The Touareg Self-Study Program Course Number 89E303
Volkswagen of America, Inc. Service Training Printed in U.S.A. Printed 03/2003 Course Number 89E303 ©2003 Volkswagen of America, Inc. All rights reserved. All information contained in this manual is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
Table of Contents Introduction ............................................................................... 1 A Luxury Utility Vehicle, Touareg, Off-Road Capability, Features, Specifications, Off-Road Driving Engines ....................................................................................... 8 3.2-Liter V6 Gasoline Engine, 4.2-Liter V8-5V Gasoline Engine, 5-Liter V10 TDI Diesel Engine Fuel Supply ..............................................................................
Introduction A Luxury Utility Vehicle Together with the advent of the Passat W8 and the Phaeton, the Touareg will complete the trio in Volkswagen’s luxury class product strategy. The Touareg is a luxury utility vehicle with outstanding off-road capabilities, that easily satisfies business and travel requirements.
Introduction Touareg The Volkswagen Touareg has the name of a traditional African desert tribe that has made a name for itself in Africa trading in precious goods. The proud Tuareg, with their camel caravans and their mysterious veils, embody the ideal of limitless freedom under the mercilessly tough conditions of the desert. 2 The name Tuareg (or Touareg) means “free people.
Introduction Off-Road Capability To test the off-road characteristics of the Touareg, an off-road test track was specially built in Ehra, Germany near Wolfsburg. Here, this multifaceted vehicle could show its stuff. The test track consists of: • • • • • A short off-road stretch. A climbing hill with a section of shelves. A dry river bed simulation. A torsion module. A shallow basin for water-hazard simulation.
Introduction Features Innovation Power • • • • • • • • Powerful engine range including a V10 diesel engine that will be available later. • Six-speed automatic transmission for continuous four-wheel drive with central differential and gear reduction level. A six-speed manual transmission will be available later. • Central differential lock. • High-performance braking system. • Roof load capacity up to 220 pounds (100 kg). On- and off-road capability. Air suspension. Two-part tailgate.
Introduction Safety Comfort • Electronic Stabilization Program (ESP). • Electronic Brake Pressure Distribution (EBPD). • Front, head, and side airbags. • Electric crash management with Battery Switch-Off Relay J655. • Antilock Braking System (ABS). • Traction Control System (TCS). • Hydraulic Braking Assistant. • Pedestrian protection taken into account in body design. • Four-zone Climatronic, two-zone Climatronic, or manual air-conditioning system. • Radio navigation system with off-road functionality.
Introduction Specifications The illustration shows the dimensions of the Touareg with a V6 engine. SSP297/005 • Length 187.17 inches (4754 mm) • Width 75.91 inches (1928 mm) • Height 67.05 – 67.95 inches (1703 – 1726 mm) (depending on the engine) • Roof load capacity 220 pounds (100 kg) • Towing capacity 7716 pounds (3500 kg) • Fuel tank volume 26.4 gallons (100 liters) • Front track width 64.76 – 65.28 inches (1645 – 1658 mm) (depending on the engine) 6 • Rear track width 65.24 – 65.
Introduction Off-Road Driving The off-road capability of the Touareg is proven by the following data: Ford depth is the depth of water the vehicle can slowly drive through without the engine taking on water or water entering the vehicle. SSP297/043 Maximum climbing capability: 45 degrees SSP297/060 Maximum possible lateral inclination: 35 degrees SSP297/006 Maximum ground clearance: Steel suspension: 9.33 inches (237 mm) Air suspension: 11.
Engines 3.2-Liter V6 Gasoline Engine The 3.2-liter V6 gasoline engine, a further development of the 2.8-liter V6 engine, is also used in the Phaeton in some markets. Due to the off-road capability of the vehicle, some of the components had to be modified. Engine Management • Motronic ME 7.1.1 engine management system. • Exhaust gas system with two preliminary catalytic converters and a main catalytic converter. • Control of the internal exhaust gas recirculation via the camshaft adjustment.
Engines Technical Data – 3.2-Liter V6 Gasoline Engine • Engine code BAA • Maximum power output 217 bhp (162 kW) @ 5400 – 6400 rpm • Type VR engine with four valves per cylinder • Maximum torque 224 lbs-ft (305 Nm) @ 3200 rpm • Displacement 194.6 cu in (3189 cm3) • Engine management Motronic ME 7.1.1 • Bore 3.31 in (84 mm) • Firing sequence 1-5-3-6-2-4 • Stroke 3.78 in (95.9 mm) • Fuel type recommendation Premium unleaded gasoline (91 AKI) • Compression ratio 11.
Engines Mechanical Innovations Oil pan Due to the off-road capability of the Touareg, special demands are made when driving on steep inclines and fording streams. To meet these demands, certain components have been modified compared to those used in the same engine in the Phaeton. A new deeper oil pan ensures that there is always sufficient oil being pumped through the engine lubrication system, regardless of the inclination of the vehicle.
Engines Seals In vehicles with the manual transmission that will be available later, the dual-weighted flywheel must be prevented from standing in water for a long time. For this reason, the joint between the transmission bell housing and the engine is sealed against water intrusion. If water gets past the seal and enters the bell housing when driving through water for a long time, it is expelled through an opening on the side of the bell housing by the rotation of the dual-weighted flywheel.
Engines 4.2-Liter V8-5V Gasoline Engine The 4.2-liter V8-5V engine was optimized and further developed for the Touareg, especially for off-road use. Touareg 4.2-Liter V8-5V Engine Modifications • Three-stage variable intake manifold. • Double-flow intake with dual hot film air mass meters. • Water-cooled 190-amp generator. • Fording seals. • Crankcase with large flange piece. • Crankshaft with 10-hole flange. • New oil filter module. • Single poly-V-ribbed accessory drive belt with seven grooves.
Engines Technical Data – 4.2-Liter V8-5V Gasoline Engine • Engine code BHX • Maximum power output 306 bhp (228 kW) @ 6200 rpm • Type V8 engine with 90-degree V-angle and five valves per cylinder • Maximum torque 302 lbs-ft (410 Nm) @ 3000 – 4000 rpm • Engine management Motronic ME 7.1.1 • Displacement 254.6 cu in (4172 cm3) • Firing sequence 1-5-4-8-6-3-7-2 • Bore 3.33 in (84.5 mm) • Fuel type recommendation Premium unleaded gasoline (91 AKI) • Stroke 3.
Engines Mechanical Innovations Oil intake Among other things, the oil intake on the 4.2-liter V8-5V engine has been adapted to off-road use. During extreme climbs and driving across slopes an optimum oil supply must be guaranteed at all times. A deep oil pan ensures safe oil intake when driving up and down slopes.
Engines Oil pump The oil pump with a drain stage supplies the engine with oil during extreme off-road driving. The drain stage stores the oil from the rear oil pan in front of the pressure pump. This ensures optimum intake at all times. Drain Stage of Oil Pump Suction Pressure Stage of Oil Pump SSP297/099 The spraying tube of the drain stage separates the air out of the oil that is transported from the rear oil pan.
Engines 5-Liter V10 TDI Diesel Engine (Late Availability for the North American Market) The 5-liter V10 TDI engine is a recently developed diesel engine. Combining an innovative lightweight construction with enormous power, it is equipped with the pump-jet injection system. Engine Management Mechanical Innovations • Pneumatically-controlled exhaust gas recirculation valves. • Dual control module concept. • Charged by two adjustable turbochargers.
Engines Technical Data – 5-Liter V10 TDI Diesel Engine • Type V engine, with 90-degree V-angle and two valves per cylinder • Maximum torque 553 lbs-ft (750 Nm) @ 2000 rpm • Engine management EDC 16 • Displacement 300 cu in (4921 cm3) • Firing sequence 1-6-5-10-2-7-3-8-4-9 • Bore 3.19 in (81 mm) • Fuel type recommendation Diesel 49 CZ minimum or biodiesel • Stroke 3.76 in (95.
Fuel Supply Fuel Tank In order to use the available installation space to the greatest extent possible, the fuel tank consists of a main chamber and a secondary chamber. Each chamber has an electric fuel pump and a suction jet pump. There is a sender for the fuel supply on each of the two electric fuel pumps. The fuel tanks for gasoline and diesel engines differ mainly in the sizes of their refilling breather bottles and in the attached lines.
Transmissions Six-Speed Automatic Transmission 09D Compared to the five-speed automatic transmission, the six-speed automatic transmission 09D provides a reduction of fuel consumption and thus a reduction of exhaust gas emissions, as well as a reduction of noise, all with significantly improved acceleration. It was developed at AISIN, the famous Japanese manufacturer of automatic transmissions, and is also manufactured by them.
Transmissions Special features of the six-speed automatic transmission 09D include: Technical Data – Six-Speed Automatic Transmission 09D • Shifting programs integrated into the Transmission Control Module J217 that depend on driver and driving situations, as well as shifting programs that depend on driving conditions. The shifting programs are controlled by fuzzy logic. • Volkswagen designation AG6 09D • Lock-up torque converter. • Lifetime automatic transmission fluid.
Transmissions Design – Six-Speed Automatic Transmission 09D In its basic design, the six-speed automatic transmission 09D is similar to other automatic transmissions. External axle drive The Touareg application uses an external axle drive that is unique for Volkswagen.
Transmissions Locking Button Selector Lever Positions P – Parking To move the selector lever out of the “P” position, the ignition must be turned on. In addition, the brake pedal and the locking button on the selector lever must be pressed. The ignition key can be removed only when the lever is in this position. R – Reverse The locking button on the selector lever must be pressed to shift into reverse. N – Neutral The transmission is idling in this position.
Transmissions Shift Program and Gear Indicator on Display Unit in Instrument Cluster Y24 After the ignition is turned on, the current selector lever position is displayed in the Display Unit in Instrument Cluster Y24. In positions “D” and “S” the gear selected in the transmission is also displayed. 76.7 mi 54.1°F 76728 mi SSP297/086 The gear being used is shown on the display if the automatic transmission is in the Tiptronic shift program. 76.7 mi 54.
Transmissions Selector Lever Tiptronic On the Touareg, Tiptronic gear selection is operated by the selector lever. The automatic transmission is switched to the Tiptronic mode by moving the selector lever to the right from the “D” position into the Tiptronic notch. Gear changes are then made by moving the selector lever. Moving the selector lever forward shifts up a gear, moving the lever back shifts down a gear.
Transmissions Selector Lever Locks The selector lever is locked by: Shift Lock Solenoid N110 • Shift Lock Solenoid N110 • Selector Lever Park Position Solenoid N380 Selector Lever Park Position Lock Switch F319 The ignition key can be removed only when the selector lever is in the “P” position. The Selector Lever Park Position Lock Switch F319 signals to the Access/Start Control Module J518 that the selector lever is in the “P” position.
Transmissions Six-Speed Manual Transmission 08D (Late Availability in the North American Market) The six-speed manual transmission 08D was developed just for the Touareg, especially for off-road use. This manual transmission is standard equipment for Touaregs equipped with the 3.2-liter V6 gasoline engine or the 5-liter V10 TDI diesel engine. Six-Speed Manual Transmission 08D 26 For smooth operation it is actuated by shift cables instead of mechanical linkage.
Transmissions The ends of the shift cables are attached with locknuts to the control levers. Mass dampers smooth out the shifting movements and absorb vibrations. Stopping Drift Gearshift Lever To ensure proper adjustment or replacement of the shift cables: • The gearshift lever must be locked in place in the left neutral position using the adjustment drift T10027 before the shift cables are loosened.
Running Gear Touareg Chassis Overview The Touareg chassis has excellent off-road driving characteristics with the 4XMOTION system. It has continuous four-wheel drive and a central differential with a reduction stage. • Tire inflation pressure connection under the driver’s seat (only in vehicles with air suspension). It also ensures the highest levels of driving comfort on normal roads with its four-wheel independent suspension. Touareg chassis features include: • Dual wishbone front suspension.
Running Gear • Rear transverse lock and longitudinal lock. • Dual-servo foot-pedal-actuated drum parking brake. • Ventilated disc brakes front and rear. • Hill incline assistant and hill descent assistant. • Conti Teves MK25 Electronic Stabilization Program (ESP) system with braking assistant and four-wheel Electronic Differential Lock (EDL). SSP297/061 For more detailed information on the chassis, refer to The Touareg Suspension and 4XMOTION System, Self-Study Program Course Number 89H303.
Body Body Structure The body of the Touareg is a completely new, self-supporting construction. It is designed to attain as much static and dynamic rigidity as possible. To accomplish this, special sheet metals are used: • High-strength sheet metals: These sheet metals, made of special steel, are more stable than “normal” sheet metals without causing an increase in weight. • Tailored blanks: Sheet metals that have different thicknesses depending on the loads where they are used.
Body Static Rigidity Dynamic Rigidity The body of the Touareg has a very high static rigidity. It does not flex or twist, even during off-road driving, where large forces affect the body. The chassis is designed so that the doors. hood, and tailgate always close without problems, even with the tightest gap tolerances. The high dynamic torsional rigidity of the body results in both favorable vibration characteristics and driving comfort.
Body Body Attachments Engine Hood Sunroof The engine hood is made entirely of aluminum. The outer hood sheet metal panel is 0.045 inch (1.15 mm) thick. The thickness of the inner panel is unusual at 0.035 inch (0.9 mm). The Touareg is available with a glass tilt and slide sunroof. Fenders and Bumpers The front fenders and front and rear bumpers are made of plastic. The wall thickness of the fenders varies between 0.106 inch and 0.134 inch (2.7 mm and 3.4 mm).
Body Rear window module Side window module The rear window module is made up of glass and a sheet metal frame. These parts feature a special new technique called plastic extrusion coating. The side windows are connected to the panels and the trim plate by plastic extrusion coating. To avoid providing a starting point for thieves, the hinges are covered by a spoiler. This consists of glass-fiber-reinforced plastic which expands only slightly when exposed to heat.
Body Body Insulation Two acoustic insulation packages were developed for the Touareg. The package for vehicles equipped with gasoline engines consists of bitumen plastic foil sound deadening. Assembly Plate For vehicles with diesel engines, four of the sound deadening parts are designed as a bitumen-aluminum sandwich foil.
Body Tailgate The tailgate of the Touareg consists of a separate flip-up rear window and the tailgate itself. The rear window and the tailgate are secured by a locking mechanism when the window is closed. Two pairs of gas-filled struts ensure comfortable opening and closing of the rear window and the tailgate. They are attached to the body so that they are invisible from the outside.
Body Rear Window Wiper The motor for the rear window wiper is located in the tailgate, while the wiper is installed in the rear window. For this reason, there is a drive mechanism between the rear window wiper and the motor. When the rear window is flipped up, the window wiper may rotate. As a result, the position of the driving stud changes in such a way that it no longer fits in the hole of the driving plate. In this case, the spring-loaded driving stud is pressed back so that nothing is damaged.
Body As soon as the rear window wiper motor is started, the driving plate turns and the driving stud locks into the opening. In this way, the window wiper mechanism and its motor are easily disengaged and re-engaged.
Body Roof Rack In order to mount a roof rack, two chamfered C-rails are embedded into the roof of the Touareg. The roof rack carrier supports are inserted into these rails at the openings in the center.
Body Each support has a lockable tensioning mechanism: If the lock is closed, the carrier is fastened. • When the lock is open and the flap disengaged, the carriers can be pushed to the desired positions with the supports on each end at matching recesses in the rails. • The carriers are fastened by closing the flaps and the locks on the supports. To avoid damage to the paint, the key for unlocking the carrier supports should be removed before moving the carriers. SSP297/018 Use the key to open the lock.
Occupant Protection Airbag System Airbags The following airbags are installed in the Touareg: • Driver airbag – approximate filling volume of 2.26 cubic feet (64 liters). • Front passenger airbag – approximate filling volume of 4.24 cubic feet (120 liters). • Driver and front passenger side airbags – approximate filling volume of 0.39 cubic feet (11 liters). • Curtain airbags – approximate filling volume of 0.78 cubic feet (22 liters). There are no side airbags in the rear of the vehicle.
Occupant Protection Airbag Control Module J234 The Airbag Control Module J234 is located in the center console. It receives the signals of the six crash sensors and evaluates the data. In the case of an accident, it can trigger the following actions: • Tightening the seat belts. • Activating the airbags. • Separating the battery positive lead from contact with the battery terminal. • Activating the hazard warning light system. • Turning off the fuel pump.
Occupant Protection Restraining Systems Seat Belts Three-point retracting seat belts are located at all five seats in the Touareg. The belt lock and the belt limit stop are located in the seat. The height of the belt can be mechanically adjusted at all outer seats. An electric belt height adjuster and a comfort mechanism for the front seats is available as an option. Ball seat belt tensioner and belt tension limiter Ball seat belt tensioners are used at all four outer seats.
Occupant Protection Pedestrian Protection Child Seat Fasteners Interior Trim The body contour, the selected materials for body panels like aluminum for the hood and plastic for the fenders, and the space between the hood and the engine, all provide some measure of pedestrian protection. The collision area at the instrument panel is optimized at knee height for the driver and the front passenger. The body structure is designed to deform strategically and quickly reduce energy upon impact.
Seats Front Seats The front seats of the Touareg have their own sporty characteristics, such as raised side cushions. They are heated by the electric seat heater using a carbon heating element. To satisfy customer requirements for fine appointments in a luxury vehicle, the upholstering of the seats is first-class. Many different cloth fabrics are available, as are several leather versions. In addition, the front seats are integrated into the memory package.
Seats Compressed Air Connection Compressed Air Connection Under the passenger seat in the seat console, there is a connection for the air compressor. For example, an air hose can be connected here. SSP297/040 Access Cover Air Hose 12-Position Seat The 12-position seat has the following adjustments in addition to those of the 8position seat: • Seat inclination angle. • Lumbar support. All adjustments except the headrest height are made electrically.
Seats Rear Bench Seat The rear of the Touareg is equipped with a bench seat. It is designed for three persons, providing a headrest and a three-point seat belt for each position. SSP297/015 There is a central armrest in the backrest with an integrated compartment for a ski sack. The entire rear bench seat can be heated. The backrests can be folded forward separately.
Seats Cargo Net The cargo net of the Touareg is located in its own storage compartment. It can be mounted either behind the rear bench seat, or… SSP297/052 …if the bench is folded down completely, behind the driver and front passenger seats. The net can be extended and anchored to the roof headliner from either of these positions.
Air Conditioning System Air Conditioning in the Touareg Three different air conditioning systems are available for the Touareg. They primarily differ in terms of temperature control, air distribution, and regulation of the volume of air distributed throughout the interior of the vehicle. Despite their variations, the three systems are based on each other. This simplifies repairs and maintenance. The different systems can easily be recognized by their controls.
Air Conditioning System Four-Zone Climatronic Climatronic Control Module J255 This system has two control modules. The Climatronic Control Module J255 is located in the instrument panel. This can be used mainly to select the settings for the climate zones of the front passenger compartment.
Air Conditioning System Two-Zone Climatronic Climatronic Control Module J255 The Climatronic Control Module J255 in the two-zone Climatronic system is also located in the instrument panel. SSP297/036 Air Conditioner Module Compared to the four-zone Climatronic system, there are the following differences in automatic operation: • The temperature can be set separately for the left and right sides of the passenger compartment.
Air Conditioning System Manual Air Conditioning System (Not Available in the North American Market) A/C Control Head E87 Using the A/C Control Head E87 in the instrument panel, the occupants can set the air conditioning of the entire interior according to their wishes. SSP297/091 Dial Air Conditioner Module In this manually controlled system, the entire passenger compartment is uniformly air conditioned. There is no automatic climate control for the temperature, air distribution, or fan speed.
Electrical System Convenience and Safety Electronics Overview The comfort and safety electronics used on the Touareg are based on those of the Phaeton. Door Control Module, Driver Side J386 Door Control Module, Passenger Side J387 Components are located throughout the vehicle. The Touareg will use the convenience entry system but NOT the convenience start function. You must use the vehicle key to start the engine.
Electrical System Vehicle Electrical System Control Module J519 Access/Start Control Module J518 Orientation Illumination in the Exterior Mirrors (Right and Left Sides) SSP297/050 Left Access/Start Authorization Antenna R134 (2, Left Side) Right Access/Start Authorization Antenna R135 (2, Right Side) Central Control Module for Comfort System J393 For more detailed information, refer to The Touareg Electrical System, Self-Study Program Course Number 89J303.
Electrical System Radio System With minor differences, the radio system used in the Touareg corresponds to the radio system that can be found in other Volkswagens, such as the 2003 Passat. The main difference in the Touareg system is the design of the user interface, with a larger display and overall dimensions that were adapted to the instrument panel. Their are also some differences in the arrangement of the function keys and their designations.
Electrical System Radio/Navigation System The radio/navigation system found in the Touareg is new to Volkswagen. The appearance, the user interface, and the overall dimensions are different than the Premium VI radio. The most important differences are: • 6.5-inch (165 mm) color display. • Function keys with new designations and functions. • Off-road function. • Position-finding display with compass display.
Electrical System Radio/Navigation System Operation The new function keys and button designations are described and summarized below. Function keys to call up various functions which are shown by the adjoining symbols in the display. Slot for an audio or navigation CD. “RADIO” button for setting FM or AM stations. “INFO” button for: • System information • Off-road display • List of routes • Text messages “TELE” button for telephone. “CD” button for calling up the menu for the audio CD.
Electrical System Off-Road Navigation In addition to the menus for entering the destination and the path to the destination, the radio/navigation system provides a further navigation option with the “Off-road tour” menu. It is especially useful during off-road driving where digital information is not available. The transition between the two navigation types from standard to off-road occurs automatically. However, the system does not automatically switch back from off-road to standard navigation.
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Knowledge Assessment An on-line Knowledge Assessment (exam) is available for this Self-Study Program. This Knowledge Assessment may or may not be required for Certification. You can find this Knowledge Assessment in the Learning Management Center at: www.vwwebsource.com For assistance please call: Certification Program Headquarters 1-877-CU4-CERT (1-877-284-2378) (8:00 a.m. to 8:00 p.m. EST) Or email: Comments@VWCertification.
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