara
rise nte
o
♦ Hot air blower from wiring harness repairautset -VAS 1978-
h eo
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nl
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rrectness of i
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♦ Nozzle attachment from wiring harness repair set -VAS 1978-

Removing
nform
ercia
– Switch off ignition.

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at
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io
– Remove wiper arms, ⇒ Electrical system; Rep. gr. 92 ; Wind‐
n
c
in t
r

o
his
ate
do
riv
– Remove plenum chamber cover ⇒ General body repairs, ex‐

p
cum
or
terior; Rep. gr. 64 ; Removing and installing plenum chamber

f
en
ng
cover.
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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Note by c lksw
cted agen
Prote AG.
The shear-head bolt threads are coated with locking compound.

Heating the shear-head bolt with a hot air blower releases the
locking effect of the locking compound.
Caution
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.
olkswagen AG
en AG. V
– Unscrew shear-head bolt using mole grips/pliersoon
lkswbolt head.
ag does
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The procedure for the second shear-head bolt riseis identical.
d
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es, in part or in w
– Remove cover -1- from control unit.
t to the co
rrectness of i
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mercia
at
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ion
c
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ate
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priv
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– Slide connector locking devices -1- on engine control unit out‐

f
en
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t.
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wards and pull off both connectors.
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– Remove engine control unit.
gh ht
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Installing cted agen
Prote AG.
– Insert engine control unit into retaining frame in plenum cham‐

ber.
– Fit connectors to engine control unit and slide locking devices

-1- inwards.

Touareg 2003 ➤
– Place cover -1- over engine control unit and fit new shear-head
bolts -arrows- by hand.
– Then tighten new shear-head bolts evenly until heads shear
off.
– Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 64 ; Removing and installing plenum chamber
cover.
– Install wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
AG. Volkswagen AG d
agen oes
olksw not
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pt
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es, in part or in w
t to the co
rrectness of i
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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 aevenly
gen AG
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♦ Renew self-locking nuts. thoris nte
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es, in part or in w
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rrectness of i
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nform
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tion in
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144 Rep. gr.26 - Exhaust system

Touareg 2003 ➤
⇒ „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 147
⇒ „1.4 Assembly overview - exhaust manifold (engine codes BPD,
BPE)“, page 148
⇒ „1.5 Removing and installing exhaust manifold (engine codes
BPD, BPE)“, page 150
⇒ „1.6 Silencer with mountings“, page 153
1.1 Assembly overview - front exhaust pipe with catalytic converters
1 - From turbocharger
AG. Volkswagen AG d
2 - Gasket agen oes
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3 - Connecting clamp, 8s aNm
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4 - Front exhaust pipe with
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starter catalytic converter
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spec
5 - Bracket
❑ Bolted to gearbox.
t to the co
6 - 25 Nm
7 - Gasket rrectne
❑ Renew.
ss
8 - Front exhaust pipe with cat‐

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alytic converter
nform
mer
9 - To rear silencer
atio
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10 - Mounting
c
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Prote AG.
1. Exhaust system 145

Touareg 2003 ➤
1.2 Assembly overview - front exhaust pipe

with particulate filter
Note
If the particulate filter or the exhaust gas pressure sensor 1 -

G450- is changed, the exhaust gas pressure sensor 1 -G450-
must always be adapted using diagnosis tester : Guided
functions; adapting exhaust pressure sensor 1 -G450- .
1 - Turbocharger
2 - Gasket
❑ Renew.
tion.
3 - Clamp, 7 Nm
❑ Renew.
4 - Exhaust gas pressure sen‐
sor 1 -G450-
❑ Guided functions;
Adapting exhaust gas
pressure sensor 1 -
G450- .
5 - Bracket
❑ For control line
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7 - Control line, 45 Nm orise nte
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8 - Temperature sender afterss a c
particulate filter -G527- , 45
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112 A3-
h re
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9 - 25 Nm
es, in part or in w
t to the co
10 - Rear support
11 - 40 Nm
rrectness of i
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❑ Guided functions;
Adapting exhaust gas
pressure sensor 1 -
nf
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G450- .
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13 - Front exhaust pipe

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14 - Mounting
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15 - Gasket
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❑ Renew.
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16 - 25 Nm
cop Vo
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17 - Exhaust gas temperature sender 2 for bank 1 -G448-
❑ 45 Nm

Touareg 2003 ➤
❑ 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
1.3 Removing and installing particulate filter
Note
If the particulate filter or the exhaust gas pressure sensor 1 -

G450- is changed, the exhaust gas pressure sensor 1 -G450-
must always be adapted using diagnosis tester : Guided
functions; adapting exhaustgen AG
pressure
. Volkswagesensor
n AG d 1 -G450- .
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Removing rised ara
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– Loosen
a cooler for exhaust gas recirculation and remove
u r a brack‐
c
ss
et.
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nl
pt
du
– Separate connectors to Lambda probe -G39- , to bank 1 ex‐

an
itte
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haust gas temperature sender 2 -G448- , exhaust gas tem‐

erm
ab
perature sender 1 -G235- and temperature sender after

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particulate filter -G527- .

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Separate cable ties.

hole
spec
es, in part or in w
– Unscrew exhaust gas pressure sensor 1 -G450- from bracket.

t to the co
The exhaust gas pressure sensor 1 -G450- and the control lines
remain connected on the particulate filter.
rrectness of i
– Remove front exhaust pipe.

l purpos
– Loosen clamp.
– Remove front support -1- and rear support -2- from particulate
nf
ercia
filter.
rm
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atio
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– Take particulate filter out upwards.

o
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Installing
thi
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sd
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– Insert particulate filter.

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t.
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Prote AG.

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.
– Align particulate filter and tighten bolt of clamp to 7 Nm.
– Tighten hexagon bolt.
Specified torque: 40 Nm.
– Tighten hexagon nut on thread of front support -1- and tighten
hexagon nut on engine support.
– Join connectors to Lambda probe -G39- , to bank 1 exhaust
gas temperature sender 2 -G448- , exhaust gas temperature
sender 1 -G235- and temperature sender after particulate filter
-G527- and connect lines at the marked points using cable
ties.
– Install front exhaust pipe.
1.4 Assembly overview - exhaust

lksw
agen
AG. Vmanifold
olkswagen AG
(engine
does
n
codes BPD, BPE)
o ot g
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⇒ page 110 . ris
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pe
ility
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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
te o
thi
s
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cum
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t.
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Cop py
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rig ht
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by lksw
cted agen
Prote AG.

Touareg 2003 ➤
Note

1 - Bracket
cooler
⇒ page 157 .
3 - Gasket
❑ Renew.
4 - Exhaust gas temperature
sender 1 -G235-
❑ 45 Nm
112 A3-
5 - 40 Nm + 90° turn
❑ Renew.
❑ Qty. 3 AG. Volkswagen AG d
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❑ Do not grease olksw not
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6 - Washers thor eo
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❑ Qty. 3 ss a c
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7 - Gasket
pt
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❑ Renew.
erm
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ility

ot p
tion.
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spec
❑ To remove: remove ex‐

t to the co

cooler and remove se‐
curing bolts securing
rrectne
turbocharger to exhaust
manifold
⇒ Item 5 (page 149) .
ss o
cial p
9 - 25 Nm
inform
❑ Renew.
mer
atio
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10 - Flange upper part

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❑ Renew.
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11 - Seal
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❑ Renew.
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12 - Connecting hose t. C rig
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❑ From air filter. cop Vo
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Prote AG.

Touareg 2003 ➤
13 - Clip
14 - Vacuum line
15 - 40 Nm + 90° turn
16 - 40 Nm + 90° turn
17 - Turbocharger
18 - Gasket
❑ Renew.
19 - Clamp, 7 Nm
❑ Renew.
21 - Gasket
❑ Renew.
22 - Flange lower part
❑ Renew.
23 - Gasket
❑ Renew.
25 - 10 Nm AG. Volkswagen AG d
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lksw not
26 - Vacuum actuator by
Vo gu
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❑ For bypass flap. horis nte
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❑ Renew only together with exhaust gas recirculation cooler
ss a c
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27 - 10 Nm
un
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28 - 15 Nm
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1.5 Removing and installing exhaust mani‐
hole
spec
fold (engine codes BPD, BPE)
es, in part or in w
Special tools and workshop equipment required t to the co

♦ Allen key, long reach -VAS 3410-
rrectness of i
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nform
mercia
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tion in
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te o
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Cop py
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by c lksw
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Prote AG.

Touareg 2003 ➤
♦ Gauge -10348-
♦ Torque wrench -V.A.G 1331/-
Removing exhaust manifold (engine codes BPD, BPE)

– Removing bracket ⇒ Item 1 (page 149) .
– Remove exhaust temperature sender 1 -G235-
⇒ Item 4 (page 149) .
– Unscrew exhaust manifold securing nut ⇒ Item 9 (page 149) s.wagen AG. Volkswagen AG does
k not
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– Unscrew bolts to turbocharger ⇒ Item 5 (page 149) . sed by ara
nte
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– Remove exhaust manifold. aut ra
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Installing exhaust manifold (engine codes BPD, BPE)
ce
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• Renew all seals and gaskets.
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• Specified torque ⇒ page 148 .

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• Install in reverse order.

h re
hole
spec
• In the process, note the following:

es, in part or in w
t to the co
♦ In the case of a used exhaust manifold:

– Clean exhaust manifold connection using abrasive paper.
rrectness of i
l purpos
Note
The abrasive paper grade must not be less than 100.

nf
ercia
orm
m
atio
m
– Fit new gasket onto turbocharger ⇒ Item 23 (page 116) .

o
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– Fit sealing set onto exhaust manifold.

thi
te
sd
iva
• The sealing set consists of:

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♦ Flange upper part ⇒ Item 10 (page 115)

t.
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♦ Gasket ⇒ Item 23 (page 150)
t. rig
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151
Prote AG.
1. Exhaust system
Touareg 2003 ➤
♦ Flange lower part ⇒ Item 22 (page 116)

– 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 149) .
– Remove cable tie from sealing set. . Volkswagen AG
gen AG does
swa
– Start bolts on turbocharger. ⇒ Item 5 (page 149) yV
olk not
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nl
pt
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ab
ility
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– Insert gauge -T10348- -1- in direction of arrow -A- and turn
, is n
h re
gauge -T10348- in direction of arrow -B-.
hole
spec
1
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
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atio
om
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– Gauge -T10348- must be located between flange upper and
thi
te
sd
a
flange lower parts.

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t.
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Cop py
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rig ht
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by lksw
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Prote AG.
– Tighten bolts -1-, -2- and -3- to 5 Nm.

– Loosen bolts by turning 180°.
– Remove gauge from turbocharger.
– Tighten bolts one by one to 30 Nm in 90° steps.
– Then turn all bolts 180° further.

Touareg 2003 ➤
1.6 Silencer with mountings
1 - From front exhaust pipe

2 - Double clamp
3 - Exhaust pipe with rear si‐
lencer
4 - 25 Nm
5 - Mounting
AG. Volkswagen AG d
agen oes
olksw not
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nl
pt
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itte
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ility
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hole
spec
es, in part or in w
t to the co
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
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by
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Prote AG.

Touareg 2003 ➤ AG. Volkswagen AG d
agen
V ol -
ksw Edition 11.2011 oes
not
y gu
db ara
rise nte
tho eo
2 Exhaust
ss gas recirculation system au ra
c
ce
e
⇒ „2.1 Assembly overview - exhaust gas recirculation“, nl
pt
du
an
itte
page 155
y li
erm
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⇒ „2.2 Checking exhaust gas recirculation valve (mechanical)“,
ility
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page 158
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spec
es, in part or in w
Note
t to the co
♦ The exhaust gas recirculation system is actuated by the en‐
gine control unit via the exhaust gas recirculation valve -N18-
rrectness of i
(electropneumatic) to the exhaust gas recirculation valve
(mechanical).
l purpos
♦ The cone-shaped plunger in the mechanical exhaust gas re‐

circulation valve ensures that various opening cross-sections
nform
ercia
are possible at different valve lifts.

m
at
om
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on
c
in t
or
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ate
do
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for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
2.1 Assembly overview - exhaust gas recir‐

culation
⇒ „2.1.1 Assembly overview - exhaust gas recirculation (engine
codes BAC and BLK)“, page 155
⇒ „2.1.2 Assembly overview - exhaust gas recirculation, intake
manifold side (engine codes BPD and BPE)“, page 156
⇒ „2.1.3 Assembly overview - exhaust gas recirculation, exhaust
gas side (engine codes BPD and BPE)“, page 157
⇒ „2.1.4 Removing and installing exhaust gas recirculation cooler
(engine codes BPD and BPE)“, page 157
2.1.1 Assembly overview - exhaust gas recirculation (engine codes BAC and
BLK)
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
tion valve and intake agen oes
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manifold flap. ed by
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❑ Perform mechanical in‐ ut
hor eo
spection of exhaust gas ss a ra
c
recirculation valve
ce
le
un
⇒ page 158 .
pt
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4 - O-ring
erm
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❑ Renew.
wit
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5 - Intake manifold
ole,
spec
6 - Coolant hose
t to the co
diagram
7 - 10 Nm rrectne

s
cooler
s o
cial p
❑ Vehicles with automatic

inform
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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10 - Exhaust manifold C py
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❑ Renew. Prote AG.
2. Exhaust gas recirculation system 155

Touareg 2003 ➤
AG. Volkswagen AG d
5-cylinder diesel engine - Edition 11.2011 ksw
agen oes
not
ol
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12 - 25 Nm orise nte
eo
h
ut ra
13 - Connecting pipe ss a c
ce
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nl
14 - Gasket
pt
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an
itte
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❑ Renew.
erm
ab
ility
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2.1.2 Assembly overview - exhaust gas recirculation, intake manifold side (engine
hole
spec
codes BPD and BPE)
es, in part or in w
t to the co
1 - 10 Nm
rrectness of i
2 - Intake manifold flap motor -
l purpos
V157-
❑ The intake manifold flap
is closed for approx. 3
nf
ercia
o
seconds when stopping
rm
m
atio
engine and then opens
om
again. This reduces the
n in
or c
stop jolt.
thi
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iva
3 - 10 Nm
o
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t.
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valve -N18- with exhaust gas Cop py
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recirculation potentiometer -
ht ht
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❑ Before installing, check Prote AG.
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‐
ed on and off again.
Then wait one minute
for the control unit to run
down (valve learns,
main relay must click)
❑ Start engine and run at
idling speed for one mi‐
nute.
❑ Then read engine con‐
trol unit event memory;
event memory must not
contain any fault
⇒ page 139 .
5 - Intake manifold
6 - Connecting pipe
❑ To exhaust gas recirculation cooler.
7 - 22 Nm
8 - Gasket
❑ Renew.

Touareg 2003 ➤
lkswage5-cylinder diesel engine
es n - Edition 11.2011
o ot g
byV ua
d ran
2.1.3 Assembly overview - exhaust gas recirculation, exhaust gas side (engine tho
ir se tee
or
codes BPD and BPE) au ac
ss
ce
le
un
pt
an
d
itte
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1 - 8 Nm
rm
ab
pe
ility
ot
wit
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h re
3 - Bracket
hole
spec
4 - 15 Nm
es, in part or in w
t to the co
5 - 8 Nm
6 - Coolant hoses
rrectness of i
❑ To remove: clamp off
exhaust gas recircula‐
l purpos
tion cooler using hose

clamps, up to 25 mm
nform
ercia
-3094- .
m
a
7 - 25 Nm
com
tion in
8 - Gasket
r
te o
thi
s
iva
❑ Renew.
do
r
rp
cum
fo
9 - Exhaust gas temperature
en
ng
t.
sender 1 -G235-
yi Co
Cop py
❑ 45 Nm
t. rig
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agen
Prote AG.
112 A3-
N345-
13 - 10 Nm
❑ For bypass flap.
❑ Renew only together
with exhaust gas recirculation cooler
16 - Gasket
❑ Renew.
17 - Connecting pipe
18 - 22 Nm
19 - 10 Nm
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-
Removing agen
AG. Volkswagen AG d
oes
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– Remove connecting d by V pipe ⇒ Item 17 (page 157) . t gua
ran
e
ris tee
– Disconnectautand
ho remove coolant hoses ⇒ Item 6 (page 157) or .
ac
ss
– Use a cloth to collect residual coolant.
ce
le
un
pt
an
d
– Disconnect connecting hose from vacuum unit

itte
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⇒ Item 14 (page 157) .
rm
ab
pe
ility
– Remove upper part bracket ⇒ Item 2 (page 157) .
ot
wit
, is n
h re
– Unbolt connection to exhaust manifold ⇒ Item 7 (page 157) .
hole
spec
– Carefully remove exhaust gas recirculation cooler. Dispose of
es, in part or in w
t to the co
residual coolant.
Installing
rrectness of i
• Install in reverse order.

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• Specified torque ⇒ page 157 .

• Replenish coolant ⇒ page 74 .
nform
ercia
2.2 Checking exhaust gas recirculation

m
a
com
tio
valve (mechanical)
n in
r
te o
thi
s
iva
Only for engine codes BAC and BLK

do
r
rp
cum
fo

en
ng
t.
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♦ Hand vacuum pump -V.A.G 1390- C py
ht. rig
rig ht
py by
co Vo
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Prote AG.
Vacuum hose schematic diagram for engine codes BAC and BLK
⇒ page 125
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
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d by ara
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or eo
h
aut ra
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pt
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rm
ab
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ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
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t.
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Cop py
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gh ht
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Vo
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by c lksw
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Prote AG.

Touareg 2003 ➤
28 – Glow plug system

1 Glow plug system
⇒ „1.1 Characteristics of glow plugs“, page 160
⇒ „1.2 Checking metal glow plugs“, page 160 .
⇒ „1.3 Removing, installing and checking ceramic glow pin plugs“,
page 162 .
1.1 Characteristics of glow plugs
Caution
Ceramic glow plugs are sensitive to knocks and bending.

For this reason a glow plug which has dropped olkfrom
sw even
n AG d a
small height (approx. 2 cm) must not be
w en AG. Veven aifgethere
agused, ises no
o
olks
no obvious damage. db
yV t gu
ar
e an
ris tee
It is absolutely essential tothofollow the installation instructions, or
au the glow plug can break and cause
otherwise the heater pinssof ac
engine damage.
ce
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nl
pt
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an
itte
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erm
ab
Optical characteristics of glow plugs
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A - Ceramic glow plugs, phase step on top (see enlargement),
h re
colour-coded white -arrow-.
hole
B - Metal glow plugs, colour-coded green -arrow-. spec

es, in part or in w
t to the co
Removing, installing and checking ceramic glow plugs
⇒ page 162 .
rrectness of i
Checking metal glow plugs ⇒ page 160 .

l purpos
nf
ercia
orm
m
atio
m
1.2 Checking metal glow plugs

o
n in
or c
thi
e

t
sd
iva
o
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rp
cu
♦ Auxiliary measuring set -V.A.G 1594C-

o
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f
en
ng
t.
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Cop py
t. rig
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pyri by
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Prote AG.
160 Rep. gr.28 - Glow plug system

Touareg 2003 ➤
♦ 10 mm jointed spanner -3220-
♦ Voltage tester -V.A.G 1527B-
AG. Volkswagen AG d
agen oes
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Test prerequisites horis nte
eo
aut ra
• Battery voltage at least 11.5 V ss c
ce
le
un
pt
• Ignition switched off
an
d
itte
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erm
Test procedure
ab
ility
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– Remove intake manifold ⇒ page 135 .
wit
is n
h re
ole,
– Pull glow plug connectors off glow plugs.
spec
– Connect voltage tester line to battery positive terminal using
t to the co
auxiliary clamps from auxiliary measuring set -V.A.G 1594C- .
– Place test probe of voltage tester on each glow plug one after
rrectne
the other. Diode lights up: glow plug OK., diode does not light
up: renew glow plug.
s
– Remove and install glow plugs with U/J extension and socket,
s o
cial p
10 mm -3220- . f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Glow plug system 161

Touareg 2003 ➤
1.3 Removing, installing and checking ceramic glow pin plugs

AG. Volkswagen AG d
agen oes
olksw not
Special tools and workshop d byV gu
ara
equipment required orise nte
eo
h
ut ra
♦ 10 mm jointed spanner ss a c
-3220-
ce
e
nl
pt
du
an
itte
y li
erm
1331-
ab
ility
ot p
♦ Hand-held multimeter -
wit
, is n
V.A.G 1526A-
h re
hole
spec
♦ Auxiliary measuring set - es, in part or in w
V.A.G 1594C-
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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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.
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
162 Rep. gr.28 - Glow plug system

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

Remove any components hindering assembly.
– Remove intake manifold ⇒ page 135 .

– 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.
Note
olkswa
Do not oil or grease thread of cylinder
ksw
head
agen bore or of ceramic
AG. V gen AG
does
glow pin plugs. by Vol not
gu
a
ed ran
oris tee
h
– Turn ceramic glow plugs
au into cylinder head
t
by hand using U/ or
ac
ss
J extension and socket, 10 mm -3220- .
ce
e
nl
pt
du
– Then tighten the ceramic glow plugs.
an
itte
y li
erm
ab
Specified torque:
ility
ot p
• WAF 8 = 12 Nm
wit
, is n
h re
hole
• WAF 10 = 15 Nm spec
es, in part or in w
t to the co
Caution
After installing and before the engine is started, perform a re‐

rrectness of i
sistance test on all ceramic glow plugs when engine is cold.

l purpos
• Specification: max. 1.0 Ω

nform
ercia
– If the specification is exceeded, renew the defective ceramic

m
at
om
glow plug.
ion
c
in t
or
his
ate
do
riv
Note
p
cum
for
en
ng
t.
If the defective ceramic glow plug is broken, remove all fragments
yi Co
op
from the engine, otherwise these can cause damage to the en‐
C py
t. rig
gh
gine.
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Glow plug system 163

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Service

5-cylinder diesel engine

BAC BLK BPD BPE

Service Department. Technical Information

23 - Mixture preparation - injection

28 - Glow plug system

All rights reserved.

Copyright © 2011 Volkswagen AG, Wolfsburg K0058961720

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

1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.2 Removing engine from scissor-type assembly platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.3 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.5 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

1.6 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

1.10 Checking fuel pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

1.11 Checking tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

1.13 Assembly overview - accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

1.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

1.6 Removing and installing parts of charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

1 Repairing diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

1.1 Engine number

The engine number („engine code“ and „serial number“) can be

Additionally there is a sticker on the front of the cylinder head with

2.1 Safety precautions when working on

Risk of injury due to highly-pressurised fuel.

To prevent injuries to persons and destruction of the injection and

glow plug system, the following must be noted:

♦ Always switch off the ignition before connecting or discon‐

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

self-diagnosis ⇒ Vehicle diagnosis tester .

♦ 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

2.2 Safety precautions for when using test

2.3 Safety precautions when working on

Hot steam/hot coolant can escape - risk of scalding.

Danger of overheating due to incorrectly fitted cap.

3 General repair notes

3.1 Rules for cleanliness n AG. Volkswagen AG do

♦ Carefully cover opened components and connections or seal

if repairs cannot be carried out immediately.

parts from packing until immediately before installing. Do not

immediately. Damaged hoses must be renewed.

3.2 Foreign objects in engine

4 Rep. gr.00 - Technical data

10 – Removing and installing engine tho eo

⇒ „1.3 Securing engine to assembly stand“, page 15

platform -VAS 6131-