VW Touran 2003 Running Gear Axles Steering Eng PDF

Service
Workshop Manual
Touran 2003 ➤
Running gear, axles, steering
Edition 11.2016
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
40 - Front suspension
42 - Rear suspension
43 - Self-levelling suspension
44 - Wheels, tyres, vehicle geometry
48 - Steering
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.
Touran 2003 ➤
Running gear, axles, steering - Edition 11.2016
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Checklist for evaluating running gear of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
40 - Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1 Appraisal of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Raising wheel suspension to unladen position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Overview - front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Assembly overview: subframe, anti-roll bar, suspension links . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Assembly overview: front left vehicle level sender G78 . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Removing and installing front left vehicle level sender G78 . . . . . . . . . . . . . . . . . . . . . . . . 12
4.3 Repairing thread in longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.4 Fixing position of subframe and brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.5 Lowering subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.6 Removing and installing subframe without steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.7 Removing and installing subframe with steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.8 Repairing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.9 Checking swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.10 Removing and installing swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.11 Removing and installing suspension link with mounting bracket . . . . . . . . . . . . . . . . . . . . 41
4.12 Removing and installing suspension link with mounting bracket (left side for vehicles with
DSG or automatic gearboxes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.13 Renewing bonded rubber bush for suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.14 Renewing mounting bracket with suspension link bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.15 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5 Assembly overview: wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.1 Removing and installing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.2 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6 Assembly overview: suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.1 Removing and installing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
6.2 Repairing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7 Removing and installing drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.1 Loosening and tightening drive shaft hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.2 Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft . . . . . . 83
7.3 Loosening and tightening twelve-point head bolt, without ribbing, securing drive shaft . . . . 84
7.4 Removing and installing drive shaft with constant velocity joint . . . . . . . . . . . . . . . . . . . . . . 86
7.5 Removing and installing left drive shaft with (push-on) constant velocity slip joint . . . . . . 89
7.6 Removing and installing right drive shaft with (push-on) constant velocity slip joint . . . . . . 94
7.7 Removing and installing drive shafts with triple roller joint AAR2600i . . . . . . . . . . . . . . . . 99
7.8 Removing and installing drive shafts with triple roller joint AAR3300i . . . . . . . . . . . . . . . . 104
7.9 Removing and installing intermediate shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
8 Repairing drive shaft - overview of drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
8.1 Heat shields for drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
9 Assembly overview: drive shaft with VL90 or VL100 constant velocity joint . . . . . . . . . . . . 113
9.1 Dismantling and assembling drive shaft with VL90 or VL100 constant velocity joint . . . . . . 115
9.2 Checking outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
9.3 Checking inner constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
10 Assembly overview: drive shaft with VL107 constant velocity joint (bolt-on) . . . . . . . . . . . . 123
10.1 Dismantling and assembling drive shaft with VL107 constant velocity joint . . . . . . . . . . . . 126
10.2 Repairing intermediate shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
11 Assembly overview: drive shaft with VL107 constant velocity slip joint (push-on) . . . . . . . . 133
Contents i
Touran 2003 ➤
11.1 Dismantling and assembling drive shaft with VL107 (push-on) constant velocity slip joint
........................................................................ 134
11.2 Checking outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
12 Assembly overview: drive shaft with triple roller joint AAR2600i . . . . . . . . . . . . . . . . . . . . 139
12.1 Dismantling and assembling drive shaft with triple roller joint AAR2600i . . . . . . . . . . . . . . 141
13 Assembly overview: drive shaft with triple roller joint AAR3300i . . . . . . . . . . . . . . . . . . . . 146
13.1 Dismantling and assembling drive shaft with triple roller joint AAR3300i . . . . . . . . . . . . . . 148
42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

2 Rear axle in unladen position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3 Overview - rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
4 Assembly overview: subframe, transverse links track rod . . . . . . . . . . . . . . . . . . . . . . . . . . 157
4.1 Fixing position of subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
4.2 Lowering rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
4.3 Rear left vehicle level sender G76 for vehicles with automatic headlight range control . . . . 163
4.4 Removing and installing rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.5 Removing and installing upper transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4.6 Removing and installing lower transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
4.7 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
5 Assembly overview: wheel bearing housing, trailing arm . . . . . . . . . . . . . . . . . . . . . . . . . . 176
5.1 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
5.2 Renewing bonded rubber bush for wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . 180
5.3 Removing and installing wheel bearing/wheel hub unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
5.4 Removing and installing wheel bearing pre-seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
5.5 Removing and installing trailing arm with mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . 188
5.6 Repairing trailing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
6 Assembly overview: shock absorber, coil spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
6.1 Removing and installing coil spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
6.2 Removing and installing shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
6.3 Repairing shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
7 Assembly overview: anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
7.1 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
8 Assembly overview: subframe attachments, Touran BlueMotion . . . . . . . . . . . . . . . . . . . . 204
43 - Self-levelling suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

1 Evaluating accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
2 Components of adaptive chassis control DCC and fitting locations . . . . . . . . . . . . . . . . . . 206
2.1 Shock absorber damping adjustment button E387 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
2.2 Removing and installing front left and right body acceleration senders G341/G342 . . . . . . 207
2.3 Renewing bracket for front left/right body acceleration sender G341/G342 . . . . . . . . . . . . 208
2.4 Assembly overview: front left/right vehicle level sender G78/G289 for adaptive chassis control
DCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
2.5 Removing and installing front left/right vehicle level sender G78/G289 . . . . . . . . . . . . . . 211
2.6 Assembly overview: rear left vehicle level sender G76 for adaptive chassis control DCC
........................................................................ 212
2.7 Removing and installing rear left vehicle level sender G76 for adaptive chassis control
DCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
2.8 Removing and installing electronically controlled damping control unit J250 . . . . . . . . . . 214
2.9 Removing and installing retainer for electronically controlled damping control unit J250 . . 215
2.10 Basic setting of adaptive chassis control DCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
2.11 Cable routing left front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
2.12 Cable routing right front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
2.13 Cable routing rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
3 Assembly overview: suspension strut for adaptive chassis control DCC . . . . . . . . . . . . . . 219
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Touran 2003 ➤
3.1 Removing and installing suspension strut for adaptive chassis control DCC . . . . . . . . . . . . 221
4 Assembly overview: shock absorber for adaptive chassis control DCC . . . . . . . . . . . . . . . . 230
4.1 Removing and installing rear body acceleration sender G343 . . . . . . . . . . . . . . . . . . . . . . 231
4.2 Removing and installing shock absorber for adaptive chassis control DCC . . . . . . . . . . . . 232
4.3 Repairing shock absorber for adaptive chassis control DCC . . . . . . . . . . . . . . . . . . . . . . . . 234
44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

2 Specified torques for wheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
3 Fitting wheel and tyre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
3.2 Fittings instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
4 Removing and fitting tyres (wheels with tyre pressure monitoring) . . . . . . . . . . . . . . . . . . 241
4.1 Notes on safety and conditions for removing and fitting tyres (wheels with tyre pressure
monitoring system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
4.2 Wheel change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
4.3 Pressing tyre off wheel rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
4.4 Removing tyre from wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
4.5 Fitting tyre to wheel rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
5 Removing and fitting tyres with run-flat properties to wheel rims . . . . . . . . . . . . . . . . . . . . 245
5.1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
5.2 Fittings instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
5.3 Pressing tyre off wheel rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
5.4 Removing tyre from wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
5.5 Fitting tyre to wheel rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
6 Tyre pressure monitor display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
6.1 System fault in the ABS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
6.2 Perform basic settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
7 Tyre pressure monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
7.1 Button behaviour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
7.2 Assembly overview: tyre pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
7.3 Removing and installing tyre pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
8 Vehicle alignment check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
8.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
8.2 Test requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
8.3 Test preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
8.4 Wheel alignment specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
8.5 Overview - wheel alignment procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
8.6 Correcting front axle camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
8.7 Adjusting camber on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
8.8 Adjusting toe at rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
8.9 Adjusting front axle toe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
8.10 Basic setting of steering angle sensor G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
8.11 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
9 Wheels, tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
9.1 Models with breakdown set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
9.2 Tyre sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
9.3 Removing a tyre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
9.4 Fitting a new tyre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
9.5 Tyre sealant disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
10 Instructions for changing or fitting wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
10.1 Fitting wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
11 Protecting wheel centring seat against corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
12 Vibration due to wheels/tyres - causes and rectification . . . . . . . . . . . . . . . . . . . . . . . . . . 274
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12.1 Causes of rough running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

12.2 Balancing wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
12.3 Conducting a road test before balancing wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
12.4 Balancing wheels on stationary wheel balancing machine . . . . . . . . . . . . . . . . . . . . . . . . 275
12.5 Vibration control system VAS 6230 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
12.6 Finish balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
12.7 Radial and lateral runout of wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
12.8 Checking radial and lateral runout on wheels and tyres with tyre gauge V.A.G 1435 . . . . 279
12.9 Checking radial and lateral run-out on wheel rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
12.10 Matching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
12.11 Flat spots caused by storage or handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
13 Front camera for driver assist systems R242 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
13.1 Adjusting front camera for driver assistance system R242 . . . . . . . . . . . . . . . . . . . . . . . . 284
48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
2 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
2.1 Steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
2.2 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
2.3 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
2.4 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
2.5 Guided fault-finding, vehicle self-diagnosis and test instruments . . . . . . . . . . . . . . . . . . . . 294
3 Assembly overview - steering columns up to model year 2010 . . . . . . . . . . . . . . . . . . . . . . 295
3.1 Removing and installing steering rack to model year 2010 . . . . . . . . . . . . . . . . . . . . . . . . 295
3.2 Removing and installing steering column to model year 2010 . . . . . . . . . . . . . . . . . . . . . . 298
3.3 After the following work, basic settings for steering angle sender G85 must be checked:
........................................................................ 303
3.4 Handling and transporting steering column, to model year 2010 . . . . . . . . . . . . . . . . . . . . 304
3.5 Checking steering column for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
3.6 Removing and installing mounting bracket with strut, to model year 2010 . . . . . . . . . . . . 305
4 Steering wheel, steering column, from model year 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . 308
4.1 Assembly overview - airbag steering wheel, from model year 2011 . . . . . . . . . . . . . . . . . . 308
4.2 Removing and installing airbag and steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
4.3 Assembly overview - steering column, left-hand drive, from model year 2011 . . . . . . . . . . 310
4.4 Removing and installing steering column, left-hand drive, from model year 2011 . . . . . . . . 311
4.5 Assembly overview - steering column, right-hand drive, from model year 2011 . . . . . . . . 316
4.6 Removing and installing steering column, right-hand drive from model year 2011 . . . . . . 317
4.7 Handling and transporting steering column, from model year 2011 . . . . . . . . . . . . . . . . . . 323
4.8 Checking steering column for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
5 Electromechanical steering rack, left-hand drive up to model year 2008 . . . . . . . . . . . . . . 325
5.1 Assembly overview - electromechanical steering rack, left-hand drive (1st and 2nd
generations) up to model year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
5.2 Removing and installing steering rack, left-hand drive vehicle (1st and 2nd generations) up
to model year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
6 Electromechanical steering rack, left-hand drive, model year 2009 to model year 2010 . . 335
6.1 Assembly overview - electromechanical steering rack, left-hand drive (3rd generation), model
year 2009 to model year 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
6.2 Removing and installing steering rack, left-hand drive (3rd generation), model year 2009 to
model year 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
7 Electromechanical steering rack, left-hand drive from model year 2011 . . . . . . . . . . . . . . 343
7.1 Assembly overview - electromechanical steering rack, left-hand drive (APA) from model year
2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
7.2 Removing and installing steering rack, left-hand drive vehicle (APA) from model year 2011
........................................................................ 344
8 Electromechanical steering rack, right-hand drive up to model year 2008 . . . . . . . . . . . . . . 352
iv Contents
Touran 2003 ➤
8.1 Assembly overview - electromechanical steering rack, right-hand drive vehicle (2nd
generation) up to model year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
8.2 Removing and installing steering rack, right-hand drive vehicle (2nd generation) up to model
year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
9 Electromechanical steering rack, left-hand drive from model year 2009 . . . . . . . . . . . . . . 363
9.1 Assembly overview - electromechanical steering rack, right-hand drive (3rd generation) from
model year 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
9.2 Removing and installing steering rack, 3rd generation, RHD vehicles, as of model year
2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
10 Differentiating between 1st and 2nd generation steering racks . . . . . . . . . . . . . . . . . . . . . . 371
11 Differentiating between 2nd and 3rd generation steering racks . . . . . . . . . . . . . . . . . . . . . . 372
12 Exchanging 1st generation steering rack for 2nd generation steering rack . . . . . . . . . . . . 373
13 Repairing electromechanical 1st generation steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . 374
13.1 Removing and installing bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
14 Repairing electromechanical 2nd and 3rd generation steering racks . . . . . . . . . . . . . . . . 379
14.1 Assembly overview: electromechanical steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
14.3 Checking play, security and boots of track rod ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
15 Repairing electromechanical steering rack, left-hand drive (APA) . . . . . . . . . . . . . . . . . . . . 386
15.1 Assembly overview: electromechanical steering rack, LHD vehicle . . . . . . . . . . . . . . . . . . 386
15.2 Renewing bonded rubber bushes for power-assisted steering rack . . . . . . . . . . . . . . . . . . 387
15.4 Removing and installing track rod ball joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
15.6 Checking play, security and boots of track rod ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
15.7 Allocation of track rod ball joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
Contents v
Touran 2003 ➤
vi Contents
Touran 2003 ➤
00 – Technical data
1 Checklist for evaluating running gear
of accident vehicles
(VRL009816; Edition 11.2016)
Damage to running gear may go unnoticed during repairs to load-
bearing and suspension parts of accident vehicles. Under certain
circumstances, this undiscovered damage could lead to serious
consequential damage during later vehicle operation. Therefore,
the following parts of accident vehicles must be examined in the
manner and order described independent of wheel alignment
which may have to be performed. If no deviations from specifica‐
tions are measured during wheel alignment, there are no defor‐
mations of the running gear.
Visual and functional examination of steering system
♦ Visual examination for deformation and cracks
♦ Examination for play in track rod joints and steering rack
♦ Visual examination for tears in boots
♦ Examine electrical and hydraulic lines and hoses for chafing,
cuts and kinks.
♦ Examine hydraulic lines, threaded connections and steering
gear for leaks.
♦ Check steering rack and lines for secure seating
♦ Check for flawless function from lock to lock by moving the
steering from stop to stop. In the process, the steering wheel
must turn with a constant force without resistance.
Visual inspection and functional check of running gear
• Adhere to the sequence of the following inspection steps!
♦ Examine all components shown in the assembly overviews for
deformation, cracks and other damage.
♦ Renew damaged parts
♦ Align wheels on a VOLKSWAGEN AG-approved wheel align‐
ment stand.
Visual and functional check of wheels and tyres
♦ Check for true running and imbalance ⇒ page 274 .
♦ Check tyres for cuts and impact damage in the tread and on
the flanks ⇒ page 274 .
♦ Check tyre inflation pressure; see tyre inflation pressure stick‐
er in fuel tank flap.
If rim of wheel and/or tyre is damaged, renew tyre. This also ap‐
plies if the circumstances of the accident and the damage to the
vehicle indicate possible damage which is not visible.
A further factor in the decision is the age of the tyre. Tyres should
not be older than 6 years.
Generally, in case of doubt:
• Whenever a safety risk cannot be excluded, the tyre(s) must
be renewed.
Complete vehicle
Check other vehicle systems as well, for example:
1. Checklist for evaluating running gear of accident vehicles 1

Touran 2003 ➤
♦ Brake system including ABS

♦ Visual and functional examination of exhaust system and pas‐
senger protection
Specifications for testing and adjusting can be found in the re‐
spective workshop manual in ELSA.
The examination for accident vehicles described here refers to
the running gear and does not purport to be a complete exami‐
nation of the entire vehicle.
Electronic vehicle systems
Safety-relevant systems like, for example, ABS/EDL; airbags;
electronically regulated suspension systems; electromechanical
or electrohydraulic steering and other driver assist systems must
be read with the ⇒ Vehicle diagnostic tester for possibly stored
fault messages. If events are saved in the event memories of the
systems mentioned above, repair them according to instructions
in workshop manuals in ELSA. Following repairs, read event
memories of the affected systems again to ensure that complete
function has been restored.
2 Rep. gr.00 - Technical data

Touran 2003 ➤
2 General information
Information concerning wheels, tyres and snow chains can be
found in “Wheel and Tyre Guide” ⇒ Wheels, tyres, wheel align‐
ment; Rep. gr. 44 .
2. General information 3
Touran 2003 ➤
40 – Front suspension
1 Appraisal of accident vehicles
A check list for evaluating running gear of accident vehicles can
be found under ⇒ page 1 .
4 Rep. gr.40 - Front suspension

Touran 2003 ➤
2 Raising wheel suspension to unladen position
Special tools and workshop

equipment required
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Tensioning strap - T10038-
♦ Support - T10149-
Caution
All bolts on running gear components with bonded rubber

bushes may be tightened only when the component is in the
unladen position (normal position).
Bonded rubber bushes can be twisted only to a limited extent.
Axle components with bonded rubber bushes must therefore
be brought to a position equivalent to the unladen (normal) po‐
sition before being tightened.
Otherwise, the bonded rubber bush would be subject to torsion
loading, shortening its service life.
To simulate this position on the lifting platform, raise the respec‐

tive wheel suspension with the engine and gearbox jack - V.A.G
1383 A- and support - T10149- .
2. Raising wheel suspension to unladen position 5

Touran 2003 ➤
Before the axle on one side is raised, both sides of the vehicle
must be strapped to the lifting platform arms with tensioning
straps - T10038- .
WARNING
If the vehicle is not strapped down, there is a danger that the

vehicle will slip off the lifting platform!
– Turn wheel hub until one of the wheel bolt holes is at the top.
– Attach support - T10149- to wheel hub using wheel bolt.
Respective nuts and bolts may be tightened only when dimension
-a- between the centre of wheel hub and edge of wheel housing,
measured before starting work, has been attained.
The dimension -a- depends on the ride height of the installed run‐
ning gear:
Running gear 1) Ride height -a- in mm

Standard running gear (G24/ 404 ± 10 mm
G25/G26)
Standard running gear with 404 ± 10 mm
adaptive chassis control DCC
(G01/G24)
Sports running gear (G27/G28) 389 ± 10 mm
Heavy-duty running gear (G29/ 424 ± 10 mm
G30)
Heavy-duty running gear, natu‐ 414 ± 10 mm
ral gas (G29)
CrossTouran (G29) 411 ± 10 mm
BlueMotion (G27) 389 ± 10 mm
ADAC (G24 + F5J + 1JC) 404 ± 10 mm
1)The type of running gear fitted to the vehicle is recorded on the
vehicle data sticker. The running gear is identified by the PR
number. Which PR. No. refers to which running gear can be found
here ⇒ page 268 .
– Raise wheel bearing housing using engine and gearbox jack
- V.A.G 1383 A- until dimension -a- is attained.
WARNING
♦ Never raise or lower the vehicle while the engine and

gearbox jack is positioned beneath the vehicle.
♦ Do not leave engine and gearbox jack - V.A.G 1383 A-
under vehicle longer than necessary.
– Tighten respective nuts and bolts.

– Lower wheel bearing housing.
– Pull engine and gearbox jack - V.A.G 1383 A- out from under
vehicle.
– Detach support - T10149- .
Volkswagen Technical Site: https://vwts.ru

Touran 2003 ➤
3 Overview - front axle
Note
♦ It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension.

♦ Always renew self-locking nuts.
♦ Always renew corroded nuts and bolts.
♦ Bonded rubber bushes can be twisted only to a limited extent. Therefore, tighten the bolted connections of
components with bonded rubber bushes only when the wheel bearing housing is raised to unladen position
⇒ page 5 .
I - Assembly overview: sub‐

frame, anti-roll bar, suspen‐
sion links ⇒ page 8
II - Assembly overview: wheel
bearing ⇒ page 61
III - Assembly overview: sus‐
pension strut ⇒ page 71
III - Assembly overview: sus‐
pension strut for adaptive
chassis control DCC
⇒ page 219
The chapter “Removing and installing drive shafts” can be found

on ⇒ page 82 .
The chapter “Repairing drive shaft” can be found on
⇒ page 110 .
3. Overview - front axle 7

Touran 2003 ➤
4 Assembly overview: subframe, anti-roll bar, suspension links
Caution
1 - Nut
❑ 65 Nm
❑ When tightening, coun‐
terhold on hexagon
socket of joint stub.
❑ Self-locking
❑ Always renew after re‐
moving
2 - Coupling rod
❑ Link between anti-roll
bar and suspension
strut
3 - Bracket
❑ Fixing position
⇒ page 15
❑ If bracket is renewed,
the wheels must be
aligned ⇒ page 257
4 - Mounting bracket
❑ Fixing position
⇒ page 15
❑ With bonded rubber
bush
5 - Bolt
❑ 50 Nm + 90° further
moving
6 - Bolt
❑ M12 x 1.5 x 90
moving
7 - Bolt Volkswagen Technical Site: https://vwts.ru
❑ M12 x 1.5 x 90
❑ Always renew after removing
8 - Front left vehicle level sender - G78-
❑ Can be tested in “Guided Fault Finding” using ⇒ Vehicle diagnostic tester
9 - Bolt
❑ 9 Nm
10 - Suspension link
❑ If damaged, also renew swivel joint.
❑ Removing and installing ⇒ page 41
❑ Removing and installing on left side for vehicles with DSG or automatic gearbox ⇒ page 44 .
❑ Renew mounting ⇒ page 50

Touran 2003 ➤
❑ Different versions of suspension links are possible (cast steel, sheet steel, aluminium).
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
Note
A mixed installation of suspension

links of different types or made of
different materials is not permissi‐
ble.
11 - Nut
❑ M12 x 1.5
❑ 60 Nm
❑ Self-locking
12 - Swivel joint
❑ Checking ⇒ page 36
❑ Renew together with suspension link if suspension link is damaged
13 - Nut
❑ For cast steel suspension link: 60 Nm
❑ For sheet steel and forged aluminium suspension link: 100 Nm
❑ Self-locking
❑ Tighten only in unladen state ⇒ page 5
14 - Nut
❑ 9 Nm
15 - Bolt
❑ M12 x 1.5 x 100
16 - Bolt
17 - Bolt
❑ M12 x 1.5 x 75
18 - Bolt
❑ M14 x 1.5 x 70
❑ Do not tighten until pendulum support is bolted to gearbox
19 - Bolt
Always observe size and strength class of the bolt. Different torque specifications apply.
❑ M10 x 75 strength class 8.8: 40 Nm and turn 90° further
4. Assembly overview: subframe, anti-roll bar, suspension links 9

Touran 2003 ➤
Caution
From model year 08,
HeliCoil inserts are in‐
stalled in the pendulum
support connection in
the 02Q gearboxes.
Identification ⇒ Rep. gr.
34 .
Use a bolt with hardness
class 10.9 for this and all
other gearboxes.
If there is no HeliCoil in‐
sert in the 02Q gearbox,
use class 8.8 bolts and
the corresponding tor‐
que setting.

20 - Bolt
Always observe strength class of the bolt. Different torque specifications apply.
❑ M10 x 35 property class 8.8: turn 40 Nm + 90° further
Caution
From model year 08,
HeliCoil inserts are in‐
stalled in the pendulum
support connection in
the 02Q gearboxes.
Identification ⇒ Rep. gr.
34 .
Use a bolt with hardness
class 10.9 for this and all
other gearboxes.
If there is no HeliCoil in‐
sert in the 02Q gearbox,
use class 8.8 bolts and
the corresponding tor‐
que setting.

21 - Bracket to pendulum support
❑ Not an individual part
22 - Pendulum support
❑ Bolt first to gearbox and then to subframe
❑ Various versions
23 - Lower bonded rubber bush for pendulum support
❑ Pressing out and in ⇒ page 28
❑ Different versions ⇒ page 11 .
24 - Bolt
❑ 6 Nm
❑ Self-locking

Touran 2003 ➤
25 - Shield
26 - Subframe
❑ Removing and installing without steering rack ⇒ page 19
❑ Removing and installing with steering rack ⇒ page 23
❑ Repairing ⇒ page 28
27 - Upper bonded rubber bush for pendulum support
❑ Pressing out and in ⇒ page 28
❑ Different versions ⇒ page 11 .
28 - Bolt
❑ M12 x 1.5 x 110
❑ Tighten only in unladen state ⇒ page 5
29 - Nut
❑ 65 Nm
❑ When tightening, counterhold on hexagon socket of joint stub.
❑ Self-locking
30 - Anti-roll bar
Distinguishing characteristics of bonded rubber bushes for pen‐

dulum support
Note
♦ There are two different types of bonded rubber bushes for

pendulum supports: the T version -I- and the V version -II-.
♦ They are allocated by means of the ⇒ Electronic parts cata‐
logue “ETKA” .
I - The corners of the inner core -1- point towards the opening for
pendulum support -arrow- (T version)
II - The corners of the inner core -2- point away from the opening
for pendulum support -arrow- (V version)

Touran 2003 ➤
4.1 Assembly overview: front left vehicle level sender - G78-
Note
♦ Assembly overview: front left/right vehicle level sender - G78/G289- for adaptive chassis control DCC
⇒ page 210
♦ The front left vehicle level sender - G78/- is only available as a replacement part complete with coupling rod
and upper and lower retaining plates.
♦ Renewing with subframe installed.
1 - Subframe
2 - Bolt
❑ M6 x 16
❑ 9 Nm
3 - Front left vehicle level send‐
er - G78- and front right vehicle
level sender - G289-
❑ Complete with attach‐
ments
❑ Lever -arrow- must face
outwards
❑ Removing and installing
⇒ page 12
❑ Following renewal, ba‐
sic settings for headlight
must be performed.
Basic setting of headlights ⇒
“Guided Fault Finding” func‐
tion of vehicle diagnostic, test‐
ing and information system
VAS 5051
4 - Suspension link
5 - Nut
❑ 9 Nm
❑ Self-locking
moving
4.2 Removing and installing front left vehicle

level sender - G78-
Special tools and workshop equipment required

Touran 2003 ➤
♦ Torque wrench - V.A.G 1331-
Removing
Note
To remove front left vehicle level sender - G78- , steering must

be turned to right lock to ensure clearance between suspension
link and anti-roll bar.
– Detach connector.
– Remove bolt and nut.
– Take out vehicle level sender.
Installing
Install in reverse order. During this step, observe the following:
Note
♦ The lever of the vehicle level sender must point towards the
outside of the vehicle.
♦ Thread of vehicle level sender must be screwed into front hole
in suspension link. Lug of bracket for vehicle level sender must
engage in rear hole in order to guarantee correct installation
position.
– Carry out basic setting of headlights ⇒ Vehicle diagnostic test‐

er
Specified torques
Component Specified torque
Bolt to subframe 9 Nm
Nut 9 Nm
♦ Use new bolts
4.3 Repairing thread in longitudinal member

Repairs to the threads of welded nuts in the longitudinal member
are only possible under certain circumstances. Body repair
⇒ Body Repairs; Rep. gr. 50

Touran 2003 ➤
4.4 Fixing position of subframe and brack‐

ets
♦ Locating pins - T10096-
♦ Engine and gearbox jack - V.A.G 1383 A-
Installing locating pins - T10096-

To fix position of subframe, locating pins - T10096- must be
screwed one after the other into positions -1-, -2-, -3- and -4-.
Caution
The locating pins - T10096- may be tightened only to a maxi‐

mum of 20 Nm; otherwise the threads of the locating pins may
be damaged.
– Replace the mounting bracket securing bolts along both sides

one after the other with locating pins - T10096- and tighten
them to 20 Nm.

Touran 2003 ➤
Fixing position of mounting bracket

– Replace the bracket securing bolts along both sides one after
the other with locating pins - T10096- and tighten them to 20
Nm.
Fixing position of bracket

The position of the front axle is now fixed.
Continue with removal of anti-roll bar ⇒ page 56 .
Continue with removal and installation of steering rack, left-hand
drive vehicle (1st and 2nd generation) up to model year 2008
⇒ page 330 .
Continue with removal and installation of steering rack, right-hand
drive vehicle (2nd generation) up to model year 2008
⇒ page 358 .
drive vehicle (3rd generation) from model year 2009
⇒ page 339 .
Continue with removal and installation of steering rack, right-hand
drive vehicle (3rd generation) from model year 2009
⇒ page 367 .
drive (APA) from model year 2011 ⇒ page 347 .
Removing locating pins - T10096-
Remove in reverse order. Ensure that the locating pins - T10096-
are replaced one after the other with new bolts.
If a crooked steering wheel is determined during the road test
even though locating pins - T10096- were used, check wheel
alignment. In this case the wheel alignment test results must be
archived in the vehicle files.
Specified torques
Subframe to body 70 Nm + 90°
♦ Use new bolts
Bracket to body 70 Nm + 90°

♦ Use new bolts
Mounting bracket to body 70 Nm + 90°

♦ Use new bolts
4.5 Lowering subframe


Touran 2003 ➤
Removing
– Turn steering wheel to straight-ahead position and remove ig‐
nition key so that the steering lock engages.
– Remove securing nuts -arrows- and remove footwell trim.

Touran 2003 ➤
– Unscrew bolt -arrow- from universal joint -1- and pull off uni‐
versal joint in -direction of arrow-.
Caution
The following work must not be performed while the universal

joint is separated from the steering rack:
♦ Switch on ignition
♦ Turn steering mechanism
♦ Turn steering column
These points must absolutely be heeded because otherwise,
irreparable damage may be caused.
– Remove lower noise insulation ⇒ General body repairs, ex‐

terior; Rep. gr. 50 ; Assembly overview - noise insulation .
– Detach exhaust system bracket from subframe -arrows-.
– Disconnect pendulum support from gearbox by unscrewing

bolts -14-.
– Disconnect coupling rods from anti-roll bar.
– Fix position of subframe ⇒ page 14 .

Touran 2003 ➤
– Position engine and gearbox jack - V.A.G 1383 A- under sub‐

frame.
– Place, for example, a wooden block -1- between engine and
gearbox jack - V.A.G 1383 A- and subframe.
– Remove bolts -9- and -10- and lower subframe a maximum of

10 cm.
Note
Be sure to observe electrical wires to avoid overstretching them.
Installing
Install in reverse order.
– Install lower noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Assembly overview - noise insulation .
Note
Ensure that boot is not damaged or twisted.

Specified torques
♦ Use new bolts
Subframe to bracket 70 Nm + 90°

♦ Use new bolts
Anti-roll bar to coupling rod 65 Nm

♦ Use new bolts
♦ Counterhold on multi-point socket of joint pin
Universal joint to steering rack 30 Nm

♦ Use new bolt
Exhaust system bracket to subframe

⇒ Engine; Rep. gr. 26

Touran 2003 ➤
Specified torques for pendulum support to gearbox
Caution
From model year 08, HeliCoil inserts are installed in the pen‐
dulum support connection in the 02Q gearboxes. Identification
⇒ Rep. gr. 34 .
Use a bolt with hardness class 10.9 for this and all other gear‐
boxes.
If there is no HeliCoil insert in the 02Q gearbox, use class 8.8
bolts and the corresponding torque setting.
Bolt Specified torque

M10 x 35 strength class 8.8 40 Nm + 90° further
♦ Use new bolt

♦ Use new bolt

♦ Use new bolt

♦ Use new bolt
4.6 Removing and installing subframe with‐

out steering rack

Touran 2003 ➤
Removing
– Remove wheels.
– Unscrew nuts -arrows-.
– Detach exhaust system bracket from subframe.
– Remove bolts -arrows- from heat shield.

– Remove heat shield from subframe.

bolts -14-.

Touran 2003 ➤
– Remove bolts -5- and -6- for steering rack.
– Remove bolts -7- and -8- for anti-roll bar.
– Remove bolts -9- and -10- for subframe.

– Lower subframe using engine and gearbox jack - V.A.G 1383
A- .

Touran 2003 ➤
– Remove cable guide from subframe -arrow-.

– Secure steering rack to body.
Installing
– Install noise insulation and tighten, specified torques ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 50 ; Overview - noise
insulation .
Specified torques
Swivel joint to cast steel suspension link 60 Nm
♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5
Swivel joint to sheet steel or forged aluminium suspension 100 Nm

link
♦ Use new nuts

♦ Use new bolts

♦ Use new bolts
Anti-roll bar to subframe 20 Nm + 90°

♦ Use new bolts

♦ Use new bolts
Shield to subframe 6 Nm
♦ Bolt M6 is self-locking
Steering box to subframe 50 Nm + 90°

♦ Use new bolts
♦ Always renew clamp on 1st and 2nd generation steering
racks


Touran 2003 ➤
Caution
⇒ Rep. gr. 34 .
boxes.

♦ Use new bolt

♦ Use new bolt

♦ Use new bolt

♦ Use new bolt
4.7 Removing and installing subframe with

steering rack
♦ Ball joint puller - T10187-

Touran 2003 ➤
Removing
– Disconnect cable -1- from electronics box.
– Disconnect earth cable -2-.

– Separate electrical connector -3-.
– Guide wiring harness out of retainers on longitudinal member

so that it can be removed together with the steering rack.

Touran 2003 ➤
Caution


– Remove hexagon nut -1- from coupling rod -3- (left and right
sides).
– Remove nuts -arrows- on left and right sides of vehicle.

– Pull swivel joint out of suspension link.

Touran 2003 ➤
– Loosen nut on track rod ball joint but do not remove complete‐
ly.
Caution
To protect thread, leave nut screwed a few turns onto joint pin.
– Push track rod ball joint off wheel bearing housing and remove
nut.
1- Ball joint puller - T10187-

bolts -14-.
– Fix position of subframe with brackets. ⇒ page 14
Position engine and gearbox jack - V.A.G 1383 A- -1- under sub‐
frame

Touran 2003 ➤
– Remove bolts -9- and -10- and lower subframe with engine
and gearbox jack - V.A.G 1383 A- .
– Secure subframe to engine and gearbox jack - V.A.G 1383 A-

with the appropriate strap.
Installing
– Install noise insulation and tighten, specified torques ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 50 ; Overview - noise
insulation .
Specified torques
♦ Use new nuts

link
♦ Use new nuts

♦ Use new bolts

♦ Use new bolts
Track rod ball joint to wheel bearing housing 20 Nm + 90°

♦ Use new bolts

♦ Use new bolt


Touran 2003 ➤
Caution
⇒ Rep. gr. 34 .
boxes.

♦ Use new bolt

♦ Use new bolt

♦ Use new bolt

♦ Use new bolt
4.8 Repairing subframe

Touran 2003 ➤

equipment required
♦ Assembly tool - T10205-
♦ Torque wrench - V.A.G
1332-
♦ Hydraulic cylinder - VAS
6178-
♦ Foot pump - VAS 6179-
♦ Assembly tool - VAS 6779-
♦ Pressure plate - VW 401-

Touran 2003 ➤
♦ Press piece - VW 412-
Renewing bonded rubber bushes for pendulum support

– Remove front noise insulation ⇒ General body repairs, exte‐
rior; Rep. gr. 50 ; Noise insulation; Assembly overview - noise
insulation .
sides).
– Pull coupling rod -3- out of anti-roll bar -2- on left and right side.

• Leave the anti-roll bar in its installation position in the vehicle.

Touran 2003 ➤
– Unscrew bolt -1-.

– Unscrew bolts -2- and -3-.
– Remove pendulum support.
Pressing out bonded rubber bush

– Fit assembly tool - VAS 6779- to subframe as shown in illus‐
tration.
– Place thrust piece for removal - VAS 6779-1- -1- on bonded
rubber bush so that flattened side -arrow- faces to direction of
travel.
1 - Thrust piece for removal - VAS 6779/1-

Touran 2003 ➤
2 - Tube - VAS 6779/4- with small outside diameter facing sub‐

frame
3 - Thrust piece - VAS 6779/5-
4 - Hydraulic press - VAS 6178- with thrust piece - T10205/13-
5 - Hexagon nut - VAS 6779/3-
6 - Threaded spindle - VAS 6779/2-
– Press out both bonded rubber bushes until upper bonded rub‐
ber bush -2- is visible in pendulum support opening -arrow- in
subframe.
– Carry out visual check of outer ring of upper bonded rubber
bush -2-.
• If outer ring of upper bonded rubber bush -2- is deformed, de‐
stroy it through opening of pendulum support -arrow- in pen‐
dulum support.
– Using a chisel or similar -1-, create a break in the outer ring of
the upper bonded rubber bush -2-.
Note
This process is necessary to prevent the canting of the outer ring

of the upper bonded rubber bush in the area of the opening of the
pendulum support in the subframe.
– Press out both bonded rubber bushes together.

Preparing bonded rubber bush for pressing in
Note
♦ There are two different types of bonded rubber bushes for

pendulum supports: the T version -I- and the V version -II-.
♦ They are allocated by means of the ⇒ Electronic parts cata‐
logue “ETKA” .
I - The corners of the inner core -1- point towards the opening for
pendulum support -arrow- (T version)
II - The corners of the inner core -2- point away from the opening
for pendulum support -arrow- (V version)

Touran 2003 ➤
– Place both bonded rubber bushes -1- and -2- together so that
the cut-outs -arrows- line up precisely.
– Bolt bonded rubber bushes -1- and -2- hand-tight together us‐
ing original bolt -3-.
– Insert bonded rubber bushes -1- into larger diameter of tube -

VAS 6779/6- -2- with bolt head facing upwards.
– Align bonded rubber bushes -1- in tube - VAS 6779/6- -2-. The
cut-out in the bonded rubber bush must align exactly with the
recess -arrow- in the tube - VAS 6779/6- -2-.
– Press in bonded rubber bush -3- in tube - VAS 6779/6- to stop,

as illustrated.
1- Press tool - VW 412-
2- Thrust piece - VAS 6779/5- , the side with the lettering »A«
must face upwards.
3- Bonded rubber bush
4- Funnel - VAS 6779/6-
5- Tube - VAS 6779/4-
6- Thrust plate - VW 401-
– Remove bolt from bonded rubber bush.
Vehicles with Generation 1 to 3 steering racks
– Set support ring - VAS 6779/11- -1- on subframe so that lug

of support ring faces left.
Note
When positioning support ring - VAS 6779/11- , ensure clearance

to steering rack -2- -arrows-.
Vehicles with APA steering rack

Touran 2003 ➤
– Set support ring - VAS 6779/11- -1- on subframe so that lug

of support ring faces left.
Note
When fitting the support ring - VAS 6779/11- , make sure there is
sufficient clearance between the support ring and the steering
rack -2- -arrow-.
Continued for all vehicles:
– Turn support ring - VAS 6779/11- -1- in -direction of arrow- so

that lug -arrow- faces rearwards.
– Fit counterhold - VAS 6779/7- -1- from the left in

-direction of arrow- on support ring - VAS 6779/11- .
– Insert counterhold attachment - VAS 6779/7-1A- -1- into pen‐

dulum support opening in subframe.
– Bolt insert - VAS 6779/7-1A- to counterhold - VAS 6779/7-
-2- using bolt -arrow-.
– Ensure that the insert - VAS 6779/7-1A- -1- is correctly seated
in the pendulum support opening of the subframe -arrow-.

Touran 2003 ➤
Pressing in bonded rubber bush

– Screw threaded spindle - VAS 6779/2- -7- into counterhold -
VAS 6779/7- -1-
– Fit assembly tool - VAS 6779- to subframe as shown in illus‐
tration.
1 - Counterhold tool - VAS 6779/7-

2 - Tube - VAS 6779/6- , -arrow mark- on tube must align centrally
between both bolts -arrow-.
3 - Thrust piece - VAS 6779/9-
4 - Stepped ring - VAS 6779/8- : the mark -III- on stepped ring
must face towards lug -arrow B- on thrust piece - VAS 6779/9- .
5 - Hydraulic press - VAS 6178- with thrust piece - T10205/13-
6 - Hexagon nut - VAS 6779/3-
7 - Threaded spindle - VAS 6779/2-
– Press in both bonded rubber bushes together.
– Remove assembly tool - VAS 6779- from subframe and check
pressed-in bonded rubber bushes are properly seated.

Touran 2003 ➤
– Bolt anti-roll bar to subframe and coupling rods.

– Insert pendulum support.
– Screw in bolts -2- and -3- and tighten.
– Screw in and tighten bolt -1-.
– Install front noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation; Assembly overview - noise in‐
sulation .
Specified torques
Pendulum support to gearbox M10 x 35 50 Nm + 90° further
♦ Use new bolt
Pendulum support to gearbox M10 x 75 50 Nm + 90° further

♦ Use new bolt
Pendulum support to subframe M14 x 1.5 x 70 100 Nm + 90° further

♦ Use new bolt
♦ Do not tighten until pendulum support is bolted to gear‐
box

♦ Use new bolts

♦ Use new bolts
4.9 Checking swivel joint

Checking axial play
– Firmly pull suspension link down in -direction of arrow- and
press up again.
Checking radial play

Touran 2003 ➤
– Press lower part of wheel forcefully inwards and outwards in

-direction of arrow-.
Note
♦ There should be no palpable or visible “play” during both tests.

♦ Observe swivel joint while performing tests.
♦ Take into account possible existing wheel bearing play or
“play” in upper suspension strut mounting.
♦ Check rubber boot for damage and renew swivel joint if nec‐
essary.
4.10 Removing and installing swivel joint

equipment required
♦ Ball joint puller - 3287A-
1332-
V.A.G 1383 A-
♦ Torque angle wrench -
V.A.G 1756-

Touran 2003 ➤
♦ Press tool - T10520-
Removing
– Loosen drive shaft bolt at wheel hub:
♦ Hexagon bolt ⇒ page 82
♦ Twelve-point bolt ⇒ page 83
Caution
Wheel bearings must not be subjected to load after bolt secur‐

ing drive shaft to wheel hub has been loosened.
If wheel bearings are loaded with weight of vehicle, bearing will
be damaged. This reduces the service life of the wheel bearing.
It is not permissible to loosen drive shaft bolt more than 90° if
vehicle is standing on its wheels.
Do not attempt to move the vehicle without the drive shafts
fitted as this would damage the wheel bearing. If a vehicle
nevertheless has to be moved, comply with the following:
♦ Install an outer joint instead of the drive shaft.
♦ Tighten outer joint to 120 Nm.
– Remove wheel.
– Pull drive shaft slightly out of wheel hub.
If the drive shaft cannot be pulled out of the wheel bearing by
hand, use press tool - T10520- .

Touran 2003 ➤
Before using press tool - T10520- ensure that thrust piece -1- is
inserted.
Using press tool - T10520- :

– To press out drive shaft -3-, secure press tool - T10520- -1- to
wheel hub using 3 wheel bolts -2-.
– It is essential to follow specified sequence.

I - Tighten knurled nut -1- hand-tight.
II - Turn only bolt -2- using a spanner in order to press out drive
shaft with press tool - T10520- .
Note
At the end of the procedure or for pressing out drive shaft further,
the spindle must be moved to its original position in order to apply
the hydraulic force.
– Pull swivel bearing out of suspension link.

– Pull suspension link downwards as far as necessary.

Touran 2003 ➤
– Loosen nut from suspension link -2- but do not remove com‐
pletely.
Caution
– Press swivel joint off wheel bearing housing, undo nut and re‐
move swivel joint -2-.
1- Ball joint puller - 3287 A-
Note
♦ Place engine and gearbox jack - V.A.G 1383 A- or similar un‐

derneath (danger of accident through falling parts when press‐
ing out the swivel joint).
♦ Leave nut screwed on a few turns to protect thread on swivel
joint.
Installing
– Fit swivel joint in wheel bearing housing.
– Fit drive shaft in wheel hub.
– Screw on new self-locking nut and counterhold with -T40- Torx
key.
– Tighten nuts -arrows-.
Note
– Install wheel and tighten. Specified torque ⇒ page 238

– Tighten drive shaft bolt at wheel hub:
♦ Twelve-point bolt ⇒ page 83
Caution
When bolt is loosened or tightened, vehicle must not be stand‐

ing on its wheels.
The wheel bearing can be damaged by the weight of the vehi‐
cle if the bolt is loosened.
Specified torques
♦ Use new nuts

Touran 2003 ➤

link
♦ Use new nuts
Swivel joint to wheel bearing housing 60 Nm

♦ Use new bolts
Drive shaft to wheel hub “hexagon bolt” 200 Nm + 180°

♦ Use new bolt
Drive shaft to wheel hub “12-point bolt” 70 Nm + 90°

♦ Use new bolt
4.11 Removing and installing suspension link

with mounting bracket
Removing
– Remove wheel.
– Remove noise insulation (bottom). ⇒ Rep. gr. 50 ; Assembly
overview - noise insulation .

Touran 2003 ➤

– Pull wheel bearing housing with swivel joint out of suspension
link.
– Fix position of mounting bracket. ⇒ page 15
– Replace bolt for left side -1- or for right side -2- with locating
pins - T10096- and tighten locating pins to 20 Nm.
Caution
The locating pins - T10096- may be tightened only to a maxi‐

mum of 20 Nm; otherwise the threads of the locating pins may
be damaged.
– Now remove bolt -10- for left side of vehicle and bolt -17- for
right side of vehicle.
– Unscrew bolts -1-.

Installing
– Insert suspension link with mounting bracket into subframe.

Touran 2003 ➤
– Start bolts -11- and -12- but do not tighten.
– Start bolt -1- and tighten.

– Now replace locating pin - T10096- with a new bolt and tighten.

Touran 2003 ➤
– Bolt transverse link to subframe -11- and -12- in unladen state

⇒ page 5 .
Further installation is performed in reverse sequence.
– Install lower noise insulation. ⇒ Rep. gr. 50 ; Assembly over‐
view - noise insulation .
– Install wheel and tighten bolts or nuts ⇒ page 238 .
Specified torques
♦ Use new bolts

♦ Use new bolts
Mounting bracket to bracket 50 Nm + 90°

♦ Use new bolts

♦ Use new nuts

link
♦ Use new nuts
Suspension link to bracket 70 Nm + 180°

♦ Use new bolt
♦ Tighten bolt in unladen state
4.12 Removing and installing suspension link

with mounting bracket (left side for ve‐
hicles with DSG or automatic gearbox‐
es)

Touran 2003 ➤
Removing
Vehicles with keyless entry and start system “Keyless Access”
– Switch off ignition and open driver’s door so that the steering
lock engages.

Touran 2003 ➤
Caution

– Remove front left wheel.

– Remove noise insulation (bottom). ⇒ Rep. gr. 50 ; Assembly


Touran 2003 ➤

bolts -14-.
– If present, detach coupling rod of front left vehicle level sender
- G78- from suspension link.
– Loosen bolt -12-.

Touran 2003 ➤
sides).
.
– Position engine and gearbox jack - V.A.G 1383 A- -1- under

subframe
– Unscrew bolts -13-.

Touran 2003 ➤
– Remove bolts -9- and -10- and lower subframe as required.
Note
Be sure to observe electrical wiring.
– Remove bolt -12- and remove suspension link from subframe.

Installing
Note
♦ Ensure proper seating of dowel sleeves for steering rack in

suspension bracket.
♦ Ensure that boot is not damaged or twisted.

Specified torques
♦ Use new bolts

♦ Use new bolts

♦ Use new bolts
Mounting bracket to bracket 50 Nm + 90°

♦ Use new bolts

♦ Use new bolts

♦ Use new nuts

Touran 2003 ➤

link
♦ Use new nuts

♦ Use new bolts

♦ Use new bolts
racks

Caution
⇒ Rep. gr. 34 .
boxes.

♦ Use new bolt

♦ Use new bolt

♦ Use new bolt

♦ Use new bolt
4.13 Renewing bonded rubber bush for suspension link

Touran 2003 ➤

equipment required
♦ Tube - T10219/1-
♦ Drift - T10219/2-

– Remove suspension link ⇒ page 41 .
– Removing and installing suspension link (left side of vehicles
with dual clutch or automatic gearbox) ⇒ page 44 .

Touran 2003 ➤

– Press out bonded rubber bush as illustrated.
2- Tube - T10219/1- (the cut-out must face the suspension link)
– Moisten outer surface of bonded rubber bush with assembly
oil - G 294 421 A1- .
– Press in bonded rubber bush as illustrated.

1- Pin - T10219/2-
3- Tube - T10219/1- (the cut-out must face the suspension link)
Note
At start of pressing-in process, bonded rubber bush is temporarily

slanted. During further procedure, it then straightens. It does not
have to be pushed further.
– Press in bonded rubber bush until core of bush -1- and hole in
suspension link -2- are flush.
– Press bush back slightly in the suspension link.

2- Tube - T10219/1-

Touran 2003 ➤
The dimensions -a- and -b- must be the same.

– Install suspension link ⇒ page 41 .
– Install suspension link (left side of vehicles with dual clutch or
automatic gearbox) ⇒ page 44 .
4.14 Renewing mounting bracket with suspension link bush

equipment required
♦ Guide - VW 439-

Touran 2003 ➤
♦ Tube - VW 418 A-
The bonded rubber bush is available as a replacement part only

in conjunction with the mounting bracket.
– Press mounting bracket with bonded rubber bush off suspen‐
sion link.
Note
Hold suspension link when pressing off.

2- Guide - VW 439-
Pressing in mounting bracket with bush onto suspension link
– Moisten hexagon flats of suspension link with assembly lubri‐
cant - G 294 421 A1- diluted 1:20.
– Carefully press bush onto suspension link to stop.

1- Tube - VW 418 A-
2- Mounting bracket with bonded rubber bush.
3- Suspension link
4.15 Removing and installing anti-roll bar


Touran 2003 ➤
Removing
– Remove front wheels.
– Remove footwell trim by unscrewing nuts -arrows-.
Caution

– Remove lower noise insulation ⇒ Rep. gr. 50 ; Assembly


Touran 2003 ➤
– Remove hexagon nut -1- from coupling rod (left and right
sides).
ly.
Caution
nut.
– Fix position of subframe with brackets. ⇒ page 14
– Unbolt anti-roll bar from subframe -7- and -8-

.

Touran 2003 ➤
– Disconnect pendulum support from gearbox by removing bolts

-14-.

subframe

Touran 2003 ➤
– Remove bolts -9- and -10- and lower subframe slightly. Ob‐
serve electrical wiring.
Note
Observe electrical wiring.
– Now lift the anti-roll bar -1- forwards over the bracket -2- and
down from the subframe.
Installing
– Install in reverse order.
Note
♦ Coat seal on steering rack with suitable lubricant, e.g. soft

soap, before installing steering rack.
♦ After fitting the steering rack to the drive shaft, ensure that the
seal is not kinked when lying against the assembly plate and
that the opening to the footwell is correctly sealed. Otherwise,
this can result in water leaks and/or noise.
♦ Ensure sealing surfaces are clean.

– Install front wheels and tighten ⇒ page 238 .
Specified torques
♦ Use new bolts

♦ Use new bolts

♦ Use new bolts

♦ Use new bolts

Touran 2003 ➤

♦ Use new nuts

link
♦ Use new nuts

♦ Use new bolts

♦ Use new bolts
Suspension link to bracket 70 Nm + 180°

♦ Use new bolt
♦ Tighten bolt in unladen state

♦ Use new bolts
racks

♦ Use new bolt
Caution
⇒ Rep. gr. 34 .
boxes.

♦ Use new bolt

♦ Use new bolt

♦ Use new bolt

♦ Use new bolt

Touran 2003 ➤
– After installation, basic setting must be performed for steering

angle sender - G85- ⇒ Vehicle diagnostic tester

Touran 2003 ➤
5 Assembly overview: wheel bearing
1 - Suspension strut
2 - Track rod ball joint
3 - Multi-point socket head bolt
❑ Tip of bolt must point in
direction of travel
moving
4 - Hexagon socket head bolt
❑ 8 Nm
5 - Front left speed sensor -
G47- / front right speed sensor
- G45-
❑ Can be tested in “Gui‐
ded Fault Finding” using
⇒ Vehicle diagnostic
tester
❑ Before inserting sensor,
clean inner surface of fit‐
ting hole and coat with
lubricating paste G 000
650.
6 - Splash plate
7 - Nut
❑ M12 x 1.5
❑ Self-locking
moving
8 - Bolt
❑ 10 Nm
9 - Ventilated brake disc
10 - Bolt
❑ Hexagon bolt, 200 Nm and turn +180° further
❑ Loosening and tightening hexagon bolt ⇒ page 82
5. Assembly overview: wheel bearing 61

Touran 2003 ➤
WARNING
There
♦ are two versions of
the twelve-point head
bolt, with and without rib‐
bing. Distinguishing fea‐
ture ⇒ page 63 .
When
♦ installing a twelve-
point head bolt, always
note which version is be‐
ing installed.
The
♦ respective specified
torque must also be
used.
The
♦ specified torque for
twelve-point head bolts
»with« ribbing is 70 Nm +
90° when loosening and
tightening ⇒ page 83 .
The
»without« ribbing is 200
Nm + 180° when loosen‐
ing and tightening
⇒ page 84 .

11 - Bolt
❑ Torque setting ⇒ Brake systems; Rep. gr. 46 ; Repairing front brake .
12 - Wheel hub with wheel bearing
❑ The ABS sensor ring is installed in the wheel hub
13 - Wheel bearing housing
❑ M12 x 1.5 x 45
15 - Drive shaft
16 - Nut
❑ M12 x 1.5
❑ Self-locking

Touran 2003 ➤
Distinguishing features between twelve-point head bolt with rib‐

bing and twelve-point head bolt without ribbing.
The twelve-point head bolts can be distinguished by the contact
surfaces -arrow A- and -arrow B-.
I - Twelve-point head bolt with ribbing -arrow A-
II - Twelve-point head bolt without ribbing -arrow B-
5.1 Removing and installing wheel bearing

unit
Removing
♦ Twelve-point head bolt with ribbing ⇒ page 83
♦ Twelve-point head bolt without ribbing ⇒ page 84
Caution

– Remove wheel.
– Detach brake caliper and tie to body with wire.
⇒ Brake system; Repair group 46; Repairing front brakes

Touran 2003 ➤
– Remove ABS speed sensor. ⇒ Brake system; Repair group

46; Repairing front brakes
– Remove brake disc.
Only vehicles with VL 100 drive shaft
– Press drive shaft as far as possible out of wheel hub (towards
gearbox).
– Unscrew bolts -arrows-.
– Take wheel bearing unit -1- out of wheel bearing housing.

– Pull drive shaft out of wheel hub.

– Take wheel bearing unit -1- out of wheel bearing housing.
Installing
– Install brake caliper. ⇒ Brake system; Repair group 46; Re‐
pairing front brakes
Caution
During this step, vehicle must not be standing on its wheels.


Touran 2003 ➤

– Install ABS speed sensor. ⇒ Brake system; Repair group 46;
Repairing front brakes
Specified torques
♦ Use new bolt
Drive shaft to wheel hub “twelve-point head bolt with rib‐ 70 Nm + 90°
bing”
♦ Use new bolt
Drive shaft to wheel hub “twelve-point head bolt without 200 Nm + 180°
ribbing”
♦ Use new bolt
Wheel hub with wheel bearing to wheel bearing housing 70 Nm + 90°

♦ Use new bolts
5.2 Removing and installing wheel bearing housing

Touran 2003 ➤

equipment required
♦ Ball joint puller - 3287A-
♦ Spreader - 3424-
1332-
V.A.G 1383 A-
V.A.G 1756-
Removing

Touran 2003 ➤
Caution

– Remove wheel.
– Remove brake caliper and hang from body using wire ⇒ Brake
system; Rep. gr. 46 ; Repairing front brake .
– Remove ABS speed sensor ⇒ Brake systems; Rep. gr. 46 ;
Repairing front brake .
– Remove brake disc.
– Now remove splash plate from wheel bearing housing.
ly.
Caution
– Push track rod off wheel bearing housing and remove nut.
– Loosen nuts -arrows-.

– Pull outer joint of drive shaft out of wheel hub.

Touran 2003 ➤
inserted.


Note
– Secure drive shaft to body with wire.
– Remove threaded connection between wheel bearing housing

and suspension strut -arrow-.

Touran 2003 ➤
– Insert spreader - 3424- in slot in wheel bearing housing.

– Turn ratchet handle through 90° and detach from spreader -
3424- .
– Pull wheel bearing housing from suspension strut.
Note
If wheel bearing housing is renewed, swivel joint must be trans‐

ferred. Always use new nuts.
Installing
Install in the reverse sequence, noting the following:
Caution


If wheel bearing housing is renewed, wheels must be aligned
⇒ page 257 .
Specified torques
Suspension strut to wheel bearing housing 70 Nm + 90°
♦ Use new bolts

♦ Use new nuts

link
♦ Use new nuts

♦ Use new bolts

Touran 2003 ➤

♦ Use new bolt
bing”
♦ Use new bolt
ribbing”
♦ Use new bolt

Touran 2003 ➤
6 Assembly overview: suspension strut
Note
Assembly overview - suspension strut for adaptive chassis control DCC ⇒ page 219
1 - Damper
❑ Can be renewed sepa‐
rately
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
2 - Buffer stop
3 - Protective cover
4 - Coil spring
⇒ page 81
❑ Observe colour coding
Spring allocation via PR No.
These numbers are located on

the vehicle data sticker.
❑ Surface of coil must not
be damaged.
5 - Deep groove ball thrust
bearing
6 - Suspension strut mounting
❑ Note installation posi‐
tion ⇒ page 76
7 - Nut
❑ M14 x 1.5
❑ 60 Nm
❑ Self-locking
moving
8 - Suspension turret
9 - Bolt
10 - Protective cap
6. Assembly overview: suspension strut 71

Touran 2003 ➤
6.1 Removing and installing suspension strut
Note
Removing and installing suspension strut for adaptive chassis control DCC ⇒ page 221

equipment required
1332-
V.A.G 1383 A-

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Removing
Caution

– Remove wheel.
– Unscrew nut -arrow- and pull coupling rod -1- off suspension
strut.
– Unhook speed sensor wiring at suspension strut.
– If fitted, unscrew vehicle level sender from suspension link.

Touran 2003 ➤

link.
inserted.


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Note
Caution
Do not allow the drive shaft to hang down under its own weight,
for this would allow the inner joint to bend too far and be dam‐
aged.
– Bolt swivel joint to suspension link again.
– Bolt engine and gearbox jack - V.A.G 1383 A- with support

-T10149- to wheel hub using a wheel bolt.
WARNING
♦ Do not raise or lower the vehicle while the engine and

gearbox jack - V.A.G 1383 A- is positioned under the ve‐
hicle. The vehicle could slip off the lifting platform.
– Separate threaded connection between wheel bearing hous‐

ing and suspension strut -arrow-.

Touran 2003 ➤
– Insert spreader - 3424- in slot in wheel bearing housing.

3424- .
– Press brake disc towards suspension strut by hand.
Note
Otherwise the shock absorber tube can cant in the bore of the
wheel bearing housing.
– Pull wheel bearing housing downwards off shock absorber

tube and lower with engine and gearbox jack - V.A.G 1383 A-
until shock absorber tube is free.
– Tie wheel bearing housing up to subframe bracket using a
piece of wire.
WARNING

– Remove centre section of bulkhead ⇒ Rep. gr. 50 ; Assembly

overview - plenum chamber bulkhead .
– Remove windscreen wiper motor ⇒ Rep. gr. 92 ; Windscreen
wash/wipe system; Removing and installing windscreen wiper
system .
– Remove hexagon bolts -arrows- for upper shock absorber

mounting and remove suspension strut.
Installing
Installation position of spring plate

– Insert suspension strut with one of the two markings
-arrows- pointing forwards.

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Tighten hexagon bolts -arrows- for upper shock absorber mount‐

ing.
– Install windscreen wiper motor ⇒ Rep. gr. 92 ; Windscreen
system .
– Install centre section of bulkhead ⇒ Rep. gr. 50 ; Assembly
– Bolt engine and gearbox jack - V.A.G 1383 A- with support

-T10149- to wheel hub using a wheel bolt.
WARNING

– Position suspension strut on wheel bearing housing.

– Remove wire from wheel bearing housing.
– Using gearbox jack, carefully raise wheel bearing housing until
bolt securing suspension strut to wheel bearing housing can
be inserted.
– Press brake disc towards suspension strut by hand while lift‐
ing.
– Remove spreader - 3424- .
– Tighten threaded connection between wheel bearing housing

and suspension strut -arrow-
WARNING


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– Fit wheel bearing housing with swivel joint in suspension link.
– Bolt swivel joint to suspension link -arrows-.
Note

Caution


– Install wheel and tighten. Torque setting ⇒ page 238 .
Specified torques
♦ Use new bolts
Suspension strut to body (suspension turret) 15 Nm + 90°

♦ Use new bolts

♦ Use new nuts

Touran 2003 ➤

link
♦ Use new nuts
Coupling rod to suspension strut 65 Nm

♦ Use new bolts

♦ Use new bolt
bing”
♦ Use new bolt
ribbing”
♦ Use new bolt
6.2 Repairing suspension strut

Touran 2003 ➤

equipment required
1332-
♦ Spring compressor - V.A.G
1752/1-
♦ Spring retainer - V.A.G
1752/4-
♦ Shock absorber set -
T10001-
♦ Commercially available
ratchet handle
– Remove coil spring strut ⇒ page 72 .

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Removing coil spring

– Clamp suspension strut support clamp - V.A.G 1752/20- -4- in
a vice.
– Clamp suspension strut in suspension strut support clamp -
V.A.G 1752/20- -4-.
– Pre-tension coil spring with spring compressor - V.A.G 1752/1-
until deep groove ball thrust bearing is free at top.
1- Torque wrench - V.A.G 1332-
2- Hexagon bit, long reach - T10001/8-
3- Spring compressor - V.A.G 1752/1-
4- Strut support clamp - V.A.G 1752/20-
5- Spring retainer - V.A.G 1752/4-
6- Hexagon bit, long reach - T10001/5-
7- Ratchet wrench - T10001/11-
WARNING
First compress spring far enough to ensure that upper spring

plate is free.
– Ensure that coil spring is correctly seated in spring retainer -

V.A.G 1752/4- -arrow-.
– Unscrew hexagon nut from piston rod.
– Remove individual components of suspension strut and coil
spring with spring compressor - V.A.G 1752/1- .
Install coil spring.
– Fit coil spring with spring compressor - V.A.G 1752/1- onto
lower spring support.
The end of the coil spring must lie against the stop -arrow-.
– Tighten new hexagon nut on piston rod.
– Relieve tension on spring compressor - V.A.G 1752/1- and
remove from coil spring.
– Install suspension strut. ⇒ page 76
Specified torques
Suspension strut mounting to shock absorber 60 Nm
♦ Use new bolts

Touran 2003 ➤
7 Removing and installing drive shafts

Loosening and tightening drive shaft hexagon bolt ⇒ page 82 .
Loosening and tightening twelve-point head bolt, with ribbing, se‐
curing drive shaft ⇒ page 83 .
Loosening and tightening twelve-point head bolt, without ribbing,
securing drive shaft ⇒ page 84 .
Removing and installing drive shaft with constant velocity joint
⇒ page 86 .
Removing and installing left drive shaft with (push-on) constant
velocity slip joint ⇒ page 89 .
Removing and installing right drive shaft with (push-on) constant
velocity slip joint ⇒ page 94 .
Removing and installing drive shafts with triple roller joint
AAR2600i ⇒ page 99 .
Removing and installing drive shafts with triple roller joint
AAR3300i ⇒ page 104 .
Removing and installing intermediate shaft ⇒ page 107 .
WARNING
When removing and installing drive shafts, do not allow them

to hang free and stop against joints due to over bending.
7.1 Loosening and tightening drive shaft

hexagon bolt
♦ Torque angle wrench - V.A.G 1756-
Wheel bearings must not be subjected to load after bolt securing

drive shaft to wheel hub has been loosened.
It is therefore important to note the following:
♦ Procedure for loosening hexagon bolt.
Do not attempt to move the vehicle without the drive shafts fitted
as this would damage the wheel bearing. If the vehicle does have
to be moved, always note the following points:
– Fit an outer joint in place of drive shaft.
– Tighten the outer joint to 120 Nm.

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Loosening hexagon bolt

– With vehicle still standing on its wheels, loosen the hexagon
bolt a maximum of 90°, as the wheel bearing will otherwise be
damaged.
– Raise vehicle so that wheels are off the ground.
– Have second mechanic apply brakes.
– Remove hexagon bolt -arrow-.
Tightening hexagon bolt
– Renew hexagon bolt.
Note
The wheels must not be in contact with the ground when the drive
shaft bolt is tightened; otherwise, the wheel bearing will be dam‐
aged.

– Tighten hexagon bolt to 200 Nm.
– Lower vehicle onto its wheels.
– Turn hexagon bolt 180° further.
7.2 Loosening and tightening twelve-point

head bolt, with ribbing, securing drive
shaft
♦ Socket AF 24 - T10361A-
♦ Torque angle wrench - V.A.G 1756 A-
7. Removing and installing drive shafts 83

Touran 2003 ➤

Caution

Loosening twelve-point head bolt

– To avoid damage to wheel bearing, do not loosen twelve-point
head bolt using 24 mm socket - T10361A- further than 90° with
vehicle still standing on its wheels.
– Remove twelve-point head bolt -arrow-.

Fitting twelve-point head bolt
– Renew twelve-point head bolt.
Note
aged.

– Tighten twelve-point bolt to 70 Nm.
– Turn twelve-point head bolt 90° further.
7.3 Loosening and tightening twelve-point

head bolt, without ribbing, securing drive
shaft

Touran 2003 ➤
♦ Socket AF 24 - T10361A-
♦ Torque angle wrench - V.A.G 1756 A-

Caution

Loosening twelve-point head bolt

– To avoid damage to wheel bearing, do not loosen twelve-point
head bolt using 24 mm socket - T10361A- further than 90° with
vehicle still standing on its wheels.

Touran 2003 ➤
– Remove twelve-point head bolt -arrow-.

Fitting twelve-point head bolt
– Renew twelve-point head bolt.
Note
aged.

– Tighten twelve-point bolt to 200 Nm.
– Turn twelve-point head bolt 180° further.
7.4 Removing and installing drive shaft with

constant velocity joint
Caution

Removing

Touran 2003 ➤

Caution


– Unbolt drive shaft from gearbox flange shaft.
– Remove wheel.
– Push drive shaft outer joint out of wheel hub by hand.
link.
inserted.

Touran 2003 ➤


Note
Installing
Remove any paint residue and/or corrosion on thread and splines
of outer joint.
– Insert drive shaft.
– Guide outer joint into wheel hub splines as far as possible.
Note
– Fit inner joint of drive shaft in position and pre-tighten bolts in

diagonal sequence to 10 Nm.
– Tighten multi-point socket-head bolts diagonally to the speci‐
fied torque.
– Attach lower noise insulation ⇒ Rep. gr. 50 ; Assembly over‐
Caution


Touran 2003 ➤

Specified torques
♦ Use new nuts

link
♦ Use new nuts

♦ Use new bolt
bing”
♦ Use new bolt
ribbing”
♦ Use new bolt
Drive shaft to flange shaft on gearbox “M8 multi-point sock‐ 40 Nm

et” ♦ Pre-tighten diagonally to 10 Nm
♦ Use new bolts
♦ Use new locking plates.
Drive shaft to flange shaft on gearbox “M10 multi-point 70 Nm

socket” ♦ Pre-tighten diagonally to 10 Nm
♦ Use new bolts
♦ Use new locking plates.
7.5 Removing and installing left drive shaft

with (push-on) constant velocity slip joint

Touran 2003 ➤
♦ Multipurpose tool - VW 771-
♦ Drive shaft puller - T10382-
Caution


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Removing
Caution


– Remove wheel.
link.
inserted.

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Note
– Secure drive shaft to prevent it from falling.
– Position puller - T10382/1- behind constant velocity slip joint

-1-.
Cut-out -arrow- of puller - T10382/1- must face constant velocity
slip joint -1-.

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– Install spindles - T10382/2- and traverse - T10382/3- on puller

plate - T10382/1- .
– Install multi-purpose tool - VW 771- on traverse - T10382/3- .
– Pull out drive shaft with a couple of strikes of multi-purpose
tool - VW 771- .
– Remove drive shaft from vehicle.
Installing
of outer joint.
– Insert new retaining ring in groove in stub shaft on gearbox.
– Lightly grease splines of stub shaft with universal grease - G
060 735 A2-
– Mesh outer and inner splines of gearbox and constant velocity
slip joint.
– Slide drive shaft into constant velocity joint to stop by hand.
– Now push constant velocity joint onto stub shaft of gearbox
with a »sudden, hard push«.
Note
Never use a hammer or other striking tool!
– Check that constant velocity slip joint is seated securely by

pulling on constant velocity joint against resistance of retaining
ring.
Caution
For this check, pull only on constant velocity slip joint, not on
drive shaft.
– Detach tensioning strap - T10038- .


Touran 2003 ➤
Note

Caution


Specified torques
♦ Use new nuts

link
♦ Use new nuts
bing”
♦ Use new bolt
ribbing”
♦ Use new bolt
7.6 Removing and installing right drive shaft with (push-on) constant velocity
slip joint

Touran 2003 ➤

equipment required
♦ Multipurpose tool - VW
771-
♦ Drive shaft puller - T10382-
1332-
V.A.G 1756-

Caution


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Removing
Caution


– Remove wheel.
link.
– Unbolt coupling rods from anti-roll bars on both sides.
inserted.

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Note
– Secure drive shaft to prevent it from falling.
– Set up drive shaft puller - T10382- .

For the constant velocity slip joint -1-, notch -arrow- in the puller
plate - T10382/2- must face the spindles - T10382/2- .
– Assemble drive shaft puller - T10382- complete with multi-
purpose tool - VW 771- .
Note
In order to pull the drive shaft out of the gearbox using the drive
shaft puller - T10382- , the suspension strut with all attachments
must be pulled to the rear.
– Using tensioning strap - T10038- e.g. on lifting platform arm,

pull suspension strut with attachments back until the drive
shaft puller - T10382- can be applied parallel to drive shaft.

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– Install drive shaft puller - T10382- .

– Install multi-purpose tool - VW 771- on traverse - T10382/3- .
– Pull out drive shaft with a couple of strikes of multi-purpose
tool - VW 771- .
– Remove drive shaft from vehicle.
Installing
of outer joint.
– Insert new retaining ring in groove in stub shaft on gearbox.
– Lightly grease splines of stub shaft with universal grease - G
060 735 A2-
– Mesh outer and inner splines of gearbox and constant velocity
slip joint.
– Slide drive shaft into constant velocity joint to stop by hand.
– Now push constant velocity joint onto stub shaft of gearbox
with a »sudden, hard push«.
Note
– Check that constant velocity slip joint is seated securely by

pulling on constant velocity joint against resistance of retaining
ring.
Caution
For this check, pull only on constant velocity slip joint, not on
drive shaft.
– Detach tensioning strap - T10038- .

Note

Caution


Touran 2003 ➤

Specified torques
♦ Use new nuts

link
♦ Use new nuts
bing”
♦ Use new bolt
ribbing”
♦ Use new bolt
7.7 Removing and installing drive shafts with triple roller joint AAR2600i

Touran 2003 ➤

equipment required
♦ Aluminium wedge -
T10161-
♦ Torque wrench -
V.A.G 1332-
Caution

Removing

Touran 2003 ➤
Caution

– Remove wheel.
link.
– Pull drive shaft out of wheel hub and tie up to body.
inserted.

Touran 2003 ➤


Note
– Insert wedge - T10161- -1- between gearbox housing and tri‐

ple roller joint.
– Press inner joint out of gearbox by striking wedge - T10161-
with a hammer.
– Remove drive shaft.
Installing
– Fit new retaining ring into groove of joint pin.
– Mesh outer and inner splines of joint body and gearbox.
– Slide drive shaft into joint body to stop by hand.
– Now »suddenly« push joint body into gearbox.
The joint travel can be used for the »sudden push«. Do not, how‐
ever, pull the drive shaft too far out of the joint body.
Note
– Check that drive shaft is seated securely in gearbox by pulling

on joint body against resistance of retaining ring.
For this check, pull only on joint body and not on drive shaft.

Touran 2003 ➤
Note

Caution


Specified torques
♦ Use new nuts

link
♦ Use new nuts

♦ Use new bolt
bing”
♦ Use new bolt
ribbing”
♦ Use new bolt

Touran 2003 ➤
7.8 Removing and installing drive shafts

with triple roller joint AAR3300i
Caution

Removing

Touran 2003 ➤
Caution

– Remove wheel.
– Unbolt drive shaft from gearbox flange shaft.
link.
inserted.

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Note
Installing
of outer joint.
– Insert drive shaft.
Note
– Fit inner joint of drive shaft in position and pre-tighten bolts in

diagonal sequence to 10 Nm.
– Tighten multi-point socket-head bolts diagonally to the speci‐
fied torque.
Caution


Touran 2003 ➤

Specified torques
♦ Use new nuts

link
♦ Use new nuts

♦ Use new bolt
bing”
♦ Use new bolt
ribbing”
♦ Use new bolt
Drive shaft to flange shaft on gearbox “M8 multi-point sock‐ 40 Nm

et” ♦ Pre-tighten diagonally to 10 Nm
♦ Use new bolts
Drive shaft to flange shaft on gearbox “M10 multi-point 70 Nm

socket” ♦ Pre-tighten diagonally to 10 Nm
♦ Use new bolts
7.9 Removing and installing intermediate

shaft

Touran 2003 ➤
Removing
– Remove drive shaft on right side ⇒ page 86 .
– Loosen all bolts on bearing bracket -arrows-.
– Pull intermediate shaft off gearbox.
Repairing intermediate shaft ⇒ page 130 .
Installing
– First renew seal -1- on gearbox.
– Now push intermediate shaft onto stub shaft of gearbox until

bearing -2- contacts bearing bracket -1- without »gap«
-arrow-.

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– Tighten bolts -arrows- to specified torque.

– Install drive shaft ⇒ page 88 .
Specified torques
Intermediate shaft bearing to bearing bracket 20 Nm

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8 Repairing drive shaft - overview of drive shafts
I - Assembly overview: drive

shaft with VL90 or VL100 con‐
stant velocity joint
⇒ page 113
II - Assembly overview: drive
shaft with VL107 constant ve‐
locity joint (bolt-on)
⇒ page 123
III - Assembly overview: drive
shaft with VL107 constant ve‐
locity slip joint (push-on)
⇒ page 133

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IV - Assembly overview: drive

shaft with triple roller joint
AAR2600i ⇒ page 139
V - Assembly overview: drive
shaft with triple roller joint
AAR3300i ⇒ page 146
Distinguishing between drive shafts when installed

VL90 VL100 VL107 VL 107 AAR2600i AAR3300i
(bolt-on) (push-on)
Diameter of 90 100 107 - - -
inner joint in
mm
Cover be‐ - - X - - -
tween inner
joint and drive
flange
With bearing - - X - - X
bracket on
right side
Inner joint fit‐ - - - - X -
ted in gearbox
Inner joint - - - x -
pushed onto
stub shaft
8. Repairing drive shaft - overview of drive shafts 111

Touran 2003 ➤
8.1 Heat shields for drive shafts

Front-wheel drive:
Hexagon bolt -1- 25 Nm

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9 Assembly overview: drive shaft with VL90 or VL100 constant velocity

joint
1 - Outer constant velocity joint

❑ Renew only as com‐
plete unit
❑ Removing ⇒ page 117
❑ Installing: drive onto
shaft to stop using a
plastic mallet
2 - Bolt
❑ Hexagon bolt, 200 Nm
and turn +180° further
❑ Loosening and tighten‐
ing hexagon bolt
⇒ page 82
WARNING
There
ture ⇒ page 115 .
When
ing installed.
The
torque must also be
used.
The
The
ing and tightening
⇒ page 84 .

3 - Right drive shaft
4 - Clamp
❑ Tightening ⇒ page 119
5 - Boot
❑ Check for splits and chafing
9. Assembly overview: drive shaft with VL90 or VL100 constant velocity joint 113
Touran 2003 ➤
❑ Material: Hytrel (polyester elastomer)
6 - Clamp
7 - Dished spring
❑ Installation position ⇒ page 117
8 - Thrust washer
9 - Retaining ring
❑ Insert in groove in shaft
10 - Boot for constant velocity joint
❑ Without breather hole
❑ Drive off constant velocity joint with a drift
❑ Coat sealing surface with D 454 300 A2 before installing constant velocity joint
11 - Clamp
12 - Left drive shaft
13 - Locking plate
❑ Pre-tighten diagonally to 10 Nm and then tighten diagonally to specified torque
M8 bolt = 40 Nm
M10 bolt = 70 Nm
❑ Always renew bolts after removing
15 - Retaining ring
❑ Remove and install with circlip pliers - VW 161 A- .
16 - Seal
❑ Adhesive surface on constant velocity joint must be free of oil and grease!
17 - Inner constant velocity joint
❑ Renew only as complete unit
❑ Pressing off ⇒ page 118
❑ Pressing on ⇒ page 118
18 - Dished spring

Touran 2003 ➤

9.1 Dismantling and assembling drive shaft with VL90 or VL100 constant ve‐
locity joint

equipment required
♦ Press piece - VW 408 A-
♦ Tube - VW 416 B-
♦ Thrust washer - VW 447 H-
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♦ Snap ring pliers - VW 161

A-
1331-
1332-
♦ Hose clip pliers - V.A.G
1682-

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♦ Puller - T10382-
Removing outer constant velocity joint

– Clamp drive shaft in vice using jaw protectors.
– Fold back boot.
– Set puller - T10382- up so that smooth side of puller plate -
T10382/1- points to spindles - T10382/2- .
– Assemble puller - T10382- complete with multi-purpose tool -
VW 771- .
– Pull constant velocity joint from drive shaft with puller -
T10382- and multi-purpose tool - VW 771- .
1- Puller plate - T10382/1-
2- Spindles - T10382/2-
Driving on outer constant velocity joint
Installation position of dished spring and thrust washer on outer

joint
1- Dished spring
2- Thrust washer
– Install new retaining ring.
– If necessary, push new joint boot onto drive shaft.
– Drive onto shaft with plastic head hammer until retaining ring
engages.
Touran 2003 ➤
Pressing off inner constant velocity joint

Assembling
1- Dished spring
Installation position of dished spring at inner joint

1- Dished spring
2- Thrust washer
Pressing on inner constant velocity joint
Note
Chamfer on internal circumference of ball hub (splines) must face

contact shoulder on drive shaft.
– Apply special pliers -V.A.G 1682- as shown in diagram. En‐

sure jaws of tool contact corners -arrows B- of clamp.

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Tighten clamp on outer joint

– Tighten clamp by turning spindle with a torque wrench (do not
cant pliers).
Note
♦ Because a stainless steel boot clamp is required due to the

hard material of the joint boot (compared to rubber), it is pos‐
sible to tighten the clamp only with clamp tensioner - V.A.G
1682- .
♦ Specified torque: 25 Nm.
♦ Use torque wrench -C- with setting range 5 … 50 Nm (e.g.
torque wrench - V.A.G 1331- ).
♦ Ensure that the spindle thread -A- moves smoothly. Lubricate
with MOS2 grease if necessary.
♦ If the thread is tight (e.g. due to dirt), the required clamping
force for the clip will not be attained despite the correct torque
being applied.
Tightening clamp on small diameter
9.2 Checking outer constant velocity joint

The joint is to be dismantled to renew the grease if it is heavily
soiled, or to check the running surfaces of the balls for wear and
damage.
Removing
– Before dismantling, mark position of ball hub in relation to ball
cage and joint body with an electric scriber or oil stone.
– Swing ball hub and ball cage.
– Remove balls one at a time.
Touran 2003 ➤
– Turn cage until the two rectangular windows -arrow- align with
joint body.
– Take out cage with hub.
– Swing segment of hub into square cage window.

– Tip hub out of cage.
The 6 balls for each joint belong to a tolerance group. Check stub
axle, hub, cage and balls for small indentations (pitting) and
traces of seizing. Too much circumferential backlash in the joint
becomes noticeable during load change jolts; in such cases, the
joint must be renewed. Smoothing and traces of wear of the balls
are no reason to change the joint.
Installing
– Pack half of total grease quantity (40 g) into joint body.
– Fit cage with hub into joint body.
– Press in opposing balls one after the other; the original position
of the hub relative to the cage and joint body must be restored.
– Fit new retaining ring into hub.
– Distribute remaining grease in boot.
9.3 Checking inner constant velocity joint

Removing
soiled, and to check the running surfaces and the balls for wear
and damage.
– Press out joint body in direction of arrow.
– Press balls out of cage.
Note
The ball hub and joint body are paired. Do not interchange them.

Touran 2003 ➤
– Tip ball hub out of ball cage via ball track -arrows-.
– Check joint body, ball hub, ball cage and balls for pitting and
traces of seizing.
Excessive circumferential backlash in the joint is noticeable dur‐
ing load change jolts. In this case the joint must be replaced.
Smoothing and traces of wear of the balls are no reason to renew
the joint.
Installing
– Insert hub into cage via the two chamfers. The hub can be
installed in any position. Press balls into cage.
The ball hub has two different distances between the ball tracks:
a smaller one and a larger one.
– Insert hub complete with cage and balls into joint body, making
sure that a smaller gap -b- faces open side of joint body.
– Also make sure that chamfer on inner circumference of ball
hub is visible after swinging it into place.
– Swing in ball hub by swinging hub far enough out of cage

-arrows- that balls have the same spacing as the races.
Touran 2003 ➤
– Swivel in hub with balls by applying firm pressure to cage

-arrow-.
Checking function of constant velocity joint
The constant velocity joint is correctly assembled if the ball hub
can be moved by hand backwards and forwards over its entire
range of axial movement.

Touran 2003 ➤
10 Assembly overview: drive shaft with VL107 constant velocity joint

(bolt-on)

plete unit
plastic mallet
2 - Bolt
ing hexagon bolt
⇒ page 82
WARNING
There
ture ⇒ page 125 .
When
ing installed.
The
torque must also be
used.
The
The
ing and tightening
⇒ page 84 .

3 - Clamp
4 - Boot
10. Assembly overview: drive shaft with VL107 constant velocity joint (bolt-on) 123
Touran 2003 ➤
5 - Clamp
6 - Dished spring
7 - Thrust washer
8 - Retaining ring
❑ Material: Hytrel
❑ Drive off constant velocity joint with a drift
10 - Dished spring
11 - Clamp
12 - Drive shaft
13 - Intermediate shaft
❑ Right side of vehicle
14 - Cover
❑ Always renew
15 - Retaining ring
❑ Remove and install with circlip pliers - VW 161 A- .
16 - Seal
❑ Adhesive surface on constant velocity joint must be free of oil and grease!
17 - Inner constant velocity joint
❑ Pressing on ⇒ page 129
18 - Cap
❑ Drive off carefully with drift
❑ Adhesive surface must be free of oil and grease!
19 - Locking plate

Touran 2003 ➤

M8 bolt = 40 Nm
M10 bolt = 70 Nm
21 - Clamp
22 - Bolt
❑ 20 Nm
23 - Countersunk bolt
❑ Initially tighten to 5 Nm and then to 35 Nm
❑ Qty. 3
25 - Bearings
❑ Pressing off and on ⇒ page 130 .

Touran 2003 ➤
10.1 Dismantling and assembling drive shaft with VL107 constant velocity joint

equipment required
♦ Support sleeve - VW 522-
♦ Tensioner - 40 - 204 A-
1682-

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♦ Puller - T10382-

– Fold back boot.
VW 771- .
2- Spindles - T10382/2-
Touran 2003 ➤

joint
1- Dished spring
2- Thrust washer
– Knock onto shaft with plastic hammer until circlip engages.
Driving off cover for inner joint

– Remove retaining ring.
– Remove both clamps and slide boot towards outer joint.
– Use drift to drive off boot.
Pressing off inner constant velocity joint

Assembling
Installation position of dished spring at inner joint

1- Dished spring

Touran 2003 ➤
Pressing on inner constant velocity joint

– Press joint on to stop.
– Install retaining ring.
– Coat sealing surface of cover with -D 454 300 A2- .

– Apply an unbroken bead of sealant of 2 to 3 mm in diameter
onto clean surface of cover in area of inner holes -arrow-.
– Using bolts -arrows-, align new cover in relation to bolt holes.

The alignment must be very accurate, because no further align‐
ment is possible once the part has been hammered on.
– Drive on cap with a plastic hammer.
– Wipe off surplus sealant.
Touran 2003 ➤

cant pliers).
Note

1682- .
being applied.

Checking outer constant velocity joint ⇒ page 119
Checking inner constant velocity joint ⇒ page 120
Checking function of constant velocity joint ⇒ page 122
10.2 Repairing intermediate shaft

Touran 2003 ➤

equipment required
♦ Press tool - 3118-
♦ Separating device Kukko -
15-2-
Pressing off bearing

– Press bearing off intermediate shaft as shown in figure.
The jaws of the Kukko splitter - 15-2- must be facing shaft.
1- Intermediate shaft with bearing
4- Splitter Kukko - 15-2-
Note
Hold shaft when pressing out.
Pressing on bearing
Touran 2003 ➤
– Press bearing to stop on intermediate shaft as shown in figure.

1- Press tool - T10032-
2- Intermediate shaft
3- Bearings
4- Press tool - 3118-
6- Splitter Kukko - 15-2-
Shoulder -arrow- of press tool - 3118- must be facing bearing.

Touran 2003 ➤
11 Assembly overview: drive shaft with VL107 constant velocity slip joint
(push-on)

plete unit
plastic mallet
2 - Bolt
WARNING
There
ture ⇒ page 134 .
When
ing installed.
The
torque must also be
used.
The
The
ing and tightening
⇒ page 84 .

3 - Retaining ring
4 - Thrust washer
5 - Dished spring
6 - Clamp
11. Assembly overview: drive shaft with VL107 constant velocity slip joint (push-on) 133
Touran 2003 ➤
7 - Boot
8 - Clamp
9 - Drive shaft
10 - Clamp
11 - Boot for constant velocity slip joint
12 - Retaining ring
13 - Clamp
14 - Constant velocity slip joint
❑ Installing: drive onto shaft to stop using a plastic mallet

11.1 Dismantling and assembling drive shaft

with VL107 (push-on) constant velocity
slip joint

Touran 2003 ➤
♦ Puller - T10382-

– Fold back boot.
VW 771- .
2- Spindles - T10382/2-
Touran 2003 ➤

joint
1- Dished spring
2- Thrust washer
Removing inner constant velocity slip joint
– Fold back boot.
VW 771- .

2- Spindles - T10382/2-
Driving on inner constant velocity slip joint

Touran 2003 ➤

cant pliers).
Note

1682- .
being applied.
11.2 Checking outer constant velocity joint

soiled, or to check the running surfaces of the balls for wear and
damage.
Removing
– Before dismantling, mark position of ball hub in relation to ball
cage and joint body with an electric scriber or oil stone.
– Remove balls one at a time.
Touran 2003 ➤
– Turn cage until the two rectangular windows -arrow- align with
joint body.
– Take out cage with hub.
– Swing segment of hub into square cage window.

– Tip hub out of cage.
The 6 balls for each joint belong to a tolerance group. Check stub
axle, hub, cage and balls for small indentations (pitting) and
traces of seizing. Too much circumferential backlash in the joint
becomes noticeable during load change jolts; in such cases, the
joint must be renewed. Smoothing and traces of wear of the balls
are no reason to change the joint.
Installing
– Pack half of total grease quantity (40 g) into joint body.
– Fit cage with hub into joint body.
– Press in opposing balls one after the other; the original position
of the hub relative to the cage and joint body must be restored.
– Fit new retaining ring into hub.
– Distribute remaining grease in boot.

Touran 2003 ➤
12 Assembly overview: drive shaft with triple roller joint AAR2600i

plete unit
shaft with plastic mallet
until compressed retain‐
ing ring seats.
2 - Bolt
ing hexagon bolt
⇒ page 82
WARNING
There
ture ⇒ page 140 .
When
ing installed.
The
torque must also be
used.
The
The
ing and tightening
⇒ page 84 .

3 - Right drive shaft
4 - Left drive shaft
5 - Clamp
12. Assembly overview: drive shaft with triple roller joint AAR2600i 139
Touran 2003 ➤

7 - Clamp
8 - Dished spring
9 - Thrust washer
10 - Retaining ring
11 - Clamp
❑ Tighten clamp with hose clip pliers - V.A.G 1275-
12 - Boot for triple roller joint
13 - Clamp
14 - Retaining ring
15 - Joint body
16 - Retaining ring
❑ Insert in groove in shaft using circlip pliers - VW 161 A- .
17 - Triple roller star with rollers
The chamfer -arrow- points towards drive shaft splines.


Touran 2003 ➤
12.1 Dismantling and assembling drive shaft with triple roller joint AAR2600i

equipment required
♦ Tube - VW 416 B-
Touran 2003 ➤

1275-
1331-
♦ Torque wrench -
V.A.G 1332-
♦ Hose clip pliers -
V.A.G 1682-

Touran 2003 ➤
♦ Puller - T10382-

– Fold back boot.
VW 771- .
2- Spindles - T10382/2-

joint
1- Dished spring
2- Thrust washer
Dismantling
– Unfasten both clamps on inner joint and push back boot.
– Pull joint body off drive shaft.
Touran 2003 ➤

1 - Pliers (commercially available)
- or circlip pliers - VW 161 A-
– Set drive shaft into press.
– Press triple roller star off drive shaft.

– Pull boot off shaft.
– Clean shaft, joint body and groove for seal.
Assembling
– Push small hose clip for boot onto shaft.
– Push joint boot onto shaft.
– Push joint body onto shaft.
Fitting triple roller star
Drive shaft (tapered version)
Chamfer on star faces towards shaft and is used as an assembly
aid.
– Fit triple roller star onto shaft and press on to stop.

– Ensure that pressure does not exceed 3.0 t.
– If necessary, coat splines of drive shaft and triple roller star
with lubricant paste G 052 142 A2.
– Insert retaining ring, ensuring that it is seated correctly.
– Press 70 grams of drive shaft grease from repair set into triple
roller joint.
– Slide joint body over rollers and hold.
– Press 60 grams of drive shaft grease from repair kit into rear
of triple roller joint.
– Install joint boot.
Drive shaft (cylindrical version)

Touran 2003 ➤

roller joint.
– Tighten both clamps with hose clip pliers - V.A.G 1275- .
Touran 2003 ➤
13 Assembly overview: drive shaft with triple roller joint AAR3300i

plete unit
shaft with plastic mallet
until compressed retain‐
ing ring seats.
2 - Bolt
ing hexagon bolt
⇒ page 82
WARNING
There
ture ⇒ page 148 .
When
ing installed.
The
torque must also be
used.
The
The
ing and tightening
⇒ page 84 .

3 - Clamp
5 - Clamp

Touran 2003 ➤
6 - Dished spring
7 - Thrust washer
8 - Retaining ring
9 - Retaining ring
10 - Triple roller star with rollers
The chamfer -arrow- points towards drive shaft splines.
11 - Clamp
12 - Boot for triple roller joint
13 - Clamp
14 - Drive shaft
15 - Bolt
❑ 20 Nm
17 - Bearings
18 - Joint body with intermediate shaft
❑ For right side of vehicle
19 - Countersunk bolt
❑ Initially tighten to 5 Nm and then to 35 Nm
20 - Joint body
❑ For left side of vehicle
M8 bolt = 40 Nm
M10 bolt = 70 Nm
Touran 2003 ➤

13.1 Dismantling and assembling drive shaft with triple roller joint AAR3300i

equipment required
♦ Tube - VW 416 B-

Touran 2003 ➤

1275-
1331-
♦ Torque wrench -
V.A.G 1332-
♦ Hose clip pliers -
V.A.G 1682-
Touran 2003 ➤
♦ Puller - T10382-

– Fold back boot.
VW 771- .
2- Spindles - T10382/2-

joint
1- Dished spring
2- Thrust washer
Dismantling
– Unfasten both clamps on inner joint and push back boot.
– Pull joint body off drive shaft.

Touran 2003 ➤

1 - Pliers (commercially available)
- or -VW 161 A-
– Set drive shaft into press.
– Press triple roller star off drive shaft.

– Pull boot off shaft.
– Clean shaft, joint body and groove for seal.
Assembling
– Push small hose clip for boot onto shaft.
– Push joint boot onto shaft.
– Push joint body onto shaft.
Drive shaft (tapered version)
Chamfer on star faces towards shaft and is used as an assembly
aid.

roller joint.
Drive shaft (cylindrical version)
Touran 2003 ➤

roller joint.
– Fit hose clip.
Note
To make it easier to insert the multi-point socket-head bolts when

installing the drive shaft, position ear -arrow A- of clamp between
mounting flanges -arrows B- of joint body.
– Tension clamp with pliers -V.A.G 1275- .
– Tighten small clamp using pliers -V.A.G 1275- .

Touran 2003 ➤
42 – Rear suspension
1. Appraisal of accident vehicles 153

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2 Rear axle in unladen position

equipment required
V.A.G 1383 A-
Caution
All bolts on running gear components with bonded rubber

bushes may be tightened only when the component is in the
unladen position (normal position).
Axle components with bonded rubber bushes must therefore
be brought to a position equivalent to the unladen (normal) po‐
sition before being tightened.
Otherwise, the bonded rubber bush would be subject to torsion
loading, shortening its service life.
To simulate this position on the lifting platform, raise the respec‐

tive wheel suspension with the engine and gearbox jack - V.A.G
1383 A- and support - T10149- .
154 Rep. gr.42 - Rear suspension

Touran 2003 ➤
Before the axle on one side is raised, both sides of the vehicle
must be strapped to the lifting platform arms with tensioning
straps - T10038- .
WARNING

vehicle will slip off the lifting platform!
– Turn wheel hub until one of the wheel bolt holes is at the top.
– Attach support - T10149- to wheel hub using wheel bolt.
Respective nuts and bolts may be tightened only when dimension
-a- between the centre of wheel hub and edge of wheel housing
has been attained.
Measuring dimension -a-

The dimension -a- depends on the ride height of the installed run‐
ning gear:
Running gear 1) Ride height -a- in mm

Standard running gear (G24/ 414 ± 10 mm
G25/G26)
Standard running gear with 414 ± 10 mm
(G01/G24)
Sports running gear (G27/G28) 399 ± 10 mm
Heavy-duty running gear (G29/ 434 ± 10 mm
G30)
Heavy-duty running gear, natu‐ 424 ± 10 mm
ral gas (G29)
CrossTouran (G29) 421 ± 10 mm
BlueMotion (G27) 399 ± 10 mm
ADAC (G24 + F5J + 1JC) 404 ± 10 mm
1)The type of running gear fitted to the vehicle is recorded on the
vehicle data sticker. The running gear is identified by the PR
number. Which PR. No. refers to which running gear can be found
here ⇒ page 268 .
– Raise wheel bearing housing using engine and gearbox jack
- V.A.G 1383 A- until dimension -a- is attained.
WARNING

– Tighten respective nuts and bolts.

– Lower wheel bearing housing.
– Pull engine and gearbox jack out from underneath vehicle.
– Remove support - T10149- .
2. Rear axle in unladen position 155

Touran 2003 ➤
3 Overview - rear axle
WARNING
Caution

Therefore, tighten the bolted connections of components with
bonded rubber bushes only when the wheel bearing housing
is raised (to the unladen position) .
⇒ page 154
I - Assembly overview: sub‐

frame, transverse links, track
rod ⇒ page 157
II - Assembly overview: wheel
bearing housing, trailing arm
⇒ page 176
III - Assembly overview: shock
absorber, coil spring
⇒ page 195
III - Assembly overview: shock
absorber for adaptive chassis
control DCC ⇒ page 230
IV - Assembly overview: anti-
roll bar ⇒ page 201

Touran 2003 ➤
4 Assembly overview: subframe, transverse links track rod
1 - Eccentric bolt
❑ For camber adjustment
❑ Check wheel alignment
whenever this compo‐
nent is loosened
⇒ page 257 .
2 - Nut
❑ M12 x 1.5
❑ 95 Nm
❑ Self-locking
moving
❑ Always tighten threaded
connections in unladen
position ⇒ page 154
3 - Eccentric washer
❑ Inner hole with lug
4 - Eccentric bolt
❑ For track adjustment
❑ Check wheel alignment
whenever this compo‐
nent is loosened
⇒ page 257 .
5 - Eccentric washer
❑ Inner hole with lug
6 - Nut
❑ 95 Nm
Note
♦ To tighten nuts, set torque

wrench - V.A.G 1332- to 80 Nm.
♦ This specified torque only ap‐
plies when using socket tool
T10179.
❑ M12 x 1.5
❑ Self-locking
❑ Always tighten threaded connections in unladen position ⇒ page 154
7 - Spacer sleeve
❑ Between subframe and body.
8 - Subframe
9 - Bolt
10 - Lower transverse link
4. Assembly overview: subframe, transverse links track rod 157

Touran 2003 ➤
11 - Nut
❑ Self-locking
12 - Bolt
13 - Rivet
❑ M6
14 - Spreader rivet
15 - Stone deflector
16 - Bolt
❑ 8 Nm
17 - Nut
❑ Self-locking
18 - Bolt
❑ 130 Nm + 180° further
19 - Upper transverse link
20 - Washer
21 - Nut
❑ Self-locking
23 - Washer
24 - Bolt
❑ 130 Nm + 180° further
25 - Track rod
♦ Forwards closed (left and right track rods differ)
♦ Downwards open (left and right track rods identical)
❑ It is permitted to install mixed types.
26 - Bolt
27 - Nut

Touran 2003 ➤
❑ Self-locking
4.1 Fixing position of subframe

Perform the following steps:

– Raise vehicle.
Installing locating pins - T10096-
– Position engine and gearbox jack - V.A.G 1383 A- underneath
subframe and secure with tensioning strap.

Touran 2003 ➤
– Remove one of the front bolts of the subframe -arrow-
– Screw in locating pins - T10096- -1-.
Note
The locating pins - T10096- may be tightened only to a maximum

of 20 Nm; otherwise the threads of the locating pins may be dam‐
aged.
– This must now be done for the second front bolt of the sub‐
frame.
The position of the subframe is now fixed.
4.2 Lowering rear axle

Touran 2003 ➤

equipment required
♦ Assembly tool - 3301-
♦ Torque wrench -
V.A.G 1332-
V.A.G 1383 A-

Lowering subframe with attachments
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheels.
– Unbolt brake calipers on both sides of vehicle and suspend
from body.
– Remove coil springs ⇒ page 195 .
– Remove rear silencer of exhaust system ⇒ Rep. gr. 26 ; Ex‐
haust system; Removing and installing parts of the exhaust
system .

Touran 2003 ➤
Vehicles with rear left vehicle level sender - G76-

– Unclip speed sensor wire from retainer -1- -arrows-.
– Unclip brake lines -1- from bracket -arrow- on left of body.

– Pull retaining clip -2- from subframe -3- and detach brake
hose.
Note
Do not open brake line.
– Secure vehicle to support arms of lifting platform on both sides

using tensioning straps - T10038- .
1- Tensioning strap - T10038-
WARNING
If the vehicle is not strapped down, it may slip off the lifting
platform.

Touran 2003 ➤
– Unscrew rear right bolt of subframe -arrow-.
– Screw spindle - 3346/2- into thread of longitudinal member

using thrust piece of assembly tool - 3301- and nut - 3346/3- .
1- Spindle -3346/2-
2- Subframe
3- Thrust piece from assembly tool - 3301-
4- Nut -3346/3-
– Unscrew rear left bolt of subframe.
– Turn nut -3346/3- on spindle -3346/2- until subframe is low‐
ered by -a- = 4 cm.
Installing subframe with attachments
– Install wheels and tighten bolts or nuts ⇒ page 238 .
Specified torques
♦ Use new bolts
4.3 Rear left vehicle level sender - G76- for vehicles with automatic headlight
range control
Note
♦ Assembly overview: rear left vehicle level sender - G76- for adaptive chassis control DCC ⇒ page 212
♦ The vehicle level sender is available as a replacement part only complete with coupling rod and upper and
lower retaining plates.
♦ Renewing with subframe installed ⇒ page 164 .
♦ Headlight range control unit - J431-

Touran 2003 ➤
1 - Subframe
3 - Bolt
❑ 5 Nm
4 - Rear left vehicle level send‐
er - G76-
ments
outwards
❑ Renew in vehicle
must be performed.
Basic setting of headlights
⇒ Vehicle diagnostic tester
4.3.1 Removing and installing rear left vehicle

level sender - G76-
Note
Removing and installing rear left vehicle level sender - G76- for
adaptive chassis control DCC ⇒ page 213

Touran 2003 ➤
Removing
– Remove bolts -2- from lower transverse link.
– Remove bolts -arrows- from subframe.
– Remove rear left vehicle level sender - G76- .
Installing
The lever of rear left vehicle level sender - G76- must face outside
of vehicle.
– Following renewal, carry out basic setting of headlights ⇒
“Guided Fault Finding” function of vehicle diagnosis, testing
and information system VAS 5051 .
Specified torques
Rear left vehicle level sender - G76- to lower transverse 5 Nm
link and subframe
4.4 Removing and installing rear axle

Touran 2003 ➤

equipment required
1332-
V.A.G 1383/A -
Removing subframe with attachments

– Remove wheels.
– Remove front and rear silencers of exhaust system ⇒ Engine
⇒ Rep. gr. 26 .
– On vehicles with automatic headlight range control, separate
wiring connection -1-.
– Remove ABS speed sensor out of wheel bearing housing.

Touran 2003 ➤
– Remove bolt -arrow-.
– Lever off spring clip -1- for handbrake cable.

– Push lever -2- in -direction of arrow- and unhook brake cable
-3-.
– Unscrew hexagon bolt -1- and detach handbrake cable -2-

from brake cable bracket.
Vehicles with retainer for hand brake cable

– Remove retainer -1- by pushing out inner pin of rivet -arrow-.

Touran 2003 ➤
– Unclip speed sensor wire from retainer -1- -arrows-.
– Pull out hose retainer -1- on both sides of vehicle.
– Mark installation position of bearing bracket on body.

– Now secure vehicle to hoist using tensioning straps - T10038

-.
WARNING

vehicle will slip off the lifting platform/hoist.

Touran 2003 ➤
– Position engine and gearbox jack - V.A.G 1383 A- under sub‐

frame using universal gearbox mounting - V.A.G 1359/2- and
secure with tensioning strap.
– Unscrew remaining 2 bolts from subframe.
– Carefully lower subframe with attachments to maximum of
30 mm.
Note
When lowering, ensure there is sufficient clearance to the brake

lines and electrical cables.
– Unclip brake line -1- from clips -arrows-.
Note
♦ The clips will be destroyed and must be renewed.

♦ For reasons of clarity, the illustration shows the subframe from
above in removed state.
– Lower subframe with attachments.

Installing subframe with attachments
Installation is performed in the reverse order of removal. During
this step, observe the following:
– Insert spacer sleeves between subframe and body.
Specified torques
♦ Use new bolts
Shock absorber to wheel bearing housing 180 Nm

♦ Use new bolts
Handbrake cable to trailing arm

⇒ Brake systems; Rep. gr. 46
4.5 Removing and installing upper trans‐

verse link

Touran 2003 ➤
Removing
– Remove wheel.
– Remove coil spring ⇒ page 195 .
– Unhook speed sensor line -arrow A- from upper transverse
link.
– Mark position of eccentric bolt -arrow- relative to subframe us‐

ing e.g. a felt tip pen.
– Remove screw -arrow-.
– Remove upper transverse link.
Installing
– Install upper transverse link on vehicle and tighten nuts hand
tight.
The transverse link may be bolted only when dimension “a” has
been attained ⇒ page 155 .
– Bolt upper transverse link to subframe and tighten new nut to
prescribed torque.
– Observe mark made for position of eccentric bolt -arrow- rel‐
ative to subframe.

Touran 2003 ➤
– Tighten bolt -1- for upper transverse link.
Note
Washer -2- must be installed so that there is a gap -arrow B- be‐

tween washer and splash plate -3-.
– Attach speed sensor line -arrow A- from upper transverse link.

– Install coil spring. ⇒ page 195
– Perform wheel alignment. ⇒ page 257
Specified torques
Upper transverse link to wheel bearing housing 130 Nm + 180°
♦ Use new nuts and bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position
Upper transverse link to subframe 95 Nm

♦ Use new bolts ♦ To tighten nuts, set torque wrench - V.A.G
1332- to 80 Nm
the normal running position ♦ Applies only in conjunction with insert tool,
18 mm - T10179-
4.6 Removing and installing lower trans‐

verse link
Removing
– Remove wheel.

Touran 2003 ➤
– Remove bolt -arrow- for lower transverse link -1-.

Vehicles with dynamic headlight range control
– Remove bolts -1- from lower transverse link.

– Mark installation position of eccentric bolt relative to subframe
-arrow B- with, for example, a felt tip pen.
– Disconnect and lower rear part of exhaust system.
– Remove bolt -arrow B-.
– Remove lower transverse link.
Installing
– Install lower transverse link on vehicle and tighten bolts hand
tight.
The transverse link may be bolted only when dimension “a” has
been attained ⇒ page 155 .
– Bolt upper transverse link to subframe and tighten new nut

-arrow- only to specified torque.
– Observe mark made for position of eccentric bolt -arrow- rel‐
ative to subframe.
– Reinstall rear section of exhaust system.
Vehicles with dynamic headlight range control
– Install bolts -1- in lower transverse link.
– Tighten bolt -arrow- for lower transverse link -1-.

– Install coil spring. ⇒ page 195 .
– Perform wheel alignment ⇒ page 257 .

Touran 2003 ➤
Specified torques
Lower transverse link to wheel bearing housing 70 Nm + 180°
Lower transverse link to subframe 95 Nm

♦ Use new bolts
4.7 Removing and installing track rod

Removing
– Remove wheel.

Touran 2003 ➤
– Remove nut -1- and pull coupling rod -2- from anti-roll bar.
– Remove bolt -arrow- for track rod -3-.
– Remove bolts -arrows- for anti-roll bar clamp.
– Remove nut -arrow- and remove bolt towards rear.

– Remove track rod.
Installing
Note
Note different versions of track rods: downwards open or forwards

closed.
– Install track rod on vehicle and tighten bolts hand tight.

The track rod may be bolted only when dimension “a” has been
attained ⇒ page 155 .
– Bolt track rod to subframe and tighten new nut to specified

torque.

Touran 2003 ➤
– Tighten bolts -arrows- for anti-roll bar clamp.
– Tighten bolt -arrow- for track rod -3-.

– Connect coupling rod -2- to anti-roll bar and tighten nut -1-.
– Install coil spring ⇒ page 196 .
Specified torques
Track rod to wheel bearing housing 130 Nm + 180°
Track rod to subframe 70 Nm + 180°


♦ Use new bolts

♦ Use new bolts

Touran 2003 ➤
5 Assembly overview: wheel bearing housing, trailing arm
1 - Bolt
moving
2 - Cover
4 - Bolt
moving
5 - Coupling rod
❑ Connects anti-roll bar to
trailing arm and wheel
bearing housing
6 - Bolt
❑ Note tightening se‐
quence ⇒ page 190
moving
7 - Bolt
❑ 8 Nm
8 - Rear right speed sensor -
G44- / rear left speed sensor -
G46-
❑ Can be tested in guided
fault finding using ⇒ Ve‐
hicle diagnostic tester
❑ Before inserting sensor,
clean inner surface of
hole and coat with lubri‐
cating paste - G 000
650- .
10 - Wheel bearing pre-seal
11 - Trailing arm
12 - Bonded rubber bush
❑ Renewing ⇒ page 180
13 - Nut
❑ 45 Nm
14 - Bonded rubber bush

Touran 2003 ➤
15 - Splash plate
16 - Bolt
❑ 12 Nm
17 - Wheel hub with wheel bearing
❑ ABS sensor ring is installed in wheel bearing
The wheel bearing and wheel hub are assembled in one housing.
This wheel bearing unit is maintenance-free and does not require adjustment. Adjustments and repairs are not
possible!
18 - Bolt
❑ Loosen and tighten using bit - T10162 A-
Caution
Observe the various
bolts and specified tor‐
ques:
Allocation
• ⇒ Electronic
Until
♦ 10 November 2014:
200 Nm +180° further
As
♦ of 11 November 2014:
200 Nm +90° further
19 - Dust cap
❑ Pressing off and driving in ⇒ page 183
A proper seal can be achieved only by installing a new grease cap.
20 - Brake disc
21 - Bolt
❑ 8 Nm
5.1 Removing and installing wheel bearing

housing
5. Assembly overview: wheel bearing housing, trailing arm 177

Touran 2003 ➤
Removing
– Remove wheel.
– Remove wheel bearing/wheel hub unit ⇒ page 183 .
– Remove splash plate.
– Remove ABS speed sensor from wheel bearing housing.
– Remove bolt for track rod -1-, upper transverse link -2- and
lower transverse link -3- from wheel housing -4-.
– Remove coupling rod -arrow- from wheel bearing housing.
– Hold wheel bearing housing and remove bolts -arrows-.

– Remove coupling rod -1- from trailing arm.
Installing
– Install bolts for track rod -1-, upper transverse link -2- and low‐
er transverse link -3-.
– Attach coupling rod -arrow- to wheel bearing housing hand
tight.

Touran 2003 ➤
Threaded connection for trailing arm and wheel bearing housing

may be tightened only after all other components (particularly the
spring and shock absorber) of respective wheel suspension have
been installed. To tighten, wheel suspension must be in extended
position. Only then do trailing arm and wheel bearing housing
move to the necessary position -arrows-.
It is important to keep to the specified sequence for the following
operations.
– Screw in and tighten bolts -arrows-.

– Install splash plate.
– Install wheel bearing/wheel hub unit. ⇒ page 185 .
Bolt connections on wheel bearing housing may be tightened only
when dimension “a” has been obtained ⇒ page 155 .
– Tighten bolt for track rod -1-.

– Tighten bolt for lower transverse link -3-.
– Tighten bolt -1- for upper transverse link.
Note
Washer -2- must be installed so that there is a gap -arrow B- be‐

tween washer and splash plate -3-.

Touran 2003 ➤
– Tighten bolt -arrow-.

– Install ABS speed sensor in wheel bearing housing.
– Install brake disc.
– Attach brake carrier with brake caliper ⇒ Brake system; Rep.
Gr. 46 .
Specified torques
Upper transverse link to wheel bearing housing 130 Nm + 180°
Wheel bearing housing to lower suspension link 70 Nm + 180°

Wheel bearing housing to track rod 130 Nm + 180°

Trailing arm to wheel bearing housing 90 Nm + 45°

♦ Use new bolts
Coupling rod to wheel bearing housing. 40 Nm

♦ Use new bolts
Splash plate to wheel bearing housing 12 Nm

ABS speed sensor to wheel bearing housing 8 Nm
Brake disc to wheel bearing housing. 8 Nm
5.2 Renewing bonded rubber bush for wheel bearing housing

Touran 2003 ➤

equipment required
♦ Drift sleeve - 41-501-
♦ Press tool - T10356/5-
Removing
– Remove wheel.
– Remove wheel bearing/wheel hub unit ⇒ page 183 .
– Remove splash plate.

Touran 2003 ➤
– Remove bolt -arrow- for lower transverse link -1-.

– Attach tools as shown in figure.

1- Nut - 3346/3-
3- Tube - 3301/3-
4- Drift sleeve - 41 - 501-
5- Press tool - 3350/1-
6- Spindle - 3346/2-
– Pull out bonded rubber bush by tightening spindle.
Pulling in bonded rubber bush
– Position tools as shown in figure.

1- Nut - 3301-
2- Assembly tool - 3301-
4- Wheel bearing housing
6- Press tool - T10356/5-
7- Press tool - 3301/2-
8- Spindle - 3301/1-
– Turn spindle and pull bonded rubber bush into wheel bearing
housing -4-.
Note
♦ Do not use lubricant.

♦ Install bonded rubber bush carefully so that it does not cant.
Installing
– Install splash plate.
– Install wheel bearing/wheel hub unit ⇒ page 183 .
Bolt connections on wheel bearing housing may be tightened only
when dimension “a” has been obtained ⇒ page 155 .

Touran 2003 ➤
– Tighten bolt -arrow- for lower transverse link -1-.

– Install brake disc.
– Attach brake carrier with brake caliper ⇒ Brake system; Rep.
Gr. 46 .
Specified torques
Wheel bearing housing to lower suspension link 70 Nm + 180°
Splash plate to wheel bearing housing 12 Nm

5.3 Removing and installing wheel bearing/wheel hub unit

Touran 2003 ➤

equipment required
♦ Hub grease cap puller - VW
637/2-
♦ Fitting sleeve - 3241-
1332-
1410-
♦ Multi-point bit - T10162 A-
Removing
– Raise vehicle.
– Remove wheel.
Loosen grease cap from seat by tapping lightly on the claw of hub
grease cap puller -VW 637/2-.

Touran 2003 ➤
– Lever off grease cap.

– Remove brake carrier with brake caliper and hang from body
with wire ⇒ Brake systems; Repair group 46 .
Note
Hang brake caliper from body.
– Remove cross-head screw for brake disc and remove brake

disc.
– Unscrew bolt -1- using socket - T10162 A- -2-.
Caution
Do not use an impact driver when removing bolt -1- with socket
- T10162 A- -2-!
– Pull wheel hub/wheel bearing unit off stub axle.

Installing
– Carefully slide wheel hub/wheel bearing unit onto stub axle.
Caution
Ensure that the wheel hubs/wheel bearing unit does not cant!
– Screw in new bolt -1- and tighten to specified torque.
Note
♦ First tighten bolt to specified torque setting using torque

wrench.
♦ Use a rigid spanner for turning further by angle.
Caution
Do not use an impact driver when tightening bolt -1- with socket
- T10162 A- -2-!

Touran 2003 ➤
– Drive on grease cap with fitting sleeve -3241/4-.
Caution
Always renew removed grease caps.

Damaged grease caps may allow moisture to enter the bear‐
ing. Therefore, always use the tool shown in the illustration.
Continue installation in reverse order.

Specified torques
Wheel hub with wheel bearing to wheel bearing housing ♦ Until 10 November 2014: 200 Nm +180° further
♦ Use new bolt
♦ As of 11 November 2014: 200 Nm +90° further
♦ Observe the various bolts and specified torques:
♦ Allocation ⇒ Electronic parts catalogue “ETKA”
5.4 Removing and installing wheel bearing pre-seal

Touran 2003 ➤

equipment required
♦ Press tool - 3002-
♦ Three-arm puller - Kukko
45-2-
Removing
– Raise vehicle.
– Remove wheel.
– Remove ABS speed sensor out of wheel bearing housing.
– Remove wheel bearing unit ⇒ page 183 .
– Pull wheel bearing pre-seal -1- off wheel bearing housing -2-.
3 - Three-arm puller - Kukko45-2-
4 - Press tool - 3002-
Note
Take care that parts do not fall when pulling off.
Installing

Touran 2003 ➤
– Align hole on wheel bearing pre-seal -1- with hole for speed
sensor in wheel bearing housing -2-.
Hole on wheel bearing pre-seal -arrow A- must align with hole for
speed sensor -arrow B-.
– Drive wheel bearing pre-seal -1- onto wheel bearing housing

-2-.
3 - Press tool - T10298-
– Install wheel bearing unit ⇒ page 183 .
– Install brake disc and brake carrier with brake caliper ⇒ Brake
systems; Rep. gr. 46 .
– Install ABS speed sensor.
5.5 Removing and installing trailing arm with

mounting bracket
Removing
– Remove wheel.

Touran 2003 ➤

– Remove bolt -arrow- securing handbrake cable -1- to trailing
arm -2-.

– Remove retainer -1- by pushing out inner pin of rivet -arrow-.
– Unbolt coupling rod -1- from trailing arm.

– Mark installation position of mounting bracket on body.

– Remove trailing arm with mounting bracket.
If the trailing arm is to be renewed, the mounting bracket must be
removed from the longitudinal member.
The position of the mounting bracket relative to the trailing arm
must then be adjusted ⇒ page 189 .
Determining position of mounting bracket in relation to trailing arm

Touran 2003 ➤
Dimension -a- is 36 ± 1 mm.

1- Mounting bracket
2- Trailing arm
– Tighten bolt when dimension -a- is set.
Installing
Threaded connection for trailing arm and wheel bearing housing
may be tightened only after all other components (particularly the
spring and shock absorber) of respective wheel suspension have
been installed. To tighten, wheel suspension must be in extended
position. Only then do trailing arm and wheel bearing housing
move to the necessary position -arrows-.
Position: threaded connection between trailing arm and wheel

bearing housing
It is important to keep to the specified sequence for the following
operations.
– Position trailing link and mounting bracket on wheel bearing

housing using bolts -2-.
– Attach coupling rod -3- to trailing arm but do not tighten nut
yet.
– Raise wheel suspension using engine and gearbox jack -
V.A.G 1383 A- and support - T10149- until mounting bracket
contacts body.
– Tighten bolts -arrows- on position of old imprint.

– Lower wheel suspension again using engine and gearbox jack
- V.A.G 1383 A- and remove support - T10149- from wheel
hub.

Touran 2003 ➤
– Tighten bolts -2- for trailing arm to specified torque, observing

the required component position ⇒ page 190 .
– Bolt coupling rod -1- to wheel bearing housing and anti-roll bar.
– Bolt handbrake cable -1- to trailing arm -2- -arrow-.

– Attach retainer -1- by pushing in new inner pin of rivet
-arrow-.
Specified torques
Trailing arm to wheel bearing housing 90 Nm + 45°
♦ Use new bolts
Trailing arm to mounting bracket 90 Nm + 90°

♦ Use new bolt

Touran 2003 ➤

♦ Use new bolts
Coupling rod to trailing arm. 45 Nm

♦ Use new bolts
Handbrake cable to trailing arm

⇒ Brake systems; Rep. gr. 46
5.6 Repairing trailing arm

equipment required
♦ Removal tool - 3372-

– Remove trailing arm ⇒ page 188 .

Touran 2003 ➤
– Set up tools as shown in figure.

1- Tube - T10230/3-
2- Press tool - T10230/10-
3- Removal tool - 3372-
– Press out bonded rubber bush.

– Mark position of bonded rubber bush on trailing arm using a
set square.
– Position outer edge of set square to lower radius of hole -1-
and to upper radius of hole -2-.
– Make a mark above and below the trailing arm bush respec‐
tively -arrows-.
α - 90°
Position the bonded rubber bush on the trailing arm so that the
marked vertical line -arrows- lies between the raised portions
-1-.
Note
Take great care to ensure that the installation position of the bon‐
ded rubber bush is correct relative to the bush in the trailing arm.

Touran 2003 ➤
– Set up tools as shown in figure.

1- Tube - T10230/5-
2- Thrust plate - T10230/12- (chamfer must face bonded rub‐
ber bush)
4- Removal tool - 3372-
– Press bonded rubber bush in flush.
– Attach mounting bracket to trailing arm ⇒ page 189 .
– Install trailing arm ⇒ page 190 .

Touran 2003 ➤
6 Assembly overview: shock absorber, coil spring
Note
Assembly overview: shock absorber for adaptive chassis control DCC ⇒ page 230
1 - Upper spring seat

2 - Coil spring
❑ Note various versions of
running gear
⇒ page 268
⇒ page 195
3 - Lower spring seat
❑ End of coil spring turned
to stop
4 - Bolt
❑ M14 x 1.5 x 70
❑ 180 Nm
5 - Bolt
moving
6 - Shock absorbers
⇒ page 197
❑ Note different versions
of running gear
⇒ page 268 , vehicle
data plate
⇒ page 171
⇒ page 177
6.1 Removing and installing coil spring

6. Assembly overview: shock absorber, coil spring 195

Touran 2003 ➤
♦ Suspension strut clamp - V.A.G 1752-
♦ Spring retainer - V.A.G 1752/3a-
♦ Adapter - V.A.G 1752/9- , not illustrated

Removing
– Remove wheel.
– Position spring compressor -3- with adapters and spring re‐
tainers on coil spring.
WARNING
Ensure that spring is properly seated in the spring holder -

V.A.G 1752/3a- -1- (danger of accident).
Please follow the instructions in the operating instructions of
your spring compressor.
– Use a spanner or a reversible ratchet handle to tighten spring

compressor.
– Tighten coil spring until it can be removed.
– Remove spring.
1- Spring retainer - V.A.G 1752/3a-
2- Adapter - V.A.G 1752/9-
3- Spring compressor - V.A.G 1752/1-
Installing
Note installation position!

Touran 2003 ➤
End of spring -arrow- must contact stop in lower spring seat.

– Install spring together with spring seat.
– The spring seat has a lug.
– Insert this lug in the hole in the lower suspension link

-arrow-.
– Then set upper spring seat on the upper end of spring.
– Release tension on spring while setting upper spring seat
against lug in body.
– Remove spring compressor.
6.2 Removing and installing shock absorb‐

ers
Removing
– Remove wheel.
– Remove wheel housing liner ⇒ General body repairs, exterior;
Rep. gr. 66 .

Touran 2003 ➤

– Remove shock absorber.
Installing
The shock absorber may be bolted to the wheel bearing housing
only when dimension “a” has been attained ⇒ page 155 .
– Install shock absorber and tighten bolts -arrows-.

– Install wheel housing liner ⇒ General body repairs, exterior;
Rep. gr. 66 .
Specified torques
Shock absorber to body 50 Nm + 45°
♦ Use new bolts

Touran 2003 ➤
6.3 Repairing shock absorber
1 - Shock absorbers
⇒ page 197
❑ Note different running
gear versions
data sticker.
2 - Protective cap
3 - Protective tube
4 - Support ring
5 - Buffer stop
6 - Shock absorber mounting
7 - Nut
❑ M10 x 1.0
❑ 25 Nm
moving
ing ⇒ page 200
8 - Cover


Touran 2003 ➤
♦ Shock absorber set - T10001-
Dismantling and assembling

Loosening and tightening threaded connection for shock absorb‐
er mounting
1- Commercially available ratchet handle
2- Insert - T10001/9-
3- Ratchet wrench - T10001/11-
4- Insert - T10001/1-
Specified torque
Shock absorber mounting to shock absorber 25 Nm
♦ Use new bolts

Touran 2003 ➤
7 Assembly overview: anti-roll bar
1 - Anti-roll bar
❑ Note different running
gear versions
data sticker.
⇒ page 201
2 - Mountings
❑ Always renew mount‐
ings/bushes on both
sides of vehicle
3 - Clip
4 - Bolt
❑ Tighten evenly
moving
❑ Always tighten threaded
connections in unladen
position ⇒ page 154
6 - Nut
❑ 45 Nm
❑ Self-locking
moving
7 - Coupling rod
❑ Modified coupling rod
for model year 2004
During production start up, a
change was made from cou‐
pling rods with two ball joints to
coupling rods with one ball joint and one bonded rubber bush. The end with the bonded rubber bush is bolted
to the anti-roll bar.
A mixed installation is not permissible.

❑ Connects anti-roll bar to trailing arm and wheel bearing housing
8 - Shield
❑ Only in vehicles having two ball joints in coupling rod. For vehicles with new coupling rod (one ball joint
and one bonded rubber bush), no shield is installed. See also ⇒ Item 7 (page 201) .
9 - Subframe
7.1 Removing and installing anti-roll bar

7. Assembly overview: anti-roll bar 201

Touran 2003 ➤
Removing
Note
The following procedure is for the left side of the vehicle. The
procedure for the right side of the vehicle is identical.
– Remove nut -1- and pull coupling rod -2- from anti-roll bar.
Note
Do not loosen bolt -arrow- for track rod -3-.
– Remove bolts -arrows- for anti-roll bar clamp.

– Remove anti-roll bar.
Installing
– Install anti-roll bar in vehicle.
– Tighten bolts -arrows- for anti-roll bar clamp.

Touran 2003 ➤
– Connect coupling rod -2- to anti-roll bar and tighten nut -1-.
Specified torques
♦ Use new bolts

♦ Use new bolts
7. Assembly overview: anti-roll bar 203

Touran 2003 ➤
8 Assembly overview: subframe attachments, Touran BlueMotion
1 - Subframe
2 - Nut
❑ 2 Nm
3 - Shield
Installing
– Hook in shield on sub‐

frame
⇒ Item 1 (page 204)
-arrow-
– Pivot shield in
-direction of arrow- onto
rivet screws and tighten
nuts
4 - Retaining straps for fuel

tank
5 - Fuel tank
6 - Nut
❑ 20 Nm
7 - Angled retainer
❑ With pop rivet screw.
8 - Bolt

Touran 2003 ➤
43 – Self-levelling suspension
1 Evaluating accident vehicles
1. Evaluating accident vehicles 205

Touran 2003 ➤
2 Components of adaptive chassis control DCC and fitting locations
Caution
Do not interchange the body acceleration senders.
1 - Shock absorber damping

adjustment button - E387-
❑ Location: in front of gear
lever in centre console
❑ Explanations
⇒ page 207
2 - Shock absorber with rear
right shock absorber damper
adjustment valve - N339- .
⇒ page 232
3 - Electronically controlled
damping control unit - J250-
❑ Location: behind lug‐
gage compartment trim
on right side
⇒ page 214
❑ If the electronically con‐
trolled damping control
unit - J250- is renewed,
the basic setting of the
adaptive chassis control
DCC must be per‐
formed. ⇒ page 215
4 - Body acceleration sender,
rear - G343-
❑ Location: on rear left
shock absorber mount
⇒ page 231
left shock absorber damper
adjustment valve - N338- .
⇒ page 232
6 - Rear left vehicle level sender - G76-
❑ If the rear left vehicle level sender - G76- is removed and installed, the basic setting of the adaptive
chassis control DCC must be performed ⇒ page 215
Basic setting of headlights ⇒ “Guided Fault Finding” function of vehicle diagnostic, testing and information
system VAS 5051
7 - Front left body acceleration sender - G341-

8 - Shock absorber with front left shock absorber damper adjustment valve - N336-
❑ Removing and installing suspension strut ⇒ page 221
❑ Repairing suspension strut ⇒ page 219
206 Rep. gr.43 - Self-levelling suspension

Touran 2003 ➤
9 - Front left vehicle level sender - G78- and front right vehicle level sender - G289-
❑ If the rear left vehicle level sender - G78- and front right vehicle level sender - G289- are removed and
installed, the basic setting of the adaptive chassis control DCC must be performed ⇒ page 215
Basic setting of headlights ⇒ “Guided Fault Finding” function of vehicle diagnostic, testing and information
system VAS 5051
10 - Shock absorber with front right shock absorber damper adjustment valve - N337-
❑ Removing and installing suspension strut ⇒ page 221
❑ Repairing suspension strut ⇒ page 219
11 - Front right body acceleration sender - G342-
2.1 Shock absorber damping adjustment

button - E387-
The shock absorber damping adjustment button - E387- is located
in front of the gear lever in the centre console.
The shock absorber damping adjustment button - E387- sets the
system to 3 different modes:
♦ Standard
♦ Sport
♦ Comfort
The operating sequence is -Normal- > -Sport- > -Comfort- >
-Normal- > …
In the shock absorber damping adjustment button - E387- , the
fields -Sport- and -Comfort- are back-lit with a yellow function LED
when the selection of the corresponding mode is active.
When -Normal- mode is selected, the shock absorber damping
adjustment button - E387- is not illuminated.
2.2 Removing and installing front left and

right body acceleration senders - G341/
G342-
Removing
– Remove wiper arms ⇒ Rep. gr. 92 ; Wiper system; Removing
and installing wiper arms .
– Remove plenum chamber cover ⇒ Rep. gr. 64 .
2. Components of adaptive chassis control DCC and fitting locations 207

Touran 2003 ➤
– Release connector and pull off.

– Unscrew bolts and remove front left body acceleration sender
- G341- .
Installing
Caution
Do not interchange the front body acceleration senders with

the rear body acceleration senders ; assignment in ⇒ Elec‐
tronic parts catalogue “ETKA” .
– Note installation position of front left body acceleration sender

- G341- on bracket.
Retaining lug -1- must engage in recess in front left body accel‐
eration sender - G341- -arrow-.
Note
Make sure to use correct bracket. An “L” is punched into bracket.
Specified torques
Front left body acceleration sender - G341- to bracket 5 Nm
2.3 Renewing bracket for front left/right

body acceleration sender - G341/G342-

Touran 2003 ➤
♦ Drift - VW 222 A-
♦ 11 mm drill bit
Removing
– Remove front left and right body acceleration senders - G341/
G342- ⇒ page 207 .
– Unscrew and remove bolts for bracket and remove bracket
from shock absorber turret.
Installing
Caution
Do not interchange the body acceleration senders; assignment

in ⇒ Electronic parts catalogue “ETKA” .
– Clean shock absorber turret.

Front left body acceleration sender - G341-
– Screw front left body acceleration sender - G341- onto brack‐
et.
– Note installation position of front left body acceleration sender

- G341- on bracket.
Note
Front right body acceleration sender - G342-

– Screw front right body acceleration sender - G342- onto brack‐
et.

Touran 2003 ➤
– Note installation position of front right body acceleration send‐

er - G342- on the bracket.
Retaining lug -1- must engage in recess in front right body accel‐
Note
Make sure to use correct bracket. An “R” is punched into bracket.
Continuation for both sides

– Pull off bonding surface seal on bracket if present and stick on
double-sided adhesive tape.
– Fix bracket using an 11 mm drill bit and drift - VW 222 A- .
Note
The holes in the bracket must line up with the holes in the shock
absorber turret.
– Screw in bolts one after another until finger-tight and then

tighten to specified torque.
– Push plug onto body acceleration sender.
Specified torques
♦ Use new bolts
2.4 Assembly overview: front left/right vehicle level sender - G78/G289- for
Note
♦ The front left/right vehicle level sender - G78/G289- is only available as a replacement part complete with
coupling rod and upper and lower retaining plates.
♦ Renewing with subframe installed.

Touran 2003 ➤
1 - Subframe
2 - Bolt
❑ M6 x 16
❑ 9 Nm
3 - Front left vehicle level send‐
er - G78- and front right vehicle
level sender - G289-
ments
outwards
⇒ page 211
❑ If the rear left vehicle
level sender - G78- and
front right vehicle level
sender - G289- are re‐
moved and installed, the
basic setting of the
DCC must be performed
⇒ page 215
must be performed.
VAS 5051
4 - Suspension link
5 - Nut
❑ 9 Nm
❑ Self-locking
2.5 Removing and installing front left/right

vehicle level sender - G78/G289-

Touran 2003 ➤
Removing
Note
♦ To remove front left vehicle level sender - G78- , steering must

be turned to right lock to ensure clearance between suspen‐
sion link and anti-roll bar.
♦ To remove front right vehicle level sender - G289- , steering
must be turned to left lock to ensure clearance between sus‐
pension link and anti-roll bar.
– Remove bolt and nut.
– Take out vehicle level sender.
Installing
Note
in suspension link. The retaining lug of the vehicle level sender
must engage in the rear hole in order to ensure the correct
installation position.
– Perform basic setting of adaptive chassis control DCC

⇒ page 215
– Perform basic setting of headlights ⇒ “Guided Fault Finding”
function of vehicle diagnostic, testing and information system
VAS 5051
Specified torques
Bolt to subframe 9 Nm
Nut 9 Nm
♦ Use new bolts
2.6 Assembly overview: rear left vehicle level sender - G76- for adaptive chassis
control DCC
Note
♦ The vehicle level sender is available as a replacement part only complete with coupling rod and upper and
lower retaining plates.
♦ Renewing with subframe installed ⇒ page 213 .

Touran 2003 ➤
1 - Subframe
2 - Bolt
❑ M5 x 20
❑ 5 Nm
3 - Rear left vehicle level send‐
er - G76-
ments
outwards
⇒ page 213
❑ If the rear left vehicle
level sender - G76- is re‐
moved and installed, the
basic setting of the
DCC must be performed
⇒ page 215
must be performed.
VAS 5051
2.7 Removing and installing rear left vehicle

level sender - G76- for adaptive chassis
control DCC

Touran 2003 ➤
Removing
– Remove bolts.
– Remove rear left vehicle level sender - G76- .
Installing
The lever of the vehicle level sender must point towards the out‐
side of the vehicle.
⇒ page 215
– Perform basic setting of headlights ⇒ “Guided Fault Finding”
function of vehicle diagnostic, testing and information system
VAS 5051
Specified torques
Bolt to subframe/lower transverse link 5 Nm
2.8 Removing and installing electronically

controlled damping control unit - J250-
Removing
Location: behind luggage compartment trim on right side
– Switch off all electrical consumers.
– Withdraw ignition key.
– Remove the luggage compartment trim on right ⇒ Rep. gr.
70 .
– Bend retaining tabs -arrows- to rear and push electronically
controlled damping control unit - J250- -1- in
-direction of arrow- out of retainer.
Installing

Touran 2003 ➤
– Push electronically controlled damping control unit - J250- into

bracket until lugs -arrows- audibly engage.
– Attach and lock connector.
⇒ page 215 .
2.9 Removing and installing retainer for

electronically controlled damping con‐
trol unit - J250-
Removing
– Remove electronically controlled damping control unit - J250-
⇒ page 214 .
– Unscrew bolt -arrow- and remove bracket -1-.
Installing
– Install electronically controlled damping control unit - J250-
⇒ page 214 .
2.10 Basic setting of adaptive chassis control

DCC
– Connect ⇒ Vehicle diagnostic tester and select “Guided Fault
Finding” ⇒ Vehicle diagnostic tester.
Running gear
Wheel damping electronic control unit
Function
Basic setting
Follow instructions on screen to perform basic setting.
2.11 Cable routing left front axle
Note
♦ Always check the cable routing.

♦ Always make sure all cables are correctly hooked into the brackets provided, and are not twisted.

Touran 2003 ➤
1 - Cable for front left shock

absorber damper adjustment
valve - N336-
❑ Cable must be hooked
into bracket on shock
absorber -arrow-
2 - Cable for front left speed
sensor - G47-
3 - Brake pad wear indicator
wire.

Touran 2003 ➤
2.12 Cable routing right front axle
Note

1 - Cable for front right shock

absorber damper adjustment
valve - N337-
absorber -arrow-
2 - Cable for front right speed
sensor - G45-

Touran 2003 ➤
2.13 Cable routing rear axle
Note

1 - Cable for rear left/right

shock absorber damper ad‐
justment valve - N338/N339-
absorber -arrow-
2 - Cable for rear right/left
speed sensor - G44/G46-

Touran 2003 ➤
3 Assembly overview: suspension strut for adaptive chassis control

DCC
1 - Shock absorber with front

left shock absorber damper
adjustment valve - N336-
❑ Can be renewed sepa‐
rately
2 - Buffer stop
3 - Protective cover
4 - Coil spring
⇒ page 221
❑ Observe colour coding
Spring allocation via PR No.
These numbers are located on

the vehicle data sticker.
❑ Surface of coil must not
be damaged.
5 - Deep groove ball thrust
bearing
6 - Suspension strut mounting
tion ⇒ page 226
7 - Hexagon nut
❑ 60 Nm
❑ Self-locking
moving
8 - Suspension turret
9 - Bracket
❑ For front left body acceleration sender - G341-
❑ An “L” is punched into bracket
Note
Make sure to use correct bracket.
10 - Front left body acceleration sender - G341-

❑ Note installation position on bracket ⇒ Item 9 (page 219) ⇒ page 220
11 - Bolt
❑ 5 Nm
3. Assembly overview: suspension strut for adaptive chassis control DCC 219
Touran 2003 ➤
12 - Bolt
13 - Bracket
❑ For front right body acceleration sender - G342-
❑ An “R” is punched into bracket
14 - Front right body acceleration sender - G342-
❑ Note installation position on bracket ⇒ Item 13 (page 220) ⇒ page 220
15 - Nut
❑ 5 Nm
Installation position front left body acceleration sender - G341- on

bracket
Note
Installation position front right body acceleration sender - G342-

on bracket
Note
Make sure to use correct bracket. An “R” is punched into bracket.

Touran 2003 ➤
3.1 Removing and installing suspension strut for adaptive chassis control DCC

equipment required
1332-
V.A.G 1383 A-
Touran 2003 ➤
Removing
– Loosen drive shaft bolt at wheel hub ⇒ page 83 .
Note
During this step, vehicle must not be standing on its wheels or

wheel bearing will be damaged.
– Remove wheel.
– Unscrew hexagon nut -arrow- of coupling rod from suspension
strut.
– Detach wire for speed sensor from suspension strut.
– Unscrew vehicle level sender from suspension link.

Touran 2003 ➤

link.
inserted.

Touran 2003 ➤

Note
Caution
Do not allow the drive shaft to hang down under its own weight,
for this would allow the inner joint to bend too far and be dam‐
aged.
– Bolt swivel joint to suspension link again.
– Use wheel bolt to attach engine and gearbox jack - V.A.G 1383
A- with support - T10149- to wheel hub.
WARNING

– Separate threaded connection between wheel bearing hous‐

ing and suspension strut -arrow-.

Touran 2003 ➤
– Insert spreader -3424- into slot of wheel bearing housing.

3424- .
– Press brake disc towards suspension strut by hand.
Note
– Pull wheel bearing housing downwards off shock absorber

tube and lower with engine and gearbox jack - V.A.G 1383 A-
until shock absorber tube is free.
– Secure wheel bearing housing to bracket/subframe with bind‐
ing wire.
WARNING

– Remove centre bulkhead ⇒ Rep. gr. 50 ; Plenum chamber

bulkhead - assembly overview .
– Remove windscreen wiper motor ⇒ Rep. gr. 92 ; Windscreen
system .
– Remove hexagon bolts -arrows- for upper shock absorber

mounting and remove suspension strut.
Installing
– Use wheel bolt to attach engine and gearbox jack - V.A.G 1383
A- with support - T10149- to wheel hub.
– Place suspension strut on wheel bearing housing and fix sus‐
pension strut in place with the multi-point socket head bolt and
a new nut.
The tip of the multi-point socket head bolt must point in the direc‐
tion of travel.
– Remove spreader - 3424- .
Touran 2003 ➤
Insert spring plate with one of the two markings -arrows- pointing
in direction of travel.
Left suspension strut

Suspension strut must be inserted so that front left shock absorb‐
er damper adjustment valve - N336- points opposite to direction
of travel.
Right suspension strut

Suspension strut must be inserted so that front right shock ab‐
sorber damper adjustment valve - N337- points in direction of
travel.
– Check installation position of bracket for front left/right body

acceleration sender - G341/G342- .
Note
♦ Use an 11 mm drill bit -1- and drift - VW 222 A- for checking

♦ The holes in the bracket must line up with the holes in the
shock absorber tower.
– Remove wire on wheel bearing housing.

Touran 2003 ➤
– Carefully raise wheel bearing housing with the gearbox jack

until bolts for connecting suspension strut to strut turret can be
inserted.
If necessary, use a ladder, e.g. step ladder - VAS 5085- , to insert
the bolts.
– Tighten hexagon bolts for upper shock absorber mounting.
– Detach support - T10149- .
– Tighten threaded connection between wheel bearing housing

and suspension strut -arrow-

– Fit wheel bearing housing with swivel joint in suspension link.
Touran 2003 ➤
Note
– Screw vehicle level sender onto suspension link.
Note
in suspension link. The retaining lug of the vehicle level sender
must engage in the rear hole in order to ensure the correct
– Push plug onto front left/right shock absorber damper adjust‐

ment valve - N336/N337- .
– Tighten drive shaft bolt at wheel hub ⇒ page 83 .
Note
During this step, vehicle must not be standing on its wheels or

wheel bearing will be damaged.
– Install plenum chamber cover ⇒ Rep. gr. 64 .

– Install wiper arms ⇒ Rep. gr. 92 ; Wiper system; Removing
and installing wiper arms .
Specified torques
♦ Use new bolts

♦ Use new bolts

♦ Use new nuts
Swivel joint to sheet metal suspension link 100 Nm

♦ Use new nuts
Coupling rod to suspension strut 65 Nm

♦ Use new bolts
Drive shaft to hub 70 Nm + 90°

♦ Use new bolt

Touran 2003 ➤

Vehicle level sender to suspension link 9 Nm
Touran 2003 ➤
4 Assembly overview: shock absorber for adaptive chassis control DCC
1 - Lower spring seat

❑ End of coil spring turned
to stop
2 - Coil spring
❑ Take different running
gear types into account
⇒ page 268
⇒ page 195
3 - Upper spring seat
4 - Bracket
❑ For rear body accelera‐
tion sender - G343-
5 - Body acceleration sender,
rear - G343-
⇒ page 231
tion on bracket
⇒ Item 4 (page 230)
⇒ page 231
6 - Bolt
❑ 5 Nm
moving
7 - Bolt
❑ M14 x 1.5 x 85
❑ 180 Nm
moving
8 - Bolt
❑ M10 x 35
9 - Shock absorber with rear left/right shock absorber damper adjustment valve - N338/N339-
❑ Take different running gear types into account ⇒ page 268 .
10 - Washer

Touran 2003 ➤
Installation position rear body acceleration sender - G343- on

bracket
Retaining lug -1- must engage in recess in rear body acceleration
sender - G343- -arrow-.
4.1 Removing and installing rear body ac‐

celeration sender - G343-
Removing
– Remove wheel.
– Remove wheel housing liner (rear left) ⇒ Rep. gr. 66 .
– Unscrew bolts and remove rear body acceleration sender -
G343- .
Installing
Caution
Do not interchange the rear body acceleration sender with the

front body acceleration senders ; assignment in ⇒ Electronic
parts catalogue “ETKA” .
4. Assembly overview: shock absorber for adaptive chassis control DCC 231
Touran 2003 ➤
– Note installation position of rear body acceleration sender -

G343- on the bracket.
Specified torques
Rear body acceleration sender - G343- to bracket 5 Nm
4.2 Removing and installing shock absorber

for adaptive chassis control DCC
Removing
– Remove wheel.
– Remove wheel housing liner ⇒ General body repairs, exterior;
Rep. gr. 66 ; . .
Only for left shock absorber
– Unscrew rear left vehicle level sender - G76- from lower trans‐
verse link.

Touran 2003 ➤
– Disconnect connector and pull cable off shock absorber.
– Remove bolts from shock absorber.

– Pull rear body acceleration sender - G343- off shock absorber
mount.

– Remove shock absorber.
Installing
The shock absorber may be bolted to the wheel bearing housing
only when dimension “a” has been attained ⇒ page 155 .
Note installation position of shock absorber.

The rear left/right shock absorber damper adjustment valve -
N338/N339- must point to the rear outwards to the wheel.
Touran 2003 ➤
– Put rear body acceleration sender - G343- on shock absorber

mount.
– Place bracket from rear onto shock absorber mount so that
retaining lugs -1- engage in recesses in shock absorber
mount.
– Turn bracket forwards so it makes contact with shock absorber
mount.
Lug -arrow- is used for calibrating bracket for rear body acceler‐
ation sender - G343- .

– Install shock absorber and tighten bolts.

– Push plug onto rear left/right shock absorber damper adjust‐
ment valve - N338/N339- .
– Screw rear left vehicle level sender - G76- onto lower trans‐
verse link.
– Install wheel housing liner ⇒ General body repairs, exterior;
Rep. gr. 66 .
Specified torques
Shock absorber to body 50 Nm + 45°
♦ Use new bolts

♦ Use new bolt
Rear left vehicle level sender - G76- to lower transverse 5 Nm

link
4.3 Repairing shock absorber for adaptive chassis control DCC

Touran 2003 ➤

left/right shock absorber
damper adjustment valve -
N338/N339-
⇒ page 232
2 - Protective cap
3 - Protective tube
4 - Buffer stop
5 - Shock absorber mounting
6 - Nut
❑ M10 x 1.0
❑ 25 Nm
moving
ing ⇒ page 236
7 - Cover
Touran 2003 ➤
Dismantling and assembling shock absorber

Special tools and work‐
shop equipment re‐
quired
♦ Torque wrench -
V.A.G 1332-

T10001-
Loosening and tighten‐

ing threaded connection
for shock absorber
mounting
1- Commercially
available ratchet
handle
2- Insert - T10001/9-
3- Ratchet wrench -
T10001/11-
4- Insert - T10001/1-
Specified torque
Shock absorber mounting to shock absorber 25 Nm
♦ Use new bolts

Touran 2003 ➤
44 – Wheels, tyres, vehicle geometry

1. Appraisal of accident vehicles 237

Touran 2003 ➤
2 Specified torques for wheel bolts

Wheel bolt to wheel hub for all vehicles
Specified torque: 120 Nm
– Before fitting wheel, protect wheel centring seat against cor‐
rosion ⇒ page 273 .
238 Rep. gr.44 - Wheels, tyres, vehicle geometry

Touran 2003 ➤
3 Fitting wheel and tyre
3.1 General information

New wheels with a modified contour have been introduced for all
vehicles as of model year 2005.
The tyre fitting unit must be fitted with the tyre fitting head de‐
signed for these wheels.
WARNING
Otherwise there is a danger that the wheel will be damaged.
If the tyre fitting unit has not been modified, please contact the
manufacture of the unit.
3.2 Fittings instructions

Warming cold tyres to minimum fitting temperature
Note
This instruction also applies to ultra-high performance tyres (as‐

pect ratio less than or equal to 45 % and speed symbol V or
higher).
WARNING
When installing a tyre, the tyre core temperature must not be

less than 15°C nor greater than 30°C.
• To install tyres without damage, it is especially important to

warm the upper part of the sidewall and the inside of the upper
bead to at least 15°C.
• This internal temperature is referred to as the core tempera‐
ture.
• Rubber is a poor conductor of heat, therefore a cold tyre must
be left in an area with the correct temperature for a sufficiently
long period so the inner rubber layers can warm up to at least
15 °C.
• The surface temperature of the tyre during the warming up
phase is no indication of its internal temperature.
• To enable cold tyres to absorb heat from the ambient air as
quickly as possible, they should not be stacked on top of one
another but instead stored individually in order to allow the
warm air to “circulate” around them effectively.
• Tyres must never be placed in front of a radiator or hot air
blower for warming, since this can very quickly lead to critical
surface temperatures.
• Except for warming with warm water or warm ambient air
(max. 50°C), there is no process available for warming tyres
without damaging the tyre!
• When cold tyres (below 0°C) are transferred to a warm envi‐
ronment (above 0°C), a layer of condensation immediately
forms on the surface of the tyre. This layer of condensation
3. Fitting wheel and tyre 239

Touran 2003 ➤
indicates that the tyre is intensively absorbing heat from its

environment through the process of water vapour in the air
condensing out on the tyre surface.
• Once the layer of frost has thawed, condensate water forms
and it should be dried off with a cloth otherwise the continua‐
tion of the warming process might be curtailed by cold due to
evaporation.
Warming times:
♦ Assuming a minimum room temperature of 19°C and a tyre
temperature of 0°C or more, a tyre must be kept at a minimum
of 19°C for at least 2 hours.
temperature of below 0°C, a tyre must be kept at a minimum
of 19°C for at least 2.5 hours.
Warming recommendations:
♦ If possible, tyres should be stored in the workshop 1 day before
they are fitted (order preparation).
♦ Store on an insulated base, pallet or the like, as high up as
possible
♦ Position the tyres individually to allow the warm air to “circu‐
late” around them effectively
♦ Wipe off condensation
♦ Never heat with a radiator or hot air blower!

Touran 2003 ➤
4 Removing and fitting tyres (wheels

with tyre pressure monitoring)
4.1 Notes on safety and conditions for re‐

moving and fitting tyres (wheels with tyre
pressure monitoring system)
• It is extremely important to adhere to the instructions and
warnings in the following descriptions.
• Check whether the tyre pressure sensor should also be re‐
placed ⇒ Vehicle diagnostic tester.
Note
♦ Ensure that the tyre does not contact the tyre pressure sensor
during removal or fitting.
♦ The tyre pressure sensor must not come into contact with wa‐
ter or be blown upon with compressed air when the wheel rim
is cleaned.
4.2 Wheel change

If the wheels are changed (e.g. switch from summer to winter
tyres), the wheel electronics transmit data as soon as the speed
of the new wheels exceeds 25 km/h. The new wheel electronics'
ID numbers are automatically detected and entered by the control
unit.
The acceleration data are additionally checked against the vehi‐
cle speed. This process takes approx. 7 minutes.
The tyre pressure monitoring system control unit - J502- must first
switch to learning mode before it can automatically learn the
wheel electronics.
To do this, the vehicle must remain stationary for 20 minutes.
Following the detection of a flat tyre, this time is 5 minutes.
If the stationary time is not maintained and the control unit con‐
sequently does not switch to learning mode, the system detects
interference in transmission and will learn the wheel electronics
automatically only after a stationary period of 20 minutes.
Note
♦ When changing wheels, note that only Volkswagen-approved

wheel and tyre combinations with the tyre inflation pressure
specified in the tank flap may be installed.
♦ If unapproved wheel and tyre combinations are installed, they
must possess a certificate from the responsible technical in‐
spection authority (in Germany, TÜV) for the respective vehi‐
cle, and a second wheel set must be adapted via the ⇒ Vehicle
diagnostic tester ⇒ page 241 .
♦ Learning is also necessary if the tyre inflation pressure devi‐
ates from the tyre inflation pressure specified in the tank flap
⇒ page 241 .
Tyre sets with other specified tyre inflation pressures

If a vehicle is fitted with tyres requiring nominal tyre inflation pres‐
sures other than those specified on the tank flap sticker, these
4. Removing and fitting tyres (wheels with tyre pressure monitoring) 241
Touran 2003 ➤
tyres (second wheel set) can also be monitored with the TPM
system.
Nominal tyre inflation pressures for the second wheel set must be
specified to the system with the ⇒ Vehicle diagnostic tester.
The wheel electronics for the wheels of the second wheel set are
not automatically detected and learned by the TPM system (unlike
the wheel electronics for the wheel set with Volkswagen-ap‐
proved wheel and tyre combinations).
The following work has to be performed to switch to the second
wheel set:
♦ Read ID numbers (IDs) of the wheel electronics (tyre pressure
sensors) prior to installation.
♦ Switch the TPM to wheel set 2.
♦ Enter the necessary nominal tyre pressures and the IDs of the
wheel electronics in the system.
4.3 Pressing tyre off wheel rim
Caution
♦ Comply with the notes on safety and conditions

⇒ page 241
– Deflate tyre by unscrewing nickel-plated valve core.

– When pressing off a tyre using tyre fitting equipment with a
press-off plate, always ensure that the tyre valve/ tyre pres‐
sure sensor -arrow- is directly opposite the bead breaker -1-.
The bead breaker must be positioned no more than 2 cm away
from the rim flange.
– Remove balance weights and excessive dirt from wheel.
– Press both tyre beads off all round and liberally coat tyre and
wheel rim flange with tyre assembly paste -arrow-.

Touran 2003 ➤
4.4 Removing tyre from wheel
Caution

⇒ page 241
♦ The assembly head must never be within area -a- of tyre
valve/tyre pressure sensor, or the assembly head will
damage the tyre pressure sensor .
Fitting tyre
– Turn wheel on tyre fitting unit so that tyre valve/ tyre pressure
sensor is in front of the assembly head.
– Position assembly head near tyre valve/ tyre pressure sensor
so that an assembly lever can be inserted approx. 30° next to
the tyre valve/ tyre pressure sensor .
– Now lever tyre bead over assembly finger on assembly head
using assembly lever then remove assembly lever.
– Run tyre fitting machine clockwise until upper bead lies com‐
pletely above wheel rim flange.
– Turn wheel on tyre fitting unit so that tyre valve/ tyre pressure
sensor is in front of the assembly head.
Note
♦ Check that the tyre pressure sensor is not loose or damaged.

If the screwed connection is loose, replace the union nut, the
valve core, the seal, the sealing washer and the valve cap with
new parts from the repair set ⇒ Electronic parts catalogue
“ETKA” .
♦ If the tyre pressure sensor is damaged, then replace the com‐
plete item ⇒ page 255 .
4.5 Fitting tyre to wheel rim
Caution
♦ Note the instruction for warming cold tyres to minimum in‐

stallation temperature ⇒ page 239 .
⇒ page 241
Note
When a tyre is changed, it is recommended also to change the

set of seals for the tyre pressure sensor.
– Coat wheel rim flanges, tyre beads and inside of upper tyre
bead generously with tyre assembly paste.
– First fit inner side of tyre.
4. Removing and fitting tyres (wheels with tyre pressure monitoring) 243
Touran 2003 ➤
– Turn wheel on tyre fitting unit so that tyre valve with tyre pres‐
sure sensor -arrow- is directly opposite assembly head.
– Press tyre into drop centre in -direction of arrow- between tyre
valve with tyre pressure sensor and assembly head.
– Run tyre fitting machine clockwise.
– Stop the fitting of lower bead before reaching tyre valve/ tyre
pressure sensor to prevent damage to tyre pressure sensor .
The tyre bead will now slide over the wheel rim flange. The wheel
rim may be turned only until the assembly head is just before the
tyre valve/ tyre pressure sensor .
– Check to ensure that tyre bead is seated correctly on assembly
head and run tyre fitting machine clockwise.
– Stop the fitting of upper bead before reaching tyre valve/ tyre
pressure sensor to prevent damage to tyre pressure sensor .
tyre valve/ tyre pressure sensor .
– Inflate tyre to a pressure of max. 3.3 bar (bead seating pres‐
sure)
Caution
Never increase the inflation pressure when the tyre bead does
not lie completely against the wheel rim flange.
This would lead to damage to the tyre and/or the wheel rim.
– When the tyre bead does not lie completely against the wheel
rim flange: deflate the tyre, press tyre bead off wheel rim flange
and generously coat again with tyre assembly paste.
sure)
– If the tyre beads seat perfectly against the shoulder of the
wheel rim, increase pressure to 4 bar to »seat« the tyre.
– Fit a new nickel-plated valve core and inflate tyre to prescribed
inflation pressure.
– Then balance wheel.
– Install wheel and tighten bolts to specified torque
⇒ page 238 .

Touran 2003 ➤
5 Removing and fitting tyres with run-

flat properties to wheel rims
5.1 Safety information

• Only specially trained mechanics may remove or install tyres
with run-flat properties.
• The special tools required must be in a perfect condition and
must not be damaged. For information about appropriate ad‐
ditional tools, directly contact the manufacture of the tyre fitting
equipment in your workshop. The recommended optional ad‐
ditional tools can be located under the VAS number of the
listed tyre fitting equipment.
• Use assembly paste recommended by the tyre manufacturer
if necessary.
• The procedure for removing and fitting may differ depending
on the type of equipment used and the manufacture of the
equipment.
• The subsequent procedure describes in general the principles
of removing and fitting tyres with run-flat properties. It is im‐
portant to identify a "run-flat" tyre before removing or fitting a
tyre in order to follow the appropriate procedure.
• Distinguishing features: the tyre can be identified by one of the
following abbreviations DSST, Euforia, RFT, ROF, RSC, SSR
or ZP. The abbreviation is located on the flank of the tyre fol‐
lowing the tyre designation of the respective tyre manufactur‐
er.
• It is extremely important to adhere to the instructions and
warnings in the following descriptions.
• Check whether the tyre pressure sensor should also be re‐
placed (where fitted) ⇒ Vehicle diagnostic tester.
Note
♦ Ensure that the tyre does not contact the tyre pressure sensor
during removal or fitting.
♦ The tyre pressure sensor must not come into contact with wa‐
ter or be blown upon with compressed air when the wheel rim
is cleaned.
5.2 Fittings instructions

Warming cold tyres to minimum fitting temperature
Note
This instruction also applies to ultra-high performance tyres (as‐

pect ratio less than or equal to 45 % and speed symbol V or
higher).
WARNING
When installing a tyre, the tyre core temperature must not be

less than 15°C nor greater than 30°C.
5. Removing and fitting tyres with run-flat properties to wheel rims 245
Touran 2003 ➤
• To install tyres without damage, it is especially important to

warm the upper part of the sidewall and the inside of the upper
bead to at least 15°C.
• This internal temperature is referred to as the core tempera‐
ture.
• Rubber is a poor conductor of heat, therefore a cold tyre must
be left in an area with the correct temperature for a sufficiently
long period so the inner rubber layers can warm up to at least
15 °C.
• The surface temperature of the tyre during the warming up
phase is no indication of its internal temperature.
• To enable cold tyres to absorb heat from the ambient air as
quickly as possible, they should not be stacked on top of one
another but instead stored individually in order to allow the
warm air to “circulate” around them effectively.
• Tyres must never be placed in front of a radiator or hot air
blower for warming, since this can very quickly lead to critical
surface temperatures.
• Except for warming with warm water or warm ambient air
(max. 50°C), there is no process available for warming tyres
without damaging the tyre!
• When cold tyres (below 0°C) are transferred to a warm envi‐
ronment (above 0°C), a layer of condensation immediately
forms on the surface of the tyre. This layer of condensation
indicates that the tyre is intensively absorbing heat from its
environment through the process of water vapour in the air
condensing out on the tyre surface.
• Once the layer of frost has thawed, condensate water forms
and it should be dried off with a cloth otherwise the continua‐
tion of the warming process might be curtailed by cold due to
evaporation.
Warming times:
temperature of 0°C or more, a tyre must be kept at a minimum
of 19°C for at least 2 hours.
temperature of below 0°C, a tyre must be kept at a minimum
of 19°C for at least 2.5 hours.
Warming recommendations:
♦ If possible, tyres should be stored in the workshop 1 day before
they are fitted (order preparation).
♦ Store on an insulated base, pallet or the like, as high up as
possible
♦ Position the tyres individually to allow the warm air to “circu‐
late” around them effectively
♦ Wipe off condensation
♦ Never heat with a radiator or hot air blower!
5.3 Pressing tyre off wheel rim
Caution
♦ Heed the safety precautions ⇒ page 245
– Deflate tyre by unscrewing nickel-plated valve core.

Touran 2003 ➤
– When pressing off a tyre using tyre fitting equipment with a

press-off plate, always ensure that the tyre valve/ tyre pres‐
sure sensor -arrow- is directly opposite the bead breaker -1-.
The bead breaker must be positioned no more than 2 cm away
from the rim flange.
– Remove balance weights and excessive dirt from wheel.
– Press both tyre beads off all round and liberally coat tyre and
wheel rim flange with tyre assembly paste -arrow-.
5.4 Removing tyre from wheel
Caution
sure sensor -2- is directly in front of assembly head -1-.
Caution
The assembly head -1- must never be within area -a- of tyre
valve/tyre pressure sensor, or the assembly head will damage
the tyre pressure sensor .
– Position assembly head -1- near tyre valve/ tyre pressure sen‐
sor so that an assembly lever can be inserted approx. 30° next
to the tyre valve/ tyre pressure sensor -2-.
– Seat depressor -3- on wheel rim opposite assembly head
-1-.
using assembly lever then remove assembly lever.
Touran 2003 ➤
– Run tyre fitting machine clockwise until upper bead lies com‐
pletely above wheel rim flange.
This action will push the depressor -1- up against the assembly
head. This allows it to be removed easily.
sure sensor -2- is directly in front of assembly head -1-.
Caution
The assembly head -1- must never be within area -a- of tyre
valve/tyre pressure sensor, or the assembly head will damage
the tyre pressure sensor .
– Position assembly head -1- near tyre valve/ tyre pressure sen‐
sor so that an assembly lever can be inserted approx. 30° next
to the tyre valve/ tyre pressure sensor -2-.
using assembly lever -3-.
– Additionally insert a plastic assembly lever -4-.
– Remove assembly lever -3-.
– Hold bead over wheel rim flange from outside using plastic
assembly lever -1- and run tyre fitting machine clockwise until
tyre is pulled completely off wheel rim.
Note
♦ Check that the tyre pressure sensor is not loose or damaged.

If the screwed connection is loose, replace the union nut, the
valve core, the seal, the sealing washer and the valve cap with
new parts from the repair set ⇒ Electronic parts catalogue
“ETKA” .
♦ If the tyre pressure sensor is damaged, then replace the com‐
plete item ⇒ page 255 .
5.5 Fitting tyre to wheel rim
Caution
♦ Note the instruction for warming cold tyres to minimum in‐

stallation temperature ⇒ page 245 .
– Coat wheel rim flanges, tyre beads and inside of upper tyre
bead generously with tyre assembly paste.

Touran 2003 ➤
– Turn wheel rim on tyre fitting unit so that tyre valve/ tyre pres‐
sure sensor -1- is directly opposite assembly head -2-.
– Run tyre fitting machine clockwise.
– Stop the fitting of lower bead before reaching tyre valve/ tyre
pressure sensor -arrow- to prevent damage to tyre pressure
sensor .
tyre valve/ tyre pressure sensor -arrow-.
– Turn wheel rim on tyre fitting unit so that tyre valve/ tyre pres‐
sure sensor -1- is directly opposite assembly head -2-.
– Fit depressor -3- on wheel rim.
– Check to ensure that tyre bead is seated correctly on assembly
head and run tyre fitting machine clockwise.
Touran 2003 ➤
– Stop the fitting of upper bead before reaching tyre valve/ tyre
pressure sensor -arrow- to prevent damage to tyre pressure
sensor .
tyre valve/ tyre pressure sensor -arrow-.
– Remove depressor from wheel rim.
sure)
Caution
Never increase the inflation pressure when the tyre bead does
not lie completely against the wheel rim flange.
This would lead to damage to the tyre and/or the wheel rim.
– When the tyre bead does not lie completely against the wheel
rim flange: deflate the tyre, press tyre bead off wheel rim flange
and generously coat again with tyre assembly paste.
sure)
– If the tyre beads seat perfectly against the shoulder of the
wheel rim, increase pressure to 4 bar to »seat« the tyre.
– Fit a new nickel-plated valve core and inflate tyre to prescribed
inflation pressure.
– Then balance wheel.
– Install wheel and tighten bolts to specified torque
⇒ page 238 .

Touran 2003 ➤
6 Tyre pressure monitor display

General information:
The tyre pressure monitoring system is part of the software in the
ABS control unit - J104- . The system is used to detect slow tyre
pressure loss from a wheel. Event memory entries for the tyre
monitor display are stored in the ABS control unit - J104- . The
tyre pressure display compares the wheel speeds and conse‐
quently the rolling circumference of the individual wheels via the
ABS sensors.
After the following work or modifications, the tyre pressure mon‐
itor display button - E492- must be pressed and held until a
confirmation is sounded.
♦ Change in tyre pressure
♦ Changing one or more wheels
♦ Interchanging wheels, e.g. from front to rear
♦ Removing and fitting one or more wheels
A change in the wheel's rolling circumference will be indicated by
the tyre pressure loss indicator warning lamp - K220- lighting up
in the instrument cluster. A tyre's rolling circumference may
change as a result of:
♦ Insufficient tyre pressure
♦ Structural tyre damage
♦ One-sided loading of vehicle
♦ Increased load on one axle, e.g. due to towing a trailer
♦ Use of snow chains.
♦ Spare wheel installed.
♦ Wheel renewal.
6.1 System fault in the ABS system

If a fault in the ABS is displayed by the ESP and TCS warning
lamp - K155- or the traction control system warning lamp - K86- ,
then the tyre pressure loss indicator warning lamp - K220-
-arrow- will also light up. However, no fault will be stored in the
Tyre Pressure Loss Indicator system.
The warning lamp cannot be extinguished by pressing the TPM
button - E492- . In this case, please carry out the following steps:
– Connect ⇒ Vehicle diagnostic tester and select “Guided Fault
Finding” ⇒ Vehicle diagnostic tester.
Running gear
Brake system
01-Self-diagnosis
03-Brake system ABS Mark 70 or
03-Brake system ESP Mark 60
Function
General functions
Adaption of tyre pressure loss indicator - RKA
Follow instructions on screen to perform basic setting.
6. Tyre pressure monitor display 251

Touran 2003 ➤
6.2 Perform basic settings

Basic setting must be performed after every modification to the
wheels.
• Ignition must be switched on.
• Handbrake of vehicle must be applied.
Vehicles up to model year 2010
– Push SET button -1- in centre console until an audible signal
sounds.
An audible signal confirms that basic setting has been performed.
Vehicles as of model year 2011

– Push SET button in centre console until an audible signal
sounds.
An audible signal confirms that basic setting has been performed.

Touran 2003 ➤
7 Tyre pressure monitor

For detailed information on the tyre pressure monitoring system
(TPMS), refer to ⇒ Self-study programme No. 347 ; Tyre Pres‐
sure Monitoring Systems .
The tyre pressure monitor system includes wheel electronics
mounted on each wheel.
At regular intervals, the wheel electronics transmit data which the
central locking and anti-theft alarm system aerial receives and
forwards to the tyre pressure monitor control unit - J502- .
This control unit is integrated with its own diagnostic address into
the convenience system central control unit - J393- .
The tyre pressure specifications (monitoring air pressures) are set
in the control unit as factory defaults.
The pressures, noted on the tank flap sticker, are valid for a set
of wheels with the Volkswagen-approved tyres.
The nominal tyre pressures for this set of wheels are specified for
the partially and fully laden vehicle and must not be changed.
Vehicles up to model year 2010
The driver can switch between partial and full load, poll the status
and switch the TPM system on or off via a SET button -1- in the
centre console.
Vehicles as of model year 2011

The driver can switch between partial and full load, poll the status
and switch the tyre pressure monitoring system on or off via but‐
ton SET in the centre console.
Caution
This button is not available for the North American region

(NAR). Therefore, the function described above is omitted in
this region.
Messages and warnings are indicated via the lamp in the dash
panel insert and texts in the dash panel insert display.
7.1 Button behaviour

This table shows the button's behaviour in the case of various
states or actions under consideration of different functions.
Caution
This button is not available for the North American region

(NAR).
7. Tyre pressure monitor 253

Touran 2003 ➤
Time for which the button is pressed

Up to 2 seconds 3-7 seconds 8-10 seconds 11-15 seconds
State or action Actual state Switch Confirm Switching off
Messages: Messages: Messages: Messages:
Desired functions:
Switch from full to Full tyre load moni‐ Partial tyre load on! On release:
partial load tored Confirmation of
(gong) switching via gong
Switch from partial to Partial tyre load Full tyre load on! On release:
full load monitored Confirmation of
(gong) switching via gong
Switching on TPM off! Partial tyre load on! On release:
Confirmation of
switching via gong
Switching off Full tyre load moni‐ Partial tyre load on! TPM off!
tored or (gong)
or Full tyre load on!
Partial tyre load
monitored
(gong)
Status query For example: After releasing:
TPM off! Press longer to acti‐
or vate!
Partial tyre load or
monitored Press longer to
(gong) switch or deactivate!
7.2 Assembly overview: tyre pressure sensor

Touran 2003 ➤
1 - Tyre pressure sensor

❑ Supplied complete as
spare part.
⇒ page 255
❑ Replace complete tyre
pressure sensor when
battery is dead
❑ After using breakdown
set, wipe clean hole for
valve and opening for
pressure sensor
2 - Valve insert
❑ Always renew when
changing tyre
Note
Always use a Genuine valve core

only. It has a special coating!
3 - Gasket
4 - Seal
5 - Wheel
❑ Fitting tyres with run-flat
properties ⇒ page 245
6 - Union nut
❑ 4 Nm
7 - Valve cap
❑ Use only genuine valve
caps from repair set ⇒
Electronic parts cata‐
logue “ETKA” .
❑ Do not use convenience valve caps or metal valve caps.
7.3 Removing and installing tyre pressure

sensor
Removing
– Remove union nut -1-.
– Remove tyre pressure sensor -2- from bed of wheel rim.
Installing
Caution
♦ Before installing tyre pressure sensor , clean valve hole.
7. Tyre pressure monitor 255

Touran 2003 ➤
– Install tyre pressure sensor -2- along with a new seal and
sealing washer and push it into wheel rim at the points marked
by -arrows-.
– Press tyre pressure sensor -2- into the wheel rim at the points
marked by -arrows-.
Screw union nut -1- onto tyre pressure sensor from outside.
– Press tyre pressure sensor -1- onto bed of rim at the points
marked by -arrows- and tighten union nut to 8 Nm.
Caution
♦ Tighten nut only to specified torque.

♦ The sealing washer -2- will be deformed slightly when
tightened.
♦ The sealing washer may be installed only once. Install a
new sealing washer with rubber seal every time the part
is fitted.
♦ Further tightening of the union nut is not permitted be‐
cause the seal may be damaged, leading to leaks.
Specified torque
Union nut to tyre pressure sensor 4 Nm

Touran 2003 ➤
8 Vehicle alignment check

equipment required
♦ Wheel alignment computer
- V.A.G 1813- or VW/Audi-
approved wheel alignment
computer
♦ Brake pedal depressor -
V.A.G 1869/2-
♦ Insert tool, 18 mm -
T10179-
T10001-
8.1 General information

Wheel alignment must always be checked with VW/Audi-ap‐
proved wheel alignment equipment.
Whenever wheels are aligned, both the front and rear axle must
be measured.
Otherwise, the steering rack may not be centred!
– Perform all measurements with wheel alignment computer.
All the information required to perform alignment can be found in
the wheel alignment computer.
Current data »updates« are located on VW Service Net.
⇒ VW ServiceNet; Systems; Wheel alignment computer soft‐
ware; Wheel alignment; Beissbarth
ware; Wheel alignment; Hunter
ware; Wheel alignment; Corghi
8. Vehicle alignment check 257

Touran 2003 ➤

ware; Wheel alignment; John Bean
Note
♦ Wheel alignment should not be checked before the vehicle has

completed 1000 to 2000 km after the coil springs have settled.
♦ When making adjustments, adhere to the relevant specifica‐
tions as closely as possible.
Wheel alignment is necessary if:

♦ The vehicle does not handle properly.
♦ Vehicle has been involved in an accident and components
have been renewed.
♦ Axle components have been removed and reinstalled.
♦ Tyres wear on one side.
Components have been renewed
Front axle component was Alignment necessary Rear axle component re‐ Alignment necessary
renewed. newed
Yes No Yes No
Lower suspension link X Lower transverse link X
Bonded rubber bush X 1) Upper transverse link X
for suspension link
Wheel bearing housing X Track rod X
Track rod/track rod ball joint X Wheel bearing housing X
Steering rack X Subframe X
Subframe X Coil spring X
Suspension strut X Shock absorbers X
Subframe bracket X Anti-roll bar X
Anti-roll bar X 1) Trailing arm X
1) Prerequisite: the positions of the subframe and brackets were
fixed before the parts were removed ⇒ page 14 .
Components removed and installed

Front axle component re‐ Alignment necessary Rear axle component re‐ Alignment necessary
moved and reinstalled moved and reinstalled
Yes No Yes No
Lower suspension link X 1) Lower transverse link X
Wheel bearing housing X Upper transverse link X
Track rod/track rod ball X Track rod X
joint
Steering rack X Wheel bearing housing X
Subframe X 1) Subframe X
Suspension strut X Coil spring X
Subframe bracket X 1) Shock absorbers X
Anti-roll bar X 1) Anti-roll bar X
Trailing arm X

Touran 2003 ➤
1) Prerequisite: the positions of the subframe and brackets were

fixed before the parts were removed ⇒ page 14 .
8.2 Test requirements

• Check suspension, wheel bearing, steering and steering link‐
age for excessive play and damage.
• Tread depth difference of no more than 2 mm on one axle.
• Tyres inflated to correct pressure.
• Vehicle unladen.
• Fuel tank must be full.
• Spare wheel and vehicle tools are stowed in correct locations.
• The fluid reservoir for the windscreen/headlight washer sys‐
tem must be full.
• When checking wheel alignment, ensure that sliding plates
and turn tables are not touching end stop.
Please note!
• The test equipment must be properly adjusted and attached
to the vehicle; observe device manufacturer's operating in‐
structions.
If necessary, contact the manufacturer for familiarisation with the
proper use of the wheel alignment equipment.
Wheel alignment platforms and wheel alignment units and com‐
puters can lose their calibration over a period of time.
Wheel alignment platforms and alignment units and computers
should be checked and adjusted as necessary during inspection
and maintenance at least once per year!
– Treat these highly sensitive units carefully and conscientious‐
ly!
8.3 Test preparations

♦ Brake pedal depressor - V.A.G 1869/2-
The existing lateral runout of the wheel must be compensated for.

Otherwise, the result of the measurement will be incorrect.
If runout compensation is not performed, it is not possible to adjust
toe-in correctly!
Observe information provided by the manufacturer of the wheel
alignment unit.
– Carry out wheel runout compensation.

Touran 2003 ➤
– Apply brake pedal depressor - V.A.G 1869/2- .

– Use brake pedal depressor to depress brake pedal.
8.4 Wheel alignment specifications

These specifications apply to all engines.
♦ Explanation of PR numbers can be found here ⇒ page 268 .
The ride heights shown in the table refer to dimension -a-.
Front axle Standard running Standard running Sports running Heavy-duty run‐
gear gear with adap‐ gear ning gear
tive chassis con‐
trol DCC
PR numbers G24, G25, G26 G01, G24 G27, G28 G29, G30
Total toe (without load) +10' ± 10’ +10' ± 10’ +10' ± 10’ +10' ± 10’
Camber (in straight-ahead -30′ ± 30′ -30′ ± 30′ -41′ ± 30′ -15’ ± 30’
position)
Maximum permissible differ‐ max. 30' max. 30' max. 30' max. 30'
ence between sides
Toe-out on turns 1) at 20° left 1°38′ ± 20′ 1°38′ ± 20′ 1° 40′ ± 20′ 1° 38′ ± 20′
and right steering angle
Caster 7° 34′ ± 30′ 7° 34′ ± 30′ 7° 47′ ± 30′ 7° 17′ ± 30′
ence between sides
Ride height 404 ± 10 mm 404 ± 10 mm 389 ± 10 mm 424 ± 10 mm
1)
Toe-out on turns can be displayed as a negative value on the
wheel alignment computer, depending on the manufacturer.
Front axle Heavy-duty run‐ CrossTouran BlueMotion ADAC

ning gear
natural gas
Russia
PR numbers G31, G73 G29 G27 G24 + F5J + 1JC
Total toe (without load) +10' ± 10’ +10' ± 10’ +10' ± 10’ +10' ± 10’
Camber (in straight-ahead -22′ ± 30′ -22′ ± 30′ -41′ ± 30′ -30′ ± 30′
position)
ence between sides
Toe-out on turns 1) at 20° left 1° 16′ ± 20′ 1° 16′ ± 20′ 1° 40′ ± 20′ 1° 38′ ± 20′
and right steering angle
Caster 7° 26′ ± 30′ 7° 26′ ± 30′ 7° 47′ ± 30′ 7° 34′ ± 30′
ence between sides

Touran 2003 ➤
Front axle Heavy-duty run‐ CrossTouran BlueMotion ADAC

ning gear
natural gas
Russia
PR numbers G31, G73 G29 G27 G24 + F5J + 1JC
1)
Toe-out on turns can be displayed as a negative value on the
wheel alignment computer, depending on the manufacturer.
These specifications apply to all engines.

♦ Explanation of PR numbers can be found here ⇒ page 268 .
Rear axle Standard running Standard running Sports running Heavy-duty run‐
gear gear with adap‐ gear ning gear
tive chassis con‐
trol DCC
PR numbers G24, G25, G26 G01, G24 G27, G28 G29, G30
Camber -1° 20′ ± 30′ -1° 20′ ± 30′ -1° 20′ ± 30′ -1° 20′ ± 30′
ence between sides
Total track (at prescribed +10′ ± 12′ +10′ ± 12′ +14' ± 12' +10′ ± 12′
camber)
Max. permissible deviation max. 20' max. 20' max. 20' max. 20'
from direction of travel
Rear axle Heavy-duty run‐ CrossTouran BlueMotion ADAC

ning gear
natural gas
PR numbers G29 G29 G27 G24 + F5J + 1JC
Camber -1° 20′ ± 30′ -1° 20′ ± 30′ -1° 20′ ± 30′ -1° 45′ ± 30′
ence between sides
Total track (at prescribed +10′ ± 10′ +10′ ± 10′ +14' ± 12' +16′ ± 12.5′
camber)
Max. permissible deviation max. 20' max. 20' max. 20' max. 20'
from direction of travel

Touran 2003 ➤
8.5 Overview - wheel alignment procedure

Always adhere to the following procedure!
– Observe instructions for your wheel alignment device.
Alignment procedure
Start → Carry out wheel runout com‐ → Bounce springs.

pensation.
↓
Turn steering wheel to ← Measure vehicle height. ← Fit brake pedal depressor - V.A.G
straight-ahead position 1869/2-
and lock in place 1)
↓
Check front axle camber → Is actual value within toler‐ → No
ance?
↓ ↓
↓ ← ← Yes Adjusting ⇒ page 263
↓ ↓
↓ ← ← ← ← ←
↓
Check rear axle camber → Is actual value within toler‐ → No
ance?
↓ ↓
↓ ↓
↓ ← ← ← ← ←
↓
Check rear axle toe → Is actual value within toler‐ → No
ance?
↓ ↓
↓ ↓
↓ ← ← ← ← ←
↓
Check front axle caster → Is actual value within toler‐ → No
ance?
↓ ↓
↓ ← ← Yes Inspect axle components and
body
↓ ↓
↓ ← ← ← ← ←
↓

Touran 2003 ➤
Check front axle toe → Is actual value within toler‐ → No

ance?
↓ ↓
End ← Yes Adjusting ⇒ page 267
↑ ↓
↑ ← ← ← ← ←
1)If steering wheel is not centred, it must be straightened after
wheel alignment is finished. Then carry out basic setting for steer‐
ing angle sender - G85- using ⇒ Vehicle diagnostic tester.
8.6 Correcting front axle camber

Note
♦ Camber correction is necessary only after body repairs. The

camber is not adjustable, but can be equalized by moving the
brackets and/or the subframe.
♦ Move subframe only to left or right, but never in or opposite to
direction of normal travel!
– Remove noise insulation.

– Loosen bolts -1- for bracket attachment and subframe to body
on both sides.
The camber adjustment range is limited by the tolerances within
the bores in the brackets and the subframe. If the specified value
is not reached by moving the components, these and the body
must be inspected ⇒ page 1 .
– Specification for camber may be adjusted by moving subframe
at brackets.
– Tighten bolts for subframe and brackets to body to specified
torque plus extra turn angle.
After shifting the subframe and steering rack, clearance between
the steering column universal joint and the cut-out in the bulkhead
must be checked.

Touran 2003 ➤
There must be a clearance of 5 mm all round between universal

joint -1- and aperture in plenum chamber bulkhead -2-.
Specified torques
♦ Use new bolts

♦ Use new bolts
8.7 Adjusting camber on rear axle

♦ Shock absorber set - T10001-

Touran 2003 ➤
♦ Insert tool, 18 mm - T10179-
– Loosen upper transverse link nut -A- on subframe.
– Adjust camber by turning eccentric bolt -B- with 18 mm socket

- T10001- .
Note
The maximum adjustment range is 90° to the left or right of centre.
– Tighten nut -A-.

Touran 2003 ➤
– Use socket (18 mm) - T10179-

– Check camber value again after tightening nut -A-.
Specified torques
Upper transverse link to subframe 95 Nm
♦ Use new bolts ♦ To tighten nuts, set torque wrench - V.A.G
1332- to 80 Nm
the normal running position ♦ Applies only in conjunction with insert tool,
18 mm - T10179-
8.8 Adjusting toe at rear axle

– Loosen nut -1-.

– Turn eccentric bolt -2- until specification is attained.
– Now tighten nut.

Touran 2003 ➤
Specified torque
Lower transverse link to subframe 95 Nm
♦ Use new bolts
8.9 Adjusting front axle toe

♦ Insert tool, 24 mm - V.A.G 1332/11-

– Loosen lock nut -3- while counterholding on head of track rod
-2-.
– Pull spring-type clip -1- off boot.
– Adjust toe by turning left and/or right track rod.
To do this, use an open-end spanner on hexagon flats on track
rod.
After turning track rods, ensure that boots are not twisted.
Twisted boots wear out quickly.
– Tighten lock nut using tool insert 24 mm -V.A.G 1332/11- while

counterholding on track rod ball joint -1-.
– Check toe values again.
It is possible that the value will change slightly when lock nut is
tightened.
However, if the measured toe value lies within the tolerance, the
adjustment is correct.
– Fit spring-type clip to boot.
Specified torques
Track rod ball joint to track rod 70 Nm

Touran 2003 ➤
8.10 Basic setting of steering angle sensor -

G85-
If steering wheel was realigned, basic settings for steering angle
sensor - G85- must be checked. ⇒ Vehicle diagnostic tester ⇒
Carry out basic setting in Guided fault finding mode using vehicle
diagnosis tester.
Select “Select function/component” by pressing Go to button.
8.11 Vehicle data sticker

Information on the individual running gear that is fitted is currently
not available on the data sticker.
To find information about the running gear, please search in EL‐
SA/Vehicle-specific notes.
In this example the vehicle is equipped with standard running gear
G02 -arrow-.

Touran 2003 ➤
9 Wheels, tyres
9.1 Models with breakdown set

Touran vehicles are equipped with either a spare wheel or a
breakdown set.
The breakdown set is located in the luggage compartment where
normally the spare wheel would sit. It consists of a compressor
-1- and a bottle of tyre sealant -2-.
9.2 Tyre sealant

The tyre sealant in the bottle has a limited shelf life.
Therefore, the expiry date is indicated on the bottle -arrow-.
In this example the expiry date of 05/2003 has been exceeded
and the bottle must be renewed.
If the bottle was opened e.g. owing to a flat tyre, it must also be
renewed.
9.3 Removing a tyre

Tyres which have been filled or sealed using tyre sealant must be
drained before removal.
WARNING
♦ Do not allow tyre sealant to come into contact with eyes

or skin!
♦ It is damaging to health and can cause eye irritation and
allergies.
♦ During assembly work, wear protective gloves and gog‐
gles.
– Place wheel on a flat surface.

– Remove valve core of tyre valve.
9. Wheels, tyres 269

Touran 2003 ➤
– Use a suitable drill or mill to carefully drill a hole in shoulder

area of tyre.
– Hold wheel over a suitable container and drain sealant.
– Remove tyre from wheel rim.
– Clean wheel rim with, for example, a moist cloth.
9.4 Fitting a new tyre

• Ensure that the wheel rim is clean.
– Insert new tyre valve with -VAS 6459- -1-.
– Remove valve core.
– Inflate tyre to approx. 3 . . . 4 bar. Bead of tyre must slip audibly
over hump of rim.
– Screw in valve core.
– Correct inflation pressure to prescribed pressure.
– Balance wheel.
9.5 Tyre sealant disposal

♦ Tyre sealant or residue must not be mixed or disposed of with
other fluids.
♦ Excess tyre sealant must be collected and stored in a plastic
container. The plastic container can be disposed of through
the disposal system along with the breakdown set (when the
expiry date is exceeded).
♦ The items can be returned or disposed of through the existing
workshop disposal system.
♦ Request information through your service provider or the dis‐
posal representative at your distribution centre or importer.

Touran 2003 ➤
10 Instructions for changing or fitting

wheels
WARNING
Perform the checks and follow the instructions listed below.

This is important to ensure that the wheel bolts and the wheels
are properly secured.
– Check to ensure that contact surfaces -arrows- on brake disc

are free of corrosion and dirt.
– Check to ensure that contact surface -arrow- on centring seat

of brake disc are free of corrosion and dirt.
– Check to ensure that contact surface -arrow- on inner side of

wheel (rim) and also centring seat of rim are free of corrosion
and dirt.
– The lug seats* in the holes for the wheel bolts and the threads
of the wheel bolts must also be free of corrosion and dirt, oil
or grease.
*The concave seat is the curved surface of a section of a sphere
cut by a plane.
10. Instructions for changing or fitting wheels 271

Touran 2003 ➤
– Check whether the wheel bolts can be easily screwed in by

hand. The thread of the wheel bolts must not come into contact
with the bore in the brake disc -arrow-.
If the thread of the wheel bolt touches the hole -arrow-, turn the
brake disc relative to the wheel hub accordingly.
Remove dirt and corrosion, oil or grease from the contact surfa‐
ces, threads in the wheel hub and/or wheel bolts as necessary.
WARNING
Damaged, badly corroded or difficult to remove wheel bolts

must be renewed.
10.1 Fitting wheels

– Preserve wheel centring seat ⇒ page 273 .
1- When fitting the wheel, screw in all wheel bolts uniformly by
hand.
2- Tighten the wheel bolts in diagonal sequence to approx.
30 Nm.
3- Lower the vehicle to the floor and tighten all wheel bolts di‐
agonally to the specified torque using the torque wrench
⇒ page 238 .
WARNING
Do not use an impact driver when screwing in the bolts!

Touran 2003 ➤
11 Protecting wheel centring seat

against corrosion
Applies to alloy and steel wheels
When changing a wheel, wheel centring seat should be waxed
using wax spray to prevent corrosion between wheel centring seat
and rim ⇒ Electronic parts catalogue “ETKA” .
– Remove wheel.
– Clean wheel centring seat of hub and centring ring of wheel
rim.
– Apply wax to centring ring -arrow- with a brush.
WARNING
Wheel bolts, contact surfaces of wheel hub and wheel rim and
wheel hub threads must not be waxed. Never treat wheel se‐
curing bolts with lubricant or corrosion protection materials!
Ensure that only centring ring -arrow- but not contact surface
of wheel rim has been waxed. Otherwise, the brakes will be
soiled, which would reduce the braking efficiency.
11. Protecting wheel centring seat against corrosion 273

Touran 2003 ➤
12 Vibration due to wheels/tyres - cau‐

ses and rectification
Causes of rough running ⇒ page 274
Balancing wheels ⇒ page 274
Conducting a road test before balancing wheels ⇒ page 274
Balancing wheels on stationary wheel balancer ⇒ page 275
Vibration control system - VAS 6230 A- ⇒ page 278
Finish balancer ⇒ page 278
Radial and lateral run-out on wheels and tyres ⇒ page 279
Checking radial and lateral run-out on wheels and tyres with tyre
gauge - V.A.G 1435- ⇒ page 279
Checking radial and lateral run-out on wheel rim ⇒ page 280
Matching ⇒ page 281
Flat spots caused by storage or handling ⇒ page 282
12.1 Causes of rough running

Rough running can have a number of different causes. It can also
be caused by tyre wear. Tyre wear caused by driving is not always
evenly spread across the entire running surface of the tyre. This
causes slight imbalances which affect the smooth running of a
wheel which was previously exactly balanced.
Minor imbalances will not be felt at the steering wheel, but that
does not mean that they are not there. They increase wear on the
tyre and thus reduce the tyre service life.
Recommendation
To ensure
• optimal safety,
• smoothest possible running and
• even wear
throughout a tyre's service life, we recommend having the wheels
and tyres balanced at least twice during the tyre's service life.
12.2 Balancing wheels

Before you start balancing the wheels, the following requirements
must be met.
• The tyre pressure must be OK.
• The tyre tread must not exhibit one-sided wear and should be
at least 4 mm deep.
• The tyre must not show any signs of damage, for example
cuts, piercing, foreign bodies, etc.
• The wheel suspension, steering and steering linkage, includ‐
ing the shock absorbers, must be in perfect condition.
• You must have conducted a road test.
12.3 Conducting a road test before balancing

wheels
If a customer brings a vehicle to the workshop complaining about
“vibration”, a road test is essential prior to balancing the wheels.

Touran 2003 ➤
♦ This will give you information about the nature of the rough
running.
♦ You will be able to determine in which speed range the rough
running occurs.
– Raise the vehicle on a lifting platform immediately after the
road test.
– Mark the positions of the tyres on the vehicle.
Tyre position Marked with …
Front left tyre FL
Front right tyre FR
Rear left tyre RL
Rear right tyre RR
– Remove wheels from vehicle.
– Balance the wheels.
12.4 Balancing wheels on stationary wheel

balancing machine
• Road test has been carried out ⇒ page 274 .
Clamp wheel into wheel balancing machine
Note
When balancing tyres, please remember that cleanliness is ab‐

solutely essential, as is the case in any other repair work you carry
out. Only then can you attain a flawless result!
Dirt and rust in the area of the contact surfaces and centre of the
wheel distort the result.
– Clean contact surface, centring element and inside of wheel
using e.g. pneumatic brush grinding set - VAS 6446- ⇒ Volks‐
wagen ServiceNet; Workshop Equipment, Catalogue before
clamping wheel on wheel balancing machine!
Note
It is very important that the correct tools for centring and clamping
the wheels are used on the wheel balancing system. Before com‐
mencing any work, find out about the respective centring system
for wheel balancing machines ⇒ Volkswagen ServiceNet; Work‐
shop Equipment, Catalogue .
12. Vibration due to wheels/tyres - causes and rectification 275

Touran 2003 ➤
– Attach the wheel (together with tyre) to the wheel balancing

machine.

Touran 2003 ➤
Note
♦ To clamp the wheel in place, use centring system for wheel

balancing machines - VAS 5271- , for example.
♦ This ensures that the wheel is 100% centred and that the
wheel will be clamped without damage!
♦ The wheel cannot be centralised 100% with conical clamping
elements on the wheel balancing machine.
♦ A deviation of 0.1 mm from the centre results in an imbalance
of 10 g at the wheel/rim.
Procedure for balancing wheels and tyres

– Rotate wheel and tyre on wheel balancer.
– Check that the indicator lines on the sidewall of the tyre near
the wheel rim flange run evenly.
– Check that the body of the tyre runs evenly while the wheel
and tyre are rotating.
Note
If one-sided wear, flat spots from braking or severely washed out

spots are apparent, balancing cannot achieve smooth running. In
this case, the tyre must be renewed.
– Check the true running of the wheel and tyre. If the wheel and
tyre do not run true although there are no flat spots, radial or
lateral runout may be the cause.
– Check the wheel for radial or lateral runout ⇒ page 279 .
– If radial and lateral runout are within the specified tolerance,
balance the wheel and tyre.
Note
♦ More than 60 g of weight per tyre should not be used.

♦ If more weight is required, you may be able to achieve smooth‐
er running by "matching" the tyre and rim. Matching tyres
⇒ page 281 .
♦ The wheel balancer display should indicate 0 g.
♦ As an alternative to match mounting, you could use the vibra‐
tion control system - VAS 6230 A- ⇒ page 278 .
– Bolt the wheel to the vehicle.

– First hand-tighten the lowest wheel bolt to about 30 Nm.
– Then tighten the remaining wheel bolts diagonally to about
30 Nm. This process centres the wheel on the hub.
– Now use a torque wrench to tighten the wheel bolts to the
specified torque in diagonal sequence.
Carry out road test
– After balancing the wheels and tyres, carry out a road test.

Touran 2003 ➤
If you detect vibration during the road test, it may be due to tol‐
erance in the wheel centring.
In unfavourable circumstances, the component tolerances of
wheels and hubs could cumulate. This too can lead to vibration.
This can be alleviated using a finish balancer. ⇒ page 278
12.5 Vibration control system - VAS 6230 A-

Using the vibration control system - VAS 6230 A- you can perform
more functions than just stationary balancing.
A special feature of this system is the testing of the radial force of
the wheel and tyre while rolling.
A roller presses against the wheel with a force of about 635 kg.
This simulates the vertical tyre force against the road surface
during travel.
Radial and lateral runout in the wheel and tyre and differences in
the stiffness of the tyre cause the vertical force of the wheel to
vary.
The -VAS 6230 A- detects and stores the position of the maximum
measured radial force in the tyre. Then the position of the smallest
distance between the wheel rim flange and the centre of the rim
is measured.
12.6 Finish balancer
Note
♦ Before working with a finish balancer , the mechanic needs to

have been instructed by the manufacturer of the balancer.
♦ To balance the wheels, set the wheels of the driven axle on
the sensor platforms (only the front wheels of a front-wheel
drive vehicle, all four wheels of an all-wheel drive vehicle).
If a residual imbalance greater than 20 g is determined when bal‐

ancing the wheels, rotate the mounting position of the wheel on
the hub.
– Mark the point at which the imbalance is indicated.
– Unbolt the wheel and rotate its position on the hub so that the
marking points downwards.
Note
The hub must not rotate during this procedure.
– First hand-tighten the lowest wheel bolt to about 30 Nm.

– Then tighten the remaining wheel bolts diagonally to about
30 Nm. This process ensures that the wheel is centred prop‐
erly on the hub.
– Check whether the imbalance is less than 20 g using the finish
balancer.

Touran 2003 ➤
Note
The imbalance must be less than 20 g before the balance weight

is changed.
– If necessary, remove the wheel bolts again.

– Rotate the wheel relative to the hub once more, turning it one
or two wheel bolt holes further.
– Tighten the wheel bolts using the method described above.
Note
Do not try to reduce the imbalance using balancing weights until

the imbalance is less than 20 g.
– Balance the wheels until the imbalance is less than 5 g.

– Tighten wheel bolts to specified torque if you have not already
done so.
WARNING
Always tighten wheel bolts to specified torque using a torque

wrench!
12.7 Radial and lateral runout of wheels and

tyres
Radial and lateral runout occur when the wheel and tyre do not
run absolutely true.
For technical reasons, 100% true running is not possible.
Therefore, the manufacturers of these components allow a pre‐
cisely determined tolerance.
Mounting the tyre in an unfavourable position on the wheel can
cause the maximum allowed tolerance for wheel with tyre to be
exceeded.
The table shows the maximum permissible tolerances for a wheel
with mounted tyre.
Tolerances for radial and lateral runout of wheels with tyres
Wheel with tyre Radial runout (mm) Lateral runout (mm)
Passenger cars 0.9 1.1
(1.3 in vicinity of lettering)
12.8 Checking radial and lateral runout on

wheels and tyres with tyre gauge - V.A.G
1435-
Checking lateral run-out
– Preload tyre gauge about 2 mm.

Touran 2003 ➤
– Set tyre gauge against sidewall of tyre.

– Slowly rotate the wheel.
– Note the smallest and the largest dial readings.
Note
If the difference is greater than 1.3 mm, the lateral runout is too
great.
In this case, you can reduce lateral runout by match mounting the
tyre ⇒ page 281 .
Extreme values on the tyre gauge due to small irregularities in the
rubber may be disregarded.
Checking radial runout
– Set the tyre gauge against the tyre tread.

Note
If the difference is greater than 1 mm, the radial runout is too great.
In this case, you can reduce radial runout by match mounting the
tyre ⇒ page 281 .
12.9 Checking radial and lateral run-out on

wheel rim
– Mount the wheel on the wheel balancer .
– Use the wheel balancing machine centring system - VAS
5271- .
S - Lateral runout
H - Radial runout
– Compare the measured values with the specifications in the
table ⇒ page 280 .
Note
Extreme values on the tyre gauge due to small irregularities may

be disregarded.
Specifications for radial and lateral runout on wheel rim

Wheel Radial runout (mm) Lateral runout (mm)
Steel wheel 0.5 0.5

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Wheel Radial runout (mm) Lateral runout (mm)

Alloy wheel 0.5 0.8
Note
If the measured value exceeds the specification, acceptably

smooth running cannot be attained.
12.10 Matching
General information
When radial or lateral runout of the wheel and tyre coincide, the
imbalance of the wheel is amplified by the tyre.
For technical reasons, 100% true running is not possible
⇒ page 279 .
Before match mounting the used wheels which are fitted on the
vehicle, run the tyres warm. This will eliminate any flat spots
caused by storage or handling, ⇒ page 282 .
Procedure for match mounting
– Deflate the tyre.
– Press the tyre beads off the rim flanges.
– Coat the tyre bead all round with tyre fitting paste .
– Rotate the tyre 180° relative to the wheel.
– Inflate the tyre to approx. 4 bar.
– Mount the wheel with tyre on the wheel balancer.
– Check true running, that is, radial and lateral runout.
Note
♦ If the specified values for radial and lateral runout are not ex‐
ceeded, the wheel can be balanced to 0 g. Specified values
appear on ⇒ page 279 .
♦ If the radial and lateral runout is not within the specifications,
the tyre must be rotated again.
– Deflate the tyre and press off the tyre beads from the rim
flanges.
– Rotate the tyre 90° with respect to the wheel (1/4 of a turn).
– Inflate the tyre to 4 bar again and check true running.
Note
♦ If the specified values for radial and lateral runout are not ex‐
ceeded, the wheel can be balanced to 0 g.
♦ If the radial and lateral runout are not within the specified val‐
ues, the tyre must be rotated again.
– Press the tyre off the rim flanges again as described above.
– Rotate the tyre 180° with respect to the wheel (1/2 a turn).

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If the radial and/or lateral runouts are still not within the specifi‐
cations, check the radial and/or lateral runout of the wheel:
⇒ page 280 .
If the measured values for radial and lateral runout of the wheel
are within the specified values, the tyre has an impermissibly high
radial or lateral runout. In this case, the tyre must be renewed.
Note
♦ After fitting the tyres there will be fitting lubricant between the
tyres and the rim flanges.
♦ Therefore, severe braking and acceleration manoeuvres must
be avoided for the first 100 or 200 km driven. The tyres may
otherwise rotate on the rims and your work will have been in
vain.
12.11 Flat spots caused by storage or handling

What is a flat spot?
The terms flat area and flats are also used for the term flat spot.
Flat spots caused by storage or handling also cause vibration in
the same way as incorrectly balanced wheels do. It is important
that flat spots on the tread are identified as such.
Flat spots caused by storage or handling cannot be balanced and
they can reoccur at any time due to various circumstances. Flat
spots caused by storage or handling can be eliminated without
complicated special tools. Assuming it is not a flat spot caused by
full-on braking ⇒ Wheel and Tyre Guide - Series; Rep. gr. 44 ;
Rolling noises due to tyres, locked brake flat spots .
Note
Flat spots caused by hard braking cannot be repaired. Such tyres

must be renewed.
Reasons for flat spots caused by storage or handling:

♦ The vehicle has been left standing in one place without being
moved for several weeks.
♦ The tyre inflation pressure is too low.
♦ The vehicle was placed in a paint shop drying booth after being
painted.
♦ The vehicle was parked with warm tyres in a cool garage or
similar for a long period of time. In this case, a standing flat
spot may even occur overnight.
Eliminating flat spots caused by storage or handling
♦ Flat spots caused by storage or handling cannot be eliminated
from the tyre using workshop equipment.
♦ Flat spots caused by storage or handling can be removed only
by running the tyres warm.
♦ The method described below is not recommended in cold and
wintry weather.
Requirements and conditions:
– Check and, if necessary, correct inflation pressures.
– Drive the car on a motorway where possible.

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– Traffic and road conditions permitting, drive a 20 to 30 km

stretch at a speed of 120 to 150 km/h (do not break the law).
WARNING
♦ Do not endanger yourself or other road users during this

road test.
♦ Observe the highway code and speed limitations in force
when performing the road test.
– Raise the vehicle immediately following the road test.

– Remove the wheels from the vehicle.
– Balance the wheels on a stationary wheel balancer
⇒ page 275 .

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13 Front camera for driver assist sys‐

tems - R242-
Note
The following situations can cause the camera function to be im‐

paired by sustained poor visibility of the lane marker lines:
♦ The field of view of the camera is contaminated or iced over.

In this case, clean the affected area.
♦ The field of view of the camera is fogged over.
The camera’s viewing window must be cleaned manually if there
is heavy soiling on the inside of the windscreen in the field of view
of the camera. To do this, the control unit and lens hood must be
removed and the windscreen cleaned using cleaning solution.
Removing the control unit and lens cover ⇒ Rep. gr. 94 .
Correct calibration is a basic precondition for the driver assistance
system's -242- front camera to function without faults.
The driver assistance system's -242- front camera must be reca‐
librated if:
♦ The entry “no or incorrect basic setting / adaptation” is stored
in the event memory.
♦ The front camera for driver assist systems - R242- was re‐
newed.
♦ Windscreen has been renewed or removed.
♦ Rear axle toe has been adjusted.
♦ Modifications having an effect on the body height have been
made to the car's running gear.
♦ The vehicle level senders have been reprogrammed on vehi‐
cles with damper control.
Note
♦ Before calibrating the front camera for driver assist systems,

read out event memory and rectify faults as necessary.
♦ The geometrical driving axis of the car must be measured in
order to calibrate the driver assistance system's front camera.
It is used as a reference position for the setting device - VAS
6430- .
♦ Calibration of the driver assistance system's front camera
must only be performed only using VW/AUDI approved wheel
alignment equipment!
♦ Calibration of the driver assistant system's front camera is
permitted only with the setting device - VAS 6430- !
13.1 Adjusting front camera for driver assis‐

tance system R242

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♦ ⇒ Vehicle diagnostic tester
♦ Setting device - VAS 6430-
♦ Wheel alignment computer
Note
♦ The front camera for driver assist systems - R242- must be

correctly located in the holder.
♦ The field of view of the camera must be clean and clear.
♦ Before driving the vehicle onto the wheel alignment platform,
make sure there is sufficient space between the midpoint of
the hub of the front wheels and the setting device - VAS 6430- .
♦ The distance between the setting device - VAS 6430- and the
centre point of the hub of the front wheels must be 1500 mm
± 25 mm.
♦ If the available space is not adequate, move the vehicle back‐
wards on the alignment platform as required.
♦ Before starting calibration, read out event memory and rectify
any faults.
– Note testing preconditions for wheel alignment ⇒ page 259 .

– Drive car onto wheel alignment platform.
– Connect battery charger ⇒ Electrical system; general infor‐
mation; Rep. gr. 27 .
– Connect ⇒ Vehicle diagnostic tester to vehicle. (Route diag‐
nostic cable through open window.)
Note
During the calibration procedure, make sure that all the car doors
remain closed and that the car's outside lighting is switched off.
13. Front camera for driver assist systems R242 285

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– Move front wheels to straight-ahead position.

– Select calibration run for front camera for driver assist systems
-R242- on wheel alignment computer.
– Mount quick-release clamps on all four wheels.
– Mount measuring transducers on wheels.
– Perform wheel runout compensation on rear wheels.
– Bounce springs.
– Measure standing height at all four wheels and make a note
of it.
Note
♦ Setting device - VAS 6430- is not allowed to be moved on

alignment beam.
♦ Wheel alignment platform must be in the lowermost levelled
position for next work step.
– Align setting device - VAS 6430- at a right angle to lengthways

axis of car.
– Turn setting device - VAS 6430- upwards so that alignment

beam is parallel to middle of measurement transducers on
front wheels, in order to perform a correct measurement with
distance measuring unit -1-.
1- Distance measuring unit with tape measure and socket pin
– Position setting device - VAS 6430- at distance -a- of 1500 mm
± 25 mm from midpoint of hub of front wheels to beam of set‐
ting device - VAS 6430- .
Caution
♦ Distance -a- of 1500 mm ± 25 mm must be measured on

both sides of vehicle and setting device - VAS 6430- must
then be aligned.
♦ Distance -a- must be same on both sides of car.
♦ To guarantee correct calibration, setting device - VAS
6430- must be at right angle to lengthways axis of car.
– Mount measurement transducer -1- of front wheels onto set‐

ting device - VAS 6430- .

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– Measure height value -a- between standing surface of setting

device - VAS 6430- and wheel support surface on wheel align‐
ment platform and enter value in wheel alignment computer.
– Unscrew clamping bolt -arrow-, place measuring bar -1- on

floor.
– Use crank -1- to set calibration panel - VAS 6430/4- to nominal

height -2- indicated by wheel alignment computer and make a
note.
When nominal height has been reached, measuring bar -1- must
be moved upwards slightly and secured with clamping screw
-arrow-.

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– Use adjuster screw -1- to level spirit level -A-.
– Move setting device - VAS 6430- sideways -arrows B- until

display on wheel alignment computer is within tolerance.
– Screw down adjuster screws -2- and -3- slightly to secure set‐
ting device - VAS 6430- against rolling away.

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– Turn fine adjuster screw -1- until display on wheel alignment

computer is within tolerance.
– Use adjuster screw -1- to level spirit level -A-.
– Use adjuster screws -2- and -3- to level spirit level -B-.

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– Unscrew clamping bolt -arrow-, place measuring bar -1- on

floor.
– Check nominal height -2- again and correct if necessary.
When nominal height has been reached, measuring bar -1- must
be moved upwards slightly and secured with clamping screw
-arrow-.
Concluding work is carried out via ⇒ Vehicle diagnostic tester.
– Switch on ignition.
– Select “Guided fault finding” using ⇒ Vehicle diagnostic tester.
Body (Rep. Gr.. 01;27;50...97)
Electrical system (Rep. Gr. (01, 27, 90…97)
01_Self-diagnosis capable systems
Front camera for driver assistance system -R242-
Camera for driver assistance systems, functions
A5 - Calibrating the control unit (Rep. Gr. 44)
Follow instructions on screen to perform calibration.
Note
The next step in Guided fault finding is to measure the body

height.

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– Enter the noted standing height.

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48 – Steering
292 Rep. gr.48 - Steering

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2 General repair instructions

To achieve the desired results when performing repairs on the
steering rack it is important to work with the greatest possible care
and cleanliness, and to use proper tools in good condition. Of
course, the basic rules on safety also apply when performing re‐
pair procedures.
A number of general notes on the individual repair procedures,
which can otherwise be found in the relevant sections of the man‐
ual, are summarised here. They apply for this particular workshop
manual.
For a description of the design and function of the steering as‐
sembly, see self-study programme ⇒ Self-study programme No.
317 ; Electromechanical power steering with dual pinion .
2.1 Steering rack

♦ Thoroughly clean all unions and the adjacent areas before
disconnecting.
♦ When installing the steering rack, make sure that dowel
sleeves between bracket and steering rack are seated cor‐
rectly.
♦ Place removed parts on a clean surface and cover them to
prevent them from getting dirty. Use sheeting and paper for
this purpose. Use only lint-free cloths.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing.
♦ Use only the grease and sealants with specified part numbers.
♦ If repair work cannot be performed immediately, cover new
parts which have been removed from their packing.
♦ Two different types of steering racks were fitted in model year
2004. Notes on identification ⇒ page 371 .
♦ From model year 2009, a new, 3rd generation, steering rack
is being used. Notes on differentiating between 2nd and 3rd
generations ⇒ page 372 .
2.2 Gaskets and seals

♦ Always renew gaskets and seals.
♦ When seals have been removed, check contact surface on
housings or shafts for burrs and damage and rectify as nec‐
essary.
♦ Completely remove all residue from liquid sealants from the
sealing surfaces, making sure that no residual sealant gets
into the steering rack housing.
2.3 Nuts and bolts

♦ Loosen and tighten securing bolts and nuts for covers and
housings diagonally.
♦ Avoid canting sensitive parts, such as servo motor with control
unit. Loosen and tighten them diagonally in stages.
♦ Specified torques given are for unoiled nuts, bolts and screws.
♦ Always renew self-locking nuts and bolts.
2. General repair instructions 293

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2.4 Electrical components

You have certainly felt an electric shock when you have touched
something metallic. This is due to the electrostatic charge of the
human body. This charge can cause malfunctions if you touch the
electric steering rack components.
– Always touch an earthed object – for example, a water pipe or
a lifting platform – before working on electric components.
Never touch them directly on the electrical contacts.
2.5 Guided fault-finding, vehicle self-diag‐

nosis and test instruments
♦ Before performing repair work on the electromechanical steer‐
ing rack, determine the cause of damage as precisely as
possible using the vehicle diagnosis, testing and information
system - VAS 5051- in “guided fault finding”, “vehicle self-di‐
agnosis” and “test instruments” operating modes.

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3 Assembly overview - steering columns up to model year 2010
Note
♦ It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension.

1 - Cross member for steering

column
⇒ page 305
3 - Bolt
❑ 20 Nm
4 - Steering column
5 - Bolt
❑ 20 Nm
6 - Crash bar for brake pedal
7 - Crash bar for clutch pedal
8 - Bolt
❑ 30 Nm
moving
9 - Anti-vibration brace
❑ Remove with mounting
bracket ⇒ page 305 .
10 - Bolt
❑ 20 Nm
11 - Bolt
❑ 20 Nm
3.1 Removing and installing steering rack to

model year 2010
3. Assembly overview - steering columns up to model year 2010 295

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Removing
WARNING
The following are prerequisites before starting work on the

electrical system and removing the steering wheel:
♦ Earth strap disconnected from battery ⇒ Rep. gr. 27 ;
Battery; Disconnecting and reconnecting battery .
♦ The wheels must be in straight-ahead position.
Failure to comply with these precautions may lead to subse‐
quent failure of the airbag system!
– Remove driver side airbag unit ⇒ Rep. gr. 69 ; Airbag; Re‐

moving and installing driver side airbag unit .
– Separate connectors -1 and 2- for coil connector.

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– Turn steering wheel to centre position (wheels straight ahead).

– Remove bolt -3- and remove steering wheel from steering col‐
umn.
Installing
– Push steering wheel onto steering column.
– Centre markings of steering wheel and steering column
-arrows- must align.

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– Guide connector for steering angle sender - G85- into intended

opening in the base of steering wheel.
– Join connector -1- with connector -2- of steering angle sender
- G85- .
– Secure steering wheel with bolt -3-.
Specified torque
Steering wheel to steering column 30 Nm + 90° further
♦ Always renew bolt
3.2 Removing and installing steering col‐

umn to model year 2010

Touran 2003 ➤
Removing
Only the complete steering column is supplied as a replacement
part. Repair is not possible.
Steering lock housing can be transferred ⇒ Electrical system;
Rep. gr. 94 ; Ignition switch and lock cylinder .
WARNING
The following are prerequisites before starting work on the

electrical system and removing the steering wheel:
♦ Mechanic must electrostatically discharge himself/herself.
This can be done by touching earthed metal such as a
water pipe, a heating pipe, metal girders or a lifting plat‐
form ⇒ page 294 .
Failure to comply with this precaution may lead to subsequent
failure of the electronic steering column lock control unit -
J764- !
♦ Unbolt the earth strap from the battery ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Battery; Disconnecting and connecting
battery .
– Turn wheels to straight-ahead position.

– Pull down lever beneath steering column.
– Pull steering column down as far as possible and out.
– Remove steering wheel. ⇒ Rep. gr. 69 ; Removing and in‐
stalling steering wheel

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– Remove steering column switch trim; ⇒ Rep. gr. 68 ; Com‐

partments, covers and trims; Removing and installing steering
column switch trim .
– Remove driver side storage compartment. ⇒ Rep. gr. 68 ;
Compartments, covers and trims; Removing and installing
driver side storage compartment
– Remove dash panel insert ⇒ Rep. gr. 90 ; Dash panel insert;
Removing and installing dash panel insert .
– Remove steering column switch ⇒ Rep. gr. 94 ; Steering col‐
umn switch; Removing and installing steering column switch .
– Disconnect earth wire -1- from steering column.
– Unclip cable -2-.
Caution


Touran 2003 ➤
– First remove securing bolt -arrow- for fuse box then remove
bolts -1-.
Vehicles with crash bars
– Unscrew screws -2-.
– Remove bolt -1- and remove crash bar for clutch pedal -2-.
– Remove bolt -3- and remove crash bar for brake pedal -4-.
– Carefully pull out steering column upwards.
Installing
– Align steering column to mounting bracket.

When positioning, align hole -arrow A- with pin arrow B.

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– Tighten steering column bolts -1-.

Vehicles with crash bars
– Tighten steering column bolts -2-.
– Fit crash bar for clutch pedal -2- and tighten bolt -1-.
– Fit crash bar for brake pedal -4- and tighten bolt -3-.
– Tighten fuse holder securing bolt -arrows-. ⇒ Rep. gr. 97 ;

Removing and installing fuse holder; Removing and installing
left fuse holder

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– Position universal joint -1- in direction of -arrow- onto steering

pinion.
– Insert new hexagon bolt -arrow- and tighten.
– Clip cable guide -2- to steering column.
– Bolt earth wire -1- to steering column.

– Install steering column switch. ⇒ Rep. gr. 94 ; Steering column
switch; Removing and installing steering column switch
– Install dash panel insert. ⇒ Rep. gr. 90 ; Dash panel insert;
Removing and installing dash panel insert
– Install trim for steering column switch. ⇒ Rep. gr. 68 ; Com‐
partments, covers and trims; Removing and installing steering
column trim
– Install driver side storage compartment. ⇒ Rep. gr. 68 ; Com‐
partments, covers and trims; Removing and installing driver
side storage compartment
– Perform basic setting for steering angle sender - G85- using
⇒ Vehicle diagnostic tester.
Specified torques
♦ Use new bolt
Steering column to mounting bracket 20 Nm
3.3 After the following work, basic settings

for steering angle sender - G85- must be
checked:
♦ If steering angle sender - G85- was removed or renewed;
♦ If steering column was removed or renewed;
♦ If steering column switch was removed or renewed;
♦ If steering lock housing was removed or renewed;

Touran 2003 ➤
♦ If steering rack was removed or renewed;

♦ If steering wheel was repositioned.
3.4 Handling and transporting steering col‐

umn, to model year 2010
WARNING
♦ Adherence to proper steering column handling is essen‐

tial.
♦ Improper handling of steering column may damage the
steering column, leading to safety risks.
Proper steering column handling and transport

♦ Use both hands to transport steering column.
♦ Hold steering column upper jacket tube and in area of upper
universal joint.
Improper handling of steering column

Transportation using the following parts leads to primary steering
column damage:
1- Clamping lever
2- Weight compensation springs
3- Deformation element

Touran 2003 ➤
Improper handling of steering column with safety risks

Following methods of handling will damage universal joint bushes
of lower steering column bearing:
♦ Transporting steering column with one hand on jointed shaft.
♦ Bending joints more than 90°.
3.5 Checking steering column for damage

Visual check
– Check all steering column parts for damage.
Checking function
– Check that steering column turns smoothly and easily.
– Check that steering column can be adjusted in reach and
height.
3.6 Removing and installing mounting

bracket with strut, to model year 2010
Removing
– Remove steering column ⇒ page 298 .
– Remove centre section of bulkhead ⇒ Rep. gr. 50 ; Assembly

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– Remove bolt -arrow- in plenum chamber.
– Remove bolts -arrows- under bracket.
– Remove bolts -arrows-.

– Mounting bracket with strut can now be detached from body.
Installing
– Position mounting bracket, fit all 4 bolts and then tighten bolts
prescribed torque.
– Secure strut to body by tightening bolt -arrow- to prescribed

torque.

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– Now tighten securing bolt for mounting bracket and strut

-arrow- to specified torque.
– Install steering column. ⇒ page 301
– Perform basic setting for steering angle sender - G85- using
Specified torques
Mounting bracket to body 20 Nm
Strut to body 20 Nm

Touran 2003 ➤
4 Steering wheel, steering column,

from model year 2011
4.1 Assembly overview - airbag steering wheel, from model year 2011
1 - Steering column
⇒ page 311
2 - Steering wheel
⇒ page 308
❑ Different versions possi‐
ble. Refer to ⇒ Electron‐
ic parts catalogue
3 - Bolt
❑ 30 Nm + 90°
moving
4.2 Removing and installing airbag and

steering wheel

Touran 2003 ➤

Removing
WARNING
The following conditions must be met before starting work on

the electrical system and removing the steering wheel:
♦ Earth strap must be disconnected from battery ⇒ Rep. gr.
27 ; Battery; Disconnecting and reconnecting the battery .
– Move steering column to middle height position.

– Remove airbag module ⇒ General body repairs, interior; Rep.
gr. 69 ; Passenger protection .
Note
The steering wheel must be removed/installed in the middle po‐

sition (wheels facing straight ahead).
4. Steering wheel, steering column, from model year 2011 309

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– Remove bolt -1-.

– Mark position of steering wheel/steering column with a felt-
tipped pen.
– Pull steering wheel -2- off steering column.
Installing
Make sure that the wheels are pointing straight ahead before fit‐
ting the steering wheel.
– When installing a steering wheel that has been removed,
make sure that the markings on the steering column and steer‐
ing wheel are in line.
– When installing a new steering wheel (without marking), the
steering wheel must be mounted in middle position (steering
wheel spoke must be horizontal and wheels in straight posi‐
tion).
– Install steering wheel.
– Installing airbag module ⇒ General body repairs, interior; Rep.
gr. 69 ; Passenger protection .
– Carry out road test.
– If the steering wheel is skewed, the steering wheel must be
removed again and fitted onto the splines of the steering col‐
umn.
Specified torque

Bolt for steering wheel 30 Nm + 90°
♦ Use new bolt
4.3 Assembly overview - steering column, left-hand drive, from model year 2011
Note
♦ It is not permitted to carry out welding and straightening operations on load-bearing or wheel-guiding sus‐
pension components.

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1 - Assembly carrier with

mounting bracket
2 - Steering column
⇒ page 311
3 - Bolt
❑ 20 Nm
5 - Bolt
❑ 20 Nm
6 - Bolt
❑ 30 Nm
moving

umn, left-hand drive, from model year
2011

Touran 2003 ➤

Removing
part. A repair is not possible.
WARNING

form ⇒ page 294 .
J764- !
battery .

– Pull down lever under steering column.
– Swing steering column down as far as possible and pull out.
– Press lever under steering column back up again.
– Remove airbag in steering wheel ⇒ General body repairs, in‐
terior; Rep. gr. 69 ; Airbag; Removing and installing driver
airbag module .
– Remove steering wheel ⇒ page 308 .
– Remove steering column trim ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments, covers and trims; Removing and
installing steering column trim .
– Remove steering column switch ⇒ Electrical system; Rep. gr.
94 ; Steering column switch; Removing and installing steering
column switch .
– Remove driver side stowage compartment ⇒ General body
repairs, interior; Rep. gr. 68 ; Compartments, covers and

Touran 2003 ➤
trims; Removing and installing driver side stowage compart‐

ment .
Vehicles with ignition/starter switch

– Unclip cable from holder on electronic steering column lock
control unit - J764- -arrow-.
– Remove footwell vent below steering column ⇒ Heating, air
conditioning; Rep. gr. 80 ; Repairing heating .
– Press lugs -arrow- on both sides of cable guide -1- inwards

and pull out cable guide -1- from guide on steering column.

Touran 2003 ➤
Caution

Vehicles with manual gearbox

– Unscrew bolt -1- on left under steering column and remove
crash strut -2- for clutch pedal.
– Remove screw -2-.

– Unscrew bolt -1- on right under steering column and remove
crash strut -3- for brake pedal.
– Remove earth wire from steering column -arrow-.

– Unscrew bolts -1-, holding steering column -2- while doing so.

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– Lower steering column -1- slightly and carefully pull column

out of guides on mounting bracket -arrow-.
Caution
Take great care to ensure the steering column is handled and

transported correctly ⇒ page 323 .
Installing
– Hook steering column -1- with lug into guide on mounting

bracket -arrow-.
When positioning, align holes -arrows A- with pins -arrows B-.
The correct installation position of the steering column relative to
the mounting bracket is guaranteed only in this way.
– Locate steering column -2- with bolts -1-.

– Screw on earth cable for steering column -arrow-.
– Position universal joint -1- in direction of -arrow- onto steering

pinion.
– Insert new hexagon bolt -arrow- and tighten.
– Install footwell vent below steering column ⇒ Heating, air con‐
ditioning; Rep. gr. 80 ; Repairing heating .

Touran 2003 ➤

– Connect connector -1-.

– Clip cable into holder on electronic steering column lock con‐
trol unit - J764- -arrow-.
– Install driver side stowage compartment ⇒ General body re‐
pairs, interior; Rep. gr. 68 ; Compartments, covers and trims;
Removing and installing driver side stowage compartment .
– Install steering column switch ⇒ Electrical system; Rep. gr.
column switch .
– Install steering column trim ⇒ General body repairs, interior;
– Install steering wheel ⇒ page 308 .
– Install airbag in steering wheel ⇒ General body repairs, inte‐
rior; Rep. gr. 69 ; Airbag; Removing and installing driver airbag
module .
– Carry out basic setting for steering angle sender - G85- using
Specified torques
♦ Use new bolt
4.5 Assembly overview - steering column, right-hand drive, from model year
2011
Note
♦ It is not permitted to carry out welding and straightening operations on load-bearing or wheel-guiding sus‐
pension components.

Touran 2003 ➤
1 - Bolt
❑ 20 Nm
2 - Assembly carrier
3 - Anti-vibration brace
4 - Bolt
❑ 20 Nm
6 - Bolt
❑ 20 Nm
7 - Bolt
❑ 30 Nm
moving
9 - Bolt
❑ 20 Nm
10 - Bolt
❑ 20 Nm
11 - Steering column
⇒ page 317

umn, right-hand drive from model year
2011

Touran 2003 ➤

Removing
part. A repair is not possible.
WARNING

form ⇒ page 294 .
J764- !
battery .

– Pull down lever under steering column.
– Swing steering column down as far as possible and pull out.
– Press lever under steering column back up again.
– Remove airbag in steering wheel ⇒ General body repairs, in‐
terior; Rep. gr. 69 ; Airbag; Removing and installing driver
airbag module .
– Remove steering wheel ⇒ page 308 .
– Remove steering column trim ⇒ General body repairs, interior;
– Remove steering column switch ⇒ Electrical system; Rep. gr.
column switch .
– Remove driver side stowage compartment ⇒ General body
repairs, interior; Rep. gr. 68 ; Compartments, covers and

Touran 2003 ➤
trims; Removing and installing driver side stowage compart‐

ment .

– Unclip cable from holder on electronic steering column lock
control unit - J764- -arrow-.
– Remove footwell vent below steering column ⇒ Heating, air
conditioning; Rep. gr. 80 ; Repairing heating .
– Press lugs -arrow- on both sides of cable guide -1- inwards

and pull out cable guide -1- from guide on steering column.
– Remove footwell trim ⇒ General body repairs, interior; Rep.
gr. 68 ; Compartments, covers and trims; Removing and in‐
stalling footwell trim .
– Unscrew nut -1-.

– Pull out pin -2- and remove entire clip.
– Push up footwell trim -3- in -direction of arrow- and remove.

Touran 2003 ➤
– Remove bolt -1- for universal joint and pull universal joint -2-
off steering rack.
Caution

Vehicles with manual gearbox

– Unscrew bolt -1- on left under steering column and remove
crash strut -2- for clutch pedal.

– Unscrew bolt -2- on right under steering column and remove
crash strut -3- for brake pedal.

Touran 2003 ➤
– Remove earth wire from steering column -arrow-.

– Unscrew bolts -1-, holding steering column -2- while doing so.
– Lower steering column -1- slightly and carefully pull column

out of guides on mounting bracket -arrow-.
Caution
Take great care to ensure the steering column is handled and

transported correctly ⇒ page 323 .
Installing
– Hook steering column -1- with lug into guide on mounting

bracket -arrow-.
When positioning, align holes -arrows A- with pins -arrows B-.
The correct installation position of the steering column relative to
the mounting bracket is guaranteed only in this way.
– Locate steering column -2- with bolts -1-.

– Screw on earth cable for steering column -arrow-.

Touran 2003 ➤
– Fit universal joint -2- onto steering rack pinion and tighten bolt
-1-.
– Install footwell vent below steering column ⇒ Heating, air con‐
ditioning; Rep. gr. 80 ; Repairing heating .


– Clip cable into holder on electronic steering column lock con‐
trol unit - J764- -arrow-.
– Install driver side stowage compartment ⇒ General body re‐
pairs, interior; Rep. gr. 68 ; Compartments, covers and trims;
Removing and installing driver side stowage compartment .
– Install footwell trim ⇒ General body repairs, interior; Rep. gr.
68 ; Compartments, covers and trims; Removing and installing
footwell trim .
– Install steering column switch ⇒ Electrical system; Rep. gr.
column switch .
– Install steering column trim ⇒ General body repairs, interior;
– Install steering wheel ⇒ page 308 .
– Install airbag in steering wheel ⇒ General body repairs, inte‐
rior; Rep. gr. 69 ; Airbag; Removing and installing driver airbag
module .
Specified torques
♦ Use new bolt

Touran 2003 ➤
4.7 Handling and transporting steering col‐

umn, from model year 2011
WARNING
♦ Adherence to proper steering column handling is essen‐

tial.
♦ Improper handling of steering column may damage the
steering column, leading to safety risks.
Proper steering column handling and transport

♦ Use both hands to transport steering column.
♦ Hold steering column upper jacket tube and in area of upper
universal joint.
Improper handling of steering column

Transportation using the clamping lever leads to primary steering
column damage.

Touran 2003 ➤
Improper handling of steering column with safety risks

Following methods of handling will damage universal joint bushes
and lower steering column bearing:
♦ Transporting steering column with one hand on jointed shaft.
♦ Bending joints more than 90°.
4.8 Checking steering column for damage

Visual check
– Check all steering column parts for damage.
Checking function
– Check that steering column turns smoothly and easily.
– Check whether steering column can be moved in the longitu‐
dinal direction and vertically.

Touran 2003 ➤
5 Electromechanical steering rack, left-

hand drive up to model year 2008
5.1 Assembly overview - electromechanical steering rack, left-hand drive (1st

and 2nd generations) up to model year 2008
Note
♦ In some cases, no 2nd generation steering racks are available as spare parts.
♦ If no 2nd generation steering rack is available in ETKA, then a new 3rd generation steering rack must be
fitted.
♦ In addition, the electrical wiring harness from the electrics box to the steering rack will then also have to be
renewed. This must also be selected when placing an order via the ⇒ Electronic parts catalogue “ETKA” .
♦ The electrical wiring harness will be delivered with the cable for the service interval display.
♦ In vehicles without a service interval display, the unused 3-pin connector must be sealed by a flat contact
housing with connector position assurance - 1J0 973 803- ⇒ Electronic parts catalogue “ETKA” .
Caution

5. Electromechanical steering rack, left-hand drive up to model year 2008 325

Touran 2003 ➤
1 - Universal joint
2 - Hexagon bolt
❑ 30 Nm
moving
3 - Wire
4 - Power steering rack
❑ With power steering
control unit - J500-
❑ With electromechanical
power steering motor -
V187-
❑ With steering moment
sender - G269-
❑ Can be tested in Guided
Fault Finding using
tester
⇒ page 327
❑ Observe notes
⇒ page 325
6 - Nut
❑ M12 x 1.5
❑ Self-locking
moving
7 - Subframe with brackets
8 - Bolt
❑ Always renew clamp for steering rack
9 - Shield
10 - Bolt
❑ 6 Nm
❑ Self-locking

Touran 2003 ➤
5.2 Removing and installing steering rack, left-hand drive vehicle (1st and 2nd
generations) up to model year 2008

equipment required
1331-
1332-
V.A.G 1383 A-

Touran 2003 ➤
Removing steering rack
Note
♦ In some cases, no 2nd generation steering racks are available

as spare parts.
♦ If no 2nd generation steering rack is available in ETKA, then
a new 3rd generation steering rack must be fitted.
♦ In addition, the electrical wiring harness from the electrics box
to the steering rack will then also have to be renewed. This
must also be selected when placing an order via the ⇒ Elec‐
♦ The electrical wiring harness will be delivered with the cable
for the service interval display.
♦ In vehicles without a service interval display, the unused 3-pin
connector must be sealed by a flat contact housing with con‐
nector position assurance - 1J0 973 803- ⇒ Electronic parts
catalogue “ETKA” .
– Disconnect battery. ⇒ Rep. gr. 27 ; Battery; Disconnecting

and reconnecting battery
Caution


Touran 2003 ➤
ly.
Caution
nut.

bolts -14-.


Touran 2003 ➤
– Unscrew bolts -5- and -6- for steering rack.

– Fix position of subframe and brackets ⇒ page 14

subframe

Touran 2003 ➤
– Remove bolts -9- and -10- and lower subframe with bracket
slightly. Observe electrical wiring.
– Remove heat shield -1- over steering rack.


– Unclip all remaining cable clips on steering rack.
– Disconnect all electrical connections on steering rack.
A- far enough that the steering rack can be removed.

Touran 2003 ➤
– Set steering rack down as illustrated.

This prevents damage to the control unit -1-.
Installing steering rack
Threaded sleeves of steering rack must seat in holes in left brack‐
et.
Note

Before inserting subframe bolts, position steering rack on sub‐

frame and insert bolts for steering rack and anti-roll bar.
– Connect electrical connections to steering rack.
Note
– Bolt universal joint to steering rack.

– Connect battery. ⇒ Rep. gr. 27 ; Battery; Disconnecting and
reconnecting battery
– Carry out basic setting for -G85 steering angle sender- using
After installation, check position of steering wheel during road
test.
If a new steering mechanism has been fitted, the wheels must be
aligned.
– Check wheel alignment ⇒ page 257 .
If a new steering rack has been installed, the power steering con‐
trol unit - J500- must be adapted using ⇒ Vehicle diagnostic
tester.
– Perform basic setting for power steering control unit - J500-
using ⇒ Vehicle diagnostic tester.

Touran 2003 ➤
Note
♦ If parking aid 2 is fitted in the vehicle, the power steering con‐

trol unit - J500- must be recoded following the installation of a
new steering rack ⇒ Vehicle diagnostic tester.
♦ Parking aid 2 is fitted only in vehicles having 2nd generation
steering racks.
Specified torques
♦ Use new bolts

♦ Use new bolts

♦ Use new bolts

♦ Use new nuts

link
♦ Use new nuts

♦ Use new bolts
♦ Always renew clamp

♦ Use new bolt
Shield to steering rack 6 Nm


♦ Use new bolts


Touran 2003 ➤
Caution
⇒ Rep. gr. 34 .
boxes.

♦ Use new bolt

♦ Use new bolt

♦ Use new bolt

♦ Use new bolt

Touran 2003 ➤

hand drive, model year 2009 to model
year 2010
6.1 Assembly overview - electromechanical steering rack, left-hand drive (3rd

generation), model year 2009 to model year 2010
Caution

1 - Wire
2 - Universal joint
3 - Bolt
❑ M8 x 35
❑ 30 Nm
moving
4 - Torx screw
❑ 6 Nm
❑ Self-locking
5 - Shield
V187-
❑ With steering torque
sender - G269-
❑ With steering angle
sender - G85-
Fault Finding using
tester
⇒ page 336
7 - Left wheel bearing housing
8 - Nut
❑ M12 x 1.5
❑ Self-locking
9 - Bolt
6. Electromechanical steering rack, left-hand drive, model year 2009 to model year 2010 335
Touran 2003 ➤
10 - Subframe
11 - Right wheel bearing housing
6.2 Removing and installing steering rack, left-hand drive (3rd generation),
model year 2009 to model year 2010

equipment required
1331-
1332-
V.A.G 1383 A-
Removing steering rack

– Disconnect battery. ⇒ Rep. gr. 27 ; Battery; Disconnecting
and reconnecting battery

Touran 2003 ➤
Caution

ly.
Caution
nut.
Touran 2003 ➤

bolts -14-.


Touran 2003 ➤


subframe
Touran 2003 ➤


– Disconnect all electrical connections on steering rack.
A- far enough that the steering rack can be removed.

Touran 2003 ➤

Installing steering rack
Threaded sleeves of steering rack must seat in holes in left brack‐
et.
Note


– Connect electrical connections to steering rack.
Note

– Connect battery. ⇒ Rep. gr. 27 ; Battery; Disconnecting and
reconnecting battery
– Carry out basic setting for -G85 steering angle sender- using
test.
aligned.
tester.
Specified torques
♦ Use new bolts
Touran 2003 ➤

♦ Use new bolts

♦ Use new bolts

♦ Use new nuts

link
♦ Use new nuts

♦ Use new bolts

♦ Use new bolt


♦ Use new bolts


M10 x 35 50 Nm + 90° further
♦ Use new bolt
M10 x 75 50 Nm + 90° further

♦ Use new bolt

Touran 2003 ➤

hand drive from model year 2011
7.1 Assembly overview - electromechanical steering rack, left-hand drive (APA)

from model year 2011
Caution

1 - Universal joint
2 - Bolt
❑ M8 x 35
❑ 30 Nm
moving
V187-
sender - G269-
Fault Finding using
tester
⇒ page 344
5 - Nut
❑ M12 x 1.5
❑ Self-locking
moving
6 - Bolt
moving
7 - Subframe
8 - Nut
❑ M12 x 1.5
❑ Self-locking
7. Electromechanical steering rack, left-hand drive from model year 2011 343
Touran 2003 ➤
10 - Heat shield
11 - Torx bolt
❑ 6 Nm
❑ Self-locking
12 - Wire
7.2 Removing and installing steering rack, left-hand drive vehicle (APA) from
model year 2011

equipment required
1331-
1332-
V.A.G 1383 A-
Removing
– Switch off ignition and open driver’s door so that the steering
lock engages.

Touran 2003 ➤

– Disconnect battery ⇒ Rep. gr. 27 ; Battery; Disconnecting and
reconnecting battery .
Caution


– Raise vehicle.
ly.
Caution
nut.
Touran 2003 ➤

bolts -14-.
– Remove bolts -arrows- on heat shield, if fitted.

– Remove heat shield from subframe, if fitted.

Touran 2003 ➤

– Separate connector for extended service intervals on oil sump.

subframe
slightly. In the process, observe electrical wiring.
Touran 2003 ➤
– Unscrew bolts -arrows- and remove heat shield -1- above

steering rack.

– Separate connectors -1- and -2- from steering rack.

– Lower subframe carefully with engine/gearbox jack - V.A.G
1383 A- .
– Lift off steering rack from subframe and remove to right.
– Position steering rack as shown in diagram.

Installing

Touran 2003 ➤
– Check that white pressure diaphragm -arrow- is clean and un‐

damaged.
– Clean pressure diaphragm carefully if necessary.
Note
Renew steering rack if pressure diaphragm is damaged.
Touran 2003 ➤
– Plug in connectors -1- and -2- so they audibly engage

Threaded sleeve of steering rack must be located in subframe
hole.
Note

♦ After fitting the steering rack to the universal joint ensure that
the seal is not kinked against the assembly plate on the steer‐
ing rack. The opening to the footwell must be sealed correctly.
Otherwise, this can result in water leaks and/or noise.

– Connect battery ⇒ Rep. gr. 27 ; Battery; Disconnecting and
test.
aligned.
If new steering rack has been installed, adapt electromechanical
power steering using ⇒ Vehicle diagnostic tester.
– Adapt electromechanical power-assisted steering using ⇒ Ve‐
hicle diagnostic tester.
Running gear (repair group 01; 40...49)
Electromechanical power steering
01 - self-diagnosis-capable system (APA-BS)
Electromechanical steering system
Function
Adapting electromechanical steering
Specified torques
♦ Use new bolts
Heat shield to subframe 6 Nm


Touran 2003 ➤

♦ Use new bolts

♦ Use new bolt
Heat shield to steering rack 6 Nm


♦ Use new bolts


M10 x 35 50 Nm + 90° further
♦ Use new bolt
M10 x 75 50 Nm + 90° further

♦ Use new bolt
Touran 2003 ➤
8 Electromechanical steering rack,

right-hand drive up to model year
2008
8.1 Assembly overview - electromechanical steering rack, right-hand drive ve‐

hicle (2nd generation) up to model year 2008
Note
♦ In some cases, no 2nd generation steering racks are available as spare parts.
♦ If no 2nd generation steering rack is available in ETKA, then a new 3rd generation steering rack must be
fitted.
♦ In addition, the electrical wiring harness from the electrics box to the steering rack will then also have to be
renewed. This must also be selected when placing an order via the ⇒ Electronic parts catalogue “ETKA” .
♦ The electrical wiring harness will be delivered with the cable for the service interval display.
♦ In vehicles without a service interval display, the unused 3-pin connector must be sealed by a flat contact
housing with connector position assurance - 1J0 973 803- ⇒ Electronic parts catalogue “ETKA” .
Caution


Touran 2003 ➤
1 - Universal joint
2 - Bolt
❑ M8 x 35
❑ 30 Nm
moving
3 - Wire
4 - Shield
5 - Torx screw
❑ 6 Nm
❑ Self-locking
6 - Clip
moving
7 - Rubber mounting
V187-
❑ With steering moment
sender - G269-
⇒ page 354
❑ Observe notes
⇒ page 352
9 - Web part
11 - Nut
❑ M12 x 1.5
❑ 50 Nm
❑ Self-locking
12 - Subframe
13 - Bolt
❑ M10 x 70
8. Electromechanical steering rack, right-hand drive up to model year 2008 353

Touran 2003 ➤
8.2 Removing and installing steering rack, right-hand drive vehicle (2nd gen‐
eration) up to model year 2008

equipment required
1331-
1332-
V.A.G 1383 A-

Touran 2003 ➤
Removing
Note
♦ In some cases, no 2nd generation steering racks are available

as spare parts.
♦ If no 2nd generation steering rack is available in ETKA, then
a new 3rd generation steering rack must be fitted.
♦ In addition, the electrical wiring harness from the electrics box
to the steering rack will then also have to be renewed. This
must also be selected when placing an order via the ⇒ Elec‐
♦ The electrical wiring harness will be delivered with the cable
for the service interval display.
♦ In vehicles without a service interval display, the unused 3-pin
connector must be sealed by a flat contact housing with con‐
nector position assurance - 1J0 973 803- ⇒ Electronic parts
catalogue “ETKA” .

off steering rack.
Caution


Touran 2003 ➤
ly.
Caution
nut.
– Remove hexagon nut -1- from coupling rod (left and right
sides).

bolts -14-.

Touran 2003 ➤


Touran 2003 ➤


subframe

Touran 2003 ➤


– Separate connectors from steering rack.
– Lower subframe carefully using engine and gearbox jack -
V.A.G 1383 A- .
– Now lift anti-roll bar -1- forwards over subframe -2- and down
while turning anti-roll bar slightly.
– Unbolt steering rack from subframe.

Touran 2003 ➤

Installing
hole.
Note

♦ After fitting the steering rack to the universal joint, make sure
that the seal is not kinked when lying against the assembly
plate and that the opening to the footwell is correctly sealed.

test.
aligned.
tester.
Note
If parking aid 2 is fitted in the vehicle, the power steering control

unit - J500- must be recoded ⇒ Vehicle diagnostic tester.
Specified torques
♦ Use new bolts

Touran 2003 ➤

♦ Use new bolts

♦ Use new bolts

♦ Use new nuts

link
♦ Use new nuts

♦ Use new bolts
♦ Always renew clamp

♦ Use new bolt


♦ Use new bolts

Caution
⇒ Rep. gr. 34 .
boxes.

♦ Use new bolt

♦ Use new bolt

♦ Use new bolt

Touran 2003 ➤

♦ Use new bolt

Touran 2003 ➤

hand drive from model year 2009
9.1 Assembly overview - electromechanical steering rack, right-hand drive (3rd

generation) from model year 2009
Caution

1 - Universal joint
2 - Bolt
❑ M8 x 35
❑ 30 Nm
moving
3 - Wire
4 - Shield
5 - Torx screw
❑ 6 Nm
❑ Self-locking
V187-
sender - G269-
❑ With steering angle
sender - G85-
⇒ page 364
8 - Nut
❑ M12 x 1.5
❑ Self-locking
9 - Bolt
Touran 2003 ➤
10 - Subframe
9.2 Removing and installing steering rack, 3rd generation, RHD vehicles, as of
model year 2009

equipment required
1331-
1332-
V.A.G 1383 A-
Removing
– Remove footwell trim ⇒ General body repairs, interior; Rep.
gr. 68 ; Compartments, covers and trims; Removing and in‐
stalling footwell trim .

Touran 2003 ➤

– Push up footwell trim -3- in -direction of arrow- and remove.
off steering rack.
Caution


– Raise vehicle.
ly.
Caution
nut.
Touran 2003 ➤

bolts -14-.


Touran 2003 ➤


subframe
Touran 2003 ➤
– Unscrew bolts -arrows- and remove heat shield -1- above

steering rack.

– Separate connectors from steering rack.

– Lower subframe carefully using engine and gearbox jack -
V.A.G 1383 A- .
– Lift off steering rack from subframe and remove to right.

Touran 2003 ➤
– Position steering rack as shown in diagram.

Installing
hole.
Note

♦ After fitting the steering rack to the universal joint, make sure
that the seal is not kinked when lying against the assembly
plate and that the opening to the footwell is correctly sealed.

test.
aligned.
tester.
Note
If parking aid 2 is fitted in the vehicle, the power steering control

unit - J500- must be recoded ⇒ Vehicle diagnostic tester.
Specified torques
♦ Use new bolts
Touran 2003 ➤

♦ Use new bolts

♦ Use new bolts

♦ Use new nuts

link
♦ Use new nuts

♦ Use new bolts

♦ Use new bolt


♦ Use new bolts


M10 x 35 50 Nm + 90° further
♦ Use new bolt
M10 x 75 50 Nm + 90° further

♦ Use new bolt

Touran 2003 ➤
10 Differentiating between 1st and 2nd

generation steering racks
At the start of production of the Touran 2004 ►, the 1st generation
steering rack was fitted. During the 2004 model year, this was
replaced with the 2nd generation steering rack.
Vehicles fitted with a 1st generation steering rack can be retrofit‐
ted with a 2nd generation steering rack ⇒ page 373 .
To identify the type of steering rack while it is fitted, count the
number of screws on the steering pinion bearing cover.
– Raise vehicle.
– Turn steering in both directions to count the number of screws
-1-.
The 1st generation steering rack has 4 bolts for the bearing cover
and the 2nd generation steering rack has 2.
The figure shows a 1st generation steering rack.
Continuation with 1st generation steering rack ⇒ page 374 .
Continuation with 2nd generation steering rack ⇒ page 379 .
10. Differentiating between 1st and 2nd generation steering racks 371
Touran 2003 ➤
11 Differentiating between 2nd and 3rd

generation steering racks
From model year 2009, a new, 3rd generation, steering rack is
being used. It replaces the 2nd generation steering rack.
To identify the type of steering rack while it is fitted, count the
number of bolts with which the steering rack is attached to the
subframe.
– Raise vehicle.
The 2nd generation steering rack is attached to the subframe with
4 bolts and the 3rd generation steering rack is attached with 3.

Touran 2003 ➤
12 Exchanging 1st generation steering

rack for 2nd generation steering rack
Note
♦ There are no new 1st generation steering racks available as

parts for renewing 1st generation steering racks.
♦ Therefore, 2nd generation steering racks must be fitted.
♦ For some vehicles, a few other parts in addition to the steering
rack must be exchanged. Which vehicles are affected and the
procedure to be followed are described below.
The parts in the following list must be renewed when a 1st gen‐
eration steering rack is exchanged:
♦ The wiring harness generally must be exchanged.
♦ Subframes from Part No. 1K0.199.369 through and including
1K0.199.369.E. must be exchanged. Subframes from Part No.
1K0.199.369.F need not be exchanged. To order parts via the
⇒ Electronic parts catalogue “ETKA” , the assembly
1K0.199.313 must be ordered with the respective index.
♦ For left-hand-drive vehicles, the right bracket from Part No.
1K0.199.296 through and including 1K0.199.296.C must be
exchanged. Brackets from Part No. 1K0.199.296.D need not
be exchanged.
♦ For right-hand-drive vehicles, the left bracket from Part No.
1K0.199.295 through and including 1K0.199.295.C must be
exchanged. Brackets from Part No. 1K0.199.295.D need not
be exchanged.
The allocation of the respective parts can be determined in the ⇒
Electronic parts catalogue “ETKA” .
Note
♦ If parking aid 2 is fitted in the vehicle, the power steering con‐

trol unit - J500- must be recoded ⇒ Vehicle diagnostic tester.
♦ Parking aid 2 is fitted only in vehicles having 2nd generation
steering racks.
12. Exchanging 1st generation steering rack for 2nd generation steering rack 373
Touran 2003 ➤
13 Repairing electromechanical 1st

generation steering rack
At present, there is no provision for performing repairs on the 1st
generation steering rack.
13.1 Removing and installing bellows

equipment required
1275-
1332-
♦ Insert tool, 24 mm - V.A.G
1332/11-
♦ Locking pliers for Phaeton
steering rack - VAS 6199-
Removing
Note
If boot is defective, moisture and dirt will enter steering rack.

There must be a palpable film of grease in the area of the teeth
on the steering rack. If there is no film of grease, the steering rack
must be renewed. Also renew steering rack if there are signs of
corrosion, damage or wear to the steering rack.
– Turn steering wheel to straight-ahead position.

– Remove wheel.
– Clean outside of steering rack in vicinity of boot.

Touran 2003 ➤
No dirt must be allowed to enter the steering rack through a de‐

fective rubber boot during this operation.
– Mark position of nut -3- on steering rack.
– Loosen nut -3- while counterholding on head of track rod -2-.
– Loosen spring-type clip -1- from boot using hose clip pliers -
V.A.G 1275- and push onto track rod.
– Remove clamp and pull boot from steering rack housing.
– Now turn track rod out of track rod ball joint.
– Pull boot with spring-type clip off track rod.
Note
♦ If the steering rack shows signs of corrosion, damage, wear or

soiling, renew the complete steering rack.
♦ Likewise, if there is no film of grease on the steering rack, the
steering rack must be renewed.
Installing
Caution
Do not grease steering rack.
– Thread new clamps and rubber boot onto track rod.

– Screw in track rod to mark made during removal.
– Tighten lock nut -3- to specified torque while counterholding

track rod ball joint -2-.
– Lightly lubricate seal point between boot and track rod with
grease - G 052 168 A1- (from repair kit Fuchs Renolit JP1619).
– Push rubber boot -2- onto track rod -1- as shown in figure.
– Secure spring-type clip on rubber boot using hose clip pliers -
V.A.G 1275- .
– Lightly lubricate seal point between boot and steering rack with
– Push rubber boot onto steering rack housing to stop.
13. Repairing electromechanical 1st generation steering rack 375

Touran 2003 ➤
– Install new clamp, as shown in figure, with locking pliers for

Phaeton steering rack - VAS 6199- .
Wheel alignment must be checked following installation.
– Carry out basic setting of steering angle sender - G85- using
⇒ Vehicle diagnostic tester ⇒ “Guided fault finding” .
– Then carry out basic setting of steering ⇒ Vehicle diagnostic
tester ⇒ “Guided fault finding” .
Specified torques

equipment required
♦ Ball joint puller - 3287 A-
1275-
1332-
♦ Open end spanner insert,
AF 38 mm - V.A.G 1923-

Touran 2003 ➤
Removing track rod

Loosen nut -3- while counterholding on head of track rod -2-.
– Remove front wheel.
ly.
– Press track rod ball joint off wheel bearing housing using ball
joint puller - 3287 A- and now remove nut.
– Loosen spring-type clip (item -1- in figure N44-10005
⇒ page 377 ) on rubber boot using hose clip pliers - V.A.G
1275- and push onto track rod.
– Unscrew track rod from steering rack using open-end insert,

38 mm - V.A.G 1923- .
Note

Installing track rod
Caution

13. Repairing electromechanical 1st generation steering rack 377

Touran 2003 ➤
– Screw track rod into track rod ball joint until dimension -a- is
attained.
Dimension -a- = 371 ± 1 mm
– Screw track rod into steering rack and tighten.
– Push rubber boot -2- onto track rod -1-, making sure that boot
is correctly positioned.
V.A.G 1275- .

– Carry out basic setting of steering angle sender - G85- using
– Then carry out basic setting of steering using ⇒ Vehicle diag‐
nostic tester ⇒ , “Guided fault finding” .
Specified torques
♦ Use new bolts
Track rod to steering rack in steering rack 100 Nm

Touran 2003 ➤
14 Repairing electromechanical 2nd

and 3rd generation steering racks
At present, there is no provision for performing repairs on the 2nd
and 3rd generation steering racks.
14.1 Assembly overview: electromechanical steering rack
1 - Right track rod ball joint

2 - Nut
❑ 70 Nm
3 - Clip
4 - Boot
❑ Must not be twisted after
toe setting has been ad‐
justed.
⇒ page 380
5 - Clamp
❑ Renewing
6 - Track rod
❑ 100 Nm
⇒ page 382
⇒ page 336
8 - Left track rod ball joint
14. Repairing electromechanical 2nd and 3rd generation steering racks 379
Touran 2003 ➤

equipment required
1275-
1332-
1332/11-
Removing boot
Note
If boot is defective, moisture and dirt will enter steering rack.

on the steering rack. If there is no film of grease, the steering rack
must be renewed. Also renew steering rack if there are signs of
corrosion, damage or wear to the steering rack.

– Remove wheel.
– Clean outside of steering rack in vicinity of boots.

Touran 2003 ➤

– Mark position of nut -3- on steering rack.
– Loosen spring-type clip -1- from boot using hose clip pliers -
V.A.G 1275- and push onto track rod.
– Now turn track rod out of track rod ball joint.
– Pull boot with spring-type clip off track rod.
Note

Installing boot
Caution

– Screw in track rod to mark made during removal.
– Tighten lock nut -3- to specified torque while counterholding

track rod ball joint -2-.
V.A.G 1275- .
Touran 2003 ➤

Specified torque for fitting wheels ⇒ page 238 .
– Carry out adaptation of steering angle sender - G85- using
– Then carry out adaptation of steering ⇒ Vehicle diagnostic
Specified torques
14.3 Checking play, security and boots of

track rod ends
– Check play by moving track rods and wheels with the vehicle
raised (wheels hanging free). Clearance: zero clearance
– Check attachment.
– Check boots are not damaged and are seated correctly.

Touran 2003 ➤

equipment required
1275-
1332-
AF 38 mm - V.A.G 1923-
Removing track rod

– Clean outside of steering rack in vicinity of boots.
– Remove front wheel.
ly.
Touran 2003 ➤
– Press track rod ball joint off wheel bearing housing using ball
joint puller - 3287 A- and now remove nut.
– Loosen spring-type clip (item -1- in figure N44-10005
⇒ page 383 ) on rubber boot using hose clip pliers - V.A.G
1275- and push onto track rod.
– Unscrew track rod from steering rack using open-end insert,

38 mm - V.A.G 1923- .
Note

Caution

attained.
Dimension -a- = 371 ± 1 mm
– Turn track rod into steering rack and tighten to specified tor‐
que.
– Position boot -2- on track rod -1-.

V.A.G 1275- .

Touran 2003 ➤

Specified torque for fitting wheels ⇒ page 238 .
– Carry out adaptation of steering angle sender - G85- using
⇒ Vehicle diagnostic tester ⇒ , “Guided fault finding” .
– Then carry out adaptation of steering ⇒ Vehicle diagnostic
Specified torques
Track rod to steering rack 100 Nm
♦ Use new bolts
Touran 2003 ➤
15 Repairing electromechanical steer‐

ing rack, left-hand drive (APA)
Currently, no repairs can be performed on steering racks.
15.1 Assembly overview: electromechanical steering rack, LHD vehicle
1 - Right track rod ball joint

❑ Marked with “A”
⇒ page 391
⇒ page 392
❑ Checking: ⇒ page 397
❑ Installation position
⇒ page 397
2 - Nut
❑ 70 Nm
3 - Clip
4 - Boot
❑ Must not be twisted after
toe setting has been ad‐
justed.
⇒ page 394
5 - Clamp
❑ Renewing
6 - Track rod
❑ 100 Nm
⇒ page 389
7 - Long bonded rubber bush
❑ Left rear with centring.
9 - Long bonded rubber bush
❑ Rear right
10 - Short bonded rubber bush
❑ Front left and right.

Touran 2003 ➤
11 - Locking plate
12 - Left track rod ball joint
❑ Marked with “B” ⇒ page 391
❑ Checking: ⇒ page 397
15.2 Renewing bonded rubber bushes for

power-assisted steering rack
Carry out the following work:

Removing
Note
♦ Always renew bonded rubber bushes in pairs per side of the

vehicle.
♦ Removal and installation are described for only one bonded
rubber bush. The procedure for the second bonded rubber
bush is similar.
♦ Always note allocation of bonded rubber bush to power-as‐
sisted steering rack ⇒ page 388 .
– Remove power steering rack ⇒ page 344 .
15. Repairing electromechanical steering rack, left-hand drive (APA) 387

Touran 2003 ➤
– Fit tools from above as shown in illustration.

1- Nut - T10390/3-
2- Tube - T10390/1-
– Pull out bonded rubber bush.
Allocation of bonded rubber bush to power-assisted steering rack

1- Short bonded rubber bush for front left
2- Short bonded rubber bush for front right
3- Long bonded rubber bush for rear right
4- Long bonded rubber bush for rear left with centring
Installing
– Note allocation of bonded rubber bush to power-assisted
steering rack ⇒ page 388 .
– Coat exterior of bonded rubber bush with soapy water.
– Position the bonded rubber bushes so that the flattened areas

point inwards in parallel -arrows-.
Note
Always draw in bonded rubber bush from above from direction of

steering shaft.

Touran 2003 ➤
– Fit tools as shown in illustration.

1- Nut - T10390/3-
3- Tube - T10390/2-
– Draw bonded rubber bush in to stop until rubber lip has folded
over edge -arrow-.
Note
After releasing assembly tool - T10390- , bonded rubber bush

slides back slightly.
– Place lock plate -1- onto bonded rubber bushes so that edges
and flattened areas engage.
– Secure lock plate -1- in position with a cable tie -2-.
Note
Tighten cable tie as securely as possible so that lock plate does

not slip when installing power-assisted steering rack.
– Install power steering rack ⇒ page 344 .

– Remove cable tie from steering rack.

Touran 2003 ➤

equipment required
1275-
1332-
AF 38 mm - V.A.G 1923-

Removing
– Raise vehicle.
– Remove wheel.
ly.
Caution
– Open clamps and push boot back.

Touran 2003 ➤
– Unscrew track rod.

1- Open-end spanner attachment - V.A.G 1923-
Note


Caution
– Make sure that correct track rod ball joint is installed on each
side.
I - Track rod ball joint on right marked with an “A”
II - Track rod ball joint on left marked with a “B”
attained.
Dimension -a- = 376± 1 mm

Touran 2003 ➤
– Tighten track rod.

1- Open-end spanner attachment - V.A.G 1923-
– Lightly lubricate sealing surface between boot and track rod
with grease - G 052 168 A1- (from repair kit Fuchs Renolit
JP1619).
– Push rubber boot -2- onto track rod -1-, making sure that boot
is correctly positioned.
V.A.G 1275- .
– Lightly lubricate sealing surface between boot and steering
rack with grease - G 052 168 A1- (from repair kit Fuchs Renolit
JP1619).
– Push rubber boot onto steering rack housing as far as it will
go.

– Install front wheel and tighten ⇒ page 238 .
– If both track rods have been renewed, basic setting must be
carried out for steering angle sender - G85- ⇒ Vehicle diag‐
nostic tester ⇒ “Guided fault finding” .
Specified torques
Track rod to steering rack 100 Nm
♦ Use new bolts
15.4 Removing and installing track rod ball

joint

Touran 2003 ➤

Removing
– Raise vehicle.
– Remove wheel.
– Loosen nut -1-.
– Mark position of track rod ball joint on track rod.
– Loosen nut -2- on track rod ball joint but do not remove com‐
pletely.
Caution
– Push track rod off wheel bearing housing and remove nut.
– Unscrew track rod ball joint from track rod.
Installing

Touran 2003 ➤
– Make sure that correct track rod ball joint is installed on each
side.
I - Track rod ball joint on right marked with an “A”
II - Track rod ball joint on left marked with a “B”
– Screw track rod ball joint onto track rod as far as previously
applied mark and secure with lock nut.
– Insert track rod ball joint into wheel bearing housing.
– Bolt track rod ball joint with new nut.
Specified torques
♦ Use new bolts

Touran 2003 ➤

equipment required
1275-
1332-
1332/11-

Removing
Note
♦ If boot is defective, moisture and dirt will enter steering rack.

on the steering rack. If there is no film of grease, the steering
rack must be renewed.
♦ The steering rack must be renewed:
♦ In the event of corrosion.
♦ In the event of damage.
♦ In the event of excessive wear
♦ In the event of soiling on the steering rack.

– Raise vehicle.
– Remove wheel.

Touran 2003 ➤
– Mark position of nut on track rod.

– Remove track rod ball joint ⇒ page 392 .
– Open hose clips.
– Pull boot off steering rack housing and track rod.
Note

Installing
Caution

– Lightly lubricate sealing surface between boot and track rod
with grease - G 052 168 A1- (from repair kit Fuchs Renolit
JP1619).
V.A.G 1275- .
– Lightly lubricate sealing surface between boot and steering
rack with grease - G 052 168 A1- (from repair kit Fuchs Renolit
JP1619).

– Screw in track rod ball joint up to mark made during removal
and install ⇒ page 392 .
– If both track rods have been renewed, basic setting must be
carried out for steering angle sender - G85- ⇒ Vehicle diag‐
nostic tester ⇒ “Guided fault finding” .

Touran 2003 ➤
Specified torques
15.6 Checking play, security and boots of

track rod ends
– Check play by moving track rods and wheels with the vehicle
raised (wheels hanging free). Clearance: zero clearance
– Check attachment.
– Check boots are not damaged and are seated correctly.
15.7 Allocation of track rod ball joints

I - Right track rod ball joint is marked with -A-.
II - Left-hand track rod ball joint is marked with -B-

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Service

Service Department. Technical Information

42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

43 - Self-levelling suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

12.1 Causes of rough running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

1. Checklist for evaluating running gear of accident vehicles 1

♦ Brake system including ABS

2 Rep. gr.00 - Technical data

4 Rep. gr.40 - Front suspension

2 Raising wheel suspension to unladen position

Special tools and workshop

All bolts on running gear components with bonded rubber

To simulate this position on the lifting platform, raise the respec‐

2. Raising wheel suspension to unladen position 5

If the vehicle is not strapped down, there is a danger that the

Running gear 1) Ride height -a- in mm

♦ Never raise or lower the vehicle while the engine and

– Tighten respective nuts and bolts.

Volkswagen Technical Site: https://vwts.ru

6 Rep. gr.40 - Front suspension

3 Overview - front axle

♦ It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension.

I - Assembly overview: sub‐

The chapter “Removing and installing drive shafts” can be found

3. Overview - front axle 7

4 Assembly overview: subframe, anti-roll bar, suspension links

8 Rep. gr.40 - Front suspension

A mixed installation of suspension

4. Assembly overview: subframe, anti-roll bar, suspension links 9

❑ Always renew after removing

❑ Always renew after removing

10 Rep. gr.40 - Front suspension

Distinguishing characteristics of bonded rubber bushes for pen‐

♦ There are two different types of bonded rubber bushes for

4. Assembly overview: subframe, anti-roll bar, suspension links 11

4.1 Assembly overview: front left vehicle level sender - G78-

4.2 Removing and installing front left vehicle

12 Rep. gr.40 - Front suspension

♦ Torque wrench - V.A.G 1331-

To remove front left vehicle level sender - G78- , steering must

– Carry out basic setting of headlights ⇒ Vehicle diagnostic test‐

4.3 Repairing thread in longitudinal member

4. Assembly overview: subframe, anti-roll bar, suspension links 13

4.4 Fixing position of subframe and brack‐

♦ Engine and gearbox jack - V.A.G 1383 A-

Installing locating pins - T10096-

The locating pins - T10096- may be tightened only to a maxi‐

– Replace the mounting bracket securing bolts along both sides

14 Rep. gr.40 - Front suspension

Fixing position of mounting bracket

Fixing position of bracket

Bracket to body 70 Nm + 90°

Mounting bracket to body 70 Nm + 90°

4.5 Lowering subframe

4. Assembly overview: subframe, anti-roll bar, suspension links 15

♦ Locating pins - T10096-

♦ Engine and gearbox jack - V.A.G 1383 A-

16 Rep. gr.40 - Front suspension

The following work must not be performed while the universal

– Remove lower noise insulation ⇒ General body repairs, ex‐

– Detach exhaust system bracket from subframe -arrows-.

– Disconnect pendulum support from gearbox by unscrewing