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
.
– Unclip gearbox breather hose from air filter housing.
– Remove bracket for engine cover on right
.
– Pull lower part of air filter from air duct
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
– 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
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