Volkswagen Touareg 2003 User manual

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Maintenance

Touareg 2003 ➤

Edition 11.2011

Service

Service Department. Technical Information

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Maintenance

Heading

1. Engine list

2. Service work

3. General

4. Descriptions of work

5. Exhaust emissions test

6. Glossary

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.

Service

No reproduction without prior agreement from publisher.

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Contents

1 Engine list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 Service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.1 Information on long-life service and time or distance dependent service . . . . . . . . . . . . . . 5

2.2 Service tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.1 Raising vehicle with lifting platform or trolley jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.2 Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.3 Connecting vehicle diagnosis tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.4 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.5 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.6 Countries with elevated sulphur content in diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.7 Engine code and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.8 RME fuel (biodiesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.9 Severe operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.10 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.11 Jacking up mode: Switching self-levelling suspension off and on . . . . . . . . . . . . . . . . . . . . 24

4 Descriptions of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.1 Removable towing bracket: Check and clean if necessary . . . . . . . . . . . . . . . . . . . . . . . . 28

4.2 Turbocharger: Lubricate control motor linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4.3 Swivel joints and axle bearings: Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.4 Additive container: Extract fluid and replenish with new additive . . . . . . . . . . . . . . . . . . . . 32

4.5 Diesel particulate filter: Reading the ash load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4.6 Automatic gearbox: Check ATF level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4.7 Battery cut-off relay: Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4.8 Battery: Check battery terminal clamps for secure seating . . . . . . . . . . . . . . . . . . . . . . . . 40

4.9 Battery: Check using battery tester with printer VAS 5097A or VAS 6161 . . . . . . . . . . . . 47

4.10 Reducing agent (AdBlue®): Replenish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4.11 Reducing agent (AdBlue®): Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

4.12 Checking tyres: Condition, wear pattern, tyre pressure, tread depth and age of tyres . . . . 56

4.13 Storing tyre pressure values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

4.14 Thickness of brake pads/linings and condition of brake discs, front and rear: Check . . . . 59

4.15 Brake system and shock absorbers: Perform visual check for leaks and damage . . . . . . 62

4.16 Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

4.17 Brake fluid level (depending on lining/pad wear): Check . . . . . . . . . . . . . . . . . . . . . . . . . . 66

4.18 Diesel particulate filter: Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

4.19 Window regulators: Check positioning (open and close functions) . . . . . . . . . . . . . . . . . . 68

4.20 Vehicles with reversing camera system: Check number plate . . . . . . . . . . . . . . . . . . . . . . 69

4.21 Vehicle system test: Perform test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

4.22 Front airbag for the front passenger: Check activation / deactivation . . . . . . . . . . . . . . . . 70

4.23 Gearbox, final drive (especially on flanges) and drive shaft bellows: Perform visual check for

leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

4.24 Dust and pollen filter: Clean housing and renew filter element . . . . . . . . . . . . . . . . . . . . . . 71

4.25 Poly V-belt: Check condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

4.26 Diesel fuel filter: Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

4.27 Diesel fuel filter: Renew (Diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

4.28 Interior and exterior body: Performing visual check for corrosion when doors and flaps are

open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

4.29 Compass in roof module: Set compass zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

4.30 Cooling system: Check frost protection and coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . 81

4.31 Air filter: Clean housing and renew filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

4.32 Engine oil level: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

4.33 Engine oil: Drain or extract; renew oil filter and replenish engine oil . . . . . . . . . . . . . . . . . . 99

4.34 Engine cover panel -top-: Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

4.35 Removing and installing engine cover -bottom- (noise insulation) . . . . . . . . . . . . . . . . . . . . 108

Touareg 2003 ➤

Maintenance - Edition 11.2011

Contents i

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4.36 Engine and components in engine compartment (from above and below): Perform visual

check for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

4.37 Tyre repair set: Check bottle for damage and if used; check date of tyre sealant . . . . . . . . 110

4.38 Performing road test (driving behaviour, noises, air conditioner etc.) . . . . . . . . . . . . . . . . 110

4.39 Wheel securing bolts: Tighten to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

4.40 Reading radio code using vehicle diagnosis tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

4.41 Radio/navigation system: Activate anti-theft coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

4.42 Power assisted steering: Check oil/fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

4.43 Headlight adjustment: Check and adjust as necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

4.44 Sunroof: Check function, clean and grease guide rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

4.45 Sliding sunroof drains: Check not blocked, clean if necessary . . . . . . . . . . . . . . . . . . . . . . 124

4.46 Window wash/wipe system and headlight washer system: Checking operation and checking

for damage, if necessary replenishing fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

4.47 Wiper blade protection: Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

4.48 Service interval display: Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

4.49 Service interval display: Recode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

4.50 Track rod ends: Check clearance, security and boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

4.51 Transportation mode: Switch off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

4.52 Door arrester: Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

4.53 Elastic drive coupling and freewheel disc: Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

4.54 Underbody: Visual check for damage to underbody sealant, underbody panels, routing of

lines, plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

4.55 Setting time, language and units: On display of combi-instrument . . . . . . . . . . . . . . . . . . 138

4.56 Transfer box and front and rear final drive: Checking oil level, replenishing if necessary . . 140

4.57 Toothed belt for camshaft drive: Renew (8-cylinder petrol engines) . . . . . . . . . . . . . . . . . . 140

4.58 Spark plugs: Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

4.59 Static cornering light (cornering light) and driving light assist: Check function . . . . . . . . . . 151

5 Exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

5.1 Exhaust emissions test for petrol engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

5.2 Exhaust emissions test for diesel engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

5.3 Exhaust emissions test for diesel engines with OBD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

6 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Touareg 2003 ➤

Maintenance - Edition 11.2011

ii Contents

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1 Engine list

This chapter provides information on the following subjects:

♦ Petrol engines ⇒ page 1

♦ Diesel engines ⇒ page 2

Note

To ease the search for an engine, the engine codes are listed in

alphabetical order.

Petrol engines

Engines ⇒ Petrol engine Petrol engine Petrol engine

Capacity I 4.2 3.2 3.2

Engine code AXQ AZZ BAA

No. of cylinders/valves per cylinder 8/5 6/4 6/4

Output kW at 1 rpm 228/6200 162/5400 162/6000

Torque Nm at rpm 410/3000 305/3200 300/4000

Bore ∅ mm 84.5 84.0 84.0

Stroke mm 93 95.9 95.9

Compression ratio 11 11.25 11.25

Injection/ignition Motronic ME 7.1.1

SRE

Motronic ME 7.1.1

SRE

Motronic ME 7.1.1

SRE

RON min.

98 unleaded

1

95 unleaded 95 unleaded

Leakage diagnosis system (e.g.

USA vehicles)

no no yes

Onboard diagnosis (OBD) yes yes yes

Camshaft drive Toothed belt Chain Chain

1) Under exceptional circumstances super unleaded, at least 95 RON, but with

reduced output.

Engines ⇒ Petrol engine Petrol engine Petrol engine

Capacity I 4.2 3.6 3.6

Engine code BAR BHK BHL

No. of cylinders/valves per cylinder 8/4 6/4 6/4

Output kW at 1 rpm 257/6500 206/6200 206/6200

Torque Nm at rpm 440/3500 360/2800 360/2800

Bore ∅ mm 84.5 89.0 89.0

Stroke mm 92.8 96.35 96.35

Compression ratio 11.5 12.0 12.0

Injection/ignition Motronic MED 9.1.1

FSI

Motronic MED 9.1

FSI

Bosch Motronic MED

9.1

FSI

RON min.

98 unleaded

1

98 unleaded

1

98 unleaded

1

Leakage diagnosis system (e.g. USA

vehicles)

yes no yes

Onboard diagnosis (OBD) yes yes yes

Camshaft drive Chain Chain Chain

Touareg 2003 ➤

Maintenance - Edition 11.2011

1. Engine list 1

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1) Under exceptional circumstances super unleaded, at least 95 RON, but with

reduced output.

Engines: ⇒ Petrol engine Petrol engine Petrol engine

Capacity I 6.0 3.2 3.2

Engine code BJN BKJ BMV

No. of cylinders/valves per cylinder 12/4 6/4 6/4

Output kW at 1 rpm 331/6200 162/5400 177/6000

Torque Nm at rpm 600/3500 305/3200 300/4000

Bore ∅ mm 84.0 84.0 84.0

Stroke mm 90.2 95.9 95.9

Compression ratio

10.75 10.85 11.25

Injection/ignition Motronic ME 7.1.1

SRE

Motronic ME 7.1.1

SRE

Motronic ME 7.1.1

SRE

RON min.

98 unleaded

1

95 unleaded 95 unleaded

Leakage diagnosis system (e.g. USA

vehicles)

no no no

Onboard diagnosis (OBD) no no yes

Camshaft drive Chain Chain Chain

1) Under exceptional circumstances super unleaded, at least 95 RON, but with

reduced output.

Engines ⇒ Petrol engine Petrol engine

Capacity I 3.2 3.2

Engine code BRJ BMX

No. of cylinders/valves per cylinder 6/4 6/4

Output kW at 1 rpm 177/6000 177/6000

Torque Nm at rpm 310/3200 305/3200

Bore ∅ mm 84.0 84.0

Stroke mm 95.9 95.9

Compression ratio 11.25 10.85

Injection/ignition Motronic ME 7.1.1

SRE

Motronic ME 7.1.1

SRE

RON min. 95 unleaded 95 unleaded

Leakage diagnosis system (e.g. USA vehicles) no yes

Onboard diagnosis (OBD) yes yes

Camshaft drive Chain Chain

Diesel engines

Engines ⇒ Diesel engine Diesel engine Diesel engine Diesel engine

Capacity I 4.9 2.5 3.0 4.9

Engine code AYH BAC BKS BKW

No. of cylinders/valves per cyl‐

inder

10/2 5/2 6/4 10/2

Output kW at 1

rpm

230/3750 128/3500 165/4000 230/3750

Touareg 2003 ➤

Maintenance - Edition 11.2011

2 1. Engine list

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Engines ⇒ Diesel engine Diesel engine Diesel engine Diesel engine

Capacity I 4.9 2.5 3.0 4.9

Engine code AYH BAC BKS BKW

Torque Nm at rpm 750/2000 400/2000 to 2300 450/1400 to 3250 750/2000

Bore ∅ mm 81.0 81.0 83.0 81.0

Stroke mm 95.5 95.5 91.4 95.5

Compression ratio 18.5 18.5 17.0 18.5

Injection/ignition TDI

unit injector

TDI

unit injector

TDI

common rail

TDI

unit injector

Diesel particulate filter (DPF) no no yes no

Additive system no no no no

Leakage diagnosis system

(e.g. USA vehicles)

no no no no

Onboard diagnosis (OBD) yes yes yes yes

Camshaft drive Gear train Gear train Chain Gear train

Engines ⇒ Diesel engine Diesel engine Diesel engine Diesel engine

Capacity I 4.9 2.5 2.5 2.5

Engine code BLE BPD BPE BLK

No. of cylinders/valves per cyl‐

inder

10/2 5/2 5/2 5/2

Output kW at 1

rpm

230/3750 120/3500 128/3500 120/3500

Torque Nm at rpm 750/2000 400/2000 400/2000 400/2000 to

2300

Bore ∅ mm 81.0 81.0 81.0 81.0

Stroke mm 95.5 95.5 95.5 95.5

Compression ratio 18.5 19.5 19.5 18.5

Injection/ignition TDI

unit injector

TDI

unit injector

TDI

unit injector

TDI

unit injector

Diesel particulate filter (DPF) yes yes yes no

Additive system yes no no no

Leakage diagnosis system

(e.g. USA vehicles)

no no no no

Onboard diagnosis (OBD) yes yes yes yes

Camshaft drive Gear train Gear train Gear train Gear train

Engines: ⇒ Diesel engine Diesel engine Diesel engine Diesel engine

Capacity I 4.9 3.0 3.0 3.0

Engine code BWF BUN CASA CASB

No. of cylinders/valves per cyl‐

inder

10/2 6/4 6/4 6/4

Output kW at 1

rpm

230/3750 155/4000 176/4000 155/3500 to

4750

Torque Nm at

rpm

750/2000 500/1400 550/2000 to 2250 550/2000 to

2250

Bore ∅ mm 81.0 83.0 83.0 83.0

Stroke mm 95.5 91.4 91.4 91.4

Compression ratio

18.5 17.0 17.0 17.0

Touareg 2003 ➤

Maintenance - Edition 11.2011

1. Engine list 3

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Engines: ⇒ Diesel engine Diesel engine Diesel engine Diesel engine

Capacity I 4.9 3.0 3.0 3.0

Engine code BWF BUN CASA CASB

Injection/ignition TDI

unit injector

TDI

common rail

TDI

common rail

TDI

common rail

Diesel particulate filter (DPF) yes yes

yes/no

1

yes

Additive system no no no no

Leakage diagnosis system

(e.g. USA vehicles)

no no no no

Onboard diagnosis yes yes yes yes

Camshaft drive Gear train Chain Chain Chain

Engines: ⇒ Diesel engine Diesel engine Diesel engine

Capacity I 3.0 3.0 4.9

Engine code CASC CATA CBWA

No. of cylinders/valves per cylinder 6/4 6/4 10/2

Output kW at 1 rpm 176/4000 to 4400 165/4500 258/3500

Torque Nm at rpm 500/1500 to 3000 550/2000 850/2000

Bore ∅ mm 83.0 83 81.0

Stroke mm 91.4 91.4 95.5

Compression ratio

17.0 16.4 18.5

Injection/ignition TDI

common rail

TDI

common rail

with and without Blue‐

TDI

unit injector

Diesel particulate filter (DPF) yes yes yes

Additive system no no yes

Leakage diagnosis system (e.g. USA

vehicles)

no no no

Onboard diagnosis yes yes yes

Camshaft drive Chain Chain Gear train

1

Vehicles with diesel particulate filter (fitted at the factory) can be

identified by PR No. 7GG, 7MB, 7MG or 7GA on the vehicle data

sticker.

Touareg 2003 ➤

Maintenance - Edition 11.2011

4 1. Engine list

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2 Service work

This chapter provides information on the following subjects:

Information on long-life service and time or distance dependent

service ⇒ page 5

Service tables ⇒ page 7

2.1 Information on long-life service and time

or distance dependent service

Service identification ⇒ page 5

LongLife service ⇒ page 5

Time or distance dependent service ⇒ page 5

Service interval display ⇒ page 6

2.1.1 Service identification

– Check vehicle data sticker ⇒ page 22 to determine whether

the vehicle is equipped with PR number „QG0“, „QG1“ or

„QG2“. The PR number is decisive for the service intervals

⇒ page 7 .

Vehicle IDs with the following PR number

„QG1“ indicates LongLife service

„QG0“ or „QG2“ indicates time or distance dependent service

2.1.2 LongLife service

Vehicles with PR number „QG1“

The LongLife service enables long service intervals, depending

on individual driving style and the conditions under which the ve‐

hicle is used.

Note

For the LongLife service a special LongLife engine oil is required

⇒ page 7

Vehicles with PR number „QG1“ are fitted at the factory with active

LongLife service. This means, these vehicles have a flexible serv‐

ice interval display and are fitted with the following components:

♦ Flexible service interval display in dash panel insert

♦ Engine oil level sensor

♦ Brake pad wear indicator (if fitted)

For vehicles with LongLife service the service interval is deter‐

mined by the control unit and is indicated on service interval

display (SID) ⇒ page 6 .

Therefore the service intervals for LongLife service are flexible.

These flexible service intervals apply to all types of service in‐

cluding an engine oil change.

2.1.3 Time or distance dependent service

For vehicles with time or distance dependent service with PR

number „QG0/QG2“ the non-flexible service intervals are set by

Volkswagen according to predetermined mileage or time values.

Touareg 2003 ➤

Maintenance - Edition 11.2011

2. Service work 5

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For normal operating conditions achieving these service intervals

is technically assured.

Therefore the service intervals for time or distance dependent

service are non-flexible.

For vehicles

♦ Which were delivered without extended servicing intervals

(ESI) (PR number „QG0“ = without ESI, PR number „QG2“ =

ESI cannot be activated)

♦ When the extended servicing interval (ESI) was stopped

♦ When no LongLife engine oil was used

the time or distance dependent service applies.

These non-flexible service intervals apply to all types of service

including an engine oil change.

Vehicles with PR number „QG0“

Vehicles are „not“ factory-fitted with components for LongLife

service. For maintenance the time or distance dependent inter‐

vals (non-flexible intervals) apply.

Vehicles with PR number „QG2“

For these vehicles the LongLife service is not factory-activated.

Therefore, these vehicles have a non-flexible service interval dis‐

play (SID) ⇒ page 6 and for maintenance the time or distance

dependent intervals (non-flexible intervals) apply. These vehicles

are fitted with the following components:

♦ Non-flexible service interval display in dash panel insert

♦ Engine oil level sensor

♦ Brake pad wear indicator (if fitted)

Vehicles with PR number „QG3“

For these vehicles the LongLife service is not factory-activated.

Therefore, these vehicles have a non-flexible service interval dis‐

play (SID) ⇒ page 6 and for maintenance the time or distance

dependent intervals (non-flexible intervals) apply. These vehicles

are fitted with the following components:

♦ Non-flexible service interval display in dash panel insert

♦ Brake pad wear indicator (if fitted)

2.1.4 Service interval display

Introduction of extended servicing intervals (ESI) ⇒ page 6

Flexible service interval display (only vehicles with LongLife serv‐

ice, PR number QG1) ⇒ page 6

Non-flexible service interval display (only vehicles with time or

distance dependent service, PR number „QG0/QG2)“

⇒ page 7

Service interval display: Reset ⇒ page 133

Service interval display: Recode ⇒ page 134

Introduction of extended servicing intervals (ESI)

Ask your importer if the extended servicing interval (ESI) is avail‐

able for your country.

Touareg 2003 ➤

Maintenance - Edition 11.2011

6 2. Service work

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Flexible service interval display (only vehicles with LongLife serv‐

ice, PR number QG1)

Calculation of service intervals:

♦ To calculate the service intervals for vehicles with LongLife

service, input values such as distance driven, fuel consump‐

tion, oil temperature and load of diesel particulate filter are

evaluated.

♦ The result of the evaluation is a measure of the deterioration

of the oil due to thermal load.

♦ Oil deterioration is the decisive factor in determining the dis‐

tance that can still be driven before the next service.

Note

For vehicles with long-life service (PR number QG1) but which

are serviced according to time or distance dependent service, the

service interval display must be recoded to „non-flexible“

⇒ page 134 .

Non-flexible service interval display (only vehicles with time or

distance dependent service, PR number „QG0/QG2)“

Calculation of service intervals:

♦ To calculate the service interval for vehicles with time or dis‐

tance dependent service the non-flexible service intervals are

set by Volkswagen according to predetermined mileage or

time values.

♦ For normal operating conditions achieving these service in‐

tervals is technically assured.

2.2 Service tables

The following chapter contains the well-known service tables with

the service specifications of the Volkswagen brand. Since, in the

past, individual service specifications were set up in various mar‐

kets, mostly through severe operating conditions, these are listed

in service tables with specific deviations.

Service tables ⇒ page 7

Service tables with market-specific deviations ⇒ page 13

Note

♦

For combined kilometre and time display applies: whichever

occurs first.

♦

Depending on conditions under which the vehicle is used

⇒ page 24 and vehicle equipment, extra service work must

be performed in addition to the interval service, inspection

service or interval service inspection.

♦

It is also possible, to perform additional work outside the serv‐

ice intervals with regard to the entries in the service schedule

(or sticker: your next service).

2.2.1 Service tables

Service intervals ⇒ page 8

VW engine oil standards ⇒ page 9

Filter change intervals ⇒ page 10

Touareg 2003 ➤

Maintenance - Edition 11.2011

2. Service work 7

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Toothed belt change intervals ⇒ page 11

Spark plug change intervals ⇒ page 11

Other time or distance dependent additional work ⇒ page 12

Service intervals

Caution

Only applies to diesel engines:

• In some countries, there is an elevated sulphur content in

diesel fuel.

• The high sulphur content leads to excessive wear of cyl‐

inders and it considerably reduces the cleanliness of pis‐

tons.

♦ Therefore, in countries with elevated sulphur content in

diesel fuel, change engine oil every 7,500 km.

♦ Countries with elevated sulphur content in diesel fuel.

⇒ page 23

Note

♦

For extremely uneconomical driving style or use under ex‐

treme conditions ⇒ page 24 , the shortest interval for an oil

change service is „7,500 km or 1 year“.

♦

However, other intervals apply for other countries. Your im‐

porter will inform you about this.

TOUAREG

SERVICE INTERVALS ►2007

From - to Engine/Engine code/

PR No./Remarks

Service/intervals Indicated on

service interval display SID

(includes oil change)

Since intro‐

duction

Diesel, in countries with elevated

sulphur content in fuel

⇒ page 23

Oil change service

every 7,500 km or 1 year

YES

Since intro‐

duction

Petrol and diesel with QG0/QG2/

QG3

or QG1 vehicles coded to non-

flexible interval

Oil change service

every 15,000 km or 1 year

YES

►2004 Petrol and diesel:

QG1 vehicles

Oil change service

flexible from 15,000 km to

max. 30,000 km or 2 years

YES

►2004 Petrol and diesel:

all vehicles

Inspection service

every 60,000 km or 4 years

YES

2005►2007 Petrol and diesel with QG0/QG2/

QG3

or QG1 vehicles coded to non-

flexible interval

Interval service

every 30,000 km or 2 years

YES

2005►2007 Petrol and diesel:

QG1 vehicles

Interval service

flexible from 15,000 km to

max. 30,000 km or 2 years

YES

2005►2007 Petrol and diesel:

all vehicles

Interval service inspection

every 60,000 km or 4 years

YES

Touareg 2003 ➤

Maintenance - Edition 11.2011

8 2. Service work

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TOUAREG

SERVICE INTERVALS 2008►

From - to Engine/Engine code/

PR No./Remarks

Service/intervals Indicated on

service interval display SID

(includes oil change)

Since in‐

troduc‐

tion

Diesel, in countries with ele‐

vated sulphur content in fuel

⇒ page 23

Oil change service

every 7,500 km or 1 year

YES

2008► Petrol and diesel:

QG0/QG2 or QG1 vehicles

coded to non-flexible interval

Oil change service

every 15,000 km or 1 year

YES

Interval service:

every 30,000 km or 2 years

YES

Petrol and diesel:

QG1 vehicles

Interval service:

flexible according to SID from

15,000 km or 1 year up to max.

30,000 km or 2 years

YES

Petrol and diesel:

all vehicles

Inspection service:

after 3 years or max 60,000 km,

then every 2 years or 60,000 km

NO

VW engine oil standards

Caution

Only engine oils approved by VW may be used, for up-to-date

information see ⇒ ServiceNet, Technical information, Inspec‐

tions and Servicing, Approved oils , or ask your importer.

TOUAREG

VW ENGINE OIL STANDARDS

PETROL ENGINES

With LongLife service (QG1) Without LongLife service (QG0, QG2, QG3)

VR6, V8 engines without FSI

504 00

1

alternative

503 00

2

VR6, V8 engines without FSI ►2007 501 01/502

00

VR6, V8 engines without FSI 2008► 502 00

VR6 FSI, W12-cylinder

504 00

1

alternative

503 01

VR6 FSI, W12 engines ►2007 502 00/505

01

VR6 FSI, W12 engines 2008► 502 00

V8 FSI engine

504 00

1

alternative

503 01

V8 FSI engine 502 00

DIESEL ENGINES

V10 engines

with and without diesel particu‐

late filter

►2006

506 01

3

V10 engines

with and without diesel particulate fil‐

ter

►2006

506 01

3

R5 with engine codes BPD and

BPE

with diesel particulate filter

►2006

507 00

1

R5 with engine codes BPD and BPE

with diesel particulate filter

►2006

507 00

1

R5 engines without diesel par‐

ticulate filter

4

506 01

3

R5 engines without diesel particulate

filter

4

506 01

3

V10 engines without diesel par‐

ticulate filter

4

2007►

507 00

1

alternative

506 01

V10 engines without diesel particulate

filter

4

2007►

507 00

1

al‐

ternative

506 01

Touareg 2003 ➤

Maintenance - Edition 11.2011

2. Service work 9

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TOUAREG

VW ENGINE OIL STANDARDS

R5, V10 engines with diesel par‐

ticulate filter

4

2007►

507 00

1

R5, V10 engines with diesel particu‐

late filter

4

2007►

507 00

1

V6 with diesel particulate filter

507 00

1

V6 with diesel particulate filter

507 00

1

V6 without diesel particulate fil‐

ter

507 00

1

V6 without diesel particulate filter 505 01

1) Combination product: 504 00/507 00

2) Combination product: 503 00/506 00

3) Combination product: 503 00/506 00/506 01

4) Vehicles with diesel particulate filter (fitted at the factory) can be identified by

PR No. 7GG, 7MB, 7MG or 7GA on the vehicle data sticker.

Filter change intervals

TOUAREG

FILTER CHANGE INTERVALS

Description of work

ENGINE OIL FILTER:

1)

2)

⇒ page 99

Vehicles with LongLife service

„QG1“

According to flexible service interval display

All remaining vehicles Every 15,000 km or 1 year

AIR FILTER: ⇒ page 86

All engines except V6 TDI ►2006 Every 120,000 km or 4 years

2007► Every 120,000 km or 6 years

Only V6 TDI ►2006 Every 90,000 km or 4 years

2007► Every 90,000 km or 6 years

DIESEL FUEL FILTER:

2 )

⇒ page 73

Diesel conforming to

EN 590

Diesel not conforming

to EN 590

Biodiesel (RME)

3)

Only R5 TDI Every 120,000 km Every 60,000 km Every 30,000 km

Only V10 TDI Every 60,000 km Every 30,000 km Every 30,000 km

Only V6 TDI Every 60,000 km Every 30,000 km Every 30,000 km

All unit injector diesel engines Draining water is deleted.

All common rail diesel engines Drain water every

30,000 km

Drain water every

15,000 km

DUST AND POLLEN FILTER: ⇒ page 71

All engine types Every 60,000 km or 2 years

1)

A new engine oil filter must be installed at every engine oil

change.

2)

Only applies to diesel engines: In some countries, there is an

elevated sulphur content in diesel fuel. The high sulphur content

leads to excessive wear of cylinders and it considerably reduces

the cleanliness of pistons. Therefore, in countries with elevated

sulphur content in diesel fuel, change engine oil every 7,500 km.

Countries with elevated sulphur content in diesel fuel.

⇒ page 23

Touareg 2003 ➤

Maintenance - Edition 11.2011

10 2. Service work

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1)

For vehicles with diesel particulate filter biodiesel must not be

used.

Toothed belt change intervals

• If the engine is fitted with toothed belt or timing chain can be

found in the engine list.

Note

The camshaft drive with timing chain is maintenance-free!

TOUAREG

TOOTHED BELT CHANGE INTERVALS

PETROL ENGINES

Engine type Engine code Model year Change interval Tensioning roller

4.2 l AXQ Since introduction Every 120,000 km 120,000 km

Spark plug change intervals

• Spark plug designation and specified torque ⇒ Power unit;

Rep. gr. 28 ; Ignition system; Test data, spark plugs →Ignition

system; Test data, spark plugs

Note

For technical reasons it is possible that several cross references

are not directed to the correct chapter. In this case select the pro‐

cedure manually in the information.

TOUAREG

Spark plug change intervals

Engine type Engine code Change intervals Description of

work

W12

V6 SRE

BJN

AZZ, BAA, BHK, BHL,

BKJ, BMV, BRJ, BMX

EVERY 60,000 km

• Mileage more than 60,000 km in 4 years

⇒ page 140

EVERY 4 years

• Mileage less than 60,000 km in 4 years

V8

V6 FSI and TFSI

AXQ, BAR

BHK, BHL

EVERY 90,000 km

• Mileage more than 90,000 km in 6 years

EVERY 6 years

• Mileage less than 90,000 km in 6 years

Touareg 2003 ➤

Maintenance - Edition 11.2011

2. Service work 11

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Other time or distance dependent additional work

Time or distance dependent additional work Interval Description of

work

– Diesel particulate filter: Read ash load

• Only valid for V10 TDI with diesel particulate filter and additive sys‐

tem

• When the ash mass limit is reached, renew diesel particulate filter.

At 90,000 km,

then every

30,000 km there‐

after

⇒ page 38

– Fuel additive container: Extract residual fluid and replenish with new

additive fluid

• Only valid for V10 TDI with diesel particulate filter and additive sys‐

tem

• Only valid for vehicles driving more than 90,000 km in 4 years

Every 90,000 km ⇒ page 32

– Elastic drive coupling and air conditioner compressor drive free‐

wheel. Renew

• Only valid for R5 TDI, engine codes BAC and BLK

Every 150,000

km

⇒ page 137

– Elastic drive coupling and alternator drive freewheel. Renew

• Only valid for R5 TDI, engine codes BAC and BLK

Every 150,000

km

⇒ page 137

– Diesel particulate filter: Read ash load

• Only valid for R5 TDI with diesel particulate filter without additive

system and 3.0 l TDI

• When the ash mass limit is reached, renew diesel particulate filter.

Every 150,000

km,

then every

30,000 km

⇒ page 38

– Elastic drive coupling and air conditioner compressor drive free‐

wheel. Renew

• Only valid for R5 TDI, engine codes BPD and BPE

Every 180,000

km

⇒ page 137

– Elastic drive coupling and alternator drive freewheel. Renew

• Only valid for R5 TDI, engine codes BPD and BPE

Every 180,000

km

⇒ page 137

– Diesel particulate filter: Read ash load

• Only valid for V10 TDI with diesel particulate filter without additive

system

Every 180,000

km

⇒ page 38

– Exhaust emissions test (EET): Perform test

• For vehicles with commercial passenger transport, e.g. taxis

• Only applies to Germany

Every 12 months ⇒ page 152

– Brake and clutch system: Change brake fluid

• Only applies to vehicles ►2007

Every 2 years ⇒ page 63

– Exhaust emissions test (EET): Perform test 3 years after ini‐

tial registration,

then every 2

years

⇒ page 152

– Brake and clutch system: Change brake fluid

• Only applies to vehicles 2008►

3 years after ini‐

tial registration,

then every 2

years

⇒ page 63

Touareg 2003 ➤

Maintenance - Edition 11.2011

12 2. Service work

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Time or distance dependent additional work Interval Description of

work

– Fuel additive container: Extract residual fluid and replenish with new

additive fluid

• Only valid for V10 TDI with diesel particulate filter and additive sys‐

tem

• Only valid for vehicles driving less than 90,000 km in 4 years

Every 4 years ⇒ page 32

– Reducing agent tank: Change fluid

• Only valid for V6 Blue TDI

• Only valid when no reducing agent has been replenished for 4 years

Every 4 years ⇒ page 56

2.2.2 Service tables with market-specific de‐

viations

Note

This chapter only provides information on market-specific devia‐

tions. This means that all maintenance points that are not shown

here are to be found in the normal service tables.

Indian market

Interval Description of

work

Interval service (QG0/QG2/QG3)

2)

Every 15,000 km

or 1 year

1)

→ Mainte‐

nance tables

Inspection service Every 30,000 km

or 2 years

1)

→ Mainte‐

nance tables

– Dust and pollen filter (cabin filter): Renew Every 15,000 km

or 1 year

1)

⇒ page 71

– Air filter element: Renew and clean housing Every 15,000 km

or 1 year

1)

⇒ page 86

– Diesel fuel filter: Replace Every 15,000 km ⇒ page 73

– Spark plugs: Renew Every 30,000 km

or 2 years

1)

⇒ page 140

– Spark plugs: Renew

• Only valid for V6 FSI and TFSI

Every 60,000 km

or 4 years

1)

⇒ page 140

1)

Whichever occurs first

2)

Oil change service has been omitted in the Indian market. The

interval service is carried out as a substitute. Changing the engine

oil is an integral part of the interval service.

Russian market from model year 2010

Interval Description of

work

Interval service (QG0/QG2/QG3)

2)

(appears on service interval display)

Every 15,000 km

or 1 year

1)

→ Mainte‐

nance tables

Touareg 2003 ➤

Maintenance - Edition 11.2011

2. Service work 13

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Interval Description of

work

Inspection service

(does not appears on service interval display)

Every 30,000 km

or 2 years

1)

→ Mainte‐

nance tables

– Dust and pollen filter (cabin filter): Renew Every 15,000 km

or 1 year

1)

⇒ page 71

– Spark plugs: Renew Every 30,000 km

or 2 years

1)

⇒ page 140

– Diesel fuel filter: Replace Every 30,000 km ⇒ page 73

– Air filter element: Check, renew and clean housing Every 30,000 km

or 2 years

1)

⇒ page 86

1)

Whichever occurs first

2)

Oil change service has been omitted in the Russian market.

The interval service is carried out as a substitute. Changing the

engine oil is an integral part of the interval service.

North American market

Interval Description of

work

–Sliding sunroof drains: Check not blocked, clean if necessary Every 60,000 km ⇒ page 124

–Diesel particulate filter: Renew

• Only valid for V10 TDI with diesel particulate filter without additive

system

Every 120,000 miles ⇒ page 67

China market

Note

In the China market, it is not permissible to use engine oils with

VW standard 504 00/507 00 due to the poor quality of the fuel

there. ⇒ page 9

Interval Description of

work

Oil change service (QG0/QG2/QG3)

(appears on service interval display)

Once after 5,000 km → Mainte‐

nance tables

Oil change service (QG0/QG2/QG3)

(appears on service interval display)

Every 10,000 km

or 1 year

1)

→ Mainte‐

nance tables

Interval service (QG0/QG2/QG3)

(appears on service interval display)

Every 20,000 km

or 2 years

1)

→ Mainte‐

nance tables

Inspection service

(does not appears on service interval display)

Every 30,000 km

or 3 years

1)

, and

then every 30,000

km / 2 years

→ Mainte‐

nance tables

– Dust and pollen filter (cabin filter): Renew Every 10,000 km

or 1 year

1)

⇒ page 71

– Spark plugs: Renew

• Only applies to 3.6 l V6 FSI and 4.2 l V8 FSI

Every 20,000 km

or 2 years

1)

⇒ page 140

Touareg 2003 ➤

Maintenance - Edition 11.2011

14 2. Service work

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Interval Description of

work

– Air filter element: Renew and clean housing Every 30,000 km

or 2 years

1)

⇒ page 86

– Diesel fuel filter: Replace Every 30,000 km ⇒ page 73

– Spark plugs: Renew

• Only applies to 6.0 l W12 MPI

Every 30,000 km

or 2 years

1)

⇒ page 140

1)

Whichever occurs first

Touareg 2003 ➤

Maintenance - Edition 11.2011

2. Service work 15

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3 General

This chapter provides information on the following subjects:

♦ Raising vehicle with lifting platform or trolley jack

⇒ page 16

♦ Sticker ⇒ page 17

♦ Entries in service schedule ⇒ page 19

♦ Connecting vehicle diagnosis tester ⇒ page 19

♦ Vehicle identification number ⇒ page 21

♦ Vehicle data sticker ⇒ page 22

♦ Countries with elevated sulphur content in diesel fuel

⇒ page 23

♦ Engine code and engine number ⇒ page 23

♦ RME fuel (biodiesel) ⇒ page 23

♦ Severe operating conditions ⇒ page 24

♦ Type plate ⇒ page 24

♦ Jacking up mode: Switching self-levelling suspension off and

on ⇒ page 24

3.1 Raising vehicle with lifting platform or

trolley jack

Note

When raising the vehicle the jacking up mode must be activated,

then the self-levelling suspension is switched off automatically.

Activate jacking-up mode see ⇒ page 24 .

3.1.1 Safety notes:

WARNING

♦ Before driving onto a lifting platform, ensure that there is

sufficient clearance between low-lying vehicle compo‐

nents and lifting platform.

♦ Before driving a vehicle onto a lifting platform it must be

ensured that the vehicle weight does not exceed the per‐

missible lifting capacity of the platform.

♦ Vehicle may be lifted only at points indicated in figure to

avoid damaging vehicle floor pan or tipping vehicle.

♦ Never start engine and engage a gear with vehicle lifted

as long as even one driven wheel has contact with the

floor! Disregarding these warnings risks the danger of an

accident!

♦ If work is to be performed under vehicle, it must be sup‐

ported by suitable stands.

Touareg 2003 ➤

Maintenance - Edition 11.2011

16 3. General

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Volkswagen Touareg 2003 User manual

Volkswagen Touareg 2003 User manual

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