Volkswagen Touareg (2003 year). Manual - part 2

intake hose and air filter housing on left.

– Separate connectors -1- to -4- for Lambda probes and lay

connectors on engine.

Note

Connector for cylinder bank 1 = black, connector for cylinder bank

2 = brown

– Remove intake hose on right leading to throttle valve module.
– Pull intake hose leading to secondary air pump motor -V101-

off upper part of air filter and remove upper part of air filter.

– Remove air filter element.

– Then pull connecting line -arrow- to air suspension compres‐

sor off right air filter housing downwards 

⇒ page 135

 .

– Unclip gearbox breather hose from air filter housing.
– Remove bracket for engine cover on right 

⇒ page 134

 .

– Pull lower part of air filter from air duct 

⇒ Item 10 (page 134)

on right and remove it.

– Extract refrigerant from air conditioning system: ⇒  Heating, air

conditioning; Rep. gr.  87

– Remove insulation tray: ⇒  General body repairs, exterior;

Rep. gr.  50 ; Body - front; Assembly overview - noise insulation

– Loosen double clamp between catalytic converter and centre

silencer and slide clamp forward.

– Support exhaust system between rear silencer and centre si‐

lencer using engine and gearbox jack -V.A.G 1383 A- , un‐

screw mountings and lower exhaust system.

– Remove rear propshaft tube ⇒  Transfer box and final drive;

Rep. gr.  39 ; Removing and installing propshaft .

– Remove front wheels.
– Remove front wheel housing liners ⇒  General body repairs,

exterior; Rep. gr.  66 ; Exterior equipment; Removing and in‐

stalling wheel housing liner; Front wheel housing liner

– Disconnect hose connection to vacuum reservoir in front left

wheel housing.

Touareg 2003 ➤

1. Removing and installing engine    

5

Repairing steering, power-assisted steering

– Separate connectors -A- on gearbox as well as transfer box

-B- and separate selector lever cable ⇒  Automatic gearbox;

Rep. gr.  37 ; Controls, housing .

– Separate brake lines at brake hoses in wheel housings and

collect brake fluid which runs out. ⇒  Brake system; Rep. gr. 

46 ; Repairing front wheel brake

– Separate all connectors between body and front axle in wheel

housings.

– Unbolt connecting lines of air suspension at suspension strut.

– Remove gearbox transverse support -A-.

WARNING

Steam may escape when expansion tank is opened. Wear eye

protection  and  protective  clothing  to  avoid  eye  injuries  and

scalding. Cover cap with cloth and open carefully.

– Open and close expansion tank cap to release pressure in

cooling system.

– Drain coolant 

⇒ page 86

 .

– Disconnect hose connection to heat exchanger working from

left wheel housing side and collect escaping coolant.

– Disconnect upper coolant hose from radiator and lower cool‐

ant hose from coolant pipe.

Touareg 2003 ➤

6

oil. Collect escaping oil.

– Now disconnect line from power steering oil cooler on bottom

left. Collect escaping oil.

– Unscrew earth cable -1- from longitudinal member on front

right.

– Disconnect coolant hose -3- and unscrew coolant pump with

bracket -2-.

– Now unscrew one of the rear securing bolts -3-.

– Secure subframe to body ⇒  Running gear, axles, steering;

Rep. gr.  40 ; l - Assembly overview - subframe, lower sus‐

pension links, anti-roll bar .

– Then proceed with other securing bolt -3- in the same way.
– On each side of vehicle, remove the two hard-to-access sus‐

pension strut bolts working from plenum chamber side ⇒ 

Preparing scissor-type assembly platform -VAS 6131- for further

procedure:

Touareg 2003 ➤

1. Removing and installing engine    

7

VAS 6131/6-2- right -2- on the assembly platform. Arrows on

the supports point forwards. Secure the bolts in the following

positions: left support -1-: A5, B4 and B5. Right support -2-:

G4, H4 and H5

– Bolt both suspension supports -3- -VAS 6131/6-3- and

6131/6-4 to the assembly platform in the following positions:

left suspension support -3-: A6 and C6. Right running gear

support -3-: F6 and H6

– Screw the suspension support turntables down.
– Place supports -4- (VAS 6131/6-5) for subframe and -5- (VAS

6131/6-6) for gearbox console in appropriate positions on as‐

sembly platform.

– Position assembly platform horizontal under engine/gearbox

assembly. Supports -1- must be guided into corresponding

receptacles on left and right -arrow-.

– At the same time, guide right and left mountings for gearbox

bracket into corresponding holes -arrow-. When all four sup‐

ports are in the receptacle holes without pressure:

– Screw the two rotating plates of running gear supports under

the suspension links applying a small amount of pre-tension.

– Guide supports -2- into their respective receptacles in sub‐

frame, correcting support height as necessary with knurled

nuts.

Touareg 2003 ➤

8