2010 Volkswagen Touareg Service & Repair Manual
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Repair Manual
Touareg 2003 ➤
Suspension, Wheels, Steering
Engine ID
CAT
A
BHK BHL BAA BMX BAR AXQ BHX BWF
BKW BLE
Edition 09.2012
Service
Service Department. Technical Information
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List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical Data
40 - Front Suspension
42 - Rear Suspension
43 - Self Leveling Suspension
44 - Wheels, Tires and Vehicle Alignment
48 - Steering
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
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2014 Volkswagen AG, Wolfsburg D3E8001BCDA
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Contents
00 - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Chassis Evaluation Checklist for Accident Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
40 - Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Air Spring Damper, Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Air Spring Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Air Spring Damper, Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5 Decoupling Stabilizer Bar Hydraulic System, Checking Oil Level and Filling . . . . . . . . . . . . 6
1.6 Decoupling Stabilizer Bar, Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.7 Evaluating Accident Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.8 Longitudinal Member Threads, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.9 Lower Spacer, Allocating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.10 Residual Pressure Retaining Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.11 Seals, Sealing Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.12 Subframe, Securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.13 Wheel Bearing, Bringing to Curb Weight Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1 Decoupling Stabilizer Bar Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2 Drive Axle Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 Front Air Spring Damper Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4 Front Air Spring Damper Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.5 Front Suspension Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.6 Subframe, Stabilizer Bar and Lower Control Arm Overview . . . . . . . . . . . . . . . . . . . . . . . . 22
2.7 Suspension Strut Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.8 Wheel Bearing Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1 Ball Joint, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2 Outer CV Joint Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.1 Air Spring Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.2 Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.3 Decoupling Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.4 Left Front Level Control System Sensor G78 and Right Front Level Control System Sensor
G289 , Vehicles with Suspension Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.5 Left Front Level Control System Sensor Bracket G78 and Right Front Level Control System
Sensor Bracket G289 , Vehicles with Suspension Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.6 Left Front Level Control System Sensor G78 and Right Front Level Control System Sensor
G289 , Vehicles with Air Spring Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.7 Left Front Vehicle Level Sensor Bracket G78 and Front Right Vehicle Level Sensor Bracket
G289 , Vehicle with Air Spring Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.8 Lower Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.9 Residual Pressure Retaining Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.10 Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.11 Subframe Front Bonded Rubber Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.12 Subframe Rear Bonded Rubber Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.13 Suspension Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.14 Upper Control Arm, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Touareg 2003 ➤
Suspension, Wheels, Steering - Edition 09.2012
Contents i
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5.15 Wheel Hub with Wheel Bearing, 16 Inch Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.16 Wheel Bearing, 17 and 18 Inch and 18 Inch Plus Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.1 Front Air Spring Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.2 Front Suspension Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.3 Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6.4 Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
7 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
42 - Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.1 Air Spring Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.2 Air Spring Damper, Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.3 Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.4 Decoupling Stabilizer Bar, Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.5 Decoupling Stabilizer Bar Hydraulic System, Checking Oil Level and Filling . . . . . . . . . . . . 102
1.6 Evaluating Accident Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.7 Inner CV Joint Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.8 Lower Spacer, Allocating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.9 Rear Longitudinal Member Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.10 Seals And Sealing Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.11 Subframe, Securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2.1 Control Arm and Tie Rod Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2.2 Decoupling Stabilizer Bar Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.3 Decoupling Stabilizer Bar Motor Pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2.4 Decoupling Stabilizer Bar Line Routing Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.5 Drive Axle Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.6 Rear Air Spring Damper Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2.7 Rear Air Spring Damper Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.8 Rear Suspension Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.9 Subframe, Stabilizer Bar and Stone Deflector Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.10 Suspension Strut Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.11 Wheel Bearing Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.1 Air Spring Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.2 Air Spring Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.3 Decoupling Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.4 Motor Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
4.5 Rear Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.6 Left Rear Level Control System Sensor G76 / Right Rear Level Control System Sensor G77
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4.7 Residual Pressure Retaining Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4.8 Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4.9 Stabilizer Decoupling Control Module J742 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.10 Suspension Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4.11 Wheel Hub with Wheel Bearing, 16 Inch Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4.12 Wheel Bearing, 17 and 18 Inch and 18 Inch Plus Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
5.1 Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
5.2 Rear Air Spring Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
5.3 Rear Suspension Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
5.4 Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
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5.5 Wheel Bearing Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
43 - Self Leveling Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.1 Air Line, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.2 Evaluating Accident Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.3 Level Control System Basic Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.4 Ride Height, Measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1.5 Vehicle Lift Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
2.1 Air Supply Unit with Solenoid Valve Block Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
2.2 Air Supply Unit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
2.3 Level Control System, Components and Component Locations . . . . . . . . . . . . . . . . . . . . 183
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
3.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
4 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
4.1 Air Spring Damper and Level Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
5 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
5.1 Air Supply Unit without Solenoid Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
5.2 Air Supply Unit with Solenoid Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
5.3 Level Control System Control Module J197 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
5.4 Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
44 - Wheels, Tires and Vehicle Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
1.1 Adaptive Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
1.2 Evaluating Accident Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
1.3 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
1.4 Vehicles with Break-Down Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
1.5 Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
1.6 Wheel Centering Seat, Protecting Against Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
1.7 Wheel, Changing and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
1.8 Wheel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
1.9 Wheel/Tire Vibration, Causes and Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
2.1 Tire Pressure Monitoring System, Generation 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
2.2 Tire Pressure Monitoring System, Generation 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
3.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
3.2 Wheel Alignment Specified Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
4.1 Tires, Wheels with Tire Pressure Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
4.2 Tire Pressure Monitoring System, Generation 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
4.3 Tire Pressure Monitoring System, Generation 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
4.4 Tires, Sealed with Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
1.1 Evaluating Accident Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
1.2 Power Steering System, Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
1.3 Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Touareg 2003 ➤
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1.4 Steering System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
2.1 Steering Column Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
2.2 Power Steering Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
2.3 Power Steering Gear Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
2.4 Power Steering Pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
2.5 Power Steering Pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
2.6 Power Steering Pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
2.7 Power Steering Pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
2.8 Power Steering Pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
3.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
4 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
4.1 Power Steering Pump, Checking Delivery Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
4.2 Power Steering Pump, Checking Delivery Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
4.3 Power Steering Pump Delivery Pressure, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
4.4 Power Steering Pump, Checking Delivery Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
4.5 Power Steering Pump, Checking Delivery Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
5 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
5.1 Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
5.2 Power Steering Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
5.3 Protective Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
5.4 Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
5.5 Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
5.6 Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
5.7 Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
5.8 Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
5.9 Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
5.10 Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
7 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
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00 – Technical Data
1 General Information
(Edition 09.2012)
⇒ “1.1 Chassis Evaluation Checklist for Accident Vehicles”, page
1
⇒ “1.2 General Information”, page 2
1.1 Chassis Evaluation Checklist for Acci‐
dent Vehicles
When servicing load-bearing or wheel-supporting components on
accident vehicles, damages on suspension could remain undis‐
covered. These undiscovered damages may lead to heavy dam‐
ages in continued vehicle operation. Therefore, on accident
vehicles, the listed components must be checked in the described
manner and sequence, independent of performing a vehicle align‐
ment. If no deviations from specified values were determined
during vehicle alignment, no deformations of the suspension are
present.
Visual and Function Check of Steering System
♦ Visual check for deformations and cracks.
♦ Check for play in tie rod joints and steering gear.
♦ Visual inspection for faulty bellows and grease boots.
♦ Check electric and hydraulic lines and hoses for chafe marks,
cuts and kinks.
♦ Check hydraulic lines, bolted connections and steering gear
for leaks.
♦ Check steering gear and lines for proper seating.
♦ Check proper function through entire steering angle by turning
steering wheel from stop to stop. Steering wheel must be ro‐
tary without hitching at equal force.
Visual and Function Check of Suspension
• Observe the sequence of the following test steps!
♦ Check all components shown in assembly overviews for de‐
formation, cracks and other damages.
♦ Replace damaged components.
♦ Perform vehicle alignment on wheel alignment stand approved
by VOLKSWAGEN AG.
Visual and Function Check For Wheels, Tires
♦ Check for run-out and imbalance, refer to ⇒ Wheel and Tire
Guide - Non-Current Models; Rep. Gr. 44 ; General Informa‐
tion
♦ Check tires for cuts and impact damage in tread and on sides,
refer to ⇒ Wheel and Tire Guide - Non-Current Models; Rep.
Gr. 44 ; General Information .
♦ Check tire inflation pressure; inflation pressure see inflation
pressure plate in tank flap, refer to Maintenance Booklet Tires,
Checking Condition, Wear Pattern, Tire Pressure, Tread
Depth.
Touareg 2003 ➤
Suspension, Wheels, Steering - Edition 09.2012
1. General Information 1
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For damage on wheel and/or tire, tire must be replaced. This also
applies when the course of the accident and damage on the ve‐
hicle points to possible non-visible damages.
Another determining factor is the age of the tires: Tires should not
be older than 6 years.
In Case of Doubt, Always Proceed As Follows:
• As soon as a safety risk cannot be ruled out, the tire(s) must
be replaced.
Entire Vehicle
Also check other vehicle systems as, for example:
♦ Brake system including Anti-lock Brake (ABS).
♦ Exhaust system and passenger protection by visual and func‐
tion check.
Test values, adjustment values and notes can be found in re‐
spective repair manuals/ELSA.
Checking of accident vehicles described here, refers to suspen‐
sion and does not lay claim to completeness for entire vehicle.
Electronic Vehicle Systems
Safety-related system such as: ABS/EDL; Airbag; Electronically
regulated vehicle systems; Electro-mechanical; Electro-hydraulic
steering and other driver assistance systems must be queried for
fault codes that could possibly be stored, using the Vehicle Diag‐
nostic Tester . Stored DTCs of systems mentioned must be
serviced according to specifications in repair manual/ELSA.
When service work is done, check affected systems again for
DTC memory to ensure function is established again.
1.2 General Information
Information on wheels, tires and snow chains can be found in the
“Wheel and Tire Guide” in ⇒ Wheel and Tire Guide - Non-Current
Models; Rep. Gr. 44 ; General Information .
Touareg 2003 ➤
Suspension, Wheels, Steering - Edition 09.2012
2 Rep. Gr.00 - Technical Data
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40 – Front Suspension
1 General Information
⇒ “1.1 Air Spring Damper, Repair Information”, page 3
⇒ “1.2 Air Spring Shock Absorber”, page 4
⇒ “1.3 Air Spring Damper, Filling”, page 4
⇒ “1.4 Bolts and Nuts”, page 6
⇒ “1.5 Decoupling Stabilizer Bar Hydraulic System, Checking Oil
Level and Filling”, page 6
⇒ “1.6 Decoupling Stabilizer Bar, Bleeding”, page 7
⇒ “1.7 Evaluating Accident Vehicles”, page 7
⇒ “1.8 Longitudinal Member Threads, Servicing”, page 8
⇒ “1.9 Lower Spacer, Allocating”, page 8
⇒ “1.10 Residual Pressure Retaining Valve”, page 8
⇒ “1.11 Seals, Sealing Rings”, page 8
⇒ “1.12 Subframe, Securing”, page 8
⇒ “1.13 Wheel Bearing, Bringing to Curb Weight Position”,
page 10
1.1 Air Spring Damper, Repair Information
When the vehicle has been driven 200,000 km, if there is damage
to an air spring, it is recommended that the opposite air spring is
also replaced.
If shock absorbers leak, replace air suspension strut completely
because shock absorber oil can damage the boot -item 4-
⇒ Item 4 (page 17 ) .
Air spring must not be rotated when it is depressurized. There is
the danger that the boot inside the air spring could be damaged
by kinking or folding.
The maximum possible care, cleanliness and proper tools are
essential to ensure satisfactory and successful air spring damper
repairs. Understandably, general safety guidelines apply when
performing repairs.
A series of applicable general notes for individual repair proce‐
dures - otherwise listed several times at many points in the repair
manual - has been collected here. They apply to all air spring
damper repairs.
A description of the design and function of air suspension can be
found in Self Study Program No. 302 The Touareg Chassis and
All Wheel Drive Design.
Touareg 2003 ➤
Suspension, Wheels, Steering - Edition 09.2012
1. General Information 3
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1.2 Air Spring Shock Absorber
– Before loosening air line when installed, check, whether air
spring is still filled with a residual pressure of approximately 3
bar.
– Press with thumbs on air spring bead. The bead must dem‐
onstrate noticeable resistance.
– If great resistance is not noticed, air spring is not pressurized
and it must be replaced together with the residual pressure
retaining valve.
♦ Thoroughly clean connecting points and their surrounding
areas before loosening.
♦ To install air spring damper, it must be filled with argon or cor‐
gon gas. Refer to
⇒ “1.3 Air Spring Damper, Filling”, page 4 .
♦ Place removed parts on a clean surface and cover to prevent
contamination. Use foils and paper. Only use lint-free cloths!
♦ Only install clean components: Only unpack replacement
parts immediately prior to installation.
♦ Only use lubricants indicated by part number.
♦ Carefully cover or seal open components, if repairs are not
carried out immediately.
1.3 Air Spring Damper, Filling
Special tools and workshop equipment required
♦ Adapter - T10157/1-
♦ Air Suspension Strut Charger - VAS 6231-
♦ Steel gas cylinder filled with Argon or Corgon, not depicted
Note
Air spring shock absorbers are supplied as replacement parts with
a minimum pressure. By sitting in storage for extended periods
this pressure can diminish (just like a tire). This minimum pressure
must be checked and if necessary restored by recharging before
air spring shock absorber is removed from the packaging. If air
spring shock absorber is removed from the packaging without this
checking/recharging, this may cause indentations or kinks to form
in the dust boot before it reaches its normal shape. These inden‐
tations lead to preliminary damage and may lead to premature
failure.
– Remove the cover from the packaging.
– Remove union bolt -arrow- from the residual pressure holding
valve.
– Close the valve of the steel gas bottle.
– Become familiar with the relevant rules for the prevention of
accidents for pressurized containers and technical gases.
Touareg 2003 ➤
Suspension, Wheels, Steering - Edition 09.2012
4 Rep. Gr.40 - Front Suspension
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If you are in need of a repair manual for your 2010 Volkswagen Touareg, look no further. This comprehensive manual is designed to assist both professional mechanics and DIY enthusiasts in performing a wide range of repairs and maintenance tasks on the Volkswagen Touareg.
In the past, obtaining a traditional service manual in book format was the norm, often at a higher cost. However, this accessible digital format manual provides a more cost-effective and convenient alternative.
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