Touareg

The Touareg

Self-Study ProgramCourse Number 89E303

Volkswagen of America, Inc.Service TrainingPrinted in U.S.A.Printed 03/2003Course Number 89E303

©2003 Volkswagen of America, Inc.

All rights reserved. All information containedin this manual is based on the latestinformation available at the time of printing andis subject to the copyright and other intellectualproperty rights of Volkswagen of America, Inc.,its affiliated companies and its licensors. Allrights are reserved to make changes at anytime without notice. No part of this documentmay be reproduced, stored in a retrievalsystem, or transmitted in any form or by anymeans, electronic, mechanical, photocopying,recording or otherwise, nor may thesematerials be modified or reposted to other siteswithout the prior expressed written permissionof the publisher.

All requests for permission to copy andredistribute information should be referred toVolkswagen of America, Inc.

Always check Technical Bulletins and theVolkswagen Worldwide Repair InformationSystem for information that may supersede anyinformation included in this booklet.

Trademarks: All brand names and productnames used in this manual are trade names,service marks, trademarks, or registeredtrademarks; and are the property of theirrespective owners.

i

Table of Contents

The Self-Study Program provides you with informationregarding designs and functions.

The Self-Study Program is not a Repair Manual.

For maintenance and repair work, always refer to thecurrent technical literature.

Important/Note!

New !

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 GasolineEngine, 5-Liter V10 TDI Diesel Engine

Fuel Supply ..............................................................................18

Fuel Tank

Transmissions ..........................................................................19

Six-Speed Automatic Transmission 09D,Six-Speed Manual Transmission 08D

Running Gear ...........................................................................28

Touareg Chassis Overview

Body .........................................................................................30

Body Structure, Body Attachments, Body Insulation,Tailgate, Roof Rack

Occupant Protection ...............................................................40

Airbag System, Restraining Systems, Interior Trim,Pedestrian Protection

Seats.........................................................................................44

Front Seats, Rear Bench Seat, Cargo Net

Air Conditioning System ........................................................48

Air Conditioning in the Touareg, Four-Zone Climatronic,Two-Zone Climatronic, Manual Air Conditioning System

Electrical System..................................................................... 52

Convenience and Safety Electronics, Radio System,Radio/Navigation System

Knowledge Assessment .........................................................61

Introduction

1

SSP297/001

A Luxury Utility Vehicle

Together with the advent of the Passat W8and the Phaeton, the Touareg will completethe trio in Volkswagen’s luxury classproduct strategy. The Touareg is a luxuryutility vehicle with outstanding off-roadcapabilities, that easily satisfies businessand travel requirements.

The Touareg’s adaptability to extreme andvarying driving conditions is a result of suchfeatures as the continuous electronicallycontrolled four-wheel drive, high-torqueengines, and a dual wishbone chassis.

Self-study programs will be available for thefollowing topics:

• SSP 89J303: The TouaregElectrical System

• SSP 89M303: The Touareg 6-SpeedManual Transmission

• SSP 89K303: The Touareg 6-SpeedAutomatic Transmission

• SSP 89G303: The Touareg Heating,Ventilation and Air-Conditioning System

• SSP 89H303: The TouaregSuspension and 4XMOTION System

• SSP 89N303: The Touareg V10 TDI Engine

• SSP 89P303: The Touareg V10 TDIEngine Management System

Introduction

2

Touareg

The Volkswagen Touareg has the name of atraditional African desert tribe that hasmade a name for itself in Africa trading inprecious goods.

The proud Tuareg, with their camelcaravans and their mysterious veils,embody the ideal of limitless freedomunder the mercilessly tough conditions ofthe desert.

The name Tuareg (or Touareg) means“free people.”

Its name was selected to characterize theVolkswagen Touareg as an exclusive off-road vehicle that proves itself as easily in arocky riverbed as on the highway.

With its excellent on- and off-roadcharacteristics and its elegant progressivedesign, the Touareg is equally as suitablefor off-road use as it is for business,recreation, and travel.

Introduction

3

Off-Road Capability

To test the off-road characteristics of theTouareg, an off-road test track was speciallybuilt in Ehra, Germany near Wolfsburg.Here, this multifaceted vehicle could showits 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.

SSP297/103-056

The Touareg was tested and optimizedon the test track for the followingcharacteristics, among others:

• Traction.• Torsion of the body structure.• Acceleration behavior and driving

on inclines.• Supply of operating fluids.• Engine drag torque.• Suspension comfort.• Impermeability to the elements.• Noise emission in load situations.• Ground clearance.• Bumper design.

Introduction

4

Features

Innovation

• On- and off-road capability.• Air suspension.• Two-part tailgate.• Modular roof rack system.• Acceleration assistant.• Hill descent assistant.• Fully galvanized self-supporting

body structure.• Engine Braking Control (EBC).• Engine and body sealing systems enable

good fording capability.

Power

• Powerful engine range including a V10diesel engine that will be available later.

• Six-speed automatic transmission forcontinuous four-wheel drive with centraldifferential and gear reduction level.A six-speed manual transmission will beavailable later.

• Central differential lock.• High-performance braking system.• Roof load capacity up to 220 pounds

(100 kg).• Fuel tank volume 26.4 gallons (100 liters).• Towing capacity 7716 pounds (3500 kg).• Acoustically optimized interior.

Introduction

5

Safety

• 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.• Extensive seat belt system.• Child seat fasteners standard.• Electronic immobilizer.

SSP297/003-004

Comfort

• Four-zone Climatronic,two-zone Climatronic, ormanual air-conditioning system.

• Radio navigation system withoff-road functionality.

• Eight- or 12-position seats.• Comfortable back seat.• Large cargo load space volume with

adjustable net.• Convenient electrical sockets.• Air-conditioned glove compartment.• Comfort interior lighting.• Adjustable steering wheel.

Introduction

6

SSP297/005

• Length187.17 inches (4754 mm)

• Width75.91 inches (1928 mm)

• Height67.05 – 67.95 inches (1703 – 1726 mm)(depending on the engine)

• Roof load capacity220 pounds (100 kg)

• Towing capacity7716 pounds (3500 kg)

• Fuel tank volume26.4 gallons (100 liters)

• Front track width64.76 – 65.28 inches (1645 – 1658 mm)(depending on the engine)

Specifications

The illustration shows thedimensions of the Touaregwith a V6 engine.

• Rear track width65.24 – 65.53 inches (1657 – 1664.5 mm)(depending on the engine)

• Permitted gross vehicle weight6283 – 6790 pounds (2850 – 3080 kg)(depending on the engine)

• Curb weight4881 – 5564 pounds (2214 – 2524 kg)(depending on the engine)

• Cargo load spaceExcept V10 TDI:19.6 – 55.4 cubic feet (555 – 1570 liters)V10 TDI:19.4 – 53.8 cubic feet (550 – 1525 liters)

• Drag coefficient0.38 to 0.42 CD(depending on the engine)

Introduction

7

Off-Road Driving

The off-road capability of the Touareg isproven by the following data:

Maximum climbing capability: 45 degrees

Ford depth is the depth ofwater the vehicle can slowlydrive through without the enginetaking on water or waterentering the vehicle.

Maximum possible ford depth:Steel suspension: 19.69 inches (500 mm)Air suspension: 22.83 inches (580 mm)

SSP297/009

Maximum driveable ramp angle:Steel suspension: 22 degreesAir suspension: 27 degrees

SSP297/008

Maximum driveable angle of slope:Steel suspension: 28 degreesAir suspension: 33 degrees

SSP297/007

Maximum ground clearance:Steel suspension: 9.33 inches (237 mm)Air suspension: 11.81 inches (300 mm)

SSP297/006

Maximum possible lateral inclination:35 degrees

SSP297/060SSP297/043

Engines

8

SSP297/044

3.2-Liter V6 Gasoline Engine

The 3.2-liter V6 gasoline engine, a furtherdevelopment of the 2.8-liter V6 engine,is also used in the Phaeton in somemarkets. Due to the off-road capability ofthe vehicle, some of the componentshad to be modified.

Engine Management

• Motronic ME 7.1.1 enginemanagement system.

• Exhaust gas system with twopreliminary catalytic converters and amain catalytic converter.

• Control of the internal exhaust gasrecirculation via the camshaft adjustment.

• Second-generation On-Board Diagnosis(OBD II) with MIL.

hp kW

241 180

214 160

188 140

161 120

134 100

107 80

80 60

54 40

27 20

lbs-ft Nm

295 400

266 360

236 320

207 280

177 240

148 200

118 160

89 120

59 80

30 40

Engines

9

SSP297/045

Technical Data –

3.2-Liter V6 Gasoline Engine

• Engine code

BAA

• Type

VR engine with four valves per cylinder

• Displacement

194.6 cu in (3189 cm3)

• Bore

3.31 in (84 mm)

• Stroke

3.78 in (95.9 mm)

• Compression ratio

11.25:1

2000 4000 6000

Speed (rpm)

• Maximum power output

217 bhp (162 kW) @ 5400 – 6400 rpm

• Maximum torque

224 lbs-ft (305 Nm) @ 3200 rpm

• Engine management

Motronic ME 7.1.1

• Firing sequence

1-5-3-6-2-4

• Fuel type recommendation

Premium unleaded gasoline (91 AKI)

• Exhaust treatment

Three-way catalytic converters withconstant fuel-air mixture regulation

The specified power data is onlypossible if 91 AKI fuel is used.A reduction in power output mustbe expected if lower grade fuelis used.

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Mechanical Innovations

Due to the off-road capability of theTouareg, special demands are made whendriving on steep inclines and fordingstreams. To meet these demands, certaincomponents have been modified comparedto those used in the same engine inthe Phaeton.

Engines

10

SSP297/073

Oil pan

A new deeper oil pan ensures that there isalways sufficient oil being pumped throughthe engine lubrication system, regardless ofthe inclination of the vehicle. The oil pumphas been adapted to the new oil pan in thearea of oil intake.

Oil Pump

Oil Intake

Engines

11

SSP297/051

SSP297/074

Seals

In vehicles with the manual transmissionthat will be available later, the dual-weightedflywheel must be prevented from standingin water for a long time. For this reason,the joint between the transmission bellhousing and the engine is sealed againstwater intrusion. If water gets past the sealand enters the bell housing when drivingthrough water for a long time, it is expelledthrough an opening on the side of thebell housing by the rotation of thedual-weighted flywheel.

The front crankshaft seal has an additionalsealing lip. It prevents the intrusion ofwater and dirt into the crankcase.

Belt drive

The accessory belt drive is designedfor more belt-to-pulley contact. Thisprevents the belt from slipping whendriving through water.

12

4.2-Liter V8-5V Gasoline Engine

The 4.2-liter V8-5V engine was optimizedand 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 airmass meters.

• Water-cooled 190-amp generator.

• Fording seals.

Engines

SSP297/101

• Crankcase with large flange piece.

• Crankshaft with 10-hole flange.

• New oil filter module.

• Single poly-V-ribbed accessory drive beltwith seven grooves.

• Engine accessories withfording capability.

• Off-road capable oil intake.

• Return flow-free fuel system.

lbs-ft Nm

369 500

332 450

295 400

258 350

221 300

184 250

148 200

111 150

74 100

37 50

0

13

Engines

Technical Data –

4.2-Liter V8-5V Gasoline Engine

• Engine code

BHX

• Type

V8 engine with 90-degree V-angle andfive valves per cylinder

• Displacement

254.6 cu in (4172 cm3)

• Bore

3.33 in (84.5 mm)

• Stroke

3.66 in (93 mm)


11:1

SSP297/072


306 bhp (228 kW) @ 6200 rpm

• Maximum torque

302 lbs-ft (410 Nm) @ 3000 – 4000 rpm


Motronic ME 7.1.1

• Firing sequence

1-5-4-8-6-3-7-2


Premium unleaded gasoline (91 AKI)

• Camshaft adjustment

Inlet camshaft adjustment

The specified power data isonly possible if 91 AKI fuel isused. A reduction in poweroutput must be expected iflower grade fuel is used.

hp kW

335 250

302 225

268 200

235 175

201 150

168 125

134 100

101 75

67 50

34 25

2000 4000 6000

Speed (rpm)

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Engines

14


Among other things, the oil intake on the4.2-liter V8-5V engine has been adapted tooff-road use. During extreme climbs anddriving across slopes an optimum oil supplymust be guaranteed at all times.

Oil Pan

SSP297/102

Oil intake

A deep oil pan ensures safe oil intake whendriving up and down slopes.

Oil pump

The oil pump with a drain stage suppliesthe engine with oil during extremeoff-road driving.

The drain stage stores the oil from therear oil pan in front of the pressure pump.This ensures optimum intake at all times.

Engines

15

SSP297/100

SSP297/099

The spraying tube of the drain stageseparates the air out of the oil that istransported from the rear oil pan.

Suction PressureStage of Oil Pump

Drain Stageof Oil Pump

Oil Intake atPressure Stage

Spraying Tubeof Drain Stage

Engines

16

SSP297/021

5-Liter V10 TDI Diesel Engine(Late Availability for theNorth American Market)

The 5-liter V10 TDI engine is a recentlydeveloped diesel engine. Combining aninnovative lightweight construction withenormous power, it is equipped with thepump-jet injection system.


• Cylinder block made of aluminum with agray cast iron bearing tunnel.

• Joining of cylinder head and cylinderblock via tie-rod screw connection.

• Balancer shaft for reducing vibrations.

• The oil pump, water pump, generator,and camshafts are gear driven.

Engine Management

• Dual control module concept.

• Charged by two adjustableturbochargers.

• Pneumatically-controlled exhaust gasrecirculation valves.

lbs-ft Nm

738 1000

590 800

443 600

295 400

148 200

0

Engines

17

Technical Data –

5-Liter V10 TDI Diesel Engine

• Type

V engine, with 90-degree V-angle andtwo valves per cylinder

• Displacement

300 cu in (4921 cm3)

• Bore

3.19 in (81 mm)

• Stroke

3.76 in (95.5 mm)


18:1


308 bhp (230 kW) @ 4000 rpm

• Maximum torque

553 lbs-ft (750 Nm) @ 2000 rpm


EDC 16

• Firing sequence

1-6-5-10-2-7-3-8-4-9


Diesel 49 CZ minimum or biodiesel

• Exhaust treatment

Exhaust gas recirculation and oxidationcatalytic converter

The specified power data is onlypossible if the specified fuel isused. A reduction in poweroutput must be expected if lowergrade fuel is used.

SSP297/022

hp kW

335 250

268 200

201 150

134 100

67 50

2000 3000 4000

Speed (rpm)

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Fuel Tank

In order to use the available installationspace to the greatest extent possible, thefuel tank consists of a main chamber and asecondary chamber.

Each chamber has an electric fuel pumpand a suction jet pump. There is a sender

Fuel Supply

18

SSP297/042

Refilling Breather Bottlefor Gasoline Engine

for the fuel supply on each of the twoelectric fuel pumps.

The fuel tanks for gasoline and dieselengines differ mainly in the sizes oftheir refilling breather bottles and in theattached lines.

Suction Jet Pumps

Fuel SupplySensors

Electric Fuel Pumps

Refilling Breather Bottlefor Diesel Engine

Transmissions

19

Six-Speed AutomaticTransmission 09D

Compared to the five-speed automatictransmission, the six-speed automatictransmission 09D provides a reduction offuel consumption and thus a reduction ofexhaust gas emissions, as well as areduction of noise, all with significantlyimproved acceleration.

It was developed at AISIN, the famousJapanese manufacturer of automatictransmissions, and is also manufacturedby them.

The tuning and adaptation of thetransmission and the TransmissionControl Module J217 to the Touaregwas carried out in co-operation withVolkswagen engineers.

SSP297/089

SSP297/083

Transmission Code

Production Date

AISIN Model Number

Spare Parts Number

Serial Number ofManufacturer

Manufacturer

Transmissions

20

Special features of the six-speed automatictransmission 09D include:

• Shifting programs integrated into theTransmission Control Module J217 thatdepend on driver and driving situations,as well as shifting programs that dependon driving conditions. The shiftingprograms are controlled by fuzzy logic.

• Lock-up torque converter.

• Lifetime automatic transmission fluid.

• Axle drive is located outside of theautomatic transmission.

• The hill-holder function keeps the vehiclefrom rolling back, making it easier tostop on an upslope.

• Selector lever Tiptronic.

Technical Data –

Six-Speed Automatic Transmission 09D

• Volkswagen designation

AG6 09D

• Automatic transmission fluid

Lifetime fill

• Maximum torque transmission

553 lbs-ft (750 Nm)

• Weight

214 – 243 pounds (97 – 110 kg)Depending on engine type, including fluid

• Emergency operation

Third and reverse gears in case of controlmodule failure

SSP297/084

Multi-FunctionTransmissionRange Switch F125

Transmission FluidCooler Connections

Ventilation

Transmissions

21

Design – Six-Speed Automatic

Transmission 09D

In its basic design, the six-speed automatictransmission 09D is similar to otherautomatic transmissions.

Major components include:

• Lock-up torque converter

• Automatic transmission fluid pump

• Simpson design simple planetarygear set

• Ravigneaux design dual planetarygear set

• Three multi-disc couplings

• Two multiple-disc brakes

• Hydraulic control valve assembly

External axle drive

The Touareg applicationuses an external axle drivethat is unique for Volkswagen.

From the automatic transmission outputdriveshaft, the torque of the engine entersa transfer case that is bolted onto thetransmission housing.

From the transfer case, the torqueis transmitted to the drives of thefront and rear axles according totraction requirements.

SSP297/088

Hydraulic Control Valve Assembly

Automatic Transmission Fluid Pump

OutputDriveshaft

Dual Planetary Gear Set

Simple Planetary Gear Set

Component Locations

Input Driveshaft

Lock-Up Torque Converter

22

Selector Lever Positions

P – Parking

To move the selector lever out of the “P”position, the ignition must be turned on. Inaddition, the brake pedal and the lockingbutton on the selector lever must bepressed.

The ignition key can be removed only whenthe lever is in this position.

R – Reverse

The locking button on the selector levermust be pressed to shift into reverse.

N – Neutral

The transmission is idling in this position.If the selector lever is in this position for along time, the Shift Lock Solenoid N110 forthe selector lever becomes active and thebrake pedal must be pressed to activatethe lever.

No power is being transmitted tothe wheels.

D – Drive

In this position, the forward gears areshifted automatically.

S – Sport

The Transmission Control Module J217selects gears automatically according to asporty shifting characteristic curve. Theshift points occur at higher engine speedsresulting in longer intervals in each gear andbrisker acceleration.

Transmissions

Locking Button

SSP297/028

Tiptronic NotchSport Setting

23

Transmissions

Shift Program and Gear Indicator on

Display Unit in Instrument Cluster Y24

After the ignition is turned on, the currentselector lever position is displayed in theDisplay Unit in Instrument Cluster Y24.

In positions “D” and “S” the gear selectedin the transmission is also displayed.

SSP297/029

SSP297/086

The gear being used is shown on thedisplay if the automatic transmission is inthe Tiptronic shift program.

76.7 mi 54.1°F 76728 mi

76.7 mi 54.1°F 76728 mi

24

Transmissions

Selector Lever Tiptronic

On the Touareg, Tiptronic gear selection isoperated by the selector lever.

The automatic transmission is switched tothe Tiptronic mode by moving the selectorlever to the right from the “D” position intothe Tiptronic notch.

SSP297/030

Shift Upa Gear

Shift Downa Gear

Gear changes are then made by moving theselector lever.

Moving the selector lever forward shiftsup a gear, moving the lever back shiftsdown a gear.

25

Transmissions

Selector Lever Locks

The selector lever is locked by:

• Shift Lock Solenoid N110

• Selector Lever Park PositionSolenoid N380

The ignition key can be removed only whenthe selector lever is in the “P” position.

The Selector Lever Park Position LockSwitch F319 signals to the Access/StartControl Module J518 that the selector leveris in the “P” position.

Shift LockSolenoid N110

Press toActuateSolenoid

SSP297/087

Selector LeverPark PositionSolenoid N380

Selector LeverPark PositionLock SwitchF319

SSP297/087

Effect of failure

If one of the signals fails or the Shift LockSolenoid N380 is defective, then theselector lever cannot be moved out of the“P” position. The selector lever mustbe manually unlocked to allow moving ofthe vehicle.

To manually unlock the selector lever:

• The selector lever covering must beremoved and the solenoid actuatedby hand.

• The selector ever must besimultaneously moved out of the“P” position.

26

Transmissions

Six-Speed ManualTransmission 08D(Late Availability in the

North American Market)

The six-speed manual transmission 08D wasdeveloped just for the Touareg, especially foroff-road use.

This manual transmission is standardequipment for Touaregs equipped with the3.2-liter V6 gasoline engine or the 5-liter V10TDI diesel engine.

Six-Speed ManualTransmission 08D

For smooth operation it is actuated by shiftcables instead of mechanical linkage. Aspecial support on the transmissionhousing provides for shift cable mountingand for the actuation of the shifter shaft inthe transmission.

Shift Cable

27

Transmissions

The ends of the shift cables are attachedwith locknuts to the control levers.Mass dampers smooth out the shiftingmovements and absorb vibrations.

Selector Lever Housing

To ensure proper adjustment orreplacement of the shift cables:

• The gearshift lever must be locked inplace in the left neutral position using theadjustment drift T10027 before the shiftcables are loosened.

• At the transmission housing, a stoppingdrift located on the bearing housing atthe shifter shaft end must be turnedclockwise to hold the shifter shaft in theleft neutral position.

SSP297/062

SSP297/059

SSP297/098

Adjustment Drift T10027

Stopping Drift

Gearshift Lever

Running Gear

28

Touareg Chassis Overview

The Touareg chassis has excellentoff-road driving characteristics with the4XMOTION system. It has continuousfour-wheel drive and a central differentialwith a reduction stage.

It also ensures the highest levels ofdriving comfort on normal roads with itsfour-wheel independent suspension.

Touareg chassis features include:

• Tire inflation pressure connectionunder the driver’s seat(only in vehicles with air suspension).

• Air suspension with regulated attenuation(standard equipment on vehicles with the5-liter V10 TDI diesel engine, optional onother models).

• Independent wheel suspension.

• Front and rear anti-roll bars.

• Dual wishbone rear suspension withdivided upper wishbone.

• Dual wishbone front suspension.

Running Gear

29

SSP297/061

For more detailed informationon the chassis, refer toThe Touareg Suspension and4XMOTION System, Self-StudyProgram Course Number 89H303.

• Conti Teves MK25 Electronic StabilizationProgram (ESP) system with braking assistant andfour-wheel Electronic Differential Lock (EDL).

• Hill incline assistant andhill descent assistant.

• Ventilated disc brakesfront and rear.

• Dual-servo foot-pedal-actuateddrum parking brake.

• Rear transverse lock andlongitudinal lock.

Body

30

Body Structure

The body of the Touareg is a completelynew, self-supporting construction. It isdesigned to attain as much static anddynamic rigidity as possible. To accomplishthis, special sheet metals are used:

• High-strength sheet metals:These sheet metals, made of specialsteel, are more stable than “normal”sheet metals without causing anincrease in weight.

• Tailored blanks:Sheet metals that have differentthicknesses depending on the loadswhere they are used.

Instead of the usual ladder frame, the bodyhas integrated longitudinal load-bearingmembers that run through the vehicle. Inthe front and the rear, they aremanufactured from tailored blanks.

C-rails with fastening points for roof racksare set into the roof.

There are cavities in the tailgate for thegas-filled support struts.

For a seamless appearance, the roofis connected to the side structure bylaser soldering.

In a self-supporting body,the supporting frameworkand the body structure forman inseparable unit.

Body

31

Static Rigidity

The body of the Touareg has a very highstatic rigidity. It does not flex or twist, evenduring off-road driving, where large forcesaffect the body. The chassis is designed sothat the doors. hood, and tailgate alwaysclose without problems, even with thetightest gap tolerances.

Side Crash Area

Passenger Compartment

Frame Structure

Crash Areas

Dynamic Rigidity

The high dynamic torsional rigidity of thebody results in both favorable vibrationcharacteristics and driving comfort.

Safety Aspects

The body is designed to survive crasheswell using profiles and an auxiliary frame.

In the sills (side members), tubes with awall thickness of 0.118 inch (3 mm) areinstalled, which optimize the side-postcrash behavior.

In addition, the roof structure is reinforcedto increase the safety for the occupantsduring a rollover.

Overall, the crash behavior of the Touaregis similar to that of a luxury sedan – unusualfor such a vehicle.

SSP297/010

32

Body

Body Attachments

Engine Hood

The engine hood is made entirely ofaluminum. The outer hood sheet metalpanel is 0.045 inch (1.15 mm) thick. Thethickness of the inner panel is unusual at0.035 inch (0.9 mm).

Fenders and Bumpers

The front fenders and front and rearbumpers are made of plastic. The wallthickness of the fenders varies between0.106 inch and 0.134 inch (2.7 mm and 3.4mm). The plastic that is used is resistant tohigh painting process temperatures. Thispermits painting of the bumpers with therest of the body.

Front fender brackets

The front fender brackets are attached withscrews and can then be adjusted. Thisresults in narrow installation gap tolerances.

Sunroof

The Touareg is available with a glass tilt andslide sunroof.

This sunroof system is like the one used inthe Volkswagen Passat.

Windows

The windshield consists of acoustic glass.An electric windshield heater is available asan option.

Privacy side and rear windows arealso available as an option. With thisfeature, the glass from the B-pillarback is darkened by 35%.

33

Body

Rear window module

The rear window module is made up ofglass and a sheet metal frame. These partsfeature a special new technique calledplastic extrusion coating.

To avoid providing a starting point forthieves, the hinges are covered by a spoiler.This consists of glass-fiber-reinforcedplastic which expands only slightly whenexposed to heat. This results in narrow gaptolerances here as well.

Side window module

The side windows are connected to thepanels and the trim plate by plasticextrusion coating.

Setscrews are also incorporated into themodules. The entire module is screwedto the body.

Doors

The doors are installed to the bodyas modular units with all of theircomponents assembled.

Doors can be adjusted for a precise fit tothe body openings.

The doors are sealed three ways to ensurethe fording capability of the Touareg.

SSP297/012

SSP297/011

Door Seals

aluminum

plastic

34

Body

Body Insulation

Two acoustic insulation packages weredeveloped for the Touareg.

The package for vehicles equipped withgasoline engines consists of bitumenplastic foil sound deadening.

Assembly Plate

For vehicles with diesel engines, four ofthe sound deadening parts are designed asa bitumen-aluminum sandwich foil.

SSP297/013

Bitumen Plastic Foil

Diesel Engine Applications,Aluminum Sandwich Foil; All OtherApplications, Bitumen Plastic Foil

Rear SpareTire Recess

Side SpareTire Recess

Cargo Compartment Floor

Lower SpareTire Recess

Wheel House

Side Part

UpperWheel House(3 places)

Side Part

Wheel House

Rear FloorTunnel, Left

Front Floor

Lower Door(4 places)

Upper Door(4 places)

Tunnel, Right

Lower Bulkhead

Front Floor

Side SpareTire Recess

35

Body

Tailgate

The tailgate of the Touareg consists ofa separate flip-up rear window and thetailgate itself.

The rear window and the tailgate aresecured by a locking mechanism whenthe window is closed.

Two Pairs of Gas-Filled StrutsSSP297/096

Two pairs of gas-filled struts ensurecomfortable opening and closing of the rearwindow and the tailgate. They are attachedto the body so that they are invisible fromthe outside.

Rear Window

Tailgate

Spoiler

Hinges

SSP297/047

36

Body

Rear Window Wiper

The motor for the rear window wiper islocated in the tailgate, while the wiper isinstalled in the rear window.

For this reason, there is a drive mechanismbetween the rear window wiper andthe motor.

Driving Stud on Rear Window

Driving Stud

SSP297/023

When the rear window is flipped up, thewindow wiper may rotate. As a result, theposition of the driving stud changes in sucha way that it no longer fits in the hole of thedriving plate. In this case, the spring-loadeddriving stud is pressed back so that nothingis damaged.

37

Body

Driving Plate on Tailgate

SSP297/024

Driving Plate

Opening

As soon as the rear window wiper motoris started, the driving plate turns and thedriving stud locks into the opening.

In this way, the window wiper mechanismand its motor are easily disengagedand re-engaged.

38

Body

Roof Rack

In order to mount a roof rack, twochamfered C-rails are embedded into theroof of the Touareg.

Opening

SSP297/017

SSP297/016

Recesses

The roof rack carrier supports areinserted into these rails at the openingsin the center.

Body

39

Each support has a lockabletensioning mechanism:

• When the lock is open and the flapdisengaged, the carriers can be pushedto the desired positions with thesupports on each end at matchingrecesses in the rails.

• The carriers are fastened by closing theflaps and the locks on the supports.

To avoid damage to the paint,the key for unlocking the carriersupports should be removedbefore moving the carriers.

If the lock is closed, the carrier is fastened.

Use the key to open the lock.

SSP297/019a

SSP297/018

Remove the key before moving the carrier.

SSP297/019b

Airbag System

Airbags

The following airbags are installed inthe Touareg:

• Driver airbag – approximate filling volumeof 2.26 cubic feet (64 liters).

• Front passenger airbag – approximatefilling volume of 4.24 cubic feet(120 liters).

• Driver and front passenger side airbags –approximate filling volume of 0.39 cubicfeet (11 liters).

• Curtain airbags – approximate fillingvolume of 0.78 cubic feet (22 liters).

There are no side airbags in the rear of thevehicle. Rear seat passengers are protectedby curtain airbags mounted along the entirelength of the vehicle.

Crash Sensors

Two external longitudinal accelerationsensors are located in the front of theTouareg. These detect an accident andits magnitude early and transfer the dataon to the Airbag Control Module J234.The airbags are activated if the accidentis severe.

External acceleration sensors detect thelongitudinal acceleration. An additionalsensor of this type is located in the AirbagControl Module J234 in the center console.

In addition, four external lateral accelerationsensors are fastened to the vehicle.

Occupant Protection

40

41

Occupant Protection

Airbag Control Module J234

The Airbag Control Module J234is located in the center console.It receives the signals of the six crashsensors and evaluates the data. In thecase of an accident, it can trigger thefollowing actions:

• Tightening the seat belts.

• Activating the airbags.

• Separating the battery positive lead fromcontact with the battery terminal.

• Activating the hazard warning light system.

• Turning off the fuel pump.

• Unlocking the vehicle through the centrallocking system.

Depending on the magnitude of the crash,the airbags are triggered in two stages.

SSP297/020

42

Occupant Protection

Restraining Systems

Seat Belts

Three-point retracting seat belts are locatedat all five seats in the Touareg. The belt lockand the belt limit stop are located in theseat. The height of the belt can bemechanically adjusted at all outer seats. Anelectric belt height adjuster and a comfortmechanism for the front seats is availableas an option.

Ball seat belt tensioner

and belt tension limiter

Ball seat belt tensioners are used at allfour outer seats. They are pyrotechnicallyactivated.

The driver and front passenger seat beltshave belt tension limiters.

With tension limiters, the belts are at firsttensioned during a collision to optimize theposition of the occupant in the seat.

After a certain belt force has been attained,the belt relaxes a bit. This provides anotherway of reducing the amount of collisionenergy transferred to the vehicle occupant.

Belt-use detection

There is a belt-use detection system for thedriver and the front passenger. It ensuresthat a warning signal sounds if the driverdoes not use the seat belt when operatingthe vehicle.

Along with the comfort mechanism, thebelt-use detection system is used todetermine which spring of the comfortmechanism is used. When the belt latch isengaged, a soft spring provides comfort tothe occupant wearing it. When the beltlatch is released, the belt rolls up quicklyand safely using a more rigid spring.

Belt Tension Limiter and Belt-UseDetection, Optional Comfort Mechanismand Electric Belt Height Adjustment

SSP297/048

Three-PointRetracting Seat Belts

Ball Seat Belt Tensioner,Mechanical Belt Height Adjustment

43

Occupant Protection

Child Seat Fasteners

Child seat fasteners are attached to thefront passenger seat as well as to the outerpositions of the rear bench seats.

Interior Trim

The collision area at the instrument panel isoptimized at knee height for the driver andthe front passenger.

Corners and sharp edges have beenavoided; paneling and absorber partsdeform in such a way that the risk of injuryis minimized.

Pedestrian Protection

The body contour, the selectedmaterials for body panels like aluminumfor the hood and plastic for the fenders,and the space between the hood and theengine, all provide some measure ofpedestrian protection.

The body structure is designed to deformstrategically and quickly reduce energyupon impact.

Seats

44

Front Seats

The front seats of the Touareg have theirown sporty characteristics, such as raisedside cushions. They are heated by theelectric seat heater using a carbon heatingelement.

To satisfy customer requirements for fineappointments in a luxury vehicle, theupholstering of the seats is first-class.Many different cloth fabrics are available, asare several leather versions.

In addition, the front seats are integratedinto the memory package. The seatposition and the easy-entry setting can besaved for different user profiles.

The Touareg comes with 8-position seatsas standard equipment. Models withcomfort equipment have 12-position seats.

SSP297/025

8-Position Seat

For the 8-position seat, seat adjustment isdone manually.

It has the following possible adjustments:

• Seat backward and forward.

• Seat height.

• Seatback inclination angle.

• Headrest height.

Seats

45

Compressed Air Connection

Under the passenger seat in the seatconsole, there is a connection for the aircompressor. For example, an air hose canbe connected here.

12-Position Seat

The 12-position seat has the followingadjustments in addition to those of the 8-position seat:

• Seat inclination angle.

• Lumbar support.

All adjustments except the headrest heightare made electrically.

SSP297/026

Compressed Air Connection

SSP297/040

Air Hose

Access Cover

46

Rear Bench Seat

The rear of the Touareg is equippedwith a bench seat. It is designed forthree persons, providing a headrest anda three-point seat belt for each position.

Seats

SSP297/014

SSP297/015

There is a central armrest in the backrestwith an integrated compartment for aski sack.

The entire rear bench seat can beheated. The backrests can be foldedforward separately.

47

Seats

Cargo Net

The cargo net of the Touareg is located inits own storage compartment.

It can be mounted either behind the rearbench seat, or…

SSP297/052

SSP297/053

…if the bench is folded down completely,behind the driver and front passengerseats.

The net can be extended and anchoredto the roof headliner from either ofthese positions.

48

Air Conditioning System

Air Conditioning in the Touareg

Three different air conditioning systemsare available for the Touareg. They primarilydiffer in terms of temperature control, airdistribution, and regulation of the volumeof air distributed throughout the interior ofthe vehicle.

There are two air conditioning systemswith automatic control:

• Four-zone Climatronic

• Two-zone Climatronic

The temperature range available inboth these systems is 61°F to 85°F(16°C to 29.5°C).

The third variant is the standard manuallycontrolled air conditioning system.

The following characteristics are commonto all three systems:

• Separate temperature control for eachside of the vehicle.

• Residual heating function.

• Activated-charcoal dust and pollen filter.

• Air conditioned glove compartment.

Despite their variations, the three systemsare based on each other. This simplifiesrepairs and maintenance.

The different systems can easily berecognized by their controls.

Due to safety regulations regardingcollision protection, the knobs and buttonsof all three A/C system control modulesare designed to give way in the eventof a collision.

On impact they will collapse into theface of the modules by shearing off atbreak-out points.

Pressure must not beexerted on these knobs andbuttons during installationor the break-out pointsmay break.

The illustration shows the Touareg with afour-zone air conditioning system.

SSP297/057

49

Four-Zone Climatronic

This system has two control modules.

The Climatronic Control Module J255is located in the instrument panel.This can be used mainly to select thesettings for the climate zones of thefront passenger compartment.

The Rear A/C Control Head (Climatronic)E265 located in the rear center consolecan be used to select the settings forthe climate zones of the rearpassenger compartment.

Two separate modules are used tocondition and distribute the air in thepassenger compartment.

The front air conditioner module is locatedbelow the instrument panel. It serves thefront passenger compartment.

The rear air conditioner module is locatedbehind the side panel in the left-hand sideof the cargo area. It serves the rear seats.

Each air conditioner module has its ownevaporator, heat exchanger, and blower.Therefore, the temperature and the fanspeeds can be independently set for thefront and rear climate zones.

Ventilation flaps in the air conditionermodules and the air distribution ducts areelectro-mechanically set, permittingindividual control of air distribution to thefour zones.


Climatronic Control Module J255

Rear A/C Control Head (Climatronic) E265

SSP297/035

SSP297/033

SSP297/038

Front AirConditionerModule

Rear AirConditionerModule

50


Two-Zone Climatronic

The Climatronic Control Module J255 in thetwo-zone Climatronic system is also locatedin the instrument panel.

Climatronic Control Module J255

SSP297/037

SSP297/036

Air Conditioner Module

Compared to the four-zone Climatronicsystem, there are the following differencesin automatic operation:

• The temperature can be set separatelyfor the left and right sides of thepassenger compartment.

• The fan speed and air distribution are setuniformly for the entire passengercompartment.

The design of the two-zone Climatronicsystem differs from the four-zone systemmainly by:

• The use of a single air conditionermodule below the instrument panel.

• Air ducts through the front doors to theair outlets in the B-pillars.

• Air ducts through the center console tothe air outlets in the rear center console.


51

Manual Air Conditioning System(Not Available in theNorth American Market)

Using the A/C Control Head E87 in theinstrument panel, the occupants can setthe air conditioning of the entire interioraccording to their wishes.

A/C Control Head E87

Air Conditioner Module

SSP297/091

Dial

SSP297/039

In this manually controlled system, theentire passenger compartment is uniformlyair conditioned.

There is no automatic climate control for thetemperature, air distribution, or fan speed.

The structural features of the air ductsare generally the same as those of thetwo-zone Climatronic system.

For more detailed informationon the air conditioning system,refer to The Touareg Heating,Ventilation and Air-ConditioningSystem, Self-Study ProgramCourse Number 89G303.

Electrical System

52

Convenience andSafety Electronics

Overview

The comfort and safety electronicsused on the Touareg are based on thoseof the Phaeton.

Components are located throughoutthe vehicle.

The Touareg will use theconvenience entry system butNOT the convenience startfunction. You must use thevehicle key to start the engine.

On-Board Power Supply Battery(Under Cargo Load Floor, withOptional 5-Liter V10 TDI Diesel Engine)

Door Control Module, Driver Side J386Door Control Module, Passenger Side J387

Starter Battery(Under the Driver’s Seat)

Door Control Module, Rear, Left J388Door Control Module, Rear, Right J389

Interior Access/StartAuthorization Antenna 2 R139

Interior Access/StartAuthorization Antenna 1 R138

Luggage Compartment Access/StartAuthorization Antenna R137

Electrical System

53

Vehicle Electrical SystemControl Module J519

SSP297/050

Central ControlModule for ComfortSystem J393

Left Access/Start AuthorizationAntenna R134 (2, Left Side)Right Access/Start AuthorizationAntenna R135 (2, Right Side)

Orientation Illuminationin the Exterior Mirrors(Right and Left Sides)

Access/StartControl Module J518

For more detailed information,refer to The Touareg ElectricalSystem, Self-Study ProgramCourse Number 89J303.

54

Electrical System

SSP297/041

Knob/Button

B/F Button

Sound Button

Radio System

With minor differences, the radio systemused in the Touareg corresponds to theradio system that can be found in otherVolkswagens, such as the 2003 Passat.

The main difference in the Touareg systemis the design of the user interface, with alarger display and overall dimensions thatwere adapted to the instrument panel.

Their are also some differences in thearrangement of the function keys andtheir designations.

The sound settings in this system areselected using the buttons “Sound” and“B/F” (for Balance and Fade). After thebutton is pressed, the corresponding menu

appears in the display. The sound settingscan then be changed by turning theright-hand knob/button.

Due to safety regulations regardingcollision protection, the knobs and buttonsare designed to give way in the event ofa collision.

On impact they will collapse into theface of the module by shearing off atbreak-out points.

Pressure must not be exerted onthese knobs and buttons duringinstallation or the break-outpoints may break.

55

Electrical System

Radio/Navigation System

The radio/navigation system found in theTouareg is new to Volkswagen.

The appearance, the user interface, and theoverall dimensions are different than thePremium VI radio.

The most important differences are:

• 6.5-inch (165 mm) color display.

• Function keys with new designations andfunctions.

• Audio-capable CD drive.

• Central connector module withcentral lock.

• Color-coded connectors and sockets forFM/AM and GPS antenna inputs.

• Signal transfer via the infotainment CANdata bus system.

• Off-road function.

• Position-finding display withcompass display.

Due to safety regulations regardingcollision protection, the knobs and buttonsare designed to give way in the event ofa collision.

On impact they will collapse into theface of the modules by shearing off atbreak-out points.

Pressure must not beexerted on these knobs andbuttons during installationor the break-out pointsmay break.

SSP297/054

Knobs/Buttons

56

Electrical System

Radio/Navigation System Operation

The new function keys and buttondesignations are described andsummarized below.

“ESC” key forcalling up the prioror main menu.

SSP297/064

Slot for an audioor navigation CD.

“RADIO” buttonfor setting FM orAM stations.

“CD” button forcalling up the menufor the audio CD. (Ifthe optional CDchanger is equipped,it is activated.)

“TELE” buttonfor telephone.

“AUX” calls up themenu for controllingan additional connectedTV tuner, audio, orvideo device.

“NAVI” calls upthe navigationmenu.

Function keys to call upvarious functions whichare shown by the adjoiningsymbols in the display.

“MAP” button forcalling up the mapdisplay or thesymbol display if anavigation CD hasbeen inserted.

“INFO” button for:• System information• Off-road display• List of routes• Text messages

57

Electrical System

Off-Road Navigation

In addition to the menus for entering thedestination and the path to the destination,the radio/navigation system provides afurther navigation option with the “Off-roadtour” menu.

It is especially useful during off-roaddriving where digital information isnot available.

The transition between the two navigationtypes from standard to off-road occursautomatically. However, the system doesnot automatically switch back from off-roadto standard navigation.

Off-road navigation can be selected usingfunction key “Off-road tour” in the“Destination” submenu.

The off-road functions have the followingpossible selections:

• Recording, calling up, and editing GPS-coded off-road tours.

• Placing way points within tours andassigning names to them to mark speciallocations (e.g. “Hunting lodge,” see flag5 in the illustration).

• Display of the next way point by a redflag and an arrow.

• Compass display with positioninformation in degrees, minutes, andseconds.

• Reverse function enables the use of therecorded way points so that they can alsobe driven in the opposite direction.

New address

Last dest.

From dst. mem.

Special dests.

To flagged dst.

SSP297/065

SSP297/075

Navigation Display

DestinationHuntinglodge

Dest. on map

Position dest.

Travel guide

Off-road tour

Edit memory

Destination back with ESC

1

2

3

4

5

58

Notes

59

Notes

Notes

60

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 thisKnowledge 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: [email protected]

Knowledge Assessment

61

Volkswagen of America, Inc.3800 Hamlin RoadAuburn Hills, MI 48326Printed in U.S.A.March 2003

Documents

Touareg