Volkswagen Touareg (2003 year). Manual - part 39

Assembly overview - silencers with mountings

1 - Exhaust tailpipe
2 - Rear silencer

❑ Centre and rear silenc‐

ers are installed as a

single component dur‐

ing production. In case

of repair, the centre and

rear silencers are sup‐

plied separately, with a

double repair clamp for

connecting.

❑ In case of repair, align

rear silencer free of

stress.

3 - Mounting

❑ Installation position

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 .

❑ Renew if damaged.

4 - 25 Nm
5 - Exhaust tailpipe
6 - Separating point

❑ For repair cases
❑ Marked by impressions

on exhaust pipe.

❑ Centre and rear silenc‐

ers are installed as a

single component dur‐

ing production. In case

of repair, the centre and

rear silencers are sup‐

plied separately, with a

double repair clamp for

connecting.

❑ Cut through connecting

pipe at right angles at

separating point using e.g. pneumatic sabre saw -V.A.G 1523A- .

❑ The notches to the left and right of the separating points must be visible following the installation of the

double clamp.

7 - Mounting

❑ Installation position 

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 .

❑ Renew if damaged.

8 - 25 Nm
9 - Mounting

❑ Installation position 

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 .

10 - Double clamp

❑ Must be slid to its mid-point on forward exhaust pipe.
❑ Note installation position: Securing bolt ends must not project beyond lower edge of clamp.

11 - Mounting

❑ Installation position 

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 .

12 - Double clamp, 40 Nm

❑ Must be slid to its mid-point on forward exhaust pipe.

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1. Removing and installing parts of exhaust system    

153

❑ Centre and rear silencers are installed as a single component during production. In case of repair, the

centre and rear silencers are supplied separately, with a double repair clamp for connecting.

15 - Double clamp

❑ For repair cases
❑ Installation position 

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 .

Installation position, double repair clamp in direction of travel
– The end of bolt -1- must not project beyond lower edge of

double clamp.

– The angle -2- must be 10° + 5°.

Aligning exhaust system
• Exhaust system cold
– Push exhaust system in direction of travel -1- and tighten dou‐

ble clamps until dimension -a- is attained at the mountings.

Centre silencer: dimension a = 10 mm; Rear silencer: dimen‐

sion a = 15 mm

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154

Secondary air system

Function
The secondary air system blows air in behind the exhaust valves

for max. 65 seconds after a cold start (+15°C … +35°C coolant

temperature). This produces an oxygen rich exhaust gas, causing

afterburning and reducing the heat-up phase of the catalytic con‐

verter. The engine control unit activates the system via the sec‐

ondary air pump relay -J299- to the secondary air inlet valve -

N112- and combination valve. Additionally, after each

subsequent engine start (up to max. 80  C engine temperature),

the secondary air system will, after a 20 second delay, switch in

for 5 seconds during idling and will be checked by the self-diag‐

nosis.
Assembly overview - removing and installing parts of secondary

air system 

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2.1

Assembly overview - removing and in‐

stalling parts of secondary air system

Note

Secondary air pump relay -J299- 

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2. Secondary air system    

155

❑ For cylinder bank 1.

2 - 10 Nm
3 - To secondary air inlet valve

-N112-
4 - Combination valve

❑ For cylinder bank 2.

5 - Gasket
6 - Connecting hose

❑ From cylinder bank 1 to

cylinder bank 2.

7 - Secondary air inlet valve -

N112-
8 - 10 Nm
9 - Bracket
10 - Vacuum reservoir
11 - Hose coupling

❑ Press together at front

to release.

12 - Pressure hose

❑ Check for secure seat‐

ing.

❑ Press together at front

to release.

13 - Secondary air pump motor

-V101-
14 - From air filter.
15 - Pressure pipe

❑ Bolted to cylinder head

cover.

16 - 8 Nm
17 - 10 Nm
18 - To secondary air inlet valve -N112-

Secondary air pump relay -J299-

Note

♦

The secondary air pump relay -1- is in socket A4.

♦

If tools are necessary to pull relays or control units out of the

relay plate, first disconnect battery earth strap ⇒  Electrical

ies.

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