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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volkswagen Touareg (from 2003 to 2006 year)

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Volkswagen Touareg
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Volkswagen
Touareg
Operation and maintenance of car
Engine
Preliminary checks on the car
Mechanical part (petrol engines 3,2 L)
Mechanical part (petrol engines 4,2 L)
Mechanical part (Diesel 5,0 L)
Removing the engine
Removing and installing subframe
Pressurization system (diesel engines)
Cooling system (petrol engines)
Cooling system (diesel engines)
Lubrication (petrol engines)
Lubrication system (diesel engines)
Injection System (petrol engines)
Fuel injection system (diesel engines)
Exhaust system
Fuel System (beninovye engines)
Tables
Transmission
Chassis
Steering mechanism
Brakes
On-board electrical
Body
Plans electrical
 


Hit Counter by Digits


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Removing the engine



NOTE
The engine is removed along with the gearbox down.
Before dismantling interrogate fault memory of all control units.

NOTE
To ensure the smooth spinning propeller shaft, set the selector lever in position В«NВ».
Leave the key in the ignition to prevent the lock the steering wheel.
Before you start dismantling it is recommended to remove the front wheels. Due to this, the car will be lower on the lift, leaving the arches between the brake discs and the floor a few centimeters. Thus, when the work will ensure optimum reach of all the components in the engine compartment.
Some components in your car or can not be hard to dismantle, without removing the engine. Therefore, before removing the engine to identify all the defective parts and after removing the engine to replace them.
To avoid damage to parts taken, you should use the container for removal of parts VAG 1698.
After installing the engine must be once again set all clamps cables, removed or cut during its dismantling.

NOTICE
In the production of works should be required to comply with the requirement to disable the battery pack.

Turn off the ignition and all electrical consumers.
First, disconnect the battery under the driver's seat.
Then disconnect the second battery, which is located in the trunk, in the depression for the spare wheel.
Remove the left and right wiper levers.
Remove the hood seal on the front wall.

MOTOR
Fig. 2.136. MOTOR


Remove the cover A, B (if any) and C in the engine compartment and D drainage box (Fig. 2.136).

Small plug of the engine control unit
Fig. 2.137. Small plug of the engine control unit


Disconnect the small connector A of the control unit of the engine and disconnect the massive terminal wiring harness (Fig. 2.137).

Connectors
Fig. 2.138. Connectors


Open the fuse box to the left in the drainage box and disconnect the connectors A, B and C (Fig. 2.138).
Izvlekte wiring harness from the drainage box and put it on the engine.
Remove the suction line between the air filter and intake pipe on both sides.

NOTE
If you choke connectors pay attention to the instructions of the Installation Guide.

Vehicles with a mark or marks Engine AYH, BKW

Socket Lambda probe G39
Fig. 2.139. Socket Lambda probe G39


Disconnect vakuumoprovody - arrows - gas recirculation valve and the brake booster, as well as Socket A lambda probe G39 first row of cylinders (Fig. 2.139).

Socket lambda probe G108
Fig. 2.140. Socket lambda probe G108


Disconnect vakuumoprovod (see Fig. 2.140) gas recirculation valve, as well as Socket A lambda probe 2 G108 second row of cylinders.

Cars with engines BLE and BWF

Vakuumprovody
Fig. 2.141. Vakuumprovody


Disconnect vakuumoprovody 1 vacuum servo bypass cover (the mark on the tube before removing) and the brake booster 2 (Fig. 2.141).

Connectors
Fig. 2.142. Connectors


Disconnect the following connectors and disconnect the cable from the following components (see Figure 2.142):
1-6 - pin connector (black) for Lambda probe G39;
2-6 - pin connector (brown) for the lambda probe 2 G108;
3-2 - pin connector (black) for the air temperature sensor to turbo-G507;
4-2 - pin connector (brown) for the air temperature sensor 2 in front of turbo-G499.

Continuation of the assembly operations for all vehicles

Connectors glow plugs
Fig. 2.143. Connectors glow plugs


Disconnect the connectors (Fig. 2.143) glow plugs cylinders of the first and second series.

Fixation strut
Fig. 2.144. Fixation strut


Secure the strut as shown in Figure 2.144, with a spring fixture VW 552.
Remove the upper anchorages. absorber struts.
Remove noise insulation.
Pump out the refrigerant.
Drain the coolant.

Tube radiator transmission oil
Fig. 2.145. Tube radiator transmission oil


Disconnect the tube (Fig. 2.145) from the transmission oil cooler at the bottom right. Substitute receptacle under the oil flowing.
Then disconnect the pipe from a radiator for hydraulic oil at the bottom left. Place a receptacle under the oil flowing.

Pipeline radiator and charge air tube
Fig. 2.146. Pipeline radiator and charge air tube


Remove the charge air pipe connections in the first and second series of cylinders (Fig. 2.146).

Clamp the connecting tube air filter first and second series of cylinders
Fig. 2.147. Clamp the connecting tube air filter first and second series of cylinders


Unscrew and remove the clamp (Fig. 2.147), the connecting tube air filter of the first and second series of cylinders.

Engine cooling system hoses
Fig. 2.148. Engine cooling system hoses


Remove the engine cooling system hoses (Fig. 2.148) and place in such a way that during the installation and removal of the engine they were not constricted.

Cables generator and starter
Fig. 2.149. Cables generator and starter


Unplug the starter and a generator and put them on the engine (Fig. 2.149).

Clips of the pipeline ventilation system gearbox
Fig. 2.150. Clips of the pipeline ventilation system gearbox


Rasklipsuyte pipeline ventilation system transmissions (Fig. 2.150).

Plugs sensor temperature at the inlet G42-A and the mass air flow sensor G70-In
Fig. 2.151. Plugs sensor temperature at the inlet G42-A and the mass air flow sensor G70-In


Disconnect the plug from the sensor temperature at the inlet G42-A and from the mass airflow sensor G70-In the first series of cylinders (Fig. 2.151).

Plugs sensor temperature at the inlet G426-A and the mass air flow sensor G299-IN
Fig. 2.152. Plugs sensor temperature at the inlet G426-A and the mass air flow sensor G299-IN


Disconnect the plug from the sensor mass air flow A - G246-A and from the sensor in air temperature at the inlet - G299-In the second row of cylinders (Fig. 2.152).

Tube compressor air suspension
Fig. 2.153. Tube compressor air suspension


Disconnect the tube (Fig. 2.153) compressor air suspension air filter housing.
Remove the two upper parts of the air filter top.

Tubes and hydraulic circuit system conditioning
Fig. 2.154. Tubes and hydraulic circuit system conditioning


Open the clamp and remove the tube hydraulic A. Put the container under the oil flowing. Remove the tube circuit air-conditioning system in the compressor air conditioning unit (Fig. 2.154).

Vehicles with a mark or marks Engine AYH, BKW

Tubes pipework
Fig. 2.155. Tubes pipework


Remove the fuel lines (see Fig. 2.155) with the fuel filter.
Disconnect the catalytic converter and an additional muffler, remove the exhaust system.

Cars with engines BLE and BWF

Tubes pipework
Fig. 2.156. Tubes pipework


Remove the fuel lines (see Fig. 2.156) with the fuel filter.
Disconnect protivosazhevy filter and the exhaust pipe, remove the exhaust system.
Continuation of the assembly operations for all vehicles.
Remove the insulation screen of gear and cardan joint.
Disconnect the connectors on the gearbox and transfer case, remove the rope drive selector lever.
Remove the rear driveshaft.

Crossbar gearbox
Fig. 2.157. Crossbar gearbox


Remove the cross-transmission A (Fig. 2.157).

Brake tube
Fig. 2.158. Brake tube


Disconnect the brake pipes shown on the site (Fig. 2.158).
Put the container under the brake fluid flowing.
Unplug all connectors between the body and the front axle to the wheel arches.
Prepare the mounting table VAS 6131 to carry out further operations.

NOTE
The basic set for the car Touareg VAS 6131 / 6 is of the pillars of VAS 6131 / 61 to VAS 6131 / 6-7. For the most visual display of the workflow are mentioned: support 1 (for VAS 6131 / 6-1) - a support 7 (for VAS 6131 / 6-7).

Installation supports
Fig. 2.159. Installation supports



Install support 1 support 2 on the left and right (arrows indicate the direction of motion) on the mounting table VAS 6131 and secure the bolts in the following positions:
- Left bracket 1 - A5, B4 and B5;
- Right bracket 2 - G4, H4 and H5.
Secure the support 3 and 4 on the mounting table in the following positions:
- Left bracket 3 - A6, and C6;
- Right bracket 4 - F6 and H6.
Remove the dish towers 3 and 4 down.
Install support 5 for the stretcher and 6 for the console gear in the appropriate position on lifting the table.
The engine and gearbox after removing the need to disconnect from each other.
Remove shumovibroizolyatsiyu under the crankcase.
Remove the starter cable clamps.
Unscrew and remove the bolts gearbox A.

Bolts mounting boxes
Fig. 2.160. Bolts mounting boxes


Through the hole in the oil sump (Fig. 2.160), unscrew six bolts gearbox. For this drive the engine of the damper with kontropory T10172 and all enclosed bolt T10172 / 2.
Install the support 7 to support the gearbox in the appropriate position on the table and remove the mounting plate supports all the way down.

Installation of a special device
Fig. 2.161. Installation of a special device


Mount directly to the rise of polyester inside out beforehand in the highest position of emphasis for the V-shaped 10, 8 and 6-cylinder engine vehicle Touareg VAS 6131 / 8 hole flange gearbox as shown in Figure 2.161.

Summing up the towers
Fig. 2.162. Summing up the towers


Move horizontally aligned mounting table under the engine. Legs 1 and 2, you must enter the left and right in the respective slots (Fig. 2.162).
At the same time, type of support 6 for the cross-transmission to the left and right into the holes.
When all four pillars are fixed in the receiving holes without pressure, if necessary, adjust the height of the palm of V-shaped 10 -, 8 - and 6-cylinder engine vehicle Touareg VAS 6131 / 8 with knurled nuts and secure the support of the position of D7 on the circuit table.
Remove both bearing plates 3 and 4, with an emphasis in the levers so that you can remove suspended for insurance, spring-loaded fixture VW 552.
Enter the support 5 in the corresponding slot on a stretcher, if necessary, adjust the height of the supports with knurled nuts.

Summing support 5
Fig. 2.163. Summing support 5


Secure the stretcher on the back (Fig. 2.163).
Loosen the bolts subframe 2 and 3, as well as cross-transmission 4.

Bolts fastening stretcher
Fig. 2.164. Bolts fastening stretcher


If a frame has not been fixed, loosen the bolts subframe 1 (Fig. 2.164).

NOTE
If a frame is not fixed, to make measurements of axes.
Now slowly lower the unit down, continuously monitoring the progress unhindered.

Installation Instructions
Installation is carried out in reverse sequence.

NOTICE
In carrying out all installation work, particularly in the engine compartment, due to the dense layout, note the following:
lines of all kinds (such as fuel, hydraulic, for additives, cooling systems, circuit conditioning systems, brake ducts, vacuum hoses), as well as electrical wires should pave the way they were originally laid.
Provide enough space to all mobile and hot components to avoid damage of any kind of lines.

It is necessary to consider the following:
Check the engine block mounting bushings for centering the engine / gearbox, if necessary, insert the bushings.
Reconnect all piping, hoses and electrical plugs that were disconnected during removal.




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Removing and installing subframe

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