Service: Touran 2003

Service
Workshop Manual
Touran 2003 ➤
4-cylinder injection engine (1.4 l direct injection
engine, turbocharger)
Engine ID BMY
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Service Department. Technical Information

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00 - Technical data
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10 - Removing and installing engine
13 - Crankshaft group
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15 - Cylinder head, valve gear
17 - Lubrication
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19 - Cooling
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20 - Fuel supply system
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21 - Turbocharging/supercharging
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24 - Mixture preparation - injection

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

No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg K0058972520

Touran 2003 ➤
4-cylinder injection engine (1.4 l direct injection engine, turbocharger) - Edition 01.2006
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.6 Additional notes and assembly work for vehicles with air conditioner . . . . . . . . . . . . . . . . 13
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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a Removing and installing poly V-belt . . .r a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.5 Removing and installing valve timing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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2 Removing and installing sealing flanges and flywheel or drive plate . . . . . . . . . . . . . . . . . . 25

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2.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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2.2 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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2.3 Removing and installing crankshaft pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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2.4 Renewing crankshaft sealing flange - flywheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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4 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

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4.2 Checking piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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1.2 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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1.3 Adjusting valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

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1.4 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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1.5 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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1.6 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
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2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.2 Checking camshaft axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.3 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.4 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.5 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1 Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Contents i
Touran 2003 ➤
1.2 Assembly overview . . . . . . . . . . . . . . . . . . . . . .G.. V. o. lk. s.w.a.ge. n. . . . . . . . . . . . . . . . . . . . . . . . . . 70

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1.3 Removing and installing sump . . . . . o. lk. s.w.ag. . . . . . . . . . . . . . . d.o.es. n.o. . . . . . . . . . . . . . . . . . 72
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1.4 Removing and installing oil pumpsed.by. . . . . . . . . . . . . . . . . . . . . . . . . . .ua. ra. n. . . . . . . . . . . . . . 73
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1.5 Checking oil pressure and oil upressure
tho switch . . . . . . . . . . . . . . . . . . . . . e.e.or. . . . . . . . . . . 76
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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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1 Parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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1.1 Assembly overview - parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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1.2 Assembly overview - parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . 80
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1.3 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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1.4 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
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1.5 Removing and installing radiator fan V7 and radiator fan 2 V177 . . . . . . . . . . . . . . . . . . . . 84
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1.6 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.7 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
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1.8 Removing and installing coolant circulation pump V50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
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20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
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1.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 93
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1.2 Releasing pressure in high-pressure section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
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2 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
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2.3 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

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2.4 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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2.5 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.6 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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3 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.4 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.5 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.6 Crash fuel shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.7 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.8 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.9 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4 Repairing electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.1 Function of EPC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.3 Removing and installing accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
5.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
5.2 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1.2 Part I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.3 Part II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.4 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.5 Checking turbocharger vacuum unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2.1 Assembly overview - compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2.2 Removing and installing compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
ii Contents
Touran 2003 ➤
3 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

3.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
3.2 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

1 Repairing injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
1.1 Parts l and II - assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
1.2 Part I - assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.3 Part II - assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.4 Assembly overview - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.5 Checking vacuum reservoir for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.6 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1.7 Removing and installing air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1.8 Removing and installing regulating flap control unit J808 and throttle valve module J338
........................................................................ 154
1.9 Cleaning throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.10 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.11 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
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1.13 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2.2 Removing and installing anti-theft engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

1 Parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.1 Assembly overview - Gcatalytic
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1.2 Assembly Voverviewwage - silencers with mountings
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Separating
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1 Repairing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

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1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

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1.2 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 174
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1.3 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

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1.4 Spark plug test data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

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Contents iii
Touran 2003 ➤
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iv Contents
Touran 2003 ➤
00 – Technical data
1 Technical data
Engine number ⇒ page 1
Engine data ⇒ page 1
1.1 Engine number

Engine code and engine number can be found on the sticker
-arrow- on the control housing.
The engine code is also on the vehicle data plate and on thewagen AG. Volkswagen AG does
crankcase above the gearbox. olks not
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The engine number consists of up to nine characters ho
ris (alphanu‐ e
meric). The first part (maximum 3 characters) makes
aut up the
or
ac
ss
“engine code”, and the second part (6 characters), the “serial
ce
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number”. If more than 999,999 engines with the same engine

un
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code are produced, the first of the six characters is replaced with
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1.2 Engine data
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Engine code BMY
Manufactured 02.06▸
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Emissions fulfil EU4
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Capacity cm3 1390

Output kW at rpm 103/5600
nform
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Torque Nm at rpm 220/2000-4000

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Bore ∅ mm 76.5
on in
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Stroke mm 75.6
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Compression ratio 10
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Valves per cylinder 4

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RON at least t. Cop 95 unleaded py
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Injection, ignition Motronic MED 9.5.10
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Firing order 1-3-4-2
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Type of mixture formation homogeneous
Lambda regulation yes
Turbocharging/supercharging Turbocharger and mechanical compressor
1. Technical data 1
Touran 2003 ➤
10 – Removing and installing engine

1 Removing and installing engine
Removing engine ⇒ page 3
Securing engine to assembly stand ⇒ page 9
Installing engine ⇒ page 9
Torque settings ⇒ page 11 .
Assembly mountings ⇒ page 12 .
Additional information and removal instructions for vehicles with
air conditioner ⇒ page 13 .
Special tools and workshop

equipment required n AG. Volkswagen AG do
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♦ Engine support -T40075- sed b ua
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♦ Torque wrench (5..0.50 t or
satelettronica
au ac
Nm) -V.A.G 1331- ss
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♦ Engine and gearbox jack -
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♦ Engine and gearbox sup‐
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port -VAS 6095-
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♦ Drip tray for workshop hoist

-VAS 6208- spec
es, in part or in w
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2 Rep. Gr.10 - Removing and installing engine

Touran 2003 ➤
♦ Spring-type clip pliers -VAS

5024A-
♦ Stepladder -VAS 5085-
♦ Torque wrench (40...200
Nm) -V.A.G. 1332-
♦ Guide rods -T10093-
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1.1 Removing engine

ion in
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Before carrying out further work, disconnect battery earth strap. Cop py
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First check whether a coded radio is fitted. Obtain anti-theft code
t
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first if necessary. cop Vo
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Prote AG.
– Release vacuum hose from vacuum reservoir -arrow- and pull
off.
– Raise engine cover at points indicated -1- and pull cover for‐
wards in -direction of arrow-.
1. Removing and installing engine 3

Touran 2003 ➤
– Unbolt heat shield over turbocharger -arrows-.

– Remove the air filter ⇒ page 153
– Open and close expansion tank cap to release pressure in
cooling system.
– Now drain coolant ⇒ page 82 .
Note
Pull cooling system hoses off engine with spring-type clip pliers -
VAS 5024A- .
– Release hose guides -arrows- and remove coolant hose -1-

from coolant reservoir.
– Disconnect fuel supply line -1- and line to activated charcoal

cannister -2-. Press release buttons to do this.
– Seal lines so that fuel system is not contaminated by dirt.
– Observe rules for cleanliness ⇒ page 96 .
satelettronica
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Touran 2003 ➤
– Remove securing bolts -arrows- for engine splash guard.

AG. Volkswagen
– Remove front right andlkleft
swa wheel housing liners:
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body repairs; Rep.d bGr.
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and installing front
orise wheel housing liners . nte
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– Bring lock scarrier
sa into service position ⇒ General body repairs,ac
exterior; Rep. Gr. 50 ; Body, front; Lock carrier - service po‐
ce
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un
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The engine is removed downwards together with the gearbox.
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– Disconnect battery ⇒ Electrical system; Rep. Gr. 27 ; Dis‐
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connecting and connecting battery .
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spec
– Remove battery and battery holder ⇒ Electrical system; Rep.
Gr. 27 ; Removing and installing battery .
t to the co
– All cable ties which are opened or cut through when the engine
is removed must be replaced in the same position when the
rrectne
engine is installed.
– Disconnect all electric wires from gearbox, alternator and
ss
starter and lay to side.
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– Pull off or disconnect all other electrical connections as nec‐
form
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satelettronica
essary from engine and lay to side.
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WARNING
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Fuel supply lines are under pressure! Wear eye protection and cum
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protective gloves to avoid injuries and skin contact. Before

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loosening hose connections, wrap a cloth around the connec‐ Cop py
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tion. Then release pressure by carefully pulling hose off con‐
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– Pull vacuum and breather hoses off engine.

– Pull connectors off thermal switch and radiator fan.
– Remove plenum chamber bulkhead ⇒ General body repairs;
Rep. Gr. 50 ; Body front; Plenum chamber bulkhead .
– Removing and installing anti-theft engine control unit
⇒ page 165 .
– Remove securing nuts -arrows- for engine control unit.

Touran 2003 ➤
4-cylinder injection engine (1.4 l direct
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– Open all cable guide fasteners
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– Remove cable fromauengine
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– Secure cables to engine with a cable tie.
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– Remove cables for lambda probe after catalytic converter -

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G130- and alternator from cable guides -arrows-.
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– Pull connector from lambda probe after catalytic converter -
G130- and remove.
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– Open hose clamp -3- and remove charge air pipe -2-.
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– Unbolt exhaust pipe from main catalytic converter -arrows-.
– Unbolt exhaust pipe with flexible joint -arrows-.

Touran 2003 ➤
– Loosen double clamp securing bolts -arrows- and pull exhaust

pipe backwards.
– Disconnect pendulum support -arrows-.

– Unbolt gear change mechanism from gearbox: ⇒ 6-speed
manual gearbox 02S; Rep. Gr. 34 ; Repairing gear change
mechanism. .
– Remove support -1-.
satelettronica
– Remove slave cylinder -arrows- and lay to side. Do not open
hydraulic system.
– Remove hydraulic clutch slave cylinder: ⇒ 6-speed manual
gearbox 02S; Rep. Gr. 30 ; Repairing clutch mechanism. .
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Clutch pedal must not be depressed. horise nte
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– Remove poly-V-belt ⇒ page 19 .
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– Remove air conditioner compressor ⇒ Heating, air condition‐

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The air conditioning system lines must not be opened.

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– Secure air conditioner compressor to lock carrier.

rrectness of i
– Ensure that lines are not kinked.

l purpos
– Observe additional notes and assembly work ⇒ page 13 .

– Remove right drive shaft, and unbolt left drive shaft from gear‐
nf
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box and tie up: ⇒ Running gear, axles, steering; Rep. Gr. 40 ;
rm
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Repairing drive shafts; Removing and installing drive shafts .

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Touran 2003 ➤
Engine support -T40075- with adapters -/4-, -/5- and -/6- are re‐
quired to lower engine with gearbox.
– Screw adapter T40075/4 into crankcase to stop.

– Position engine support -T40075- with adapters -/5- and -/6-
onto crankcase.
satelettronica
– Secure engine support -T40075- hand-tight to crankcase us‐
ing bolt -1-.
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– Tighten all bolts on engine support -T40075- to 20 Nm.

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Touran 2003 ➤
– Unbolt engine side of assembly mounting from above

-arrows-.
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– Unbolt gearbox side of assembly mounting from above
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♦ To remove securing bolts use stepladder -VAS 5085- .
♦ When lifted out, the assembly must be carefully guided to pre‐
satelettronica
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vent damage to the bodywork.
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– Carefully lower engine with gearbox.
s o
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1.2 Securing engine to assembly stand
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Secure engine to engine and gearbox support -VAS 6095- to car‐
thi
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1.3 Installing engine
Prote AG.
Installation is carried out in the reverse order. When installing,

note the following:
Caution
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant, refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ To avoid damage to lines, ensure sufficient clearance to
all moving or hot components.
– Check clutch release bearing for wear and renew if necessary.

– Lightly grease clutch release bearing, release bearing guide
sleeve and splines on input shaft with G 000 100.
– Check whether dowel sleeves for centring engine/gearbox are
in cylinder block and install if necessary.

Touran 2003 ➤
– Hook intermediate plate onto sealing flange and slide onto

dowel sleeves -arrows-.
– When swinging engine in, ensure that there is clearance be‐
tween drive shafts.
Align engine mounting as follows:
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Touran 2003 ➤
♦ There must be a distance of -a- at least 10 mm between engine

support and longitudinal member (right-side).
♦ The side surface of the engine support -2- should be located
parallel to the support arm -1-.
♦ Ensure that the edges of the support arm (on the gearbox as‐
sembly mounting) -2- and gearbox support -1- are parallel.
– Install pendulum support.
Note
AG. Volkswagen AG d
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Torque settings for engine and gearboxed by V mountings ⇒ page 12 . gu
ara
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– Install drive shafts ⇒ Running
ss a gear, axles, steering; Rep. Gr. ra
c
40 ; Repairing drive shafts; Removing and installing drive
ce
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shafts .
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– Install air conditioning system compressor ⇒ Heating, air con‐
erm
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ditioning system; Rep. Gr. 87 .
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– Install poly-V-belt ⇒ page 19 .
h re
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satelettronica
spec
– Electrical connections and routing ⇒ Electrical system; Rep.
es, in part or in w
Gr. 97 .
t to the co
– Install hydraulic clutch slave cylinder: ⇒ 6-speed manual gear‐
box 02S; Rep. Gr. 30 ; Repairing clutch mechanism. .
rrectness of i
– Install gear change mechanism: ⇒ 6-speed manual gearbox
l purpos
02S; Rep. Gr. 34 ; Repairing gear change mechanism .

– Install engine splash guard.
nform
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– Filling with coolant ⇒ page 82

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– Install air filter ⇒ page 153 .
on
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– Install battery and battery tray ⇒ Electrical system; Rep. Gr.

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ate
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27 ; Removing and installing battery

p
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for
– Connect battery ⇒ Electrical system; Rep. Gr. 27 ; Discon‐

en
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– Connect the vehicle diagnosis and service information system
rig ht
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– Erase learnt values and adapt engine control unit to regulating
value control unit and throttle valve module ⇒ Vehicle diagno‐
sis, testing and information system VAS 5051 “Guided func‐
tion”.
– Carry out the vehicle system test ⇒ Vehicle diagnosis, testing
and information system VAS 5051 “Guided fault finding”.
– Finish the vehicle system test so that any incorrect entries
created during assembly can be deleted automatically.
Observe applicable safety precautions during road test.
– Carry out a road test.
– Then carry out the vehicle system test again and correct any
faults that have been created.
1.4 Torque settings

Threaded connections Torque setting
Bolts, nuts M6 10 Nm
M8 20 Nm
M10 45 Nm

Touran 2003 ➤
Threaded connections Torque setting

M12 60 Nm
Note
Torque settings for engine and gearbox mountings ⇒ page 12 .
1.5 Assembly mountings

Torque settings
Note
Securing bolts for assembly mountings are stretch bolts and must
be renewed.
Engine assembly mounting

A1) = 20 Nm + 90° (1/4 turn) further
satelettronica
B1) = 40 Nm + 90° (1/4 turn) further
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C1) = 60 Nm + 90° (1/4 turn) further lksw
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Gearbox assembly mounting

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A2) = 40 Nm + 90° (1/4 turn) further

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B2) = 60 Nm + 90° (1/4 turn) further

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2) Renew.
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Pendulum support
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A3) = 40 Nm + 90° (1/4 turn) further

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B3) = 100 Nm + 90° (1/4 turn) further

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Touran 2003 ➤
1.6 Additional notes and assembly work for

vehicles with air conditioner
Note
To prevent damage to condenser and also to refrigerant lines/

hoses, ensure that the lines and hoses are not stretched, kinked
or bent.
To facilitate removing and installing engine without opening re‐

frigerant circuit:
– Remove retaining clamp(s) for refrigerant lines.
– Remove poly-V-belt ⇒ page 19 . n AG. Volkswagen AG do
lkswage es n
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– Bring lock carrier into service position ⇒ General bodyiserepairs,
d b ua
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exterior; Rep. Gr. 50 ; Body, front; Lock carrier - service
thor po‐ tee
or
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Touran 2003 ➤
13 – Crankshaft group
1 Dismantling and assembling engine
Note
♦ If metal shavings or larger quantities of metal particles or other

deposits (caused for example, by partial seizure of the conrod
bearings) are found in the engine oil when making repairs,
clean the oil passages thoroughly and renew the oil filter in
order to prevent further damage from occurring later.
AG. Volkswagen AG d
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♦ All bearing and running surfaces must be oiled before assem‐
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Parts l and II - assembly overview ⇒ page 15 ss c
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Part I Assembly overview - belt drive ⇒ page 16
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Part II Assembly overview - cylinder block ⇒ page 17
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Removing and installing poly-V-belt ⇒ page 19
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Removing and installing valve timing housing ⇒ page 22 .
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Note
Secure engine to engine and gearbox support -VAS 6095- to car‐
rrectness of i
ry out repairs.
l purpos
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14 Rep. Gr.13 - Crankshaft group

Touran 2003 ➤
1.1 Parts I and II - assembly overview
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1. Dismantling and assembling engine 15

Touran 2003 ➤
1.2 Part I Assembly overview

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2 - Pulley
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❑ For compressor.
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3 - 23 Nm
rrectness of i
4 - Tensioning element
❑ For compressor poly-V-
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belt.
❑ Slacken with spanner.
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❑ Lock with locking pin -

m
T10060 A- .
satelettronica
com
tion in
5 - 8 Nm
r
te o
thi
s
iva
6 - Coolant pump with magnet‐

do
r
rp
c
ic clutch for supercharger -
um
fo
en
N421-
ng
t.
yi Co
op py
7 - 23 Nm t. C rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote
❑ For poly V-belt.
AG.
❑ Slacken with open-end

spanner, 16 mm -
T10241- .
❑ Lock with locking pin -
T10060 A- .
9 - 23 Nm
10 - Alternator
11 - Pulley
❑ For crankshaft
❑ Contact surfaces must be free of oil and grease.
12 - Securing bolt
❑ Removing and installing crankshaft pulley ⇒ page 29 .
❑ Renew.
❑ Contact surface for securing bolt must be free of oil and grease.
❑ Oil threads before inserting.
❑ Secure pulley against turning with counter-hold tool -3415- .
❑ Turning further can be done in several stages.
❑ The extra turn angle can be checked using a commercial protractor e.g. Hazet 6690.
13 - 20 Nm + 1/4 turn (90°) further
❑ Renew.
❑ Removing and installing from below.

Touran 2003 ➤
14 - Air conditioner compressor.

15 - 25 Nm
❑ For poly V-belt.
❑ Lock with 4 mm Allen key.
17 - Poly-V-belt
❑ Mark direction of rotation before removing.
18 - Poly-V-belt
❑ For compressor.
❑ Mark direction of rotation before removing.
1.3 Part II Assembly overview - cylinder block
1 - Cylinder head with cam‐

shaft housing
satelettronica
❑ Sealing surface must
not be reworked.
❑ With integrated cam‐
shaft bearings.
❑ Remove sealant rem‐
nants.
❑ Coat with
AMV 188 001 02 before
fitting.
❑ When installing, insert
vertically from above so
that dowel pins fit into gen AG
. Volkswagen AG
does
swa
holes in cylinder head. y V olk not
gu
d b ara
e nte
2 - Cylinder block horis
eo
ut ra
❑ Dismantling ands assem‐
s a c
bling cylinder block
ce
e
nl
pt
⇒ page 25
du
an
itte
y li
❑ Dismantling and assem‐

erm
ab
bling pistons and con‐

ility
ot p
rods ⇒ page 41 .
wit
, is n
h re
3 - Bracket
hole
spec
❑ For tensioning element

es, in part or in w
t to the co
and air conditioner com‐

pressor.
4 - Cover
rrectness of i
5 - Sprocket
l purpos
❑ For oil pump drive and

timing chain.
nf
ercia
❑ Contact surfaces must

rm
m
atio
be free of oil and grease.

om
n in
c
6 - 20 Nm + 1/4 turn (90°) fur‐

or
thi
te
sd
a
ther
iv
o
r
rp
cu
o
7 - Sprocket
f
en
ng
t.
yi
❑ Lock sprocket using counter-hold tool -T10172- .
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touran 2003 ➤
8 - Drive chain
❑ Before removing, mark direction of rotation (installation position).
9 - 25 Nm
10 - 15 Nm
11 - Chain tensioner with tensioning plate
❑ For oil pump drive. agen
AG. Volkswagen AG d
oes
olksw not
12 - Tensioning spring byV gu
ara
ed
ris nte
o
13 - Sump aut
h eo
ra
s c
❑ Removing and installing on engines with a liquid gasket ⇒ page 72 . s
ce
le
un
pt
❑ Clean sealing surface before fitting.
an
d
itte
y li
❑ Install with silicone sealant D 176 404 A2.
rm
ab
pe
ility
14 - 15 Nm
ot
wit
, is n
h re
15 - Piston
hole
spec
❑ For drive chain tensioner.
es, in part or in w
t to the co
16 - Spring
satelettronica
17 - Chain tensioner
rrectness of i
18 - 9 Nm
l purpos
19 - Control housing
❑ When installing, install two -M6x80- studs in cylinder block and camshaft housing as a guide.
nform
ercia
❑ To guide valve timing housing better, secure sump in position with two bolts.
m
a
com
tio
20 - 10 Nm
n in
r
te o
thi
21 - Pulley
s
iva
do
r
❑ Observe tightening procedure ⇒ page 29 .

rp
cum
fo
en
g

n
t.
yi Co
op
C py
ht. rig
rig ht
❑ Removing and installing poly-V-belt ⇒ page 19 py by
co Vo
by lksw
cted agen
22 - Securing bolt Prote AG.

❑ Renew.
23 - Mounting bush
24 - O-ring
❑ Renew.
25 - 50 Nm
26 - Gasket
27 - 40 Nm + 1/4 turn (90°) further
❑ Lock chain sprockets using counterhold -T10172- .
❑ Left-hand thread bolt.
❑ Renew.

Touran 2003 ➤
28 - 50 Nm + 1/4 turn (90°) further

29 - Tensioning plate
30 - Camshaft adjuster
❑ Must not be taken apart.
❑ Removing and installing ⇒ page 49 .
31 - Timing chain
AG. Volkswagen AG d
32 - Sprocket wage
n oes
Volks not
gu
❑ For exhaust camshaft. ed
by ara
nte
ris
❑ Lock sprockets using counter-hold
ut tool -T10172- .
ho eo
ra
a c
ss
33 - Guide rail
ce
le
un
pt
❑ For timing chain.
an
d
itte
y li
erm
ab
34 - Guide pins
ility
ot p
❑ Torque setting: 20 Nm.
wit
is n
h re
35 - Mounting bush
ole,
spec
t to the co
satelettronica
1.4 Removing and installing poly V-belt
rrectne
Special tools and workshop equipment required
♦ Mandrel -T10060 A-
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Open-end spanner, 16 mm -T10241-
♦ 4 mm Allen key
Removing
Note
Two tensioning elements must be removed to remove poly-V-belt.

Touran 2003 ➤
– Remove front right wheel housing liner ⇒ General body re‐

pairs, exterior; Rep. Gr. 66 ; Removing and installing wheel
housing liner .
– Mark direction of rotation of poly-V-belt.
– To slacken poly-V-belt, swivel tensioning element in

-direction of arrow- from above using open-end spanner, 16
mm -T10241- .
– Lock tensioning element in position with locking pin -T10060
A- .
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
s c
– To slacken poly-V-belt, swing tensioning element in s
ce
le
-direction of arrow- from below using open-end spanner, 16

un
pt
an
d
mm.
itte
y li
rm
ab
– Lock tensioning element with a 4 mm Allen key -1-.
pe
ility
ot
wit
, is n
– Remove poly-V-belt -2-.
h re
hole
Installing
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ Ensure, before installing poly V-belt, that all ancillaries (alter‐
nator, air conditioner compressor) are secured tightly.
l purpos
♦ When fitting poly-V-belt, check direction of belt rotation and

proper seating of belt in pulleys.
nform
mercia
a
com
– Place poly V-belt on crankshaft pulley first. Finally, push belt

ion in
onto tensioning roller.

r
te o
thi
s
iva
Further assembly is basically the reverse of the dismantling pro‐

do
r
cedure.
rp
cum
fo
en
ng
t.
After completing repairs always:
yi Co
Cop py
t. rig
– Start engine and check belt running. gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touran 2003 ➤
1.4.1 Poly-V-belt routing

Belt drive with air conditioner compressor
1 - Coolant pump pulley
2 - Crankshaft pulley
3 - Tensioning roller
4 - Tensioning roller
5 - Alternator pulley
6 - Air conditioner compressor pulley
7 - Poly-V-belt
Compressor belt drive
Note
♦ Pulley for magnetic clutch for supercharger -N421- is located
satelettronica
behind coolant pump pulley.
♦ Poly-V-belt -4- runs via pulley for magnetic clutch for super‐
charger -N421- .
AG. Volkswagen AG d
1 - Compressor pulley agen oes
olksw not
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b ara
2 - Tensioning roller rise
d
nte
tho eo
3 - Coolant pump pulley with pulley for magnetic
ss au
clutch for super‐ ra
c
charger -N421-
ce
e
nl
pt
du
an
4 - Poly-V-belt
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
1.5 Removing and installing valve timing housing

equipment required
♦ Support bracket -10-222A- AG. Volkswagen AG d
agen oes
lksw not
♦ Adapter -10 - 222 A /22- by Vo gu
ara
d
ise nte
♦ Counterhold tool -3415-uthor eo
a ra
s c
♦ Pins -3415/1- s
ce
e
nl
pt
du
♦ Torque wrench (5..0.50
an
itte
y li
Nm) -V.A.G. 1331-
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
satelettronica
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Torque wrench (40...200 Nm) -V.A.G. 1332-
1.5.1 Removing
– Remove engine splash guard.
pairs, exterior; Rep. Gr. 66 ; Removing and installing wheel
housing liner .

Touran 2003 ➤
– Mark the direction of rotation of the poly-V-belt and remove

belt ⇒ page 19 .
– Turn crankshaft in direction of engine rotation to TDC No. 1
cylinder ⇒ page 47 .
– Drain coolant ⇒ page 82 .
– Remove coolant pump ⇒ page 87 .
– Remove air conditioner compressor from bracket with refrig‐
erant lines still connected ⇒ Heating, air conditioning; Rep.
Gr. 87 .
– Remove bracket for tensioning element and air conditioner
compressor.
– Remove alternator.
– Install support device -10 - 222 A- with adapter -10 - 222 A /
22- as shown and hook into lifting eye. en AG. V
olkswagen AG
wag does
olks not
byV gu
ara
ed nte
ris
tho eo
au ra
c
ss
satelettronica
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Take up weight of engine and remove securing bolts
t to the co
-arrows-.
– Remove sump ⇒ page 72 .
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
– Now remove pulley securing bolt. Hold pulley with counter-

en
ng
t.
yi Co
hold tool -3415- and -3415/1- . . Cop py
rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
ksw
Touran 2003 ➤ by
Vol not
gu
d ara
4-cylinderoinjection
ris
e engine (1.4 l direct injection engine, nte turbocharger) - Edition 01.2006
h eo
aut ra
c
– Remove Allen
ss
head bolts for valve timing housing and hexa‐
ce
gon bolts indicated by -arrows-. e
nl
pt
du
an
itte
y li
– Remove valve timing housing.
erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
Note that crankshaft bearing bush remains in sealing flange.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
1.5.2 Installing
o
m
f
satelettronica
en
ng
t.
yi Co
op
– Clean sealing surfaces carefully. They must be free of oil and C py
t. rig
grease.
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
Note that pulley contact surfaces, securing bolt, bearing bush and
crankshaft sprocket must be free of oil and grease.
– Fit new gasket onto dowel pins.

– When fitting, install two -M6x80- studs into cylinder head and
cylinder block as a guide.
– Fit valve timing housing with crankshaft bearing bush simul‐
taneously onto studs, dowel pins and crankshaft journal.
– Tighten valve timing housing securing bolts evenly and diag‐
onally.
Ensure that valve timing housing is not canted.
Torque settings:
M6 bolt to 10 Nm.
M10 bolt to 50 Nm.
Align engine mounting as follows:
♦ There must be a distance of -a- at least 10 mm between engine
support and longitudinal member (right-side).
♦ The side surface of the engine support -2- should be located
parallel to the support arm -1-.
♦ Ensure that the edges of the support arm (on the gearbox as‐
sembly mounting) -2- and gearbox support -1- are parallel.
Installing crankshaft pulley ⇒ page 29 .
cedure.

Touran 2003 ➤
2 Removing and installing sealing

flanges and flywheel or drive plate
Assembly overview ⇒ page 25
Renewing crankshaft oil seal - belt pulley end ⇒ page 27 .
Removing and installing crankshaft pulley ⇒ page 29 .
Renewing crankshaft sealing flange - flywheel end ⇒ page 31
Crankshaft dimensions ⇒ page 40 .
Caution agen
AG. Volkswagen AG d
oes
o lksw not
y V gu
b ara
The crankshaft must not be removed.rise
d Just loosening the main nte
bearing caps will cause deformation
utho
of the cylinder block bear‐ eo
ra
ing pedestals. This deformation
ss a
will cause a reduction of the c
bearing clearance. Even if the bearing shells are not renewed
ce
le
un
pt
bearing damage could occur due to a different bearing clear‐
an
d
itte
ance.
y li
erm
ab
ility
If the bearing cap bolts are loosened, the cylinder block must
ot p
satelettronica
wit
be replaced complete with the crankshaft.
is n
h re
ole,
Measuring the main bearing clearance is not possible with nor‐
spec
mal workshop equipment.
t to the co
2.1 Assembly overview
rrectnes
Caution
s o
cial p
f in
The crankshaft must not be removed. Just loosening the main
form
mer
bearing caps will cause deformation of the cylinder block bear‐

atio
m
ing pedestals. This deformation will cause a reduction of the

o
n
c
bearing clearance. Even if the bearing shells are not renewed

i
or
n thi
bearing damage could occur due to a different bearing clear‐

te
sd
a
ance.
iv
o
pr
cum
r
fo
If the bearing cap bolts are loosened, the cylinder block must
en
ng
t.
yi
be replaced complete with the crankshaft.
Co
Cop py
t. rig
gh
Measuring the main bearing clearance is not possible with nor‐
ht
pyri by
Vo
o
mal workshop equipment.
c by lksw
cted agen
Prote AG.
Note
Repairing clutch ⇒ Repairing clutch; Rep. Gr. 30 ; Removing and

installing clutch .
2. Removing and installing sealing flanges and flywheel or drive plate 25

Touran 2003 ➤
1 - Securing bolt
❑ Removing and installing
crankshaft pulley
⇒ page 29 .
❑ Renew.
❑ Contact surface for se‐
curing bolt must be free Volkswagen AG
of oil and grease. swagen AG. does
olk not
❑ Oil threads ebefore
d by V in‐ gu
ara
serting. horis nte
eo
ut
❑ Securess pulley against
a ra
c
turning with counter-
ce
e
nl
hold tool 3415.
pt
du
an
itte
y li
❑ The extra turn angle can
erm
ab
be checked using a
ility
ot p
commercial protractor
wit
, is n
e.g. Hazet 6690.
h re
hole
spec
2 - Pulley
es, in part or in w
t to the co
satelettronica
❑ Secure against turning
rrectness of i
with counter-hold tool
3415 when removing
l purpos
and installing.
nf
ercia
poly-V-belt ⇒ page 19
orm
m
atio
3 - Seal
om
n in
c
❑ Renew.
or
thi
te
sd
a
4 - Mounting bush
iv
o
r
rp
cu

o
m
f
en
ng

t.
yi Co
Cop py
.
5 - O-ring
t rig
gh ht
pyri by
Vo
❑ Renew.
co lksw
by
cted agen
Prote AG.
6 - Aluminium cylinder block
7 - 60 Nm + 1/4 turn (90°) further
8 - Flywheel/drive plate
❑ When removing and installing flywheel, lock with counterhold -T10044- .
9 - Intermediate plate
❑ Must seat on dowel sleeves.
❑ Do not damage or bend when assembling.
10 - 12 Nm
❑ Renew.
11 - Sealing flange with sender wheel and oil seal
❑ With engine speed sender -G28- (not illustrated)
❑ Torque setting for engine speed sender -G28- : 5 Nm
❑ Renew sealing flange complete with oil seal and sender wheel only.
❑ Renewing crankshaft sealing flange - flywheel end ⇒ page 31 .

Touran 2003 ➤
2.2 Renewing crankshaft oil seal - belt pulley end

equipment required
♦ Oil seal extractor -3203-
Nm) -V.A.G 1332-
♦ Assembly tool -T10117-
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing
pairs; Rep. Gr. 66 ; Removing and installing wheel housing
rrectness of i
liner; Front wheel housing liner .

l purpos

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

Touran 2003 ➤
AG. Volengine,
kswagen Aturbocharger) - Edition 01.2006
n G do
wage es n
Volks ot g
– Now remove pulley securing bolt. Holded
by pulley with counter- ua
ran
hold tool -3415- and -3415/1- . horis tee
t or
au ac
– Remove centre bolt and remove
ss crankshaft pulley.
ce
le
un
pt
– Screw inner part of oil seal extractor -3203- three turns (ap‐
an
d
itte
prox. 5 mm) out of outer part and lock using knurled screw.
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Lubricate threaded head of oil seal extractor, place it in posi‐
rrectness of i
tion and exerting firm pressure screw it into oil seal as far as
l purpos
possible.
– Loosen knurled screw and turn inner part against crankshaft
nform
ercia
until the oil seal is pulled out.

m
a
– Remove bearing bush from crankshaft journal and clean con‐
com
tio
tact surfaces of crankshaft sprocket and bearing bush.
n in
r
te o
thi
satelettronica
Installing
s
iva
do
r
rp
cum
fo
en
ng
t.
Note
yi Co
Cop py
ht. rig
rig ht
Note that pulley contact surfaces, securing bolt, bearing bush and py by
co Vo
lksw
by
cted agen
Prote AG.
– Push bearing bush onto crankshaft journal.
– Fit sleeve -T10117/2- onto bush and slide oil seal onto bush.
– Remove sleeve -T10117/2- from bush.
– Drive oil seal into valve timing housing to stop using assembly
tool -T10117- and striking evenly with a hammer.
cedure.

Touran 2003 ➤
2.3 Removing and installing crankshaft pulley

equipment required
♦ Torque wrench -V.A.G
1601-
♦ Counterhold tool -3415-
♦ Pin -3415/1- (not illustra‐
ted)
♦ Clamping bolt -T10340-
Nm) -V.A.G 1331-
wage es n
satelettronica
olks ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
io
Removing
n
c
in t
or
his
e
– Loosen pulley securing bolt. Hold pulley with counter-hold tool

at
do
riv
-3415- and -3415/1- .

p
cum
for
en
Installing
ng
t.
yi Co
op py
t. C rig
gh ht
cooling system. pyri by
Vo
co lksw
by
cted agen
– Now drain coolant ⇒ page 82 . Prote AG.

Touran 2003 ➤
– Remove coolant hoses and line guides -arrows-.

– Unscrew securing bolts and remove camshaft cover -1-.
– Unscrew plug from crankcase.

– Screw locating bolt -T10340- into crankcase to stop.
– Tighten locating bolt -T10340- to 30 Nm.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
satelettronica
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
Locating bolt -T10340- blocks crankshaft in direction of engine
wit
is n
h re
rotation.
ole,
spec
t to the co
Note
♦ Note that all contact surfaces from the securing bolt to the
rrectne
♦ Always use a new bolt.
ss o
cial p
f in
Torque setting: 150 Nm + 1/2 turn (180°) further.
form
mer
atio
m
Hold pulley with counter-hold tool -3415- and -3415/1- .

o
n
c
i
or
n thi
e
– Unscrew locating bolt -T10340- from crankcase.

t
sd
iva
o
pr
cum
– Screw plug into crankcase.

r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touran 2003 ➤
Torque setting: 30 Nm.

cedure.
2.4 Renewing crankshaft sealing flange - flywheel end

equipment required
♦ Assembly tool -T10134-
satelettronica
Nm) -V.A.G 1331-
♦ Tool insert 24 mm -V.A.G
1332/11-
♦ Hexagon bolts (Qty. 3)
M6×35 mm
♦ Feeler gauges
♦ Vernier gauge
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
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Cop py
ht. rig
rig ht
py by
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by lksw
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31
Prote AG.
2. Removing and installing sealing flanges and flywheel or drive plate
Touran 2003 ➤
2.4.1 Pressing sealing flange with sender

wheel off crankshaft
Note
♦ For the sake of clarity, the work is performed with the engine
removed.
♦ The procedure is identical whether the engine is installed or
removed.
Procedure
– Remove flywheel or drive plate as applicable.
– Set engine to TDC No. 1 cylinder ⇒ page 47
– Remove engine speed sender -G28- -arrow-.
– Undo sealing flange securing bolts.
satelettronica
Note
olkswagen AG
en AG. V
Sealing flange and sender wheelolkare
swa pressed off the crankshaft
g does
not
together using three M6×35edmm
by bolts.
V gu
ara
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ss
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un
pt
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ab
– Screw three M6×35 mm bolts into threaded holes -arrows- of

ility
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sealing flange.
wit
is n
h re
ole,
– Screw bolts alternately (maximum 1/2 turn (180°) for each bolt)
spec
into sealing flange and press sealing flange together with

t to the co
sender wheel off crankshaft.

rrectness o
cial p
f inform
mer
atio
om
n
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or
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sd
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
2.4.2 Pressing sealing flange with sender

wheel onto crankshaft
Note n AG. Volkswagen AG do

lkswage es n
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byV ua
♦ The sealing flange
ir se with a PTFE seal is equipped with a sealing
d ran
tee
lip support ring.
uth This support ring serves as a fitting sleeve and
o
or
must not sbe
s removed prior to installation.
a ac
ce
le
♦ Sealing flange and sender wheel must not be separated or

un
pt
an
d
turned after removal from packaging.

itte
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erm
ab
♦ The sender wheel is held in its installation position on the as‐
ility
ot p
sembly device -T10134- by a locating pin.
wit
is n
h re
ole,
♦ Sealing flange and seal are one unit and must be replaced
spec
together with the sender wheel only.
t to the co
♦ The assembly device -T10134- is held in its position relative
to the crankshaft by a guide pin inserted into a hole in the
crankshaft.
rrectne
satelettronica
Assembly tool -T10134-
ss o
A - Clamping surface
cial p
f inform
B - Hexagon nut
mer
atio
m
C - Assembly housing
o
n
c
i
or
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D - Locating pin
te
sd
iva
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E - Hexagon socket head bolt

p
cum
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fo
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ng
F - Guide pin for diesel engines (black knob)

t.
yi Co
Cop py
t. rig
G - Guide pin for petrol engines (red knob) opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.
2.4.3 A - Assembling sealing flange with send‐

er wheel on assembly appliance -
T10134-
– Screw in hexagon nut -B- to just before clamping surface -A-
of threaded spindle.

Touran 2003 ➤
– Clamp assembly device -T10134- in a vice on clamping sur‐

face -A- of threaded spindle.
– Press assembly hub -C- downwards so that it lies on hexagon
nut -B- -arrow-.
– Screw hexagon nut onto threaded spindle until inner part of
assembly device and assembly hub are level.
– Remove securing clip -arrow- from new sealing flange.
Note
The sender wheel must not be taken out of the sealing flange or
turned.
satelettronica
– Locating hole -A- on sender wheel -C- must align with marking
-B- on sealing flange.
– Place sealing flange with front side downwards on a clean flat
surface. lkswage es n
ot g
o
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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e
nl
pt
du
an
itte
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ab
ility
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wit
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hole
– Push sealing lip support ring -A- downwards in direction of ar‐

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

Touran 2003 ➤
– Upper edge of sender wheel and front edge of sealing flange

must align -arrows-.
– Place sealing flange with front side on assembly device -

T10134- so that locating pin -A- can be inserted in sender
wheel hole -A-.
Note
Ensure sealing flange lies flat on assembly device.
satelettronica
– Push sealing flange and support ring for sealing lip -B- against
surface of assembly device -T10134- whilst tightening the
three knurled screws -A- so that locating pin cannot slide out
of sender wheel hole.
AG. Volkswagen AG d
Note agen oes
o lksw not
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When installing sealing flange, ensure
thor that sender wheel remains eo
fixed in assembly device. ss au ra
c
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
2.4.4 B - Attaching assembling tool -T10134-

wit
, is n
h re
with sealing flange to crankshaft flange

hole
spec
es, in part or in w
• Crankshaft flange must be free of oil and grease.

t to the co
• Engine positioned at TDC No. 1 cylinder

– Screw hexagon nut -B- to end of threaded spindle.
rrectness of i
– Press threaded spindle of assembly tool -T10134- in direction

l purpos
of arrow, until hexagon nut -B- lies against assembly hub -A-.
– Align flat side of assembly housing on sump side of crankcase
nf
ercia
sealing surface.
rm
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atio
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Cop py
ht. rig
rig ht
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by lksw
cted agen
Prote AG.

Touran 2003 ➤
– Secure assembly tool -T10134- to crankshaft flange using

hexagon socket head bolts -A-.
Note
Screw hexagon socket head bolts -A- into crankshaft flange (ap‐
prox. 5 full turns).
– To guide sealing flange, screw two M6 × 35 mm bolts -A- into

cylinder block.
satelettronica
olkswagen AG
en AG. V
2.4.5 C - Bolting assembly tool -T10134-olks
wag onto does
not
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crankshaft flange or
ise
d b ara
nte
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ut ra
– Push assembly hub -C- by hand in direction
ss
a of arrow until c
sealing lip support ring -B- contacts crankshaft -A-.
ce
e
nl
pt
du
an
– Push guide pin for petrol engines (red knob) -F- into hole in
itte
crankshaft. This ensures that the sender wheel reaches its fi‐ y li
erm
ab
nal installation position. ility
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wit
, is n
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hole
spec
Note
es, in part or in w
t to the co
The guide pin for diesel engines (black knob) -D- must not be
inserted in threaded hole of crankshaft.
rrectness of i
– Hand tighten both hexagon socket head bolts of assembly

l purpos
tool.
– Screw hexagon nut -E- onto threaded spindle by hand until it
nf
ercia
is in contact with assembly hub -C-.

orm
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om
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thi
te
sd
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touran 2003 ➤
2.4.6 D - Pressing sender wheel onto crank‐

shaft flange using assembly tool -
T10134-
Volkswa
– Tighten hexagon nut of assembly tool -T10134-
agen to 35 Nm us‐
AG. gen AG
does
ksw
ing torque wrench -V.A.G 1331- and y tool
Vol insert AF 24 -V.A.G not
gu
1332/11- . edb ara
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tho eo
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c
s
Note
ce
le
un
pt
an
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itte
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After hexagon nut is tightened to 35 Nm torque, a small air gap
erm
ab
must be present between cylinder block and sealing flange.
ility
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wit
is n
h re
ole,
spec
t to the co
2.4.7 E - Checking sender wheel installation
rrectne
position on crankshaft
satelettronica
– Screw hexagon nut -E- to end of threaded spindle.
ss o
cial p
f
– Remove the two bolts -A- from cylinder block.
inform
mer
– Screw the three knurled screws -B- out of sealing flange.
atio
om
– Remove assembly tool -T10134- .
n
c
i
or
n thi
e
– Remove sealing lip support ring.

t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– The sender wheel is in the correct installation position on the

crankshaft if a gap -a- = 0.5 mm exists between crankshaft
flange -A- and sender wheel -B-.
– Set vernier gauge on crankshaft flange.

– Measure distance -a- between crankshaft flange and sender
wheel.
If measurement -a- is too small:
– Re-press sender wheel ⇒ page 38 .
If dimension -a- is attained:
– Tighten new securing bolts for sealing flange to 15 Nm using
alternate and diagonal sequence.

Touran 2003 ➤
– Install engine speed sender -G28- -arrow- and tighten secur‐

ing bolt to 5 Nm.
– Install sump ⇒ page 72 .
– Install intermediate plate.
– Install flywheel using new bolts. Tighten securing bolts to 60
Nm +1/4 turn (90°).
2.4.8 F - Re-pressing sender wheel

– Secure assembly tool -T10134- to crankshaft flange using
hexagon socket head bolts -A-.
– Hand tighten both hexagon socket head bolts.
– Push assembly tool -T10134- by hand to sealing flange.
satelettronica
– Screw hexagon nut -E- onto threaded spindle by hand until it
is in contact with assembly hub -C-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
– Tighten hexagon nut of assembly tool -T10134- to 40 Nm us‐

ab
ility
ing torque wrench -V.A.G 1331- and tool insert AF 24 -V.A.G

ot p
wit
1332/11- .
, is n
h re
hole
– Check installation position of sender wheel on crankshaft

spec
again. ⇒ page 37
es, in part or in w
t to the co
If dimension -a- is too small again:

– Tighten hexagon nut for assembly tool -T10134- to 45 Nm.
rrectness of i
– Check installation position of sender wheel on crankshaft

l purpos
again ⇒ page 37 .
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
38
by lksw
cted agen
Rep. Gr.13 - Crankshaft group Prote AG.
Touran 2003 ➤
3 Crankshaft
3.1 Assembly overview - crankshaft
1 - 50 Nm + 1/4 turn (90°) fur‐

ther
❑ Only tighten to 50 Nm
when measuring crank‐
shaft radial clearance.
Do not turn further.
2 - Bearing cap
❑ Do not interchange
bearing caps (mark allo‐
cation)
❑ Bearing cap 3 with re‐
cesses for thrust wash‐
ers.
satelettronica
❑ Bearing shell retaining
lugs in cylinder block
and bearing caps must
align.
3 - Crankshaft
❑ Axial clearance new:n AG. Volkswagen AG
0.07...0.18 mm ksw
age does
not
y Vol gu
❑ Wear limit:
ised b 0.20 mm ara
n
r tee
ho
Check radial
au clearance with
t or
ac
ss
Plastigage.
ce
le
un
pt
❑ New: 0.03...00.08 mm
an
d
itte
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❑ Wear limit: 0.17 mm

erm
ab
ility
ot p
❑ Do not rotate crankshaft

wit
is n
when checking radial

h re
clearance.
ole,
spec
❑ Crankshaft dimensions
t to the co
⇒ page 40 .
4 - Sealing flange with sender
wheel and oil seal
rrectne
❑ With engine speed

sender -G28- (not illustrated)
ss o
❑ Torque setting for engine speed sender -G28- : 5 Nm

cial p
f inform
❑ Renew sealing flange complete with oil seal and sender wheel only.
mer
atio
❑ Renewing crankshaft sealing flange - flywheel end ⇒ page 31 .

om
n
c
5 - 12 Nm
or
n thi
te
sd
a
❑ Renew.
iv
o
pr
cum
r
fo
6 - Thrust washers
en
ng
t.
yi
❑ For bearing cap 3.
Co
Cop py
t. rig
❑ Note fixing arrangement.
gh ht
pyri by
Vo
o
by c lksw
7 - Bearing shell cted agen
Prote AG.
❑ In cylinder block.
8 - Sprocket
❑ For oil pump drive and timing chain.
3. Crankshaft 39
Touran 2003 ➤
9 - Bearing shell
❑ In bearing cap.
❑ Do not interchange used bearing shells (mark).
3.2 Crankshaft dimensions

Honing Crankshaft Conrod
dimension in mm main journal ∅ journal ∅
Basic dimension -0.022 -0.022
54.00 47.80
-0.037 -0.037
1st undersize -0.022 -0.022
53.75 47.75
-0.037 -0.037
2nd undersize --- -0.022
47.50
-0.037
AG. Volkswagen AG d
satelettronica
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
4 Dismantling and assembling pistons

and conrods
Checking piston ⇒ page 42
wage es n
Checking cylinder bores ⇒ page olks
y V43 .
ot g
b ua
ed ran
Piston and cylinder dimensions
tho
ris ⇒ page 43 . tee
or
au ac
4.1 Assembly overview ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
All bearing and running surfaces must be oiled before assembly.
h re
hole
spec
es, in part or in w
t to the co
1 - Circlip
2 - Piston pin
rrectness of i
satelettronica
❑ If difficult to remove,
heat piston to 60 °C.
l purpos
❑ Remove and install with

drift -10 - 14- .
nform
ercia
3 - Piston
m
at
om
i
❑ Checking ⇒ page 42 .
on
c
in t
or
❑ Mark installation posi‐

his
ate
tion and cylinder num‐ do

priv
ber.
um
for
en
g
❑ Arrow on piston crown

n
t.
yi Co
op
points to pulley end. C py
t. rig
gh ht
❑ Install using piston ring yri
p by
co Vo
clamp.
by lksw
cted agen
Prote AG.
4 - Compression rings
❑ Offset gaps by 120°
❑ Remove and install
compression rings with
piston ring pliers.
❑ “TOP” faces towards
piston crown.
❑ Checking ring gap
⇒ page 42
❑ Checking ring-to-groove
clearance ⇒ page 42
5 - Oil scraper rings
❑ Carefully remove and
install 3-part oil scraper
rings by hand.
❑ Checking ring gap
⇒ page 42
❑ Ring-to-groove clear‐
ance cannot be measured.
6 - Conrod bolt
❑ M7×0.75: 20 Nm + 1/4 turn (90°) further.
❑ M8×1: 30 Nm + 1/4 turn (90°) further.
4. Dismantling and assembling pistons and conrods 41

Touran 2003 ➤
4-cylinder injection engine (1.4 w
l direct
agen injection engine,
AG. Volkswagen AG d turbocharger) - Edition 01.2006
oe
olks s no
yV t gu
❑ Renew. ed b ara
nte
ris
❑ Oil threads and contact
au
thosurface. eo
ra
ss c
❑ To measure radial clearance, tighten to corresponding specified torque but not further.
ce
e
nl
pt
du
7 - Conrod bearing cap
an
itte
y li
❑ Caps fit only in one position and only on the corresponding con-rod due to breaking procedure (cracking)
erm
ab
ility
for separating cap from con-rod.
ot p
wit
, is n
❑ Mark with cylinder number before removing -A-.
h re
hole
❑ Installation position: Mark -B- points to pulley side (mark before removing if mark is missing).
spec
es, in part or in w
8 - Bearing shell
t to the co
❑ Do not interchange used bearing shells.
❑ Insert bearing shells centrally.
rrectness of i
Checking radial clearance with Plastigage:
l purpos
❑ New: 0.020...0.060 mm
❑ Wear limit: 0.090 mm
nform
ercia
❑ Do not rotate crankshaft when checking radial clearance

m
at
om
io
9 - Conrod
n
c
in t
or
his
e
❑ Renew as set only.
satelettronica
at
do
riv
❑ Mark with cylinder number -A-.

p
cum
for
en
g
❑ Installation position: Mark -B- points to pulley side (mark before removing if mark is missing).
n
t.
yi Co
op
❑ Guided axially by piston.
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
4.2 Checking piston
♦ External micrometer 75...100 mm
Checking piston
– Measure pistons approx. 12 mm from the lower edge of skirt,
at 90° to the piston pin axis. Difference between actual and
nominal diameter: not more than 0.04 mm. Nominal dimension
⇒ page 43
Checking piston ring gap

– Push ring squarely from above down into cylinder bore to ap‐
prox. 15 mm from bottom end of cylinder.
Piston ring New Wear limit
dimensions in mm
1st compression ring 0.20...0.50 1.0
2nd compression ring 0.40...0.60 1.0
Oil scraper ring 0.20...1.10 ---4)
4) No wear limit details

Touran 2003 ➤
Checking ring-to-groove clearance

Clean groove before check.
Piston ring New Wear limit
dimensions in mm
1st compression ring 0.04...0.08 0.15
2nd compression ring 0.02...0.06 0.15
Oil scraper ring Cannot be measured
4.2.1 Checking cylinder bores

♦ Internal dial gauge 50...100 mm
Checking cylinder bores
– Take measurements at 3 positions in both lateral -A- and lon‐
gitudinal -B- directions. Difference between actual and nomi‐
satelettronica
nal diameter: not more than 0.08 mm.
– Nominal dimension ⇒ page 43
Note
Cylinder bores must not be measured when cylinder block is

mounted on engine and gearbox support -VAS 6095- , as meas‐
urements may be incorrect.
AG. Volkswagen AG d
agen oes
ksw
4.3 Piston and cylinder dimensions ol not
V gu
d by ara
ise nte
or eo
h
Honing dimen‐ Piston ∅5) Cylinder
aut bore ∅ ra
c
sion ss
ce
e
nl
pt
Basic dimen‐ mm 76.455 76.51

du
an
itte
sion
y li
erm
ab
1st oversize mm 76.705 76.76

ility
ot p
wit
, is n
2nd oversize mm 76.955 77.01

h re
hole
spec
5) Measured approx. 12 mm from bottom of piston skirt

es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
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thi
te
sd
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en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
43
agen
Prote AG.
4. Dismantling and assembling pistons and conrods
Touran 2003 ➤
15 – Cylinder head, valve gear

1 Cylinder head
Note
♦ When installing an exchange cylinder head, all the contact

surfaces between the support elements, roller rocker arms
and the cams must be oiled before installing the camshaft
housing.
♦ The plastic packing pieces for protecting the open valves must
not be removed until immediately before fitting cylinder head.
♦ If the cylinder head is renewed, all the coolant in the system AG. Volkswagen AG d
must also be renewed. lksw
agen oes
not
Vo gu
y
♦ All bearing and running surfaces must be oiled before assem‐ d b ara
rise nte
bly. utho eo
ra
s a c
♦ Dismantling and assembling intake manifold ⇒ page 147 . s
satelettronica
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
Checking valve timing ⇒ page 47 .
ot p
wit
, is n
Adjusting valve timing ⇒ page 49
h re
hole
spec
Removing and installing camshaft housing ⇒ page 55 .
es, in part or in w
t to the co
Removing and installing cylinder head ⇒ page 58 .
Checking compression ⇒ page 61
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
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thi
te
sd
iva
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f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
44 Rep. Gr.15 - Cylinder head, valve gear

Touran 2003 ➤
1 - 8 Nm
2 - High-pressure pump
❑ For fuel supply.
❑ With fuel pressure regu‐
lating valve -N276- .
⇒ page 114 .
3 - Cable guide
❑ Bolt to camshaft hous‐
ing with 8 Nm torque.
4 - To air filter
5 - 10 Nm
6 - Hall sender -G40-
❑ With O-ring
❑ O-ring, renew if dam‐
satelettronica
aged
7 - Stud, 6 Nm
8 - 10 Nm + 1/4 turn (90°) fur‐
ther
❑ Renew.
❑ Tighten from inside out‐
wards.
9 - Camshaft housing
⇒ page 55 .
❑ Remove sealant rem‐ olkswage es n
ot g
nants. d by
V ua
ran
e
ris
❑ Carefully clean tsealing tee
ho or
surfaces. They
ss
au
must be ac
oil and grease free.
ce
e
nl
pt
du
❑ Coat with
an
itte
y li
AMV 188 003 A1 before fitting.

erm
ab
ility
❑ When installing, fit vertically from above onto studs and dowel pins.
ot p
wit
, is n
10 - 20 Nm
h re
hole
spec
11 - Lifting eye
es, in part or in w
t to the co
12 - Turbocharger
13 - Oil pressure switch -F1- , 25 Nm
rrectness of i
l purpos
❑ If sealing ring is leaking, nip open and renew.

14 - Cylinder head gasket
nf
ercia
❑ Renew.
orm
m
atio
❑ Metal gasket
om
n in
c
❑ If renewed, change coolant in entire system.

or
thi
te
sd
a
15 - Cylinder head
iv
o
r
rp
cu

o
m
f
en
ng
t.
❑ Check for distortion ⇒ page 46 .
yi Co
Cop py
❑ Sealing surfaces to camshaft housing must be oil and grease free.
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Cylinder head 45
Touran 2003 ➤
❑ If renewed, change coolant in entire system.
16 - Guide pins
17 - Dowel pin
18 - Support element
❑ Do not interchange.
❑ With hydraulic valve clearance compensation.
❑ Oil contact surface.
19 - Roller rocker finger
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❑ Check roller bearing for ease ofAG
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❑ When installing, ut
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❑ Renew.
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❑ Note installation instructions and sequence when loosening and tightening ⇒ page 58 .
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21 - Roller tappet
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❑ Coat contact surface lightly with engine oil.
h re
hole
spec
22 - O-ring
es, in part or in w
t to the co
❑ Renew.
❑ Moisten with oil before inserting.
rrectness of i
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Checking cylinder head for distortion

Max. permissible distortion: 0.05 mm.
nform
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Prote AG.

Touran 2003 ➤
1.2 Checking valve timing

equipment required
♦ Spark plug spanner -3122
B-
Nm) -V.A.G 1331-
♦ Dial gauge -VAS 6079-
♦ Puller -T10094-
♦ Dial gauge adapter -
T10170-
♦ Camshaft clamp -T10171-
AG. Volkswagen AG d
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t to the co
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mer
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i
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Test procedure
pr
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fo
en
ng

t.
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Cop py
– Remove spark plug from No. 1 cylinder. Use puller -T10094-
t. rig
gh ht
yri
and spark plug wrench 3122 B.
p by
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by lksw
cted agen
– Screw dial gauge adapter -T10170- into spark plug hole to
Prote AG.
stop.
– Screw dial gauge -VAS 6079- and extension -T10170/1- in to
stop and lock in position with lock nut -arrow-.
– Turn crankshaft in direction of engine rotation, to TDC No. 1
cylinder. Note position of small needle on dial gauge.
1. Cylinder head 47
Touran 2003 ➤
The holes -arrows- in the camshaft must align as shown. Other‐

wise turn crankshaft one rotation (360°) further.
Note
♦ If crankshaft is turned more than 0.01 mm past TDC, then turn

crankshaft back 45° against engine direction of rotation. Then
turn crankshaft in direction of engine rotation to TDC No. 1
cylinder.
♦ Permissible deviation from TDC No. 1 cylinder: ±0.01 mm.
– Insert camshaft clamp -T10171- to stop in camshaft openings.

Locking pins -arrows 1- must engage in holes -arrows 2-. Inscrip‐
tion “TOP” -arrow 3- must be readable from above.
If camshaft clamp -T10171- cannot be fitted into camshaft open‐
ings to stop, then timing is incorrect and must be readjusted
⇒ page 49 .
Timing is OK. when camshaft clamp -T10171- can be fitted into
satelettronica
camshaft openings to stop.
cedure. In the process, note the following:
♦ Renew oil seals for camshaft sealing cover and oil them before
fitting.
AG. Volkswagen AG d
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t to the co
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Prote AG.

Touran 2003 ➤
1.3 Adjusting valve timing

equipment required
♦ Dial gauge -VAS 6079-
♦ Puller -T10094-
T10170-
♦ Counterhold tool -T10172-
♦ Locking pin -T40011-
satelettronica
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erm
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
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or c
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sd
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Cop py
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Prote AG.
1. Cylinder head 49
Touran 2003 ➤
♦ Torque wrench -V.A.G

1601-
♦ Counterhold tool -3415-
♦ Clamping bolt -T10340-
Nm) -V.A.G 1331-
B-
satelettronica
AG. Volkswagen AG d
agen oes
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nl
pt
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nf
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Procedure
or
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– Remove valve timing housing ⇒ page 22 .

iv
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rig ht
py by
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by lksw
cted agen
Prote AG.

Touran 2003 ➤
– To turn crankshaft, reinstall bearing bush, crankshaft pulley

-2- and crankshaft bolt -3- and securely tighten crankshaft bolt
(use counter-hold tool 3415).
– Remove spark plug from No. 1 cylinder. Use puller -T10094-
and spark plug socket and extension 3122 B.
– Screw dial gauge adapter -T10170- into spark plug hole to

stop.
– Screw dial gauge -VAS 6079- and extension -T10170/1- in to
stop and lock in position with lock nut -arrow-. gen AG. Volkswagen AG d
a oes
lksw not
– Turn crankshaft in direction of enginedrotation,
by
Vo to TDC No. 1 gu
ara
cylinder. Note position of small needle
or
is on dial gauge.
e nte
eo
h
ut ra
– Then turn crankshaft back 45°sopposite
sa direction of engine ro‐ c
satelettronica
tation.
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nl
pt
du
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itte
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erm
ab
ility
ot p
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– Press tensioning guide rail -1- in direction of arrow and lock
hole
spec
piston with locking pin -T40011- .
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
te
– Mark direction of rotation of timing chain -3- using coloured felt

a
do
riv
tip marker pen.

p
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for
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op py
Note
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Camshaft adjuster centre bolt -2- has a left-hand thread. cted agen
Prote AG.
– Remove bolts -2- and -4- and remove camshaft adjuster -1-
with timing chain -3-. Counterhold using counter-hold tool -
T10172- .
– Install camshaft adjuster -1- again.
– Renew bolts -2- and -4-. Tighten bolt -2- to 40 Nm and bolt
-4- to 50 Nm (use counterhold -T10172- ).
1. Cylinder head 51
Touran 2003 ➤
– Turn inlet and exhaust camshafts until camshaft clamp -

T10171- can be pushed into holes in camshaft to stop.
Locking pins -arrows 1- must engage in holes -arrows 2-. Inscrip‐
tion “TOP” -arrow 3- must be readable from above.
Note
Camshafts must not be pushed axially whilst turning.
– Install a M6 bolt -arrow- hand tight (do not tighten) to secure

camshaft clamp -T10171- .
– Remove camshaft sprocket bolts. It is absolutely necessary to
use counter-hold tool -T10172- for this.
Note
satelettronica
Camshaft clamp -T10171- must not be used as a counter-hold
tool.
– Remove one camshaft sprocket.

– Place timing chain over camshaft sprockets, observing chain
direction of rotation, and install camshaft sprocket again.
– Tighten camshaft bolts until camshaft sprockets can still just
be turned on camshafts.
– Tension timing chain by removing locking pin -T40011- .
. Volkswag
– Turn crankshaft in engine direction
ksw
agen of rotation toAG
AG en
TDC
does No. 1
cylinder. Permissible deviation
y Vol
from TDC No. 1 cylinder: ±0.01
not
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Note
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If crankshaft is turned more than 0.01 mm past TDC, then turn

rm
ab
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crankshaft back 45° against engine direction of rotation. Then turn

ility
ot
crankshaft in direction of engine rotation to TDC No. 1 cylinder.

wit
, is n
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spec
es, in part or in w
t to the co
– Remove plug -arrow- from crankcase.

rrectness of i

l purpos

nform
mercia
a
com
tion in
r
te o
thi
s
iva
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rp
cum
fo
en
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t.
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Cop py
t. rig
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pyri by
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cted agen
Prote AG.

Touran 2003 ➤
Locating bolt -T10340- blocks crankshaft in direction of engine

rotation.
lkswage es n
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rm
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– Hold camshaft sprockets -1- and -5- in this position with coun‐
pe
ility
terhold tool -T10172- then tighten bolt -2- (left-hand thread) to
ot
wit
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40 Nm and bolt -4- to 50 Nm.
h re
hole
spec
es, in part or in w
Note
t to the co
Crankshaft must not move and timing chain -3- must remain ten‐
sioned on both sides when tightening camshaft bolts.
rrectness of i
satelettronica
l purpos
– Remove camshaft clamp -T10171- .
nform
mercia
– Unscrew locating bolt -T10340- from crankcase. a

com
tion in
r
– Turn crankshaft two rotations in direction of engine rotation to

te o
thi
TDC No. 1 cylinder. Permissible deviation from TDC No. 1

s
iva
do
cylinder: ±0.01 mm.

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cum
fo
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t. rig
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pyri by
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cted agen
Prote AG.
– Insert camshaft clamp -T10171- to stop in camshaft openings.

If camshaft clamp -T10171- cannot be fitted
– Repeat adjustment.
If camshaft clamp -T10171- can be fitted
1. Cylinder head 53
Touran 2003 ➤

AG. Volkswagen AG d
agen oes
olksw not
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nl
– Remove camshaft clamp -T10171- , hold camshaft sprockets
pt
du
an
with counter-hold tool -T10172- and tighten bolts -2- (left-hand
itte
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erm
thread) and -4- a 1/4 turn (90°) further with a rigid wrench.
ab
ility
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Note
hole
spec
es, in part or in w
Camshaft adjuster centre bolt -2- has a left-hand thread.
t to the co
satelettronica
rrectness of i
Note
l purpos
Camshaft sprockets must not move on camshaft whilst tightening.
nf
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Note
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Until crankshaft pulley is installed, locating bolt -T10340- remains
ng
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in crankcase. ht. Cop py
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♦ Installing valve timing housing ⇒ page 24 .
co lksw
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Prote AG.
♦ Installing crankshaft pulley ⇒ page 29 .
♦ Installing poly-V-belt ⇒ page 19 .
♦ Renew oil seals for camshaft sealing cover and oil them before
fitting.

Touran 2003 ➤
1.4 Removing and installing camshaft housing

AG. Volkswagen AG d
Special tools and workshop lksw
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not
equipment required d by
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♦ Dial gauge -VAS 6079- ut
ho eo
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s a c
♦ Puller -T10094- s
ce
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nl
pt
du
an
itte
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T10170-
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
♦ Locking pin -T40011- es, in part or in w
t to the co
rrectness of i
l purpos
satelettronica
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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f
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t.
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Cop py
t. rig
gh ht
pyri by
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by c lksw
cted agen
Prote AG.
1. Cylinder head 55
Touran 2003 ➤
♦ Spark plug spanner -3122 B-

♦ Torque wrench (5..0.50 Nm) -V.A.G 1331-
♦ Two studs (M 6 x 80)
♦ D 188 003 A1 Sealant
1.4.1 Removing
Note
lkswage es n
Vo ot g
♦ The camshaftsedare by mounted in the camshaft housing ua on this
ran
engine. Before or removing camshaft housing, first remove
is tevalve
eo
timing housing
auth
⇒ page 22 . ra
satelettronica
ss c
♦ The camshaft housing sealing surface must not be reworked.
ce
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nl
pt
du
an
♦ Removing and installing camshaft housing ⇒ page 55 .

itte
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erm
ab
ility
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– First check whether a coded radio is fitted. If so, obtain anti-

wit
, is n
theft coding.
h re
hole
spec
– With ignition switched off, disconnect battery earth strap.

es, in part or in w
t to the co

rrectness of i
– Remove coolant hoses and line guides -arrows-.

l purpos
– Unscrew securing bolts and remove camshaft cover -1-.

– Remove valve timing housing ⇒ page 22 .
nf
ercia
orm
– Turn crankshaft to TDC no. 1 cylinder. Then turn crankshaft

m
atio
m
back 45° against engine direction and remove camshaft timing

o
n in
c
sprockets with timing chain ⇒ page 49

or
thi
te
sd
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– Unbolt camshaft covers.

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– Pull connectors off fuel pressure sender, low pressure -G410-

f
en
ng
t.
and off the high-pressure pump.
yi Co
Cop py
t. rig
– Unbolt earth cable from camshaft housing. gh ht
pyri by
Vo
co lksw
by
– Remove ignition coils. Use puller -T10094- for this purpose. Prote
cted AG.
agen
– Remove cable guide with wiring harness from camshaft hous‐

ing.
WARNING
Fuel supply lines are under pressure! Wear eye protection and
loosening hose connections, wrap a cloth around the connec‐
nection.

Touran 2003 ➤
– Pull connector and fuel supply line -arrows- off high pressure
pump.
– Remove wiring guide -2- and take clip -4- off high pressure
line.
Note
Counterhold threaded connections on high pressure pump and

on bottom of intake manifold using wrench when loosening unionagen
AG. Volkswagen AG d
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nuts. not
satelettronica
Vol
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– Loosen union nuts -3- and -1- of high pressureau line.
t or
ac
ss
– Pull connector off Hall sender -G40- .
ce
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nl
pt
du
an
itte
– Pull out oil dipstick.
y li
erm
ab
– Remove lower part of intake manifold ⇒ Item 9 (page 151) .
ility
ot p
wit
, is n
– Remove left lifting eye.
h re
hole
spec
– Loosen camshaft housing bolts from outside to inside, alter‐
es, in part or in w
nately and diagonally and remove.
t to the co
– Carefully lift camshaft housing off.
rrectness of i
1.4.2 Installing
l purpos
Prerequisite
nf
ercia
• The pistons must not be positioned at TDC.
orm
m
– Remove residual sealant on cylinder head and camshaft hous‐ atio

m
ing with a commercially available sealant remover.

o
n in
or c
thi
e
– Prevent dirt and residual sealant from entering cylinder head.

t
sd
iva
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rp
cu
– Clean sealing surfaces carefully. They must be free of oil and

o
m
f
en
grease.
ng
t.
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op py
– Turn inlet and exhaust camshafts until camshaft clamp - t. C rig
gh ht
T10171- can be pushed into holes in camshaft to stop. pyri by
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cted agen
– Secure camshaft clamp -T10171- with an M6 bolt hand tight Prote AG.
(do not tighten).
1. Cylinder head 57
Touran 2003 ➤
– Apply a thin, even coat of sealant to clean camshaft housing

sealing surface. See hatched area on illustration.
Note
The sealant must not be applied too thick; otherwise excess seal‐
ant can enter the oil channels and cause damage to the engine.
AG. Volkswagen AG d
agen o
– Ensure that all roller rocker fingers
yV
olkcontact
sw valve stem endses not g
-1- correctly and that they are
ise
d clipped into their respective
b ua
ran
support elements -2-. thor tee
o
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sa c
– Screw two studs (M6x80)
s into cylinder head before installing
ce
le
camshaft housing.
un
pt
an
d
itte
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rm
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pe
ility
ot
satelettronica
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Carefully fit camshaft housing vertically onto cylinder head
rrectness of i
studs -arrows- and dowel pins from above.
l purpos
Note nform
ercia
Ensure that no oil residue can drip onto sealing surfaces.

m
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tion in
– Evenly tighten new camshaft housing securing bolts from in‐

r
te o
thi
side to outside alternately and diagonally.

s
iva
do
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rp
cum
Ensure that camshaft housing is not canted. Torque setting: 10

fo
en
g
Nm + 1/4 turn (90°) further.

n
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Cop py
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Note
lksw
cted agen
Prote AG.
Sealant must dry for approx. 30 minutes after camshaft housing

is installed.
– Adjust valve timing ⇒ page 49 .

♦ Installing crankshaft pulley ⇒ page 29 .
♦ Attaching fuel lines ⇒ page 114 .
1.5 Removing and installing cylinder head


Touran 2003 ➤
AG. Volkswagen AG d
agen oes
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Note ss a c
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Engine and gearbox must be removed from vehicle to remove the
an
itte
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cylinder head. Secure engine on engine and gearbox support -
erm
ab
VAS 6095- to carry out repairs.
ility
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wit
, is n
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satelettronica
1.5.1 Removing
hole
spec
es, in part or in w
Procedure
t to the co
– Remove gearbox.
– Secure engine on engine and gearbox support -VAS 6095- .
rrectness of i
Remove following components:
l purpos
♦ Intake manifold
nf
ercia
♦ Intake manifold, lower part

orm
m
atio
– Remove thermostat housing from cylinder head.
om
n in
or c
Remove control housing ⇒ page 24

thi
te
sd
iva
– Remove camshaft housing ⇒ page 55 .

o
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rp
cu
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m
f
en
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– Remove roller rocker fingers together with support elements

t.
yi Co
and lay aside on a clean surface. Cop py
ht. rig
rig ht
– Ensure that roller rocker fingers and support elements are not py by
co Vo
lksw
interchanged.
by
cted agen
Prote AG.
– Loosen socket head bolts in sequence given and then remove
completely.
– Carefully remove cylinder head.
1.5.2 Installing
Prerequisite
• The pistons must not be positioned at TDC.
1. Cylinder head 59
Touran 2003 ➤
Note
♦ Do not remove new cylinder head gasket from its packing until
immediately before installing.
♦ Handle new gasket with extreme care. Damage will cause
leakage.
– Place clean cloths in cylinders so that no dirt or emery cloth

particles can get in between cylinder wall and piston.
– Now carefully clean sealing surfaces of cylinder head and cyl‐
inder block. Ensure thereby that surfaces are not scored or
scratched (if abrasive paper is used, grade must not be less
than 100).
– Carefully remove metal particles, emery residue and cloths.
– Set No. 1 cylinder piston to top dead centre and then turn
crankshaft back slightly.
– Fit new cylinder head gasket. Lettering (Part No.) must be
readable.
satelettronica
– Fit cylinder head. When doing this, observe centring pins in
cylinder block.
– Insert new cylinder head bolts and tighten hand-tight.
– Tighten cylinder head bolts in tightening sequence as follows:
– Tighten all bolts to 30 Nm.
– Then tighten all bolts 1/4 turn (90°) further using a rigid wrench.
– Then tighten all bolts again 1/4 turn (90 °) further.
– Install support elements in cylinder head and fit respective

roller rocker finger onto respective valve stem G end and support
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element. lkswagen A does
n o ot g
yV ua
– Install camshaft housing ⇒ page
ise 55 .
db ran
r tee
tho
– Adjust valve timing ⇒ page
s a 49 .
u or
ac
s
ce

le
un
pt

an
d
itte
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erm
ab

ility
ot p
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♦ Attaching fuel lines ⇒ page 114 .

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

lkswage es n
o ot g
byV ua
d ran
ir se tee
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auth or
ac Touran 2003 ➤
ss 4-cylinder injection engine (1.4 l direct injection engine, turbocharger) - Edition 01.2006
ce
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nl
pt
du
an
1.6 Checking compression
itte
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erm
ab
ility
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equipment required
hole
spec
es, in part or in w
t to the co
B-
rrectness of i
Nm) -V.A.G 1331-
l purpos
♦ Compression tester -V.A.G

1763-
nform
ercia
♦ Puller -T10094-
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
. rig
satelettronica
t
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Test prerequisite
• Engine oil temperature must be at least 30 °C.
Procedure
– Remove ignition coils. Use puller -T10094- for this purpose.
– Remove spark plugs using spark plug socket 3122 B.
– Remove fuse for fuel pump control unit from fuse holder on left
under dash panel. Fuse assignment ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations
Note
Removing fuse interrupts voltage supply for fuel pump control

unit.
– Check compression using compression tester -V.A.G 1763- .
1. Cylinder head 61
Touran 2003 ➤
Note
How to use the test unit is described in the respective operating

instructions.
– Operate starter until tester shows no further pressure in‐

crease.
Compression pressures:
New: 10..0.15 bar
Wear limit: 7 bar
Maximum permissible difference between all cylinders: 3 bar
– Insert spark plugs with spark plug spanner 3122B and tighten
to 30 Nm.
cedure.
– Read fault memory, repair faults as necessary and then clear
fault memory ⇒ Vehicle diagnosis, testing and information
satelettronica
system VAS 5051 “Guided fault finding”.
The readiness code will have to be created once the fault memory
has been deleted.
AG. Volkswagen AG d
agen oes
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spec
t to the co
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cial p
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mer
atio
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Cop py
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Prote AG.

lkswage es n Touran 2003 ➤
Vo ot g
4-cylinder injection engine d by (1.4 l direct injection engine, turbocharger)
ua
ran - Edition 01.2006
ir se tee
tho
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ss
2 Valve gear
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un
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Checking camshaft axial clearance ⇒ page 64
ility
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Reworking valve seats ⇒ page 65 .
h re
ole,
spec
Checking valve guides ⇒ page 66 .
t to the co
Renewing valve stem seals ⇒ page 67
rrectne
1 - 40 Nm + 1/4 turn (90°) fur‐
ss o
cial p
ther
f inform
❑ Left-hand thread.
mer
atio
❑ Renew.
om
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2 - Camshaft adjuster
thi
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sd
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❑ Must not be taken apart.

iv
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cum
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satelettronica
fo
en
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⇒ page 49 .
t.
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Cop py
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3 - Camshaft pulley
t
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❑ Note position when in‐
c by lksw
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stalling timing chain. Prote AG.
4 - O-ring
❑ Renew if damaged.
❑ Coat lightly with engine
oil before installing.
5 - Inlet camshaft timing ad‐
justment valve -1- -N205-
6 - 10 Nm
7 - 10 Nm + 1/4 turn (90°) fur‐
ther
❑ Renew.
❑ Tighten from inside out‐
wards.
8 - Camshaft housing
❑ Remove sealant rem‐
nants.
❑ Coat with
AMV 188 003 A1 before
fitting.
❑ When installing, fit verti‐
cally from above onto studs and dowel pins.
9 - 10 Nm
10 - Cap
❑ For inlet camshaft
❑ For exhaust camshaft
11 - Roller rocker finger
❑ Check roller bearing.
❑ When installing, secure to support element using securing clip.
2. Valve gear 63
Touran 2003 ➤
12 - Cotters
13 - Valve stem seal
❑ Renew.
14 - Support element
❑ Check oil spray holes.
❑ With hydraulic valve clearance compensation.
❑ Do not interchange.
❑ Before installing, check camshaft axial clearance ⇒ page 64 .
15 - Valve guide
16 - Valve spring
❑ Remove and install with cylinder head removed using valve spring tool -3362-
❑ With cylinder head installed ⇒ page 67
17 - Cylinder head
❑ Reworking valve seats ⇒ page 65 .
satelettronica
❑ Reworking sealing surface ⇒ page 64 .
18 - Valves
❑ Do not rework, only lapping-in is permitted.
❑ Valve dimensions ⇒ page 65
wage
19 - Exhaust camshaft olks es n
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❑ Do not interchange with inlet camshaft. ir se
d ran
tee
ho
❑ Checking axial clearance ⇒ page 64 . aut or
ac
ss
❑ Coat with oil before inserting (also axial bearing shoulder).
ce
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20 - Guide sleeve
itte
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21 - Inlet camshaft
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❑ With cam for high-pressure pump -arrow-.
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❑ Before removing, remove and renew bucket tappet for high pressure pump.
hole
spec
❑ Do not interchange with exhaust camshaft.
es, in part or in w
t to the co
❑ Checking axial clearance ⇒ page 64 .
❑ Coat with oil before inserting (also axial bearing shoulder).
rrectness of i
22 - 50 Nm + 1/4 turn (90°) further
l purpos
nform
ercia
Reworking cylinder head sealing surface

m
Cylinder head reworking dimension: a = at least 108.25 mm

com
tion in
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Note
do
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When the sealing surface has been reworked, the valves must be
n
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set deeper by the same amount (valve seat inserts reworked) or Cop py
.
valves will contact pistons. When doing this, ensure that the per‐
t rig
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missible minimum dimension is maintained ⇒ page 65 . cop Vo
by lksw
cted agen
Prote AG.
2.2 Checking camshaft axial clearance


Touran 2003 ➤
♦ Universal dial gauge bracket -VW 387-

♦ Dial gauge
Perform measurements with camshaft housing removed and
sealing cover fitted.
Checking camshaft axial clearance
Wear limit: max. 0.40 mm.
Valve dimensions
AG. Volkswagen AG d
agen oes
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Note by V ol
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satelettronica
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Valvesamust
ut
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not be reworked. Only lapping-in is permitted. ra
c
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Dimension Inlet valve Exhaust valve

du
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∅a mm 29.5 26.0
erm
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∅b mm 5.973 5.953
wit
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c mm 100.9 100.5
hole
spec
α ∠° 45 45
es, in part or in w
t to the co
2.3 Reworking valve seats

rrectness of i

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

sd
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to reface or renew valve seats and valves. Particularly on high

rp
cu
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mileage engines, it is necessary also to check valve guides for

f
en
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t.
yi
wear ⇒ page 66 .
Co
Cop py
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♦ Valve seats should be reworked only enough to produce a
gh ht
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perfect seating pattern. Before beginning to rework valve
co Vo
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seats, calculate the maximum permissible reworking dimen‐
agen
Prote AG.
sions. If the reworking dimension is exceeded, hydraulic valve
compensation can no longer be guaranteed and the cylinder
head should be renewed.
The maximum permissible reworking dimension is calculated as

follows:
– Insert valve and press firmly against seat.
Note
If the valve is to be renewed as part of a repair, use a new valve

for the calculation.
2. Valve gear 65
Touran 2003 ➤
– Measure distance between end of valve stem and upper edge

of cylinder head.
– Calculate maximum permissible reworking dimension from
measured distance and minimum dimension.
Minimum dimension: inlet valve 7.6 mm, exhaust valve 7.6 mm
Measured distance minus minimum dimension = max. permissi‐
ble machining dimension.
Example:
-Measured distance 8.0 mm
Minimum dimension 7.6 mm
=max. perm. rework dimension 6) 0.4 mm
6) The max. permissible reworking dimension is shown on illustrations for re‐
working valve seats as dimension “b”.
Reworking inlet valve seat

a = ∅ 28.7 mm
b = Max. permissible reworking dimension1
c = 1.5...1.8 mm
satelettronica
Z = Cylinder head lower edge
α = 45° valve seat angle agen
AG. Volkswagen AG d
oes
β ksw not
= 30° upper correction angle by Vol
gu
γ = 60° lower correction angle rise
d ara
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7) Calculating max. permissible reworking dimension ⇒ page 65 . ss a c
ce
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Reworking exhaust valve seat

un
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a = ∅ 25.0 mm
rm
ab
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ility
b = Max. permissible reworking dimension1
ot
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= approx.1.8 mm
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Z = Cylinder head lower edge
hole
spec
= 45° valve seat angle
β
es, in part or in w
= 30° upper correction angle
t to the co
γ = 60° lower correction angle
8) Calculating max. permissible reworking dimension ⇒ page 65 .
rrectness of i
2.4 Checking valve guides
l purpos
nform
ercia
♦ Universal dial gauge bracket -VW 387-

m
a
com
tion in
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thi
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fo
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Dial gauge

Touran 2003 ➤
Test procedure
– Insert new valve into guide. The end of the valve stem must
be flush with the guide. Due to slight differences in stem di‐
ameters, use only an inlet valve in inlet guide and an exhaust
valve in exhaust guide.
– Determine rock. Wear limit: 0.8 mm
If rock tolerance is exceeded:
– Renew cylinder head.
2.5 Renewing valve stem seals

equipment required
♦ Spark plug spanner
satelettronica
-3122B-
♦ Valve spring tool -3362-
with thrust piece -3362/1-
♦ Valve stem seal puller agen
AG. Volkswagen AG d
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-3364- Volksw not
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♦ Valve stem seal fitting tool orise nte
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-3365- aut
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♦ Pressure hose -VW 653/3-
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
m
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thi
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sd
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f
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
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Prote AG.
Removing
(with cylinder head installed)
– Remove camshaft housing ⇒ page 55 .
2. Valve gear 67
Touran 2003 ➤
– Remove roller rocker fingers and place onto a clean surface.

When doing this, ensure that roller rocker fingers are not in‐
terchanged.
– Remove spark plugs with spark plug spanner -3122B- .
– Set piston of respective cylinder to “bottom dead centre”.
– Attach valve spring tool -3362- with thrust piece -3362/1- .
– Now screw pressure hose -VW 653/3- into spark plug hole.
– Connect pressure hose to compressed air system supplying
at least 6 bar and remove valve springs.
– Pull off valve stem seals with 3364.
Installing
satelettronica
– Place plastic sleeve supplied on respective valve stem. This
will prevent damage to new valve stem seal.
– Place new valve stem seal in valve stem seal fitting tool
-3365- . en AG. V
olkswagen AG
ag does
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– Oil valve stem seal sealingy V lip and press carefully onto the
o ot g
ua
db
valve guide. orise ran
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– Install camshaftsshousing
a ⇒ page 57 . c
ce
e
– Adjust valve timing ⇒ page 49 .

nl
pt
du
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itte
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erm
ab

ility
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hole
spec
♦ Installing fuel lines ⇒ page 114

es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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t.
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Cop py
t. rig
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Vo
co lksw
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cted agen
Prote AG.

Touran 2003 ➤
17 – Lubrication y Volkswagen AG. Volkswagen AG does not g

b ua
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1 Parts of slubrication system tho
or
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Note
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ility
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♦ Finding metal shavings or a large quantity of small metal par‐
wit
, is n
ticles during engine repair could indicate that the conrod bear‐
h re
ings are damaged. To prevent this from causing further
hole
spec
damage, perform the following repairs:
es, in part or in w
t to the co
♦ Thoroughly clean oil channels.
♦ Renew oil filter.
rrectness of i
♦ The oil level must not be above the max. mark - danger of
damage to catalytic converter! Markings ⇒ page 71
l purpos
Engine oil (oil capacities, engine oil specification) ⇒ page 69
nform
ercia
satelettronica
m
at
om
io
Removing and installing sump ⇒ page 72
n
c
in t
or
his
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Removing and installing oil pump ⇒ page 73 .

at
do
priv
cum
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Checking oil pressure and oil pressure switch ⇒ page 76

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1.1 Engine oil Cop py
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Oil capacities
op Vo
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Prote
With oil filter 3.6 l
AG.
Engine oil specification

Use engine oils conforming to VW standard 503 00 or 504 00.
Note
♦ The engine is factory-filled with oil that is determined for long

service intervals.
♦ Engine oils conforming to VW standard 501 01 or 502 00 can
continue to be used. These oils must be changed every 12
months or 15,000 kilometres. The service interval display must
be programmed accordingly. Procedure: ⇒ Maintenance ;
Booklet 38
1. Parts of lubrication system 69

Touran 2003 ➤
1 - Dipstick
❑ The oil level must not be
above the max. mark! n AG. Volkswagen AG do
lkswage es n
o ot g
❑ Markings ⇒ page 71 d byV ua
ran
ir se tee
2 - Oil cooler autho
or
ac
ss
3 - O-ring
ce
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nl
pt
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❑ Renew.
an
itte
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4 - Coolant pipe
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❑ For oil cooler.
wit
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❑ Torque setting for
hole
spec
bracket to crankcase:
es, in part or in w
20 Nm.
t to the co
5 - 8 Nm
6 - Cap
rrectness of i
❑ Renew seal if damaged
satelettronica
l purpos
7 - Seal
nform
ercia
8 - Oil filter cover, 25 Nm

m
at
om
io
❑ With by-pass valve,
n
c
in t
or
opening pressure: 2.50
his
te
bar.
a
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priv
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❑ With non-return valve.
um
for
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9 - Filter element
Co
Cop py
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gh
10 - Valve
ht
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Vo
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cted
11 - Control housing
agen
Prote AG.

valve timing housing
⇒ page 22 .
❑ When installing, install
two -M6x80- studs in
cylinder block and camshaft housing as a guide.
❑ To guide valve timing housing, secure sump in position with two bolts.
12 - 10 Nm
13 - Securing bolt
❑ Renew.
❑ Secure pulley against turning with counter-hold tool 3415.
14 - Pulley
❑ Contact surfaces of pulley must be free of oil and grease.
❑ Removing and installing poly-V-belt ⇒ page 19
15 - Seal
❑ Renew.
70 Rep. Gr.17 - Lubrication

Touran 2003 ➤
16 - Mounting bush
❑ Contact surfaces of bearing bush must be free of oil and grease.
17 - Gasket
18 - Sprocket
❑ For oil pump drive.
19 - 20 Nm + 1/4 turn (90°) further
20 - Sprocket
❑ For oil pump.
❑ Lock with counter-hold toollks-T10172-
wage . es n
o Vo t gu
by
21 - Drive chain ris
ed
ara
nte
o eo
❑ For oil pump. auth
ra
ss c
❑ Before removing, mark direction of rotation (installation position).
ce
e
nl
pt
du
an
22 - 10 Nm
itte
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erm
ab
23 - Oil level and oil temperature sender -G266-
ility
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satelettronica
wit
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❑ Checking: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.
hole
spec
es, in part or in w
24 - Oil drain plug, 30 Nm
t to the co
❑ With attached seal.
❑ Renew.
rrectness of i
25 - 13 Nm
l purpos
❑ Loosen and tighten flywheel end bolts only with socket insert -T10058- .
26 - 45 Nm nf
ercia
or
27 - Sump
m
m
atio
m

o
n in
or c
❑ Clean sealing surface before fitting.

thi
te
sd
iva
❑ Install with silicone sealant D 176 404 A2.

o
r
rp
cu
o
m
f
28 - 25 Nm
en
ng
t.
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op py
29 - Oil pump t. C rig
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❑ Renew complete only. cop Vo
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Prote
30 - 5 Nm
AG.
31 - Oil separator
Markings on oil dipstick

1 - Max. mark
2 - Min. mark
a - Area above hatched field up to max. mark: do not top-up with
engine oil!
b - Oil level within hatched zone: can be topped up with engine
oil
c - Area from min. mark up to hatched field: must be topped-up,
max. 0.5 l of engine oil!

Touran 2003 ➤
1.3 Removing and installing sump

♦ Special wrench, long reach -T10058-
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
♦ Hand drill with plastic brush attachment

ot p
wit
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♦ Flat scraper
h re
hole
spec
♦ Eye protection
es, in part or in w
t to the co
♦ Silicone sealant D 176404 A2

Removing
rrectness of i

l purpos
– Unbolt front exhaust pipe from exhaust manifold

⇒ page 168
nform
ercia
– Pull 3-pin connector off oil level and oil temperature sender -
m
G266- -1-.
at
om
ion
c
– Drain engine oil.

in t
or
his
ate
– Unbolt sump sealed with liquid gasket.

do
priv
cum
or
– Remove sump. Loosen sump with light blows of a rubber-

f
en
ng
t.
yi
headed hammer if necessary.
Co
Cop py
t. rig
– Remove sealant residue on cylinder block with a flat scraper.
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

Touran 2003 ➤
– Remove sealant residue on sump with a rotating brush, e.g. a

hand drill with a plastic brush (wear eye protection).
– Clean sealing surfaces. They must be free of oil and grease.
Installing
Note
♦ Observe expiry date of sealing compound.

♦ The sump must be installed within 5 minutes after applying
silicone sealing compound.
♦ Sump can be positioned more easily and with greater security
if M6 studs are inserted into the cylinder block flange at two
positions as guides.
– Cut off tube nozzle at forward marking (approx. 3 mm nozzle

∅).
– Apply silicone sealing compound, as shown, to clean sealing
surface on sump. Sealing compound bead must be:
satelettronica
♦ 2...3 mm thick.
♦ Run bead along inner side of bolt holes -arrows-.
Note
The sealing compound bead must not be thicker, or excessive

sealing compound will enter the sump and may block the oil suc‐
tion pipe strainer.
. Volkswagen AG
gen AG does
swa
– Install sump immediately and tighten all sump bolts b
lightly.
yV
olk not
gu
d ara
ise nte
– Tighten sump bolts to 13 Nm. hor eo
aut ra
ss c
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nl
Note pt
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ab
Let sealing compound dry for approx. 30 minutes after installing ility
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sump. Only then fill with engine oil.

wit
, is n
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hole
spec
1.4 Removing and installing oil pump

es, in part or in w
t to the co

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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cu
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f
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t.
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Cop py
ht. rig
rig ht
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Removing
co Vo
by lksw
cted agen
Prote AG.

Touran 2003 ➤
– Hold oil pump sprocket with counter-hold tool -T10172- .

– Loosen sprocket securing bolt.
Note
Do not remove bolt completely.
– Press chain tensioner in direction of arrow with a screwdriver.

– Remove sprocket securing bolt.
– Take sprocket off oil pump and out of chain.
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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un
pt
an
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ab
– Loosen oil pump securing bolts -arrows- and remove them.
ility
ot p
wit
– Remove oil pump from cylinder block.
is n
h re
ole,
Installing
spec
t to the co
rrectness o
cial p
f inform
mer
atio
– Press chain tensioner in direction of arrow with a screwdriver.

om
n
c
i
or
– Seat sprocket in chain and fit sprocket onto oil pump shaft.
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
– Observe installation position of sprocket on oil pump shaft

-arrows-.
– Fit sprocket securing bolt.
– Hold sprocket with counter-hold tool -T10172- .
– Fit torque wrench (5...50 Nm) -V.A.G. 1331- as shown.

– Tighten securing bolt to 20 Nm +1/4 turn (90°) further.
– Install sump ⇒ page 72 .
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touran 2003 ➤
1.5 Checking oil pressure and oil pressure switch

equipment required
♦ Oil pressure tester -V.A.G
1342-
♦ Voltage tester -V.A.G
1527B-
♦ Auxiliary measuring set -
V.A.G 1594C-
AG. Volkswagen AG d
agen oes
ksw not
satelettronica
Vol
by gu
d ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
atio
om
n in
or c
thi
e
Note
t
sd
iva
o
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cu
Functional check and repair of the visual and acoustic oil pressure
o
m
f
en
ng
warning: ⇒ Current flow diagrams, Electrical fault finding and Fit‐

t.
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op
ting locations.
C py
t. rig
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pyri by
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by c lksw
Test procedure Prote
cted AG.
agen
Oil pressure switch is located on gearbox side beneath the two

camshaft covers.

Touran 2003 ➤
– Remove oil pressure switch -F1- and screw into oil pressure
tester -V.A.G 1342- .
– Screw tester into cylinder head in place of oil pressure switch.
– Connect brown wire of tester to earth (-).
– Connect voltage tester -V.A.G 1527B- to battery positive (+) n AG. Volkswagen AG do
and oil pressure switch using cables from auxiliary test set -olkswage es n
ot g
V.A.G 1594C- . db
yV ua
r e an
ris tee
– If LED lights up, renew oil pressure switch -F1- . utho or
a ac
ss
If LED does not light up:
ce
e
nl
pt
du
an
– Start engine and increase speed slowly. At 0.3...0.7 bar the
itte
y li
LED must light up; otherwise renew oil pressure switch.
erm
ab
ility
ot p
– Increase engine speed further. At 2000 rpm and an oil tem‐
wit
perature of 80 °C the oil pressure should be at least 2.0 bar. , is n
h re
hole
spec
At higher engine speed, oil pressure must not exceed 7.0 bar.
es, in part or in w
t to the co
rrectness of i
satelettronica
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touran 2003 ➤
19 – Cooling
1 Parts of cooling system
Caution agen
AG. Volkswagen AG d
oes
olksw not
V gu
by ara
♦ When doing any repair work, especially in the engine
rised com‐ nte
partment, pay attention to the following due ato
ut the cram‐
ho eo
ra
ped conditions: ss c
ce
le
un
pt
an
vated charcoal filter system, coolant, refrigerant, brake d
itte
y li
rm
ab
pe
ility
sitions.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
Note
rrectness of i
l purpos
♦ When the engine is warm, the cooling system is under pres‐

sure. If necessary, release pressure before beginning repair
work.
nform
ercia
♦ Hoses are secured with spring-type clips. In case of repair,

m
a
com
only use spring-type clips.
tion in
r
te o
♦ Spring-type clip pliers -VAS 5024A- are recommended for in‐
thi
s
stallation of spring-type clips.
iva
do
r
rp
cum
fo
♦ When installing coolant hoses, route stress-free so that they
en
ng
t.
do not come into contact with other components (observe
yi Co
op
markings on coolant connection and hose).
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
Test for leaks in cooling system using cooling system tester - Prote
cted AG.
agen
V.A.G 1274- and adapters -V.A.G 1274/8- and -V.A.G 1274/9- .
Assembly overview - parts of cooling system - body side
⇒ page 79 .
Assembly overview - parts of cooling system - engine side
⇒ page 80 .
Coolant hose schematic diagram ⇒ page 81 .
Draining and filling with coolant ⇒ page 82 .
Removing and installing radiator fan -V7- and radiator fan 2 -
V177- ⇒ page 84
Removing and installing radiator ⇒ page 86 .
Removing and installing coolant pump ⇒ page 87 .
Removing and installing coolant circulation pump -V50-
⇒ page 91 .
78 Rep. Gr.19 - Cooling

Touran 2003 ➤
1.1 Assembly overview - parts of cooling system, body side
1 - Radiator
⇒ page 86 .
❑ If renewed, change
coolant in entire system.
2 - O-ring
3 - Upper coolant hose
❑ To connection on cylin‐
der head.
❑ Coolant hose schematic
diagram ⇒ page 81 .
olkswagen AG
en AG. V
4 - Expansion tank ksw
ag does
not
y Vol gu
❑ Carry out leakage ed
b test in ara
nte
ris
cooling system
tho using eo
au
coolingsssystem tester - ra
c
satelettronica
V.A.G 1274- and adapt‐
ce
le
un
er for cooling system
pt
an
d
itte
tester -V.A.G 1274/8- .
y li
rm
ab
pe
5 - Connector
ility
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6 - Cap
h re
hole
❑ Check using cooling spec

es, in part or in w
system tester -V.A.G

t to the co
1274- and adapter for
cooling system tester -
V.A.G 1274/9- .
rrectness of i
❑ The pressure relief

valve must open at a
l purpos
pressure of
1.4...1.6 bar.
nform
ercia
7 - 5 Nm
m
a
com
ti
8 - Plastic inserts
on in
r
te o
❑ For securing bolts.

thi
s
iva
do
9 - Bracket
r
rp
cum
fo
❑ For radiator.
en
ng
t.
yi Co
op py
10 - Cowling t. C rig
gh ht
pyri by
11 - 5 Nm
co Vo
by lksw
cted agen
Prote AG.
12 - Radiator fan 2 -V177-
13 - Connector
14 - Radiator fan -V7-
❑ With radiator fan control unit -J293- .
15 - Bracket
❑ For connector.
16 - Lower coolant hose
❑ To connection for thermostat.
1. Parts of cooling system 79

Touran 2003 ➤ AG. Volkswagen AG d
agen
4-cylinder injection
Volksw engine (1.4 l direct injection
oes
not engine, turbocharger) - Edition 01.2006
y gu
db ara
ise nte
17 - Securing cliptho
r eo
s au ra
c
18 - Radiators outlet coolant temperature sender -G83-
ce
e
nl
pt
du
19 - 5 Nm
an
itte
y li
erm
ab
ility
ot p
wit
, is n
1.2 Assembly overview - parts of cooling
h re
hole
system, engine side
spec
es, in part or in w
t to the co
Thermostat side
rrectness of i
1 - Connection
l purpos
2 - O-ring
❑ Renew.
nform
ercia
3 - Spring
m
at
4 - Plunger
om
ion
c
in t
r
5 - Thermostat
o
his
ate
❑ Opening starts at 87 °C.
do
riv
satelettronica
p
cum
or
6 - Coolant temperature send‐

f
en
ng
t.
yi
er -G62-
Co
Cop py
t. rig
❑ If necessary, release yri
gh by
ht
pressure in cooling sys‐
op Vo
by c lksw
tem before removing
cted agen
Prote AG.
7 - Securing clip
❑ Check for secure seat‐
ing.
8 - Thermostat housing
9 - Seal
❑ Renew.
10 - To expansion tank
11 - Connection
12 - Coolant pipe
13 - Coolant pipe
14 - 5 Nm
15 - From bottom of radiator
❑ Coolant hose schematic diagram ⇒ page 81 .
16 - To top of radiator
❑ Coolant hose schematic diagram ⇒ page 81 .

Touran 2003 ➤
1.3 Coolant hose schematic diagram
1 - Expansion tank
2 - Intake manifold
3 - Heater unit heat exchanger
4 - Thermostat housing
5 - Engine oil cooler
6 - Radiator
7 - Coolant circulation pump -
V50-
⇒ page 91 .
8 - Turbocharger
⇒ page 126 .
9 - Cylinder head/cylinder
satelettronica
block
❑ If renewed, renew cool‐
ant.
10 - Auxiliary heater agen
AG. Volkswagen AG d
oes
lksw not
❑ Optional extra d byV
o gu
ara
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or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touran 2003 ➤
1.4 Draining and filling coolant

equipment required
♦ Refractometer -T10007-
5024A-
♦ Cooling system charging
unit -VAS 6096-
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Draining
rrectnes
WARNING
s o
cial p
f inform
Steam may escape when expansion tank is opened. Wear eye

mer
protection and protective clothing to avoid eye injuries and

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

o
n
c
i
or
n thi
te
sd
iva
– Remove cap from coolant expansion tank.

o
pr
cum
r
fo
en
ng

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

Touran 2003 ➤
– Pull retaining clip out -arrow- and remove coolant hose from
radiator.
Note
Observe environmental regulations for disposal.
Filling
Note
♦ Use only coolant additive G12 in accordance with

“TL VW 774 F”. Identification: purple colour.
♦ G12 purple conforming with “TL VW 774 F” can be mixed with
the previous coolant additive G12 red!
♦ G12 and coolant additives marked conforming to
“TL VW 774 F” prevent frost and corrosion damage, scaling
and also raise boiling point of coolant. Therefore, the system
must be filled all year round with frost and corrosion protection
satelettronica
additives.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
. Volkswagen AG
gen AG
♦ Frost protection is required down toVoabout
lksw -25 °C (in countries es not
a o d
with arctic climates: down to about
ed
by -35 °C). gu
ara
ris nte
♦ tho
The coolant concentrationaumust not be reduced by adding wa‐ eo
ra
ter even in warmer seasons
ss and in warmer countries. The anti- c
freeze must be at least 40% of mixture.
ce
e
nl
pt
du
an
itte
♦ If for climatic reasons greater frost protection is required, the

y li
erm
ab
amount of G 12 can be increased, but only up to 60% (frost
ility
ot p
protection to about -40°C). Otherwise frost protection and

wit
, is n
cooling effectiveness are reduced again.

h re
hole
♦ If radiator, heat exchanger, cylinder head or cylinder head

spec
gasket is replaced, do not reuse old coolant.

es, in part or in w
t to the co
Recommended mixture proportions:

rrectness of i
Frost Anti-freeze G 129) Water9)

protection to proportion
l purpos
-25 °C 40 % 2.25 l 3.35 l

-35 °C 50% 2.8 l 2.8 l
nf
ercia
orm
m
9) The quantity of coolant can vary depending upon vehicle equipment.

atio
om
n in
or c
– Press union against radiator and push retaining clip -arrow-

thi
te
sd
into groove.
iva
o
r
rp
cu
o
– Install engine splash guard.

m
f
en
ng
t.
yi Co
With cooling system charge unit -VAS 6096- Cop py
ht. rig
rig ht
– Fill coolant circuit using cooling system charge unit - py by
co Vo
by lksw
VAS 6096- ⇒ Operating instructions for cooling system filler Prote
cted AG.
agen
unit VAS 6096 .
Without cooling system filling unit -VAS 6096-

Touran 2003 ➤
– Fill with coolant up to max. mark on expansion tank.

With and without cooling system filling unit -VAS 6096-
– Fit expansion tank cap.
– Turn off heater control.
Vehicles without auxiliary heater
– Start engine and maintain an engine speed of about 2000 rpm
for about 3 minutes.
– Run engine until radiator fan -V7- cuts in.
Vehicles with auxiliary heater
Caution n AG. Volkswagen AG do

lkswage es n
o ot g
byV ua
ed ran
The auxiliary heater must only hor be switched on when the coolant
is tee
circuit is filled, describeds aas
u follows:
t or
ac
s
ce
e
nl
pt
du
an
itte
y li
– Connect Vehicle diagnosis, testing and information system -
erm
ab
satelettronica
VAS 5051 A- as follows:
ility
ot p
wit
, is n
– Push diagnosis cable connector onto diagnosis connector in
h re
driver footwell.
hole
spec
es, in part or in w
– Start engine and maintain an engine speed of about 2000 rpm
t to the co
for about 3 minutes.
– Press buttons on display one after the other for “Vehicle self-
rrectness of i
diagnosis”, “18 - Auxiliary heater” and “03 - Final control diag‐
nosis”.
l purpos
– Press right arrow button on display up to final control diagnosis

for heater coolant shut-off valve -N279- .
nform
ercia
– Initiate final control diagnosis for heater coolant shut-off valve

m
at
-N279- . Continue to maintain engine speed at 2000 rpm for

om
ion
approx. 1 minute.
c
in t
or
his
te
– Run engine until radiator fan -V7- cuts in.

a
do
priv
cum
or
Continuation for all vehicles

f
en
ng
t.
yi Co
Cop py
WARNING
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
Steam may escape when expansion tank is opened. Wear eye
agen
Prote AG.
protection and protective clothing to avoid eye injuries and
scalding. Cover cap with cloth and open carefully.
– Check coolant level and top up if necessary. When the engine

is at normal operating temperature, the coolant level must be
on the max. mark; when the engine is cold, between the min.
and max. marks.
1.5 Removing and installing radiator fan -

V7- and radiator fan 2 -V177-
Removing radiator fan
– Remove engine cover.

Touran 2003 ➤
– Remove upper securing bolts of cowling -arrows-.

– Remove noise insulation ⇒ General body repairs, exterior;
Rep. Gr. 50 ; Body front; Noise insulation.
– Disconnect connector -1- and remove lower securing bolts of

cowling -arrows-.
– Remove cowling downwards.
AG. Volkswagen AG d
agen oes
lksw not
satelettronica
Vo gu
by ara
d
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
– Disconnect electrical connection -1- and free wiring.
erm
ab
ility
ot p
– Remove nuts -arrows- and remove fans.
wit
, is n
h re
Install radiator fan.
hole
spec
es, in part or in w
t to the co
note the following:
Torque settings:
rrectness of i
Component Nm
l purpos
Radiator fan to cowling 10

Cowling to radiator 5
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
1.6 Removing and installing radiator

equipment required
5024A-
Nm) -V.A.G 1331-
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing
– Bring lock carrier into service position ⇒ General body repairs, rrectness of i
l purpos
sition .
nf

ercia
orm
m
– Pull coolant hoses off radiator.

atio
om
n in
c
– Pull connectors off thermal switch and radiator fan.

or
thi
te
sd
a
– Remove radiator securing bolts and remove radiator with fan

iv
o
r
rp
cu
downwards.
o
m
f
en
ng
t.
yi Co
Cop py
t.
Note
rig
gh ht
pyri by
Vo
o
by c lksw
cted
To prevent damage to condenser and also to refrigerant lines/
agen
Prote AG.
hoses, ensure that the lines and hoses are not stretched, kinked
or bent.
– Remove retaining clamp(s) for refrigerant lines.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
nte Touran 2003 ➤
ed
ris
o eo
4-cylinder injection engine
aut (1.4 l direct injection engine, turbocharger) - Edition
h
ra 01.2006
ss c
ce
e
– Unbolt condenser from radiator and secure to lock carrier.
nl
pt
du
an
itte
y li
Installing
erm
ab
ility
ot p
wit
, is n
note the following:
h re
hole
Filling with new coolant ⇒ page 82 .
spec
es, in part or in w
t to the co
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
1.7 Removing and installing coolant pump
rrectness of i
l purpos

equipment required
nf
ercia
orm
m
atio
om
n in
or c
5024A-
thi
te
sd
iva
o
r
rp
cu
o
m
Nm) -V.A.G 1331-
f
en
ng
t.
yi Co
satelettronica
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
Coolant pump with magnetic clutch for supercharger -N421- can

only be renewed complete.
Removing

AG. Volkswagen AG d
agen oes
olksw not
yV gu
Touran 2003 ➤ ed b ara
nte
ris
4-cylinder injection engine (1.4 l direct injectionut
h engine, turbocharger) - Edition 01.2006
o eo
ra
s a c
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Unscrew hose clamp -1- from charge air pipe.
nform
ercia
– Unscrew securing bolt for charge air pipe -2-.

m
a
com
tio
n in
r

te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
satelettronica
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Press securing clip on charge air cooler in

-direction of arrow- and pull hose -arrow- off.
– Unscrew securing bolt for charge air pipe -arrow- and remove
charge air pipe -1- downwards.

Touran 2003 ➤
– Slacken compressor poly-V-belt by swinging tensioning ele‐

ment in -direction of arrow- with a spanner.
. Volkswagen AG
does gen AG
– Lock tensioning elementVol
ina position with locking
ksw pinno-T10060
t gu
A- . ed by ara
ris nte
utho eo
ra
a c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
– Unscrew securing bolts -arrows- for tensioning element and
t to the co
remove tensioning element.
– Tightly hold compressor shaft with a spanner -1-.
rrectness of i
l purpos
nform
ercia
satelettronica
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
– Remove securing bolt -2- for pulley and remove pulley and
en
ng
t.
yi
compressor poly-V-belt -3-.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
– Loosen bolts for coolant pump with magnetic clutch for super‐
charger -N421- -arrows-.
– Remove coolant pump with magnetic clutch for supercharger
-N421- from cylinder block.
Installing
note the following:
– Insert coolant pump with magnetic clutch for supercharger -
N421- into cylinder block.
– Tighten securing screws to 8 Nm.
Torque settings:
Part I Assembly overview - belt drive ⇒ page 16
AG. Volkswagen AG d
Assembly overview - compressor ⇒ page 133 agen oes
olksw not
byV gu
ara
Assembly overview - charge air system ⇒ page 141 rised
nte
ho eo
ut
– Installing poly-V-belt ⇒ page 19 . ss a ra
c
ce
e
– Install front right wheel housing liner ⇒ General body repairs;

nl
pt
du
satelettronica
an
Rep. Gr. 66 ; Removing and installing wheel housing liner;
itte
y li
Front wheel housing liner .
erm
ab
ility
ot p
– Fill with coolant ⇒ page 82 .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
d byV gu
ara Touran 2003 ➤
e
4-cylinder horisinjection engine (1.4 l direct injection engine,
nte
e o turbocharger) - Edition 01.2006
aut ra
s s c
1.8 Removing and installing coolant circulation pump -V50-
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
equipment required
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
5024A-
Nm) -V.A.G 1331-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
g
satelettronica
n
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing
– Drain off coolant ⇒ page 82 .

Touran 2003 ➤
– Remove spring clips -arrows- and pull coolant hoses off.

– Pull off connector -1- and unscrew securing bolt -2-. agen
AG. Volkswagen AG d
oes
olksw not
– Remove coolant circulation pump -V50- . ed by
V gu
ara
ris nte
Installing aut
ho eo
ra
ss c
ce
le
un
note the following:
pt
an
d
itte
y li
Specified torque setting for securing bolt: 10 Nm.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
satelettronica
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touran 2003 ➤
20 – Fuel supply system

1 Safety precautions
Safety precautions when working on fuel supply system
⇒ page 93 .
Releasing pressure in high-pressure section ⇒ page 93
1.1 Safety lksw

precautions
agen
AG. Volkswagewhen
n AG d
oesworking on
not
fuel
b supply system
Vo gu
y ara
d
ise
r n tee
ho
aut or
ac
ss Caution
ce
le
un
pt
an
d
Observe safety precautions when releasing pressure in high-

itte
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pressure section ⇒ page 93
rm
ab
pe
ility
ot
wit
, is n
h re
hole
tions:
spec
satelettronica
es, in part or in w
t to the co
sitions.
♦ To avoid damage to lines, ensure sufficient clearance to rrectness of i
l purpos

nform
ercia
When removing and installing fuel gauge sender or fuel pump

m
(fuel delivery unit) from a full or partly full fuel tank, observe the
com
tion in
following:
r
te o
thi
s
♦ Before beginning work, place an extraction hose close to

iva
do
r
sender opening in fuel tank to extract escaping fuel fumes and

rp
cum
fo
switch on exhaust extraction system. If no exhaust extraction

en
ng
t.
yi
system is available, a radial fan with a displacement greater
Co
op py
than 15 m3/h can be used providing that motor is not in air flow.
t. C rig
gh ht
pyri by
Vo
o
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
c by lksw
cted agen
Prote AG.
1.2 Releasing pressure in high-pressure

section
WARNING
The injection system consists of a high-pressure section (max‐

imum approx. 120 bar) and a low-pressure section (approx. 6
bar).
Before opening the high-pressure section (e.g. when removing
the high-pressure pump, the fuel rail, the injectors, the fuel
pipes or the fuel pressure sender -G247- ) the fuel pressure in
the high-pressure section must be reduced to a residual pres‐
sure of approx. 6 bar. The appropriate procedure is described
as follows.
1. Safety precautions 93
Touran 2003 ➤
– Pull electrical connector off fuel pressure regulating valve -

N276- -arrow-.
– Run engine at idling speed for approx. 10 seconds. lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
Note au ac
ss
ce
le
un
pt
♦ If the electrical connector is pulled off fuel pressure regulating
an
d
itte
valve -N276- at idling speed, the pressure in the high-pressure
y li
erm
ab
section is reduced to approx. 6 bar.
ility
ot p
♦ When the high pressure is reduced, the high-pressure system
wit
is n
h re
must be opened immediately, because the fuel pressure rises
ole,
by warming up.
spec
t to the co
– Switch off ignition.
rrectne
WARNING
s
The fuel lines are under fuel pressure! Wear eye protection and
s o
protective clothing to avoid injuries and skin contact. Before
cial p
f in
opening the high-pressure system place a cloth around the
form
satelettronica
mer
connection.
atio
om
n
c
i
or
n thi
e
– Wrap a clean cloth around the connection and carefully open

t
sd
va
to release residual pressure of approx. 6 bar. Any discharged

i
o
pr
cum
fuel must be collected.
r
fo
en
ng
t.
yi Co
– After completing work, read fault memory of engine control Cop py
unit, erase all incorrect entries that have been created by pull‐
t. rig
gh ht
yri
ing off connector.
p by
co Vo
by lksw
cted agen
Prote AG.
Note
If the fault memory was erased, the readiness code must be gen‐
erated ⇒ Vehicle diagnosis, testing and information system VAS
5051 “Guided functions”.
94 Rep. Gr.20 - Fuel supply system

Touran 2003 ➤
2 Fuel tank
Safety precautions when working on fuel supply system
⇒ page 95 .
Observe rules for cleanliness ⇒ page 96
Assembly overview - fuel tank with attachments ⇒ page 97
Emptying fuel tank ⇒ page 98 .
Removing and installing fuel tank ⇒ page 101
2.1 Safety precautions when working on

fuel supply system
Caution

satelettronica
tions:
G. Volkswagen AG d
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐ lkswagen A oes
not
vated charcoal filter system, coolant, refrigerant, brakedb
yV
o gu
ara
fluid and vacuum) and electrical wiring in their original
ris
e po‐ nte
sitions. au
tho eo
ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
following:
spec
t to the co
rrectne
ss o
cial p
f
2.2 Releasing pressure in high-pressure inform
mer
section
atio
om
n
c
i
or
n thi
WARNING
te
sd
iva
o
pr
cum
r

fo
en
ng
imum approx. 120 bar) and a low-pressure section (approx. 6

t.
yi Co
op
bar). C py
ht. rig
rig ht
by
Before opening the high-pressure section (e.g. when removing copy Vo
by lksw
the high-pressure pump, the fuel rail, the injectors, the fuel cted agen
Prote AG.
pipes or the fuel pressure sender -G247- ) the fuel pressure in
as follows.
2. Fuel tank 95
Touran 2003 ➤
4-cylinder injection engine (1.4 l direct injectioneengine,
n AG. Volkturbocharger)
swagen AG - Edition 01.2006
ag does
ksw not
y Vol gu
– Pull electrical connector off fuel pressuresregulating
ed
b valve - ara
nte
N276- -arrow-. thori eo
au ra
c
– Run engine at idling speed for approx.ss 10 seconds.
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
wit
♦ If the electrical connector is pulled off fuel pressure regulating , is n
h re
hole
spec
es, in part or in w
t to the co
by warming up.
rrectness of i
l purpos
WARNING
nf
ercia
orm
m
atio
The fuel lines are under fuel pressure! Wear eye protection and
om
n in
or c
thi
e
satelettronica
t
sd
a
connection.
iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
– Wrap a clean cloth around the connection and carefully open Cop py
t. rig
to release residual pressure of approx. 6 bar. Any discharged yri
gh by
ht
fuel must be collected. cop Vo
by lksw
cted agen
Prote
– After completing work, read fault memory of engine control
AG.
ing off connector.
Note
2.3 Rules for cleanliness

When working on the fuel supply and injection systems, pay care‐
ful attention to the following “5 rules” for cleanliness:
♦ Thoroughly clean all unions and adjacent areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover. Do not use
fluffy cloths!
♦ Carefully cover opened components or seal if repairs cannot
be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
♦ When system is open: do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely nec‐
essary.

Touran 2003 ➤
2.4 Assembly overview - fuel tank
1 - Cap
2 - Securing bolt
3 - Tank flap unit
❑ With rubber cup.
⇒ General body repairs,
exterior; Rep. Gr. 55 ;
Tank flap unit; Remov‐
ing and installing fuel
tank flap unit .
4 - Earth connection
ing.
5 - 11 Nm
6 - Fuel tank
satelettronica
❑ When removing, sup‐
port using engine and
gearbox jack -V.A.G
1383 A-
⇒ page 101 .
7 - 20 Nm
Note
AG. Volkswagen AG d
8 - Heat shield agen oes
olksw not
byV gu
9 - Securing strap rised ara
nte
ho eo
aut ra
Note ss c
ce
le
un
pt
an
d
itte
10 - Supply line
y li
erm
ab
❑ Black
ility
ot p
wit
❑ Check for secure seating.
is n
h re
ole,
11 - Fuel filter spec

❑ Installation position: arrow points in direction of flow.

t to the co
12 - Breather line
rrectne
13 - Activated charcoal filter

s
❑ Location: on fuel tank

s o
cial p
f in
14 - Breather line
form
mer
15 - Fuel delivery unit

atio
om

c
i
or
n thi
e
❑ With fuel gauge sender -G- ⇒ page 107 .

t
sd
iva
o
r
❑ Checking fuel pump

p
cum
r
fo
en
ng
❑ Note installation position on fuel tank ⇒ page 98 .

t.
yi Co
op
❑ Removing and installing fuel gauge sender -G- ⇒ page 107 .
C py
ht. rig
rig ht
❑ Clean strainer if soiled
py by
co Vo
by lksw
cted
❑ Adapt fuel pump control unit -J538- to engine control unit ⇒ Vehicle diagnosis, testing and information
agen
Prote AG.
system VAS 5051 after installing “Guided function”
2. Fuel tank 97
Touran 2003 ➤
16 - Seal
❑ When installing, insert seal dry into fuel tank opening.
❑ Moisten with fuel only when installing flange.
17 - Union nut, 80 Nm
❑ Remove and install using union nut tool -3217-
❑ Apply union nut tool -3217- to the three rounded ribs.
18 - Supply line
❑ Black
❑ Clipped onto side of fuel tank.
❑ Check for secure seating. agen
AG. Volkswagen AG d
oes
olksw not
V gu
19 - Return line d by ara
rise nte
❑ Blue utho eo
ra
a c
❑ Clipped onto side of fuel tank. ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
satelettronica
ot
Fitting position of fuel delivery unit flange
wit
, is n
h re
Marking on sender must align with the marking on fuel tank
hole
spec
-arrows-.
es, in part or in w
t to the co
Return line (blue or with blue mark) -2-.
Supply line (black) -3-.
rrectness of i
l purpos
Note
nform
ercia
After installing fuel delivery unit flange, check that supply, return
and breather lines are still clipped onto fuel tank.
m
a
com
tion in
r
te o
2.5 Emptying fuel tank thi

s
iva
do
r
rp
cum

fo
en
ng
t.
yi Co
♦ Fuel extractor -VAS 5190- t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
♦ Union nut tool -3217-
♦ Torque wrench (40...200 Nm) -V.A.G 1332-
satelettronica
– Note safety precautions before starting work ⇒ page 95 .
Emptying fuel tank if it is more than 3/4 full ⇒ page 99
Emptying fuel tank if it is less than 3/4 full ⇒ page 100
2.5.1 Emptying lksw

afuel
gen AGtank if itnis
. Volkswage AG
more
does
not
than 3/4
Vo
full by gu
ara
ed nte
ris
tho eo
s au ra
c
s
Caution
ce
e
nl
pt
du
an
itte
Secure earth wire of fuel extractor -VAS 5190- to a bare metal

y li
erm
ab
part of the body.

ility
ot p
wit
, is n
h re
– Pull cone piece -2- off fuel extractor -VAS 5190- shaft -1-.
hole
spec
es, in part or in w
– Make a mark -arrow- on hose with insulating tape from end of

t to the co
hose at distance -a- = 1,200 mm.

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Fuel tank 99
Touran 2003 ➤
– Remove filler cap from fuel tank filler neck.

– Screw shaft -1- of fuel extractor -VAS 5190- onto fuel tank filler
neck.
– Push extraction hose into fuel tank until marking on hose
-arrow- coincides with shaft end.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
u ra
Note ss a c
ce
e
nl
pt
du
A ball valve -2- is located at the lower end of filler neck in fuel tank
an
itte
y li
-1-, which must not be damaged by the extraction hose -3-.
erm
ab
Therefore push hose into filler neck only as far as marking
ility
ot p
-arrow-.
wit
, is n
h re
hole
satelettronica
spec
– Drain fuel tank as much as possible through fuel filler neck.
es, in part or in w
t to the co
– Carefully pull out extraction hose.
rrectness of i
Note
l purpos
♦ When no more fuel is extracted, the tank is emptied just

enough for the sender flange to be opened without danger.
nform
The tank may be removed while containing remaining fuel.
mercia
♦ If work must be performed on fuel pump or fuel tank sender,
at
om
io
proceed as follows:
n
c
in t
or
his
ate
do
riv
2.5.2 Emptying fuel tank if it is less than 3/4 full

p
cum
for
en
ng
t.
yi Co
– Remove seat bench ⇒ General body repairs, interior; Rep. Cop py
t. rig
Gr. 72 ; Rear seat; Removing and installing seat bench . opyri
gh by
Vo
ht
c
– Remove cover from fuel delivery unit.
by lksw
cted agen
Prote AG.
WARNING
The fuel supply line is under pressure! Wear eye protection and
nection.
– Pull connector and fuel lines off flange.
Note
Press buttons on hose couplings to do this.

Touran 2003 ➤
– Open locking ring using union nut tool -3217- .

– Lift fuel delivery unit.
– Insert extraction hose of fuel extractor -VAS 5190- as deeply
as possible into fuel tank and extract fuel.
. Volkswagen AG
a gen AG d
If fuel tank needed only to be emptied,Volreinstall fuel delivery unit
ksw
oes
not
gu
⇒ page 105 . ed by ara
n
ris tee
utho or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
2.6 Removing and installing fuel tank
wit
, is n
h re
hole
• Fuel tank must not be more than 1/2 full.
spec
es, in part or in w
t to the co
Note
rrectness of i
If necessary, empty fuel tank using fuel extractor -VAS 5190-
⇒ page 98 .
satelettronica
l purpos
nform
ercia

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Engine and gearbox jack -V.A.G 1383 A-
Removing
theft coding.
– With the ignition switched off, disconnect battery earth strap.
– Unscrew securing bolts and remove tank flap unit.
– Drain fuel tank and clean fuel filler neck and surrounding area.
2. Fuel tank 101

Touran 2003 ➤
– Fold rear seat bench forwards.

– Pull 5-pin connector -1- off flange.
olkswagen AG
en AG. V
– Remove right rear wheel.
olks
wag does
not
y V gu
b ara
– Remove rear right risewheel housing liner ⇒ General body re‐
d
nte
pairs, exterior;
aut Rep. Gr. 66 ; Removing and installing wheele or
ho
ac
housing liner;
ss Rear wheel housing liner .
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unbolt filler pipe from body -arrows-.
– Disconnect all rear exhaust system retainers from body. Sup‐
port lowered exhaust system on body with suitable wire.
rrectness of i
l purpos
satelettronica
WARNING
nf
ercia
Fuel supply lines are under pressure! Wear eye protection and
orm
m
atio
m

o
n in
c

or
thi
e
nection.
t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
– Disconnect breather line -1- (white) and fuel line -2- (black) at C py
t. rig
connecting point. gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Press in securing ring to release fuel lines.
– Remove securing strap bolt and securing strap. When doing

this, support fuel tank with engine and gearbox jack -
V.A.G 1383 A- .
– Lower fuel tank.
Installing
Installation is performed in the reverse sequence. When doing
this, note the following:
♦ To secure the securing straps for the fuel tank only bolts with
loose washers must be used. If other bolts are used, the se‐
curing straps may be twisted on tightening.
♦ Install breather and fuel lines free of kinks.
♦ Ensure that fuel line connections are tight.
♦ After installing fuel tank, check that the supply, return and
breather pipes are still clipped onto the fuel tank.
– Erase learnt values and adapt fuel pump control unit -J538- to
engine control unit ⇒ Vehicle diagnosis, testing and informa‐
tion system VAS 5051 “Guided functions”.

Touran 2003 ➤
3 Removing and installing parts of fuel

supply system
Note
♦ Hose connections are secured with either spring-type or

clamp-type clips.
♦ Always renew clamp-type clips with spring-type clips.
♦ Fuel hoses in engine compartment must be secured only with
spring-type clips. The use of clamp or screw-type clips is not
permissible.
Observe safety precautions ⇒ page 103

Removing and installing fuel delivery unit ⇒ page 105
satelettronica
Removing and installing fuel gauge sender G ⇒ page 107
Observe crash fuel shut-off ⇒ page 107 .
Checking fuel pump ⇒ page 108 .
Checking delivery rate ⇒ page 108 .
Checking fuel pump non-return valve ⇒ page 112 .
Assembly overview - high-pressure pump ⇒ page 114 .
Removing and installing high-pressure pump ⇒ page 114 .
3.1 Safety precautions when working on

fuel supply system
AG. Volkswagen AG d
agen oes
olksw not
V
e
Caution
d by gu
ara
ris nte
ho eo
ut
Observe
ss a safety precautions when releasing pressure inc
ra
high-
ce
e
nl
pt
du
an

itte
y li

erm
ab
tions:
ility
ot p
wit
, is n
h re

hole
spec

es, in part or in w
sitions.
t to the co

rrectness of i
l purpos

nform
ercia
following:
m
at

om
io

n
c
in t
or

his
ate

do
priv
um
for
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
yri by
103
op Vo
by c lksw
Prote
cted AG.
agen 3. Removing and installing parts of fuel supply system
Touran 2003 ➤
3.2 Releasing pressure in high-pressure

section
WARNING

imum approx. 120 bar) and a low-pressure section age(approx.
n AG. Volks6wagen AG do
es n
ksw
bar). by
Vol ot g
u d ara
se nte
Before opening the high-pressure section
ho
ri (e.g. when removing e
ut
the high-pressure pump, the fuels arail, the injectors, the fuel
or
ac
pipes or the fuel pressure sender s-G247- ) the fuel pressure in
ce
e
nl
pt
du
an
itte
y li
as follows.
erm
ab
ility
ot p
wit
, is n
h re
– Pull electrical connector off fuel pressure regulating valve -
hole
spec
N276- -arrow-.
es, in part or in w
t to the co
– Run engine at idling speed for approx. 10 seconds.
satelettronica
rrectness of i
Note
l purpos
♦ If the electrical connector is pulled off fuel pressure regulating

nf
ercia
orm
m
atio
om
n in
or c
by warming up.
thi
te
sd
iva
o
r
rp
– Switch off ignition. cu

o
m
f
en
ng
t.
yi Co
op py
WARNING
t. C rig
gh ht
pyri by
Vo
o
by c lksw
The fuel lines are under fuel pressure! Wear eye protection and cted agen
Prote AG.
connection.
– Wrap a clean cloth around the connection and carefully open

to release residual pressure of approx. 6 bar. Any discharged
fuel must be collected.
– After completing work, read fault memory of engine control
ing off connector.
Note

connecting.

Touran 2003 ➤

fluffy cloths!
be carried out immediately.
tool boxes etc.).
essary.
3.4 Removing and installing fuel delivery

unit
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
♦ Torque horwrench
is (40...200 Nm) -V.A.G 1332- nte
eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Removing
l purpos
Prerequisite
nform
ercia
• The fuel tank must not be more than 1/2 full.

m
a
com
tion in
Note
r
te o
thi
s
iva
do
r
If necessary, empty fuel tank using fuel extractor -VAS 5190-

rp
cum
fo
⇒ page 98 .
en
ng
t.
yi Co
Cop py
.
ht rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
theft coding.
– With the ignition switched off, disconnect battery earth strap.
3. Removing and installing parts of fuel supply system 105

Touran 2003 ➤
– Fold rear seat forwards.

– Remove cover from fuel delivery unit -arrows-.
– Remove cover -1- with fuel pump control unit -J538- -2- from
fuel delivery unit.
WARNING n AG. Volkswagen AG do

lkswage es n
o ot g
byV ua
ed ran
Fuel supply lines are under pressure!
oris Wear eye protection and tee
protective gloves to avoid ainjuries
uth
and skin contact. Before or
ac
ss
ce
le

un
pt
nection.
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
– Pull connector -1- and fuel lines -2- and -3- off flange.
spec
es, in part or in w
t to the co
Note
rrectness of i
satelettronica
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
– Position union nut tool -3217- on three rounded pins of union
r
rp
cum
nut and unscrew union nut from flange. When doing this, press
fo
en
g
union nut tool -3217- firmly onto union nut.

n
t.
yi Co
Cop py
– Pull fuel delivery unit and seal out of the opening in fuel tank.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
If delivery unit is to be renewed, drain old delivery unit before dis‐

posal.
Installing
– Installation of fuel delivery unit is carried out in reverse order.

Touran 2003 ➤
Note
♦ When inserting fuel delivery unit, ensure that fuel gauge send‐
er is not bent.
♦ Insert seal for fuel delivery unit dry into opening of fuel tank.
♦ Moisten seal with fuel only when installing fuel delivery unit.
♦ Note installation position of fuel delivery unit flange: mark on
flange must align with mark -arrows- on fuel tank.
♦ Do not interchange supply and return lines.
♦ Ensure that fuel line connections are tight.
♦ After installing fuel delivery unit, check that supply, return and
G. Volkswage
breather lines are still clipped onto fuel tank. ksw
agen
A n AG d
oes
not
y Vol gu
♦ Adapt fuel pump control unit -J538- to engine edcontrol unit
b ara
nte
ris
⇒ Vehicle diagnosis, testing and informationtho system VAS 5051 eo
after installing “Guided function” ss au ra
c
ce
le
un
pt
an
d
satelettronica
itte
3.5 Removing and installing fuel gauge
y li
rm
ab
pe
sender G
ility
ot
wit
, is n
h re
Removing
hole
spec
– Remove fuel delivery unit ⇒ page 105 .
es, in part or in w
t to the co
– Release connectors for lines -1- and -2- and pull off.
– Raise retaining tabs -3- and -4- using a screwdriver and pull
rrectness of i
fuel gauge sender off downwards -arrows-.
l purpos
Installing
– Insert fuel gauge sender into guides on fuel delivery unit and
nform
ercia
press upwards until it engages.

m
a
– Reconnect connector and check that it has engaged correctly.
com
tion in
r
– Install fuel delivery unit ⇒ page 105 .

te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3.6 Crash fuel shut-off

Function
Crash fuel shut-off system reduces the risk of a vehicle burning
in event of a crash in that the fuel pump is switched off. The sys‐
tem also improves the starting characteristics of the engine. When
door is opened, the fuel pump is activated for 2 seconds to build
up pressure in the fuel system.
When opening fuel system:

Touran 2003 ➤
3.7 Checking fuel pump

equipment required
♦ Pressure tester -V.A.G
1318-
♦ Adapter -V.A.G 1318/11-
♦ Hose adapter -V.A.G
1318/16-
♦ Adapter set -V.A.G
1318/17-
♦ Connector -V.A.G 1318/23-
AG. Volkswagen AG d
satelettronica
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touran 2003 ➤

Nm) -V.A.G 1332-
♦ Remote control for V.A.G
1348 -V.A.G 1348/3A- with
adapter cable -V.A.G
1348/3-2-
♦ Auxiliary measuring set -
V.A.G 1594C-
♦ Multimeter -V.A.G 1715-
♦ Measuring container
satelettronica
AG. Volkswagen AG d
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Test prerequisites
• The battery voltage must be at least 11.5 V.
rrectne
• Voltage supply and electrical wiring are OK.
s
• Fuse for fuel pump in fuse holder on left under dash panel is
s o
cial p
OK. Fuse assignment ⇒ Current flow diagrams, Electrical fault

f in
finding and Fitting locations.

form
mer
atio
Test procedure
om
n
c

or
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te
sd
va
– Switch on ignition. The fuel pump must audibly run briefly.

i
o
pr
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op py
If the fuel pump does not run: t. C rig
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pyri by
– Remove fuel delivery unit ⇒ page 105 .
o Vo
by c lksw
cted agen
Prote AG.
– Check that electrical wires between flange and fuel pump are
connected.
If no open circuit can be found:
– Fuel pump is defective. Renew fuel delivery unit ⇒ page 105 .

Touran 2003 ➤
Checking delivery rate

Test procedure
– Remove cover from fuel delivery unit -arrows-.
– Take cover -1- with fuel pump control unit -J538- -2- off fuel
delivery unit.
– Pull 5-pin connector off flange on fuel delivery unit.
– Connect remote control for V.A.G 1348 -V.A.G 1348/3A- using
satelettronica
adapter cables to contact -1- on fuel pump and battery positive
(+).
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agen oes
olksw not
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by
– Connect contacts -5- of connector and fuelripump
sed using an ara
nte
auxiliary cable from adapter set -V.A.G 1594C-
ut
ho . eo
ra
s a c
– Remove filler cap from fuel tank filler neck.
s
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Pull off supply line -1- and catch escaping fuel with a cloth.
l purpos
Note
nf
ercia
orm

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atio
om
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or c
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Prote AG.

Touran 2003 ➤
– Connect pressure tester -V.A.G 1318- with connector -V.A.G

1318/23- and adapter set -V.A.G 1318/17- to fuel supply line
– Push hose adapter -V.A.G 1318/16- onto adapter -V.A.G
1318/11- of pressure tester and hold it in measuring container.
– Open cut-off tap of pressure tester. The lever then points in
the direction of flow -A-.
– Operate remote control -V.A.G 1348/3A- . Then slowly close
cut-off tap until a pressure of 3 bar is displayed on pressure
gauge. From this point on do not move position of cut-off tap.
– Empty measuring container.
– The quantity delivered by the fuel pump depends on the bat‐
tery voltage. Therefore connect multimeter with adapter ca‐
bles from auxiliary measuring set -V.A.G 1594C- to vehicle
battery.
– Operate remote control for 30 seconds while measuring bat‐
tery voltage.
– Compare quantity of fuel delivered with specification.
satelettronica
10) Minimum delivery cm3/30 seconds
AG. Volkswagen AG d
11) Voltage at fuel pump with engine not running and pump runningo(approx.agen2 oes
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volts less than battery voltage). byV gu
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Example: utho eo
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ss
During the test a voltage of 12.5 volts is measured at the battery.
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nl
As the voltage at the pump is approx. 2 volts less than the battery
pt
du
an
voltage, this will equate to a minimum delivery rate of 540 cm3/30
itte
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erm
ab
s.
ility
ot p
If the minimum delivery rate is not attained:
wit
, is n
h re
hole
– Check fuel lines for possible restrictions (kinks) or blockages.
spec
es, in part or in w
t to the co
– Pull supply hose -1- off fuel filter inlet.
– Connect pressure tester -V.A.G 1318- with adapter set -V.A.G
1318/17- to hose.
rrectness of i
– Repeat delivery rate check.
l purpos
If the minimum delivery rate is now attained:

nform
ercia
– Renew fuel filter.

m
at
om
If the minimum delivery rate is again not attained:

ion
c
in t
or
– Remove fuel delivery unit and check for dirt in filter strainer.
his
ate
do
riv
Only if still no fault has been detected:

p
cum
for
en
g
– Renew fuel delivery unit.

n
t.
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Cop py
If delivery rate has been attained, but nevertheless you suspect
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a fuel supply system fault (e.g. intermittent failure of fuel supply
p by
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system): Prote
cted AG.
agen
– Check current draw of fuel pump as follows:

– Reconnect all disconnected fuel lines.

Touran 2003 ➤
– Set multimeter to measuring range 20 A and connect in series

between contacts -1- of connector and fuel pump using auxil‐
iary leads from auxiliary measuring set -V.A.G 1594C- .
Note
Current pick-up clamp of multimeter -V.A.G 1715- can also be

attached to an adapter cable between contacts -1- of connector
and fuel pump.
– Start engine and run at idling speed.

– Measure current draw of fuel pump. Specification: max. 4
amps
AG. Volkswagen AG d
agen oes
olksw not
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Note ed by ara
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ris
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If the fuel system malfunction is intermittent, you can perform
ss a the c
check during a road test with the help of a 2nd person.
ce
le
un
pt
an
d
itte
y li
If current consumption is exceeded:
satelettronica
rm
ab
pe
ility
– Fuel pump defective. Renew fuel delivery unit ⇒ page 105 ,
ot
wit
, is n
Removing and installing fuel delivery unit.
h re
hole
spec
3.7.1 Checking fuel pump non-return valve
es, in part or in w
t to the co
Test prerequisites
• Remote control for V.A.G 1348 -V.A.G 1348/3A- is still con‐
rrectness of i
nected.
l purpos
• The pressure tester -V.A.G 1318- is still connected.
nform
Test procedure
mercia
a
com
tion in
Note
r
te o
thi
s
iva
At the same time, this test checks for leaks in the fuel supply line
do
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connections from the fuel delivery unit to the point at which the
um
fo
en
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pressure tester -V.A.G 1318- is connected.

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t.
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Cop py
t. rig
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by c lksw
cted agen
Prote AG.

Touran 2003 ➤
– Close pressure tester shut-off valve (lever against direction of

flow -position B-).
– Operate remote control at short intervals until a pressure of
approx. 3 bar has built up.
WARNING
Danger of spray when shut-off tap is opened; wear eye pro‐

tection and protective clothing to avoid injuries and skin con‐
tact. Hold container in front of open connection of pressure
tester.
– If pressure builds up too high, relieve excess pressure by

carefully opening cut-off tap.
– Watch pressure drop on pressure gauge. After 10 minutes,
pressure must not drop below 2.5 bar.
If the pressure drops further:
gen AG
. Volkswagen AG
d wa oes
olks not
– Check line dconnections
by
V for leaks. gu
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satelettronica
If no faultuin
tho lines is detected: eo
ra
sa c
– Fuels pump is defective. Renew fuel delivery unit ⇒ page 105 .
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
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Cop py
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co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
3.8 Assembly overview - high-pressure pump
1 - Roller tappet
oil when installing.
2 - O-ring
❑ Renew.
oil when installing.
3 - High-pressure pump with
fuel pressure regulating valve -
N276- .
⇒ page 114 .
❑ Observe safety precau‐
tions when releasing
pressure in high-pres‐
sure section ⇒ page 93
AG. Volkswagen AG d
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satelettronica
4 - 8 Nm olksw
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5 - Connection rised
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❑ High pressure aut ra
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6 - Union nut, 18 Nm
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❑ Observe safety precau‐

itte
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tions when releasing
rm
ab
pe
pressure in high-pres‐
ility
ot
sure section ⇒ page 93

wit
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❑ Counterhold when loos‐ h re

hole
ening connection to spec

es, in part or in w
high-pressure pump.
t to the co
7 - Fuel hose
❑ Low pressure
rrectness of i
❑ With spring clip.

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8 - Connection
❑ Low pressure
nform
mercia
a
com
tion in
3.9 Removing and installing high-pressure

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pump
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Prote AG.

Touran 2003 ➤
♦ Spring-type clip pliers -VAS 5024A-
Prerequisite
• Engine must be cold.
Removing
WARNING
satelettronica
– Separate fuel supply line -arrow-.
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ility
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– Pull connector and fuel supply line -arrows- off high pressure
wit
pump.
is n
h re
ole,
spec
Note
t to the co
Catch escaping fuel in a cloth.

rrectness o
cial p
f inform
mer
atio
om
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Prote AG.

Touran 2003 ➤
– Remove wiring guide -2- and take clip -4- off high pressure
line.
Note

on bottom of intake manifold using wrench when loosening union
nuts.
– Loosen union nuts -3- and -1- of high pressure line.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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– Remove securingut bolts -1-, -2- and -3- equally.
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ab
ility
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satelettronica
spec
es, in part or in w
t to the co
rrectness of i
– Pull high-pressure pump -3- and roller tappet -1- out of cam‐
l purpos
shaft housing.
Installing
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ercia

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at
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note the following:

on
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ate
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Note
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♦ Coat roller tappet of high-pressure pump with clean engine oil.
Co
Cop py
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♦ Always replace high-pressure pump O-ring.
ht
pyri by
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by c lksw
cted agen
Prote AG.
– Push roller tappet -1- into camshaft housing.

Touran 2003 ➤
– Insert new, lubricated O-ring -2- in groove of high-pressure

pump -3-.
– Place high pressure pump -3- on camshaft housing.
– Tighten securing bolts -1-, -2- and -3- equally.
satelettronica
lkswage es n
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– Tighten union nuts of high pressure pump -1- and -3- by hand.
un
pt
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– Install wiring guide -2- and fit clip -4- on high pressure line.
rm
ab
pe
ility
Torque setting of wiring guide securing bolt: 8 Nm

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wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co

on bottom of intake manifold using wrench when tightening union
nuts.
rrectness of i
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– Tighten union nut -1- of high pressure line to 18 Nm.

nform
ercia
– Tighten union nut -3- of high pressure line to 18 Nm.

m
a
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tion in
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te o
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s
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Touran 2003 ➤ agen
AG. Volkswagen AG d
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4-cylinder injection
by
V engine (1.4 l direct injection engine,
ol not
gu turbocharger) - Edition 01.2006
ara
ed nte
oris
– Secure fuel supply
au
th line and connector -arrows- on high pres‐ or a e
sure pump. ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Fit fuel supply line -arrow- together.

– Install air filter ⇒ page 153 .
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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satelettronica
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Touran 2003 ➤
AG. Volkswagen AG d
agen oes
4 Repairing electronic power control d byV
olksw not
gu
ara
(EPC) ise nte
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aut ra
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Function of EPC system ⇒ page 119 s
ce
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nl
pt
du
an
itte
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erm
ab
Removing and installing accelerator pedal module ⇒ page 120
ility
ot p
wit
4.1 Function of EPC system
, is n
h re
hole
spec
With the EPC system, the throttle valve is not operated by a cable.
es, in part or in w
There is no mechanical connection between the accelerator pedal
t to the co
and the throttle valve.
The position of the accelerator pedal is transmitted to the engine
rrectness of i
control unit by two accelerator pedal position senders (variable
resistors together in one housing) connected to the accelerator
l purpos
pedal.
The position of the accelerator pedal (driver's requirement) is a
nform
ercia
main input value for the engine control unit.

m
at
The throttle valve is actuated by a servomotor (throttle valve po‐
om
satelettronica
on
sitioner) in the throttle valve control part over the full range of
c
in t
or
engine speeds and load conditions.
his
ate
do
riv
The throttle valve is operated by the throttle valve positioner which

p
cum
or
is controlled by the engine control unit.

f
en
ng
t.
yi Co
op
When the engine is not running and the ignition is switched on, C py
ht. rig
the engine control unit moves the throttle valve exactly as pre‐ rig ht
py by
scribed by the accelerator pedal position sender. That is, when
co Vo
by lksw
cted
the accelerator is depressed halfway, the throttle valve positioner
agen
Prote AG.
opens the throttle valve by the same amount. The throttle is then
approximately half open.
When the engine is running (under load), the engine control unit
can open or close the throttle valve independently of the accel‐
erator pedal position sender.
This means that the throttle valve can already be completely open
even though the accelerator pedal is depressed half way. This
has the advantage of preventing throttling losses at the throttle
valve.
After evaluating the torque requirements of various components
(e.g. air conditioning system, automatic gearbox, ABS/ESP and
so on), the engine control unit calculates the optimal throttle valve
opening angle for the respective situation.
This also results in significantly improved consumption and ex‐
haust emission values under certain load conditions.
“EPC” is a system comprising all components which contribute to
determining, controlling or monitoring the position of the throttle
valve, e.g. accelerator position sender, throttle valve control part,
EPC warning lamp, engine control unit and so on.
4. Repairing electronic power control (EPC) 119

Touran 2003 ➤
1 - Connector
❑ Black, 6-pin.
2 - Accelerator position sender
-G79- and accelerator position
sender 2 -G185-
❑ Openings -A- for re‐
lease tool .
⇒ page 120 .
3 - 10 Nm
4 - Cap
lkswage es n
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satelettronica
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un
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itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
4.3 Removing and installing accelerator

en
ng
t.
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pedal module Cop py
t. rig
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yri by
Special tools and workshop equipment required cop Vo
by lksw
cted agen
Prote
♦ Release tool -T10269- (for right drive vehicles -T10297- ).
AG.
Removing
– Remove steering column cover -arrows-.
– Pull connector off accelerator pedal module.
– Pull off cover cap in upper area of accelerator module.
– Remove securing bolt.

Touran 2003 ➤
– To remove accelerator module, slide release tool -T10269-

(for right drive vehicles -T10297- ) onto stop in openings
provided.
– Pull out accelerator module.
Installing
– Push wiring guide -1- and electrical connector -2- onto accel‐
erator pedal module.
– Press accelerator pedal module onto securing pins -6-.
– Insert centring pin -7- into hole in floor of vehicle.
– Secure accelerator pedal module with bolt -3-, torque setting
satelettronica
10 Nm and install cap -4-.
– Install steering column trim.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
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nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4. Repairing electronic power control (EPC) 121

Touran 2003 ➤
AG. Volkswagen AG d
agen oes
lksw not
5 Activated charcoal filter system Vo gu
d by ara
ise nte
or eo
h
Function ⇒ page 122 aut ra
c
ss
Checking fuel tank breather ⇒ page 122
ce
e
nl
pt
du
an
itte
5.1 Function
y li
erm
ab
ility
ot p
Fuel vapour will form above the fuel in the tank at different quan‐
wit
, is n
tities depending on the air pressure and ambient temperature.
h re
hole
spec
The activated charcoal filter system prevents these HC emissions
es, in part or in w
escaping to the atmosphere.
t to the co
Fuel vapours pass from the highest point in fuel tank through the
gravity valve and pressure retention valve, in reduced quantities,
rrectness of i
to activated charcoal filter.
l purpos
The activated charcoal stores these vapours like a sponge.
When the car is being driven and the lambda control is active
nf
ercia
(engine warm), the activated charcoal filter solenoid valve 1 -
or
N80- , also known as regeneration valve, is activated (pulsed) by
m
m
atio
the engine control unit depending upon load and engine speed.
om
The opening period depends on the input signals.
n in
satelettronica
or c
thi
e
Intake manifold vacuum draws fresh air through the vent opening
t
sd
iva
o
during the purging procedure (activated charcoal regeneration).
r
rp
cu
o
m
The fuel vapours stored in the activated charcoal and fresh air are
f
en
ng
t.
fed to combustion in metered quantities.
yi Co
Cop py
t. rig
The pressure retention valve prevents fuel vapours from being
gh ht
yri by
drawn from the fuel tank when activated charcoal filter system
op Vo
by c lksw
cted
solenoid valve 1 -N80- is open and intake manifold vacuum is
agen
Prote AG.
present. It thus ensures that the evacuation of the activated char‐
coal filter has priority.
When not energised (e.g. open circuit), the solenoid valve is
closed. The activated charcoal filter will not be purged.
Note
♦ Hose connections are secured with either spring-type or

clamp-type clips.
♦ Always renew clamp-type clips with spring-type clips.

5.2 Checking fuel tank breather


agen
AG. Volkswagen AG d
oes Touran 2003 ➤
ksw not
4-cylinder injection engine
by Vol
(1.4 l direct injection engine, guturbocharger)
ara
- Edition 01.2006
d
rise nte
o eo
♦ Hand vacuum pump -VAS aut 6213-
h
ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Test prerequisite
• Ignition must be switched off.
nform
ercia
Test procedure
m
a
com
tion in
– First disconnect white breather hose at hose connection -2-.
r
te o
thi
s
iva
do
r
rp
satelettronica
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Then connect hand vacuum pump -VAS 6213- to hose -1- as

shown.
– Operate hand vacuum pump -VAS 6213- several times. Vac‐
uum must not build up.
If vacuum builds up:
– Check breather hose -3- on activated charcoal filter -2- for
soiling and clean if necessary.
If vacuum does not build up:
– Hold breather connection -3- shut and operate vacuum pump
again several times. A vacuum must build up.
If vacuum does not build up:
– Renew activated charcoal filter -2-.
5. Activated charcoal filter system 123

Touran 2003 ➤
21 – Turbocharging/supercharging
1 Turbocharger
Assembly overview - turbocharger ⇒ page 124
Removing and installing turbocharger ⇒ page 126
Checking turbocharger vacuum unit ⇒ page 130 .
1.1 Assembly overview - turbocharger

Part I ⇒ page 125
Part II ⇒ page 126
satelettronica
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du
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itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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cted agen
124
Prote AG.
Rep. Gr.21 - Turbocharging/supercharging
Touran 2003 ➤
1.2 Part I
1 - Charge pressure control

solenoid valve -N75-
2 - 10 Nm
3 - 7 Nm
4 - Turbocharger divert air
valve -N249-
AG. Volkswagen AG d
agen
5 - O-ring Volksw
oes
not
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by ara
❑ Renew. rised
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ut
6 - Turbocharger ss a ra
c
❑ Can only be renewed
ce
le
un
pt
with exhaust manifold.
an
d
itte
y li
erm
ab
⇒ page 126 .
ility
ot p
wit
is n
7 - Connecting hose
h re
ole,
spec
satelettronica
8 - Connecting hose
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Turbocharger 125
Touran 2003 ➤
1.3 Part II
1 - 8 Nm
2 - Coolant pipe
3 - O-ring
❑ Renew.
4 - Turbocharger
❑ Can only be renewed
with exhaust manifold.
⇒ page 126 .
5 - Gasket
❑ Renew.
6 - 20 Nm
7 - Gasket
❑ Renew.
satelettronica
8 - 8 Nm
9 - Oil return pipe
10 - Seal
❑ Renew.
11 - Banjo bolt, 30 Nm
12 - Oil supply pipe
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
1.4 Removing and installing turbocharger

hole
spec
es, in part or in w

t to the co

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
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ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
126 Rep. Gr.21 - Turbocharging/supercharging

Touran 2003 ➤
Removing
Note
Before carrying out further work, disconnect battery earth strap.

first if necessary.
satelettronica
off.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
– Unbolt heat shield over turbocharger -arrows-. ab

ility
ot p

wit
, is n
cooling system.
h re
hole
spec

es, in part or in w
t to the co
Note
rrectness of i
l purpos
VAS 5024A- .
nf
ercia

orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Turbocharger 127
Touran 2003 ➤
AG. Volkswagen AG d
– Pull off connecting hoses -1- and coolant hoses -3-. agen oes
olksw not
byV gu
ara
– Unbolt bracket -2- and unscrew securing nuts -4- from turbo‐
rised
nte
charger. ut
ho eo
ra
s a c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unscrew securing bolt -2- and remove upper coolant pipe.
rrectness of i
l purpos
Note
Lower coolant pipe can only be removed following removal of
nform
ercia
main catalytic converter.

m
at
om
io
satelettronica
n
c
– Unscrew bolts -1- and remove pressure pipe.
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
– Remove securing bolts -arrows- for engine splash guard. rig ht
py by
co Vo
by lksw
– Remove front right wheel housing liner: ⇒ General body re‐ cted agen
Prote AG.
– Remove cables for lambda probe after catalytic converter -
G130- and alternator from cable guides -arrows-.
– Pull connector from lambda probe after catalytic converter -

G130- and remove.

Touran 2003 ➤
– Open hose clamp -3- and remove charge air pipe -2-.
– Unbolt exhaust pipe from rear silencer -arrows-.
satelettronica
pipe backwards.
– Also pull out exhaust pipe with flexible joint.
– Remove main catalytic converter downwards.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
– Unscrew securing bolts for tensioning element -arrows- and

le
un
pt
remove.
an
d
itte
y li
erm
ab

ility
ot p

wit
is n
h re
ole,
spec
Note
t to the co
The air conditioning system lines must not be opened.

rrectne
– Secure air conditioner compressor to lock carrier.

– Ensure that lines are not kinked.
ss o
cial p
– Remove alternator ⇒ Electrical system; Rep. Gr. 27 ; Re‐

in
moving and installing alternator .

form
mer
atio
– Bring lock carrier into service position ⇒ General body repairs,

om

c
i
or
sition .
thi
te
sd
iva
– Unscrew securing bolt -arrow- for oil return pipe -2- from tur‐
pr
cum
r
fo
bocharger.
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
129
co Vo
by lksw
cted
1. Turbocharger
agen
Prote AG.
Touran 2003 ➤
– Pull oil return pipe downwards.

– Unbolt charge air hose -1- from turbocharger.
– Unscrew banjo bolts for oil supply pipe -arrows- from turbo‐
charger and crankcase.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
– Remove oil supply pipe.

itte
y li
erm
ab
– Unscrew all securing nuts from exhaust manifold -1-.
ility
ot p
wit
is n
– Pull out exhaust manifold with turbocharger upwards.
h re
ole,
spec
Note
t to the co
satelettronica
Turbocharger can only be renewed with exhaust manifold.
rrectne
Installing
ss
o
cial p
f i
note the following:
nform
mer
atio
♦ Renew seals, gaskets and self-locking nuts.
om
n
c
i
or
n
♦ Fill turbocharger with engine oil at connection for oil supply thi
te
sd
line.
iva
o
pr
cum
r
♦ After installing turbocharger, run engine for about 1 minute at

fo
en
ng
idling speed to insure that oil is supplied to turbocharger.

t.
yi Co
Cop py
t. rig
♦ Hose connections and hoses for charge air system must be yri
gh by
ht
free of oil and grease before assembly. cop Vo
by lksw
cted agen
Prote
♦ Secure all hose connections with hose clamps comparable to
AG.
production standard.
♦ Install exhaust system and align it free of stress.
♦ If renewed, place seal in groove of charge air hose. Ensure
that seal is completely in groove.
♦ Lightly coat seal with engine oil.
♦ Bring securing clip -arrow- to release position.
♦ When installing air pipes with plug-in connectors, ensure that
the securing clip -arrow- engages audibly on the retaining lug
-A-.
Torque settings:
Assembly overview - turbocharger ⇒ page 124
Assembly overview - charge air system ⇒ page 141
Assembly overview - catalytic converter and attachments
⇒ page 168 .
1.5 Checking turbocharger vacuum unit


Touran 2003 ➤
♦ Hand vacuum pump -VAS 6213-
lkswage es n
Vo ot g
– Check correct seat of securing clip -1- on vacuum unit d bylinkage. ua
ran
ir se tee
Securing nut -2- must be locked with sealing paint.utho
or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
satelettronica
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Pull hose -arrow- from vacuum unit.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
– Place hose -2- onto vacuum unit union.
cop Vo
by lksw
cted agen
Prote AG.
– Slide switch ring -1- on hand vacuum pump -VAS 6213- to stop
in -direction of arrow-.
1. Turbocharger 131
Touran 2003 ➤
– Operate hand vacuum pump -VAS 6213- until a pressure of

700 bar is attained on pressure gauge.
Vacuum unit linkage -1- must move in -direction of arrow-.
If pressure of 700 bar is displayed:
Pressure unit is OK.
wage es n
If pressure drops abruptly: yV
olks ot g
ua
b
ed ran
– Renewing turbocharger with vacuum unit and exhaust
horis mani‐ tee
fold ⇒ page 126 . aut or
ac
ss
ce
e
nl
pt
du
an
Note itte
y li
erm
ab
ility
ot p
Vacuum unit can only be renewed together with turbocharger.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
satelettronica
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
AG. Volkswagen AG d
agen oes
olksw not
yV gu
2 Compressor d b ara
ise nte
or eo
h
aut ra
Assembly overview - compressor ⇒ spage 133
s c
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le
un
Removing and installing compressor ⇒ page 134 .
pt
an
d
itte
y li
2.1 Assembly overview - compressor
erm
ab
ility
ot p
wit
is n
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1 - Housing with noise insula‐ ole,
spec
tion
t to the co
❑ For intake silencer.
2 - Intake silencer
rrectne
❑ For intake air.
3 - Intake hose
ss
❑ Secure with spring-type
o
cial p
f
clips.
inform
mer
4 - 7 Nm
atio
m
❑ Self-tapping screw.
o
n
c
i
or
satelettronica
thi
❑ Securing bolt may only
te
sd
a
be tightened with a
iv
o
pr
c
pneumatic nut runner if
um
r
fo
en
ng
this has a max. speed of yi

t.
Co
500 rpm and a tighten‐ . Cop py
ing torque of max. 7 Nm
ht rig
rig ht
by
is set. copy Vo
by lksw
cted agen
Prote
5 - 7 Nm
AG.
6 - 7 Nm
be tightened with a
this has a max. speed of
500 rpm and a tighten‐
is set.
7 - O-ring
❑ Renew.
8 - Pressure pipe
9 - Noise insulation
10 - Housing
❑ For noise insulation.
11 - Intake silencer
❑ For charge air.
❑ With seal.
❑ Renewing seal between compressor and intake silencer.
12 - Pulley
❑ For compressor.
13 - 8 Nm
14 - Coolant pump with magnetic clutch for supercharger -N421-
15 - Poly-V-belt
❑ For compressor.
2. Compressor 133
Touran 2003 ➤
16 - 23 Nm
❑ For compressor poly-V-belt.
❑ Lock with locking pin -T10060 A- .
18 - 40 Nm + 1/4 turn (90°) further
❑ Renew.
❑ To loosen and tighten securing bolt, counterhold compressor shaft with spanner.
19 - Compressor
20 - 25 Nm
2.2 Removing and installing

lksw
agen
AG. Vocompressor
lkswagen AG
does
n
o ot g
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edb ran
ris tee
ut
ho or
satelettronica
equipment required ss a ac
ce
e
nl
pt
du
an
5024A-
itte
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erm
ab
ility
ot p
Nm) -V.A.G 1331-

wit
, is n
♦ Guide pins -T10341- h re

hole
spec
es, in part or in w
♦ Mandrel -T10060 A-
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
4-cylinder injection engine (1.4 l direct injection engine,
. Volkswage
turbocharger) - Edition 01.2006
AG n AG d
agen oes
olksw not
Removing db
yV gu
ara
rise nte
tho eo
s au ra
c
Note s
ce
e
nl
pt
du
an
Before carrying out further work, disconnect battery earth strap.
itte
y li
erm
ab
ility
first if necessary.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
cooling system.
rrectness of i
l purpos
Note
nf
ercia
or
m
m
atio
VAS 5024A- .
om
n in
or c
satelettronica
thi
e

t
sd
iva
off.
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
wards in -direction of arrow-. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Unclip spring clip from intake hose -arrow-.
2. Compressor 135
Touran 2003 ➤

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Unscrew hose clamp -1- from charge air pipe.
es, in part or in w
t to the co
– Unscrew securing bolt for charge air pipe -2-.
– Remove front right wheel housing liner: ⇒ General body re‐
rrectness of i
l purpos
satelettronica
nform
ercia
– Remove right drive shaft ⇒ Running gear, axles, steering;

Rep. Gr. 40 ; Repairing drive shafts; Removing and installing
m
at
drive shafts. .
om
ion
c
in t
r
– Remove lambda probe after catalytic converter -G130- -1-.

o
his
ate
do
priv
c
um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Unbolt exhaust pipe from front silencer -arrows-.

Touran 2003 ➤

pipe backwards.
– Also pull out exhaust pipe with flexible joint.
– Press securing clip on charge air cooler in

-direction of arrow- and pull hose -arrow- off.
satelettronica
– Unscrew securing bolt for charge air pipe -arrow- and remove
charge air pipe -1- downwards. agen
AG. Volkswagen AG d
o w es n
olks ot g
byV ua
ed ran
ris tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Slacken compressor poly-V-belt by swinging tensioning ele‐

ment in -direction of arrow- with a spanner.
– Lock tensioning element in position with locking pin -T10060
rrectness of i
A- .
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Compressor 137
Touran 2003 ➤
– Unscrew securing bolts -arrows- for tensioning element and

remove tensioning element.
– Tightly hold compressor shaft with a spanner -1-.
– Remove securing bolt -2- for pulley and remove pulley and
compressor poly-V-belt -3-.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
– Pull both coolant hoses -1- from heating heat exchanger.hor eo
aut ra
s c
– Open hose guide clips -2- and push hoses to side. s
ce
e
nl
pt
du
– Carefully press locking lugs on noise insulation housing
an
itte
y li
-arrows- outwards.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Pull off front housing with noise insulation.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touran 2003 ➤
AG. Volkswagen AG d
– Unscrew compressor securing bolts -1- and remove compres‐ wage
n oes
olks not
sor together with intake air silencer. db
y V gu
ara
e nte
ris
Remove intake silencer for charge air: utho eo
ra
a c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Pull intake silencer for charge air -2- together with pressure
pipe in -direction of arrow-.
rrectne
Installing
ss o
cial p
f in
Note
form
mer
atio
m
♦ Renewing O-rings on pressure pipe ⇒ Item 7 (page 133) .

o
satelettronica
n
c
i
or
n
♦ Before installing, lightly coat O-rings with engine oil.
thi
te
sd
iva
o
r
♦ Pressure pipe can only pushed in one position into intake si‐
p
cum
r
fo
lencer for charge air (note locating pin).
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
– Push intake silencer for charge air -2- together with pressure p by
co Vo
pipe in -direction of arrow- into intake connecting pipe.
by lksw
cted agen
Prote AG.
– Push intake silencer for charge air -2- against crankcase so
both fitted sleeves -3- are seated in bores.
– Screw guide bolts -T10341- hand-tight into both lower threa‐

ded holes to stop.
– Renew seal -1- and ensure it is positioned correctly in groove.
– Push compressor with intake silencer for intake air onto guide
bolts -T10341- and tighten upper securing bolts hand-tight.
– Unscrew guide bolts -T10341- .
– Tighten lower securing bolts hand-tight.
– Tighten securing bolts evenly and diagonally.
2. Compressor 139
Touran 2003 ➤

– Position housing with noise insulation onto compressor.
Note
Ensure noise insulation is correctly positioned in housing.
– Press housing with noise insulation against compressor until

locking lugs -arrows- engage audibly.
Perform further installation in reverse order, paying attention to
the following:
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
u ra
satelettronica
s a c
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
♦ Renew seals, gaskets and self-locking nuts.
h re
hole
spec
♦ Renew securing bolt for compressor pulley.
es, in part or in w
t to the co
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly.
rrectness of i
l purpos
♦ Install exhaust system and align it free of stress.
nform
ercia
♦ If renewed, place seal in groove of charge air hose. Ensure

that seal is completely in groove.
m
a
com
tio
♦ Lightly coat seal with engine oil.
n in
r
te o
♦ Bring securing clip -arrow- to release position. thi

s
iva
do
r
rp
♦ When installing air pipes with plug-in connectors, ensure that

um
fo
en
g
the securing clip -arrow- engages audibly on the retaining lug

n
t.
yi Co
-A-. Cop py
t. rig
gh ht
yri
Torque settings: p by
co Vo
by lksw
cted agen
Assembly overview - charge air system ⇒ page 141 Prote AG.

⇒ page 168 .

AG. Volkswagen AG d Touran 2003 ➤
agen(1.4 l direct injection
4-cylinder injectionVoengine oes engine, turbocharger) - Edition 01.2006
lksw not
by gu
ara
ed nte
oris eo
th
3 Charge
ss air system
au ra
c
ce
e
nl
Assembly overview - charge air system ⇒ page 141
pt
du
an
itte
y li
Checking charge air system for leaks ⇒ page 141 . erm
ab
ility
ot p
3.1 Assembly overview - charge air system
wit
, is n
h re
hole
spec
1 - Charge air cooler
es, in part or in w
t to the co
❑ To remove, bring lock
carrier into service posi‐
tion ⇒ General body re‐
rrectness of i
pairs, exterior; Rep. Gr.
50 ; Body, front; Lock
l purpos
carrier - service posi‐

tion .
nf
ercia
o
2 - 5 Nm
rm
m
atio
m
3 - Mounting
o
n in
or c
❑ For charge air cooler
thi
te
sd
iva
satelettronica
4 - Seal
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
❑ Coat lightly with engine C py
ht. rig
oil before installing. rig ht
py by
co Vo
by lksw
5 - Charge air hose Prote
cted AG.
agen
6 - Intake manifold connection

❑ With seals.
7 - Throttle valve module -
J338-
❑ Clean ⇒ page 157 .
❑ If renewed, erase learnt
values and adapt en‐
gine control unit ⇒ Vehi‐
cle diagnosis, testing
and information system
VAS 5051 “Guided func‐
tions”.
8 - 7 Nm
9 - Hose clip
10 - Charge air hose
11 - 10 Nm
12 - Charge air pipe
13 - Charge air pressure sender -G31- with intake air temperature sender 2 -G299-
14 - 5 Nm
❑ To turbocharger
16 - Charge air pipe
3.2 Checking charge air system for leaks

3. Charge air system 141

Touran 2003 ➤
♦ Charge air system tester -V.A.G 1687-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b
satelettronica
d ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
♦ Engine bung set -VAS 6122- (not illustrated)
wit
, is n
h re
hole
spec
off.
es, in part or in w
t to the co
rrectness of i
– Press hose lock and pull hose for crankcase breather -1- from
intake connecting pipe.
l purpos
Caution
nform
ercia
Crankcase breather hose must be removed when checking for

m
a
com
leaks to avoid damage to engine. tion in

r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
– Seal intake connecting pipe with a bung from engine bung set
Co
op py
-VAS 6122- .
t. C rig
gh ht
pyri by
Vo
– Remove spring clips -2- from intake hose and remove intake
co lksw
by
cted agen
hose. Prote AG.

Touran 2003 ➤
– Replace spring clips -arrows- with screw clips from charge air
system tester -V.A.G 1687- .
– Push adapter -V.A.G 1687/6- into intake hose -2- and secure
hose to intake connecting pipe using screw clips -1- from
charge air system tester -V.A.G 1687- .
Prepare charge air system tester -V.A.G 1687- as follows: agen AG. Volkswagen AG do
lksw es n
o ot g
yV ua
db ran
ir se tee
ho
aut or
ac
ss
satelettronica
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Unscrew pressure regulating valve -2- and close valves -3-
hole
spec
and -4-.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
a
– Connect charge air system tester -V.A.G 1687- as shown.

iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Charge air system 143

Touran 2003 ➤
– Connect pressure hose -1- (compressed air supply) to charge

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

– Adjust pressure to 0.5 bar with pressure regulating valve -2-.
Caution
The pressure must not exceed 0.5 bar! If the pressure is too
high this can cause damage to the engine.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary readjust pressure to 0.5 bar.
– Check the charge air system for leaks by listening, touching,
with commercially available leak detector spray or using ultra‐
satelettronica
sonic tester -V.A.G 1842- .
Note
♦ Slight leaks in the area of the intake connecting pipe

-arrows- are permissible, as the intake hoses are not designed
for high pressure.
♦ A small amount of air escapes via the valves into aengine.
gen AG
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Therefore a holding pressure test is not possible.
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♦ How to use the ultrasonic tester -V.A.G oris1842- ⇒ operating tee
instructions au
th or
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ss
♦ Before removing the adapter, depressurise the test circuit by
ce
le
un
pt
pulling coupling off adapter -V.A.G 1687/6- .

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d
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♦ Hose connections and hoses must be free of oil and grease

ab
ility
before assembly.
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♦ After pressure testing, the intake hoses must be secured with

h re
ole,
spring clips again.

spec
t to the co
rrectness o
cial p
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mer
atio
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Touran 2003 ➤
24 – Mixture preparation - injection

1 Repairing injection system
Parts l and II - assembly overview - intake manifold
⇒ page 145 .
Assembly overview - fuel rail with injectors ⇒ page 151
Checking vacuum reservoir for leaks ⇒ page 152 .
Assembly overview - air filter ⇒ page 153 .
Removing and installing
wage
air
n AGfilter
. Volk⇒
swpage 153
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Vol t
Removing and ed installing regulating flap control unit -J808-
by gu
ara and
throttle valve
ho module -J338- ⇒ page 154 .
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Clean sthrottle
s valve module -J338- ⇒ page 157
ce
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nl
pt
Removing and installing injectors ⇒ page 158 .
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Safety precautions ⇒ page 161 .
erm
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ility
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Technical data ⇒ page 163 .
hole
spec
es, in part or in w
General notes on injection

t to the co
♦ The engine control unit is equipped with self-diagnosis. Before
carrying out repairs and fault finding, read fault memory. Also
rrectness of i
the vacuum hoses and connections must be checked (unme‐

tered air).
l purpos
♦ Fuel hoses in engine compartment must be secured only with

spring-type clips. The use of clamp or screw-type clips is not
nf
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permissible.
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♦ For trouble-free operation of electrical components, a voltage

om
of at least 11.5 V is necessary.

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♦ Do not use sealants containing silicone. Particles of silicone

t
sd
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drawn into the engine will not be burnt in the engine and dam‐
r
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age the lambda probe.

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♦ Vehicles are fitted with a crash fuel shut-off circuit. It reduces
C py
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the danger of a fire in a crash as the fuel pump is switched off
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via the fuel pump relay. The system also improves the starting
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characteristics of the engine. When door is opened, the fuel
agen
Prote AG.
pump is activated for 2 seconds to build up pressure in the fuel
system.
1.1 Parts l and II - assembly overview - in‐

take manifold
Part I - assembly overview - intake manifold ⇒ page 147 .
Part II - assembly overview - intake manifold ⇒ page 149 .
1. Repairing injection system 145

Touran 2003 ➤
satelettronica
AG. Volkswagen AG d
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ab
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spec
es, in part or in w
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146 Rep. Gr.24 - Mixture preparation - injection

AG. Volkswagen AG d
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d ara
4-cylinder injection engine ris (1.4 l direct injection engine, turbocharger)
e nte - Edition 01.2006
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1.2 Part I - assembly overview - intake manifold
ce
le
un
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ab
1 - Intake air temperature
pe
ility
sender 3 -G520- with intake
ot
wit
manifold pressure sender 3 -
, is n
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G583-
hole
spec
2 - 5 Nm
es, in part or in w
t to the co
3 - 7 Nm
rrectness of i
be tightened with a
l purpos

this has a max. speed of
nform
ercia
500 rpm and a tighten‐

m
a
is set.
com
tion in
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4 - Intake connecting pipe
thi
s
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5 - Seal
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❑ Coat lightly with clean
satelettronica
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engine oil when instal‐
Co
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❑ Renew.
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6 - Regulating flap control unit
-J808-
⇒ page 154 .
❑ If renewed, erase learnt
values and adapt en‐
gine control unit ⇒ Vehi‐
cle diagnosis, testing
and information system
VAS 5051 “Guided func‐
tions”.
7 - 7 Nm
be tightened with a pneumatic nut runner if this has a max. speed of 500 rpm and a tightening torque of
max. 7 Nm is set.
8 - Intake connecting pipe
9 - Intake manifold connection
10 - 7 Nm
❑ Securing bolt may only be tightened with a pneumatic nut runner if this has a max. speed of 500 rpm and
a tightening torque of max. 7 Nm is set.
11 - 5 Nm
12 - Intake manifold pressure sender -G71-
13 - O-ring
❑ Renew.
14 - Intake manifold
❑ To remove, removing and installing regulating flap control unit -J808- and throttle valve module -J338-
⇒ page 154 .

Touran 2003 ➤
15 - 20 Nm
16 - Fuel pressure sender -G247- , 20 Nm
17 - 20 Nm
18 - Intake manifold, lower part
and intake manifold ⇒ page 154 .
❑ Erase learnt values and adapt intake manifold flap potentiometer -G336- to engine control unit ⇒ Vehicle
diagnosis, testing and information system VAS 5051 “Guided functions”.
❑ Before removing and installing, lock vacuum actuator using a 2.5 mm drill bit.
❑ After installing new intake manifold lower part, remove vacuum actuator retaining clip .
❑ After installing, check function of intake manifold flap using hand vacuum pump -VAS 6213-
19 - Gasket
❑ Renew.
❑ Note installation position.
20 - 1.5 Nm
21 - Intake manifold flap potentiometer -G336-
❑ If renewed, erase learnt values and adapt engine control unit ⇒ Vehicle diagnosis, testing and information
satelettronica
system VAS 5051 “Guided functions”.
22 - 10 Nm
23 - Vacuum actuator
❑ For intake manifold flap.
24 - 20 Nm AG. Volkswagen AG d
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25 - Throttle valve module -J338- d b ara
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❑ Removing and installing ⇒ page 154 . autho eo
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❑ Clean ⇒ page 157 . s
ce
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nl
pt
❑ If renewed, erase learnt values and adapt engine control unit ⇒ Vehicle diagnosis, testing and information
du
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26 - 7 Nm
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27 - Pressure pipe
h re
hole
❑ Coat seals lightly with clean engine oil when installing. spec
es, in part or in w
❑ From turbocharger
t to the co
28 - Securing clip
rrectness of i
29 - 7 Nm
l purpos
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mercia
at
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c
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ate
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co lksw
by
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Prote AG.

Touran 2003 ➤
1.3 Part II - assembly overview - intake manifold
1 - Connection
2 - Fuel hose
clips.
ing.
3 - Connecting pipe
4 - Fuel hose
❑ Low pressure
❑ To high-pressure pump
5 - Retaining clip
6 - Connecting hose
satelettronica
❑ To activated charcoal fil‐
ter solenoid valve 1 -
N80-
. Volkswagen AG
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7 - Activated charcoalolkfilter
swa sol‐ not
enoid valve 1 -N80-byV gu
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8 - Connecting
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9 - To pressure pipe
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10 - Connecting pipe
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ab
11 - Connecting hose
ility
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❑ To intake manifold con‐

, is n
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nection.
hole
spec
12 - 8 Nm
es, in part or in w
t to the co
13 - Fuel pipe
❑ High pressure
rrectness of i
❑ Torque setting for union

nuts: 18 Nm.
l purpos
14 - Connection
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❑ To intake connecting pipe

m
at
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ion
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16 - Non-return valve
or
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ate
❑ For crankcase breather

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18 - Charge pressure control solenoid valve -N75- C py
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❑ To turbocharger
21 - Connection
22 - 5 Nm
❑ To turbocharger

Touran 2003 ➤
AG. Volkswagen AG d
24 - Connection agen oes
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25 - Connection rised
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❑ To charge pressure control solenoid valve -N75- .
, is n
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hole
28 - Connection
spec
es, in part or in w
t to the co
❑ Connected to valve timing housing.
29 - Vacuum hose
rrectness of i
❑ From vacuum reservoir
l purpos
30 - Vacuum hose
❑ To vacuum actuator
nform
ercia
31 - Vacuum hose
m
a
com
ti
❑ To intake manifold flap valve -N316-
satelettronica
n in
r
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thi
32 - Vacuum hose
s
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do
❑ To intake manifold
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33 - Filter
n
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34 - Intake manifold flap air flow control valve -N316- ht. rig
rig ht
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35 - Connection
by c lksw
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❑ For vacuum hoses.
36 - Connection
37 - Vacuum hose
❑ To intake manifold
38 - Fuel hose
❑ To intake manifold lower part.
❑ For fuel return.

Touran 2003 ➤
1.4 Assembly overview - fuel rail with injectors

AG. Volkswagen AG d
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1 - Securing clip d byV gu
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❑ Ensure correct seating hor eo
ut
on injector and retaining ss a ra
c
plate.
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an
2 - O-ring
d
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ab
❑ Renew. pe
ility
❑ Before installing lightly
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wit
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moisten with clean en‐
h re
hole
gine oil.
spec
es, in part or in w
3 - Spacer sleeve
t to the co
4 - No. 4 cylinder injector -N33-
❑ No. 1 cylinder injector -
rrectness of i
N30-
l purpos

N31-
nform
ercia
satelettronica
N32-
m
a
com
t
❑ With seal.
ion in
r
❑ Seal must be renewed

te o
thi
after removing injector.
s
iva
do
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rp
c
um
fo
en
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⇒ page 158 .
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t.
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5 - Vacuum hose
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rig by
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6 - Return line
co lksw
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❑ From high-pressure
AG.
pump.
❑ Blue or with blue mark‐
ing.
clips.
ing.
7 - 20 Nm
8 - Pressure limiting valve
❑ Renew removed valve
❑ Before installing lightly moisten O rings with clean engine oil.
❑ Press in by hand using an 8 mm hexagon key.
9 - Intake manifold, lower part
and intake manifold ⇒ page 154 .

Touran 2003 ➤
Checking function of intake manifold flap

– After installing a new intake manifold lower part, remove vac‐
uum positioning element retaining clip -arrow-.
– Connect hand-operated vacuum pump -VAS 6213- as shown.
– Generate a vacuum and check function of vacuum positioning AG. Volkswagen AG d
agen
element on lever arm. Volksw
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Note ss
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When intake manifold is removed, the function of intake manifold
du
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itte
flap can be checked simultaneously.
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erm
ab
ility
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1.5 Checking vacuum reservoir for leaks
h re
hole
spec
es, in part or in w
t to the co
♦ Hand vacuum pump -VAS 6213-
rrectness of i
satelettronica
l purpos
nform
mercia
at
om
ion
c
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ate
do
priv
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Test prerequisites
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Perform visual check if all vacuum hoses on intake manifold are co Vo
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not damaged and connected properly.
agen
Prote AG.
Test procedure
– Pull vacuum hose -arrow- from vacuum reservoir.
Vacuum reservoir is integrated into engine cover.
– Connect hand vacuum pump -VAS 6213- to union -arrow-.
– Screw in knurled screw on hand vacuum pump -VAS 6213- .
– Operate hand vacuum pump until a pressure of 0.3 bar is at‐
tained on pressure gauge.
Note
Due to the high volume in the vacuum reservoir 20 strokes can

be necessary to generate a pressure of 0.3 bar.
– Observe pressure approx. 3-5 minutes.

If pressure of 0.3 bar is displayed:
Vacuum reservoir is OK.
If pressure drops:
– Renew engine cover with vacuum reservoir.

Touran 2003 ➤
1.6 Assembly overview - air filter

Removing and installing air filter ⇒ page 153
1 - 8 Nm
2 - Air filter housing - upper part
3 - Vacuum hose
Caution
To avoid damaging un‐ olks
wage es n
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ion and vacuum hose, by V do ua
ed ran
not use sharp oristools to tee
pull off hose.
au
th or
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❑ From camshaft housing.
erm
ab
ility
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4 - Spring-type clip
wit
, is n
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❑ Remove and install us‐
satelettronica
hole
ing spring-type clip pli‐
spec
ers -VAS 5024A-
es, in part or in w
t to the co
5 - Intake hose
6 - Cover
rrectness of i
7 - Intake air duct
l purpos
8 - Air filter housing - lower part

❑ With intake connection.
nf
ercia
orm
m
9 - Water drain connection

atio
om
❑ On installation, arrows
n in
or c
on air filter housing low‐

thi
te
sd
a
er part and water drain

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connection must align.

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t.
10 - O-ring
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❑ Renew.
t. rig
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11 - Filter element
lksw
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Prote AG.
1.7 Removing and installing air filter

Removing
– Pull coolant hose up out of brackets -arrows-.
– Press latches -1- and pull intake air duct cover up.

Touran 2003 ➤
– Press latches -arrows- and pull intake air duct up.

– Release spring clip -1- and pull intake hose from air filter.
– Pull vacuum hose -3- from air filter housing.
Caution
To avoid damaging union and vacuum hose, do not use sharp

tools to pull off hose.
satelettronica
– Loosen securing bolt -2- and pull air filter housing up off lo‐
cating pins -arrows-.
Installing
Installation is carried out in the reverse sequence of removal. In
the process, note the following:
– Press air filter housing from above onto locating pins
-arrows-.
. Volkswagen AG
– Tighten securing bolt -2- to 8 Nm and push spring
swa
gen AGclip -1- with does
intake hose onto air filter connection.by Volk not
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– Push vacuum hose -3- onto union
tho on air filter housing.
ri e or
au ac
ss
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pt
du
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itte
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erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
1.8 Removing and installing regulating flap

rrectness of i
control unit -J808- and throttle valve

module -J338-
l purpos
nf
ercia
Note
rm
m
atio
om
To remove throttle valve module -J338- , regulating flap control

n in
or c
unit -J808- must first be removed.

thi
te
sd
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cu

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en
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t.
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Cop py
t. rig
gh ht
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by
cted agen
Prote AG.

Touran 2003 ➤
AG. Volkswagen AG d
agen oes
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byV gu
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ed
♦ Spring-type clip pliers -VAS 5024A- horis nte
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nl
pt
du
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itte
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erm
ab
ility
ot p
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, is n
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satelettronica
hole
spec
es, in part or in w
t to the co
rrectness of i
Removing regulating flap control unit -J808-
l purpos

off.
nform
ercia
m
at
om
ion
c
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ate
do
riv
– Unscrew securing bolts -1-.

p
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
– Loosen spring clips and pull hose -2- from active charcoal filter
system solenoid valve 1 -N80- and pressure pipe -3-.
– Unscrew securing bolt for pressure pipe -3- from turbocharger
and pull pressure pipe -3- off.

Touran 2003 ➤
– Pull all connectors and hose connections from intake connect‐

ing pipes -4- and regulating flap control unit -J808- .
AG. Volkswagen AG d
agen oes
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y V gu
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– Unscrew securing bolts -arrows- from intake connecting
utho
pipes eo
ra
a
and pull intake connecting pipes up with regulating
ss flap control c
unit -J808- .
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nl
pt
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itte
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erm
ab
ility
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, is n
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hole
satelettronica
spec
es, in part or in w
t to the co
rrectness of i
– Unscrew securing bolts -arrows-.
l purpos
Removing throttle valve module -J338-
nf
ercia
o
– Detach coolant hose -1- from hose clamps.
rm
m
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om
n in
or c
thi
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sd
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t.
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pyri by
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co lksw
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cted agen
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– Pull connector -2- from intake air temperature sender 3 -G520-
with intake manifold pressure sender 3 -G583- .
– Remove charge air hose -3- from throttle valve module -J338-
and charge air pipe.

Touran 2003 ➤
– Unscrew securing bolts -arrows- and pull throttle valve module

-J338- from intake manifold connection.
Installing
note the following:
♦ Gaskets and seals must be renewed.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly.
Torque settings:
Part I - assembly overview - intake manifold ⇒ page 147 .
If a new regulating flap control unit or throttle valve module has
been installed:
– Erase learnt values and adapt engine control unit to regulating
olks
wage es n
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flap control unit or throttle valve module ⇒ Vehicle diagnosis,
db
y V ua
ran
testing and information system VAS 5051 “Guided or functions”.
ise tee
th
satelettronica
or
s au ac
s
1.9 Cleaning throttle valve module -J338-
ce
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un
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erm
ab
Note
ility
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♦ If a new engine control unit is installed the throttle valve mod‐
ole,
ule must be adapted. Adaption must only be performed with a
spec
new or cleaned throttle valve module, because soiling/carbon
t to the co
deposits in closed throttle valve can lead to incorrect adaption
values.
♦ When cleaning the throttle valve housing it must not be
rrectne
scratched.
ss o
cial p
f inform
– Remove throttle valve module ⇒ page 154 .
mer
atio
m
– Open throttle valve by hand and lock in open position using a

o
n
c
suitable object (e.g. wood or plastic wedge) -arrow-.

i
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WARNING
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ng
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Acetone is highly inflammable. Please observe the accidental Cop py
t.
regulations and safety notes when handling with highly inflam‐
rig
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mable fluids. Do not use compressed air when cleaning the
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throttle valve. Wear eye protection and protective clothing to cted agen
Prote AG.
avoid injuries and skin contact.

Touran 2003 ➤
– Thoroughly clean throttle valve housing, especially around

closed throttle valve -arrows-, using commercially available
acetone to DIN 53247 standard and a cleaning brush. AG. Volkswagen AG d
agen oes
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– Wipe off throttle valve housing using a lint-free cloth. by Vol not
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– Wait until the acetone is fully evaporated and reinstallththe
or eo
cleaned throttle valve module. ss au ra
c
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e
– Erase learnt values and adapt engine control unit to throttle
nl
pt
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valve module ⇒ Vehicle diagnosis, testing and information
itte
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erm
ab
ility
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hole
spec
1.10 Removing and installing injectors
es, in part or in w
t to the co
rrectness of i
equipment required
l purpos

Nm) -V.A.G. 1331-
nf
ercia
satelettronica
orm
5024A-
m
atio
om
♦ Workshop set for FSI en‐
n in
or c
gines -T10133-
thi
te
sd
iva
o
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f
en
ng
t.
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Cop py
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gh ht
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Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
1.10.1 Removing
WARNING

– Remove fuse for fuel pump from fuse holder. Fuse assignment
AG. Volkswagen AG d
⇒ Current flow diagrams, Electrical fault finding andl
Fitting
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agen lo‐ oes
not
cations d byV
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Note ss
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nl
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du
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For reasons of safety, the voltage supply to the fuel pump is in‐
itte
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terrupted through the removal of fuse. Otherwise opening the
erm
ab
ility
driver door would start the fuel pump.
ot p
wit
, is n
h re
hole
spec
WARNING
es, in part or in w
satelettronica
t to the co
Fuel system is under pressure! Wear eye protection and pro‐
tective clothing to avoid injuries and skin contact. Before loos‐
ening hose connections, wrap a cloth around the connection.
rrectness of i
Then release pressure by carefully pulling hose off connection.
l purpos
nform
ercia

m
at
om
– Seal lines so that fuel system is not contaminated by dirt.
ion
c
in t
or
– Remove the upper part and lower part of the intake manifold
his
ate
⇒ page 147
do
priv
cum
or
– Pull retaining clip and spacer sleeve off injector.

f
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ng
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Cop py
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rig ht
py by
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cted agen
Prote AG.
– Set puller -T10133/1- on injector -1-. Ensure that puller hooks

engage into recesses of injector -arrows-.
– Tighten knurled nut of puller hand-tight.

Touran 2003 ➤
– Screw slide hammer -T10133/3- onto -T10133/1- .

– Pull injector out of cylinder head by tapping gently.
1.10.2 Installing
– Clean hole in cylinder head with nylon cylinder brush -
T10133/4- .
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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– Carefully clean injector in area of seal -arrow-. Remove
aut
h coking ra
deposits using a wire brush. ss c
ce
e
nl
pt
– Carefully cut open seal with a knife.
du
an
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erm
– Clean groove for seal.
ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Attach assembly cone -T10133/5- with a new oil seal -1- to

injector -2-.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Touran 2003 ➤
– Slide oil seal further onto assembly cone -T10133/5- using

assembly sleeve -T10133/6- .
– Turn assembly sleeve -T10133/6- and slide seal into groove
for seal.
– Press calibration sleeve -T10133/7- onto injector to stop by

turning gently (approx. 180°).
– Pull off calibrating sleeve -T10133/7- by turning in opposite
direction.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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– Press calibration sleeve ised-T10133/8- onto injector to stop by uara
b
nte
turning gently (approx. ho 180°).
r eo
aut ra
s c
– Pull off calibrating
s sleeve -T10133/8- by turning in opposite
ce
le
direction.
un
pt
an
d
itte
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– Replace O-rings on injector and on spacer sleeve.

erm
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– Before installing, moisten O-rings with clean engine oil.

wit
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spec
Note
t to the co
The seal must not be oiled.

rrectne
– Insert injector into cylinder head.

ss o
Note
cial p
f inform
mer
The injector must be easily inserted. If necessary wait until the

atio
m
seal has contracted sufficiently.

o
n
c
i
or
n thi
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– Install retaining clip and spacer sleeve.

t
sd
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cedure.
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1.11 Safety precautions py by
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cted agen
Prote AG.
WARNING
Fuel system is under pressure! Wear eye protection and pro‐

tective clothing to avoid injuries and skin contact. Before loos‐
ening hose connections, wrap a cloth around the connection.
Then release pressure by carefully pulling hose off connection.

Touran 2003 ➤
To prevent injuries to persons and/or damage to the injection and

ignition system, the following must be observed:
♦ For safety reasons, fuse for fuel pump must be removed from
fuse holder on left under dash panel before opening fuel sys‐
tem. Otherwise fuel pump may be activated by driver door
contact switch. Fuse assignment ⇒ Current flow diagrams,
♦ Do not touch or pull off ignition wiring when engine is running
or turning at starter speed.
♦ Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as test instrument cables.
AG. Volkswagen AG d
agen oes
olksw Caution not
byV gu
ara
ed
ris nte
When doing anyut repair work, especially in the engine compart‐
ho eo
ra
ment, pay attention
ss a to the following due to the cramped condi‐ c
tions:
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
satelettronica
wit
sitions.
, is n
h re
hole

spec
es, in part or in w
t to the co
Observe following if test and measuring instruments are required

rrectness of i
during a road test:

l purpos
♦ Test and measuring instruments must be secured to rear seat

and operated by a second person from this location.
nform
ercia
If test and measuring instruments are operated from front pas‐

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

r
te o
thi
s
♦ If the engine is to be turned at starter speed without starting:

iva
do
r
rp
cum
– Pull all 4-pin connectors -arrows- off ignition coils.

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

Touran 2003 ➤
– Fit puller -T10094- on ignition coil with final output stage

-arrow- for this purpose.
– Pull ignition coil with final output stage out slightly.
– Fit assembly tool -T10118- as shown.
– Carefully release connector locking mechanism and pull off
connector.
– When installing ignition coil for final output stage, slide con‐
agen
AG. Volkswagen AG d
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nector on until it audibly engages. Volksw not
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– Fit puller -T10094- as shown. nl
pt
du
an
itte
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– Press ignition coil with final output stage into cylinder head in
erm
ab
direction of -arrow-.
ility
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hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
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or c
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connecting.
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fluffy cloths! C py
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be carried out immediately. Prote
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agen

tool boxes etc.).
essary.
1.13 Technical data

Engine code BMY
Idling check
Idling speed12) rpm 630...780
Engine control unit
System Motronic MED 9.5.10
Engine speed governor rpm from approx. 5600
12) Not adjustable

Touran 2003 ➤
2 Engine control unit

. Volkswage
Removing and installing engine gen AG unit ⇒ page
acontrol 164
n AG d
oes .
ksw n ol ot g
yV ua
Removing and installing ed banti-theft engine control unit ran
ris
⇒ page 165 . ut
ho
tee
or
a ac
ss
2.1 Removing and installing engine control
ce
le
un
pt
unit
an
d
itte
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rm
ab
If you wish to replace the engine control unit, connect the ⇒ Ve‐
pe
ility
hicle diagnosis, testing and information system VAS 5051 and
ot
wit
, is n
carry out the guided function “Renew control unit”.
h re
hole
spec
Removing
es, in part or in w
t to the co
Rep. Gr. 50 ; Body front; Plenum chamber bulkhead
rrectness of i
– Loosen securing nuts -arrows- for control unit bracket.
l purpos
– Release connector on engine control unit and pull off connec‐
satelettronica
tor.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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rp
cum
fo
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Push bracket -1- off engine control unit.
Installing
– Push bracket -1- onto engine control unit.

Touran 2003 ➤
– Tighten securing nuts -arrows- to 10 Nm.

– Fit connector to engine control unit and lock in position.
– If engine control unit is renewed, clear learnt values and adapt
– Install plenum chamber bulkhead ⇒ General body repairs;
– The readiness code will have toAbe created once the fault
G. Volkswagen AG d
memory has been deleted.
lkswagen oes
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– Carry out a road ritest.
se
db ran
tee
tho or
– Read controls aunit
u fault memory again. ac
s
ce
le
un
pt
2.2 Removing and installing anti-theft en‐
an
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itte
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gine control unit
rm
ab
pe
ility
satelettronica
ot
wit
, is n
h re
hole
♦ Hot air blower from wiring harness repair set -VAS 1978-
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
♦ Nozzle from wiring harness repair set -VAS 1978-

rp
cum
fo
en
ng
t.
If you wish to replace the engine control unit, connect the ⇒ Ve‐ op
yi Co
hicle diagnosis, testing and information system VAS 5051 and
C py
t. rig
gh
carry out the guided function “Renew control unit”.
ht
pyri by
Vo
co lksw
by
Removing
cted agen
Prote AG.

Rep. Gr. 50 ; Body front; Plenum chamber bulkhead .
Note
The shear bolt threads are coated with locking compound. Heat‐
ing the shear bolts with a hot air blower releases the locking effect
of the locking compound.
Caution
Cover lines, connections and control units in the vicinity of the

engine control unit to prevent damage through heat (scorching/
melting of plastics etc.).
2. Engine control unit 165

Touran 2003 ➤
Perform settings on hot air blower -4- as shown:

– Turn temperature setting potentiometer -2- to maximum power
(600°C).
– Set two-stage switch for volume of air -3- to position 3.
WARNING
Parts of the protective housing will become very hot as a result

of heating the shear bolts. Wear protective gloves to avoid
possible injury.
– Place nozzle of hot air blower close to shear bolt.

– Switch on hot air blower and heat bolt for approximately 20 to
25 seconds.
– Twist shear bolts -arrows- out using pliers and remove cover
of protective housing. olks
wage es n
o V t gu
by ara
– Release connector on engine control unit and
ris pull off connec‐
ed nte
tor. o
satelettronica
th eo
au ra
c
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Then remove securing nuts for control unit bracket -arrows-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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op
– Press catches -1- and -2- outwards. Then pull engine control C py
t. rig
unit off control unit bracket in -direction of arrow-.
gh ht
pyri by
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Installing cted agen
Prote AG.
– Push engine control unit onto control unit bracket until it en‐
gages in catches.

Touran 2003 ➤
– Tighten securing bolts -arrows- to 10 Nm.

– Remove cover of protective housing.
– Tighten new shear bolts -arrows- evenly until heads shear off.
– Select “guided functions” in the vehicle diagnosis, testing and
information system -VAS 5051B- .
– Perform vehicle identification and select engine code.
– Perform function “Renew control unit”.
– If engine control unit is renewed, clear learnt values and adapt
satelettronica
– Install plenum chamber bulkhead ⇒ General body repairs;
Volkswag
– The readiness code will have to be created AG.
agen once the faultAG does
en
ksw
memory has been deleted. by
Vol not
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a
ed ran
– Carry out a road test. ris tee
tho or
s au ac
– Read control unit fault memory
s again.
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
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c
i
or
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fo
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Engine control unit 167

Touran 2003 ➤
26 – Exhaust system
1 Parts of exhaust system
Note
♦ After working on the exhaust system ensure that the system

is not under stress, and that there is sufficient clearance to the
bodywork. If necessary, loosen double and single clamps and
align silencer and exhaust pipe so that sufficient clearance is
maintained to the bodywork and the support rings are evenly
loaded.
♦ Renew self-locking nuts.

⇒ page 168 .
Assembly overview - silencer with mountings ⇒ page 170
satelettronica
Separating centre and rear silencers ⇒ page 170 .
1.1 Assembly overview - catalytic converter and attachments
1 - Heat shield
2 - 10 Nm
3 - Lambda probe after catalyt‐
ic converter -G130-
❑ Grease only the threads
AG. Volkswagen AG d
with “G 052 112 A”; lksw
agen oes
not
“G 052 112 A” must not by V o gu
ara
get into the slots on the rised
nte
o
probe body. aut
h eo
ra
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❑ If sealing ring is leaking,
s
ce
le
nip open and renew.

un
pt
an
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itte
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4 - Gasket
erm
ab
ility
❑ Renew.
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5 - Exhaust pipe
h re
ole,
spec
6 - Double clamp, 25 Nm
t to the co
❑ For separate replace‐

ment of centre and rear
silencers.
rrectne
❑ Tighten bolted connec‐

tions evenly.
ss
7 - 25 Nm
o
cial p
f in
❑ Renew.
form
mer
8 - Mounting
atio
om
n
c
9 - 25 Nm
or
n thi
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sd
a
10 - Exhaust pipe
iv
o
pr
cum
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❑ With flexible connection

fo
en
ng
(de-coupling element).
t.
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Cop py
❑ Do not bend flexible
t. rig
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connection more than p by
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cted agen
Prote AG.
168 Rep. Gr.26 - Exhaust system

Touran 2003 ➤
10° - otherwise it can be

damaged.
11 - 25 Nm
❑ Renew.
12 - 40 Nm
❑ Renew.
❑ Coat studs of turbocharger with high-temperature paste.
13 - Main catalytic converter with exhaust pipe
AG. Volkswagen AG d
14 - 25 Nm ksw
agen oes
not
Vol
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15 - Bracket ise
d b ara
nte
or eo
h
16 - Lambda probe -G39- , 50 Nm s aut ra
c
s
❑ Grease only the threads with “G 052 112 A3”; “G 052 112 A3” must not get into the slots on the probe
ce
e
nl
pt
body.
du
an
itte
y li
❑ Remove and install with lambda probe open ring spanner set -3337- .
erm
ab
ility
ot p
17 - 10 Nm
wit
, is n
h re
18 - 20 Nm
hole
satelettronica
spec
❑ Renew.
es, in part or in w
t to the co
❑ Coat studs of exhaust manifold with high-temperature paste.
19 - Turbocharger
rrectness of i
❑ Turbocharger and exhaust manifold can only be renewed together.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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o
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en
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t.
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.
1. Parts of exhaust system 169

Touran 2003 ➤
1.2 Assembly overview - silencers with mountings
1 - Mounting
2 - 25 Nm
3 - Bracket
❑ Note installation posi‐
tion.
4 - Centre silencer
❑ Combined in one unit
with rear silencer as
original equipment. Can
be renewed individually
for repair purposes
❑ Aligning exhaust sys‐
tem free of stress
❑ Separating centre and
rear silencers
⇒ page 170 .
satelettronica
5 - 25 Nm
6 - Bracket
❑ Note installation posi‐
tion.
7 - Mounting
8 - Rear silencer
9 - Mounting
lkswage es n
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byV ua
d ran
ir se tee
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nl
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ility
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, is n
1.3 Separating centre and rear silencers

h re
hole
spec
♦ The connecting pipe can be cut through at the point marked

es, in part or in w
t to the co
in order to renew the centre and rear silencers separately.

♦ The cutting location is marked by an indentation on the cir‐
cumference of the exhaust pipe.
rrectness of i

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
170 Rep. Gr.26 - Exhaust system

Touran 2003 ➤
♦ Chain-type pipe cutter -VAS 6254-
or
♦ Pneumatic sabre saw -V.A.G 1523A-
Procedure
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c ce
e
– Cut through exhaust pipe at separating point -arrow 2- using

nl
pt
du
chain pipe cutter -VAS 6254- or body saw -V.A.G 1523A- .

an
itte
y li
erm
ab
– Position clamp -4- centrally at side marks when installing - ar‐

ility
ot p
rows -1- and -3-.

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Install clamp so that the bolt ends do not protrude beyond bot‐
nf
ercia
tom of clamp -arrow-.

orm
m
• Bolted connection faces rear.

atio
om
n in
c
– Aligning rear silencer free of stress ⇒ page 172

or
thi
te
sd
a
Torque settings
iv
o
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f
en
Component Nm
ng
t.
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op
Double clamp 25
C py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Parts of exhaust system 171

Touran 2003 ➤
Align rear silencer.

– Align rear silencer so that dimensions -a- are identical.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
172
AG.
Rep. Gr.26 - Exhaust system
Touran 2003 ➤
28 – Ignition system
1 Repairing ignition system
General notes on ignition system
♦ The engine control unit is equipped with self-diagnosis.
gen AG
. Volkswagen AG
d wa oes
olks not
♦ For trouble-free operation of electrical components,
db
yV a voltage gu
ara
of at least 11.5 V is necessary. orise nte
eo
h
ut ra
♦ During some checks, the engine ss control unit may detect and
a c
store a fault. Therefore after completing all checks and repairs
ce
le
un
pt
the fault memory must be read and if necessary cleared.
an
d
itte
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erm
Assembly overview - ignition system ⇒ page 173
ab
ility
ot p
Removing and installing ignition coils with output stage
wit
is n
⇒ page 174
h re
ole,
spec
Safety precautions ⇒ page 175 .
t to the co
Spark plug test data ⇒ page 176 .
satelettronica
1.1 Assembly overview - ignition system
rrectnes
1 - Connector
s o
cial p
f
❑ Black, 4-pin
inform
❑ with assembly tool -
mer
atio
T10118-
om
n
c
i
2 - Ignition coil 3 with output
or
n thi
e
stage -N291-
t
sd
iva
o
pr
c
❑ Ignition coil 1 with output
um
r
fo
stage -N70- en
ng
t.
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❑ Ignition coil 2 with output C py
ht. rig
stage -N127- rig ht
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❑ Ignition coil 4 with output
by c lksw
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stage -N292-
Prote AG.

⇒ page 174 .
3 - Connector
❑ Black, 2-pin.
❑ For knock sensor 1 -
G61- .
❑ Gold-plated connector
contacts.
4 - Knock sensor 1 -G61-
❑ Gold-plated connector
contacts.
❑ Remove to remove
compressor
⇒ page 134 .
5 - 20 Nm
❑ The torque setting influ‐
ences the function of the
knock sensor.
6 - Connector
❑ Black, 3-pin
❑ For Hall sender -G40- .
1. Repairing ignition system 173

Touran 2003 ➤
7 - Hall sender -G40-

8 - O-ring
9 - 10 Nm
10 - Spark plug, 30 Nm
❑ Remove and install with spark plug spanner -3122 B- .
❑ Type and electrode gap ⇒ page 176 .
11 - Cable guide
❑ Bolt to camshaft housing with 5 Nm torque.
12 - Earth wire
❑ Loosen or tighten only with ignition switched off.
13 - 10 Nm
❑ Loosen or tighten only with ignition switched off.
1.2 Removing and installing ignition coils
satelettronica
with output
swa
gstage
en AG. V
olkswagen AG
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Special tools andseworkshop
db equipment required ara
nte
ri
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♦ Assemblyautool
t -T10118- ra
c
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
♦ Puller -T10094-
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
174 Rep. Gr.28 - Ignition system

AG. Volkswagen AG d
agen oes
Volksw Touran no2003
t gu ➤
y
rised engine,
b
turbocharger) - Edition 01.2006
ara
nte
tho eo
au ra
Removing ss c
ce
le
un
– Fit puller -T10094- on ignition coil with final output stage
pt
an
d
itte
-arrow-
y li
rm
ab
pe
– Pull ignition coil with final output stage out slightly.
ility
ot
wit
, is n
– Fit assembly tool -T10118- as shown.
h re
hole
spec
– Carefully release connector locking mechanism and pull off
es, in part or in w
connector.
t to the co
Installing
– Fit puller -T10094- on ignition coil with final output stage.
rrectness of i
– Push connector onto ignition coil with final output stage until it
l purpos
audibly engages.
nform
ercia
– Press ignition coil with final output stage into cylinder head in
m
direction of -arrow-.
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
satelettronica
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.3 Safety precautions

To prevent injuries to persons and/or damage to the injection and
ignition system, the following must be observed:
♦ Do not touch or pull off ignition wiring when engine is running
or turning at starter speed.
♦ Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as test instrument cables.
Observe following if test and measuring instruments are required
during a road test:
♦ Test and measuring instruments must be secured to rear seat
and operated by a second person from this location.
If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there is a
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
♦ If the engine is to be turned at starter speed without starting:
– Pull all 4-pin connectors -arrows- off ignition coils with final
output stages ⇒ page 174 .
– Remove fuse for fuel pump control unit from fuse holder on left
under dash panel. Fuse assignment ⇒ Current flow diagrams,
Note
Removing fuse interrupts voltage supply for fuel pump control

unit.
1. Repairing ignition system 175

Touran 2003 ➤
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176 Rep. Gr.28 - Ignition system

Service: Touran 2003

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Service

Edition 01.2006 AG. Volkswagen A

Service Department. Technical Information

20 - Fuel supply system

24 - Mixture preparation - injection

All rights reserved.

Copyright © 2010 Volkswagen AG, Wolfsburg K0058972520

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 Removing and installing sealing flanges and flywheel or drive plate . . . . . . . . . . . . . . . . . . 25

2.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.2 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.3 Removing and installing crankshaft pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.4 Renewing crankshaft sealing flange - flywheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

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

1.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

1.2 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

1.3 Adjusting valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

1.2 Assembly overview . . . . . . . . . . . . . . . . . . . . . .G.. V. o. lk. s.w.a.ge. n. . . . . . . . . . . . . . . . . . . . . . . . . . 70

1.3 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

1.4 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 95

2.3 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

3 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

1 Repairing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

1.3 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

1.4 Spark plug test data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

1.1 Engine number

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

Capacity cm3 1390

Torque Nm at rpm 220/2000-4000

Valves per cylinder 4

10 – Removing and installing engine

Special tools and workshop

♦ Engine and gearbox jack -

♦ Engine and gearbox sup‐

♦ Drip tray for workshop hoist

2 Rep. Gr.10 - Removing and installing engine

♦ Spring-type clip pliers -VAS

1.1 Removing engine

1. Removing and installing engine 3

– Unbolt heat shield over turbocharger -arrows-.

– Release hose guides -arrows- and remove coolant hose -1-

– Disconnect fuel supply line -1- and line to activated charcoal

4 Rep. Gr.10 - Removing and installing engine

– Remove securing bolts -arrows- for engine splash guard.

– Disconnect battery ⇒ Electrical system; Rep. Gr. 27 ; Dis‐

connecting and connecting battery .

Gr. 27 ; Removing and installing battery .

protective gloves to avoid injuries and skin contact. Before

– Pull vacuum and breather hoses off engine.

– Remove securing nuts -arrows- for engine control unit.

1. Removing and installing engine 5

– Remove cables for lambda probe after catalytic converter -

G130- and alternator from cable guides -arrows-.

– Unbolt exhaust pipe with flexible joint -arrows-.

6 Rep. Gr.10 - Removing and installing engine