Volkswagen TOUAREG - Service Manual Page 1

Self-Study Programme 297Service.Touareg

10BodyThe Touareg’s raw bodyStatic rigidityThe body of the Touareg has a very high static rigidity. It does not warp, even during offroad driving, whe

11To improve the look of the vehicle, the roof is connected to the side parts by laser soldering. As a result, the seam is unnecessary. Safety aspects

12BodyBodywork attachmentsEngine bonnetThe engine bonnet is completely constructed of aluminium. The outer plate is 1.15 mm thick, the inner plate 0.9

13Rear window moduleThe rear window module is made up of glass and a sheet metal frame. The parts have a new, special technique of plastic extrusion c

14BodyTwo acoustic insulation packages were developed for the Touareg. The package for petrol engines consists of bitumen foil sound deadening. For di

15Four different systems are available for the Touareg: - a rigid design, - a USA design with a square seat to fasten a separate towing ball, - a desi

16BodyThe tailgate of the Touareg is divided into two parts, consisting of an individual flip-up rear window and the tailgate itself. Two pairs of gas

17Rear window wiperThe motor for the rear window wiper is located in the tailgate, while the wiper is installed in the rear window. For this reason, t

18BodyThe front seats of the Touareg have their own sporty characteristics, such as raised side cushions. They are heated by the electric seat heater

1912-position seatThe 12-position seat has the following additional possible adjustments: ● Seat horizontal inclination● Lordosis supportAll adjustmen

2After the Passat W8 and the innovative Phaeton, the Touareg completes the trio in Volkswagen’s luxury class product strategy. The Touareg is primaril

20BodyThe rear of the Touareg is equipped with a bench. It is designed for three persons, providing a head rest and a 3-point belt for each position.

21S297_016S297_017S297_019In order to mount a roofrack, two chamfered C-rails are inserted into the roof of the Touareg; the carriers can be inserted

22Passenger protectionAirbag systemAirbagsThe following airbags are installed in the Touareg: - Driver and (front) passenger airbag (approx. 64 l and

23Airbag control deviceThe airbag control device is located in the centre console. It receives the signals of the six crash sensors, evaluates the dat

24Passenger protectionRestraining systemsBeltsThree-point retracting seat belts are located at all five seats in the Touareg. The belt lock and the be

25Child seat fastenersIsofix child seat fasteners are attached to the front passenger seat as well as to the outer seats of the rear bench. Additional

26Drive units3.2l V6 petrol engineThe 3.2l V6 petrol engine, a further development of the 2.8l V6 engine, is also installed in the Phaeton. Due to the

27Engine mechanics technical featuresDue to the offroad capability of the Touareg, special demands are made in terms of inclination and fordability. T

28Drive units4.2l V8 petrol engineThe V8 engine was optimised and further developed especially for the Touareg, especially for offroad use.Technical d

29Offroad-capable oil intakeAmong other things, the oil intake was adapted to offroad use. During extreme climbs and driving perpendicular to slopes,

3In a nutshell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30Drive units5l V10 TDI engineThe V10 TDI engine is a newly developed diesel engine. It is equipped with the pump-jet injection system and combines in

31In order to utilise the available installation space to the greatest extent possible, the fuel tank consists of a main chamber and a secondary chamb

32Power transmission6-speed automatic gearbox 09DCompared to the 5-speed automatic transmission, the 09D 6-speed automatic transmission provides a red

33Technical data Volkswagen designation AG6 09DGearbox codes with V10 TDI enginewith V6 engineEXGEXLATF Lifetime fillingATF filling amount with V10 TD

34Power transmissionIn its basic design, the 6-gear automatic gearbox does not differ from other automatic gearboxes. It consists of: ● the torque tra

35P - ParkingTo move the selector lever out of the Park setting, the ignition must be switched on. In addition, the foot brake and the locking button

36Power transmissionThe Tiptronic in the Touareg is available as a selector lever Tiptronic as well as a steering wheel Tiptronic. The current gear is

37The function of the selector lever lock and the ignition key removal lock is identical to that in the Phaeton. The selector lever is locked by - the

38Power transmission6-speed manual gearbox 08DThe 6-gear manual gearbox was developed just for the Touareg, especially for offroad use.The manual gear

39S297_059Gear-shift leverGearbox housingThe ends of the cable are attached with locknuts to the steering levers. Mass dampers act as a gear shift mas

4In a nutshellThe name Tuareg (or Touareg) means ”free people”. Thus, the Volkswagen Touareg has the name of a traditional African desert tribe that h

40ChassisChassis● Tyre inflation pressure connection under the driver’s seat (only in vehicles with air suspension)● Dual wishbone front suspension● D

41● Foot parking brake,Duo servo drum brake● Conti Teves MK25, ESP system with braking assistant and 4-wheel EDLS297_061● Rear transverse lock and lon

42The comfort and safety electronics are based on that of the Phaeton. Here, we will discuss certain components and installation locations. Electric s

43Control unit for on-board networkAccess and start authorisation relayOrientation illuminationin the exterior mirrorsdriver and front passenger sides

44Heating/air-conditioning systemA total of three different equipment versions are available for the air-conditioning of the vehicle interior in terms

45This system has two operating and display units. The front operating and display unit is located in the dash panel; this can be used mainly to selec

46Heating/air-conditioning system2C-Climatronic The 2C-Climatronic has an operating and display unit in the dash panel. Compared to the 4C-Climatronic

47Manual air-conditioning systemUsing the operating unit in the dash panel, the occupants can set the air-conditioning of the entire interior accordin

48Radio and navigationDelta radio systemWith small deviations, the Delta radio system corresponds to the Delta radio system that can be found, for exa

49The RN S2 radio/navigation systemThe radio/navigation system in the Touareg is a further development that is technically based on the MFD radio/navi

5To test the offroad characteristics of the Touareg, an offroad test track was specially built in Ehra (near Wolfsburg), Germany. Here, the multifacet

50Radio and navigationOperation of RN S2 radio/navigation systemINFO button for: - system information, -off-road display,- list of routes,-TIM functio

51Offroad navigationThe transition between the two navigation types (standard and offroad) occurs automatically; however, the RN S2 does not automatic

52Radio and navigationStarting offroad navigationAfter navigation has been started using the main menu button ”NAVI”, the submenu ”Destination” must b

53WaypointsThe memory of the navigation system allows a total of 50 waypoints to be stored. In the example shown, a tour in which one waypoint has alr

54Service● Portal calibre supplement VAS 5007/16● Spring tensioning unit VAS 6046● Spring bracket VAS 6046/3● Uptake kit for scissors lifting table VA

55Notes

Only for internal use © VOLKSWAGEN AG, WolfsburgAll rights reserved000.2811.17.20 Issued 09/02❀ No chlorine was used to bleach this paperduring manufa

6In a nutshellTechnical equipment● off- and onroad suitability● electronic differential block (EDB)● 4-corner air suspension● two-part tailgate● modul

7Safety● Electronic Stability Programme (ESP)● Electronic Brake Pressure Distribution (EBPD)● front, head and side airbags● electric crash management

8Dimensions and weightsLength Approx. 4,754 mmWidth Approx. 1,928 mmHeight from 1,703 to 1,726 mm*Roof load 100 kgTrailer load 3,500 kgTank volume 100

9Offroad drivingGround clearance: Steel suspension max.: 237 mm Air suspension max.: 300 mmDrivable angle of slope: Steel suspension max.: 28°Air su