VOLKSWAGEN TOUAREG 2003 (02) PDF Document

For your VOLKSWAGEN TOUAREG 2003, understanding the battery types is important for proper maintenance. The two main types are:

Battery with magic eye:

This is a maintenance-free battery with liquid electrolyte (wet battery). It is equipped with a magic eye that provides information on the electrolyte level and the charge state through a colored display. Caution: Do not remove any stickers or replenish with distilled water. Only perform a visual check.

Absorbent glass mat (AGM) battery:

This is a maintenance-free, sealed lead-acid battery where the electrolyte is contained within a microscopic glass mat. It has no magic eye. AGM batteries are identified by the abbreviation “AGM” on the battery case. Note: Always replace an absorbent glass mat battery with another absorbent glass mat battery.

WARNING: Batteries where the magic eye is colorless or light yellow must not be checked or charged. Do not slave/jump start the vehicle! There is a danger of explosion. These batteries must be renewed.

When handling the battery in your VOLKSWAGEN TOUAREG 2003, you must observe the following safety regulations to avoid injury and damage:

Dangers and Warnings:

• Corrosive Acid: Battery acid is highly corrosive. Always wear eye protection and gloves. Have a neutralizing solution (like a soap solution) available in case of spills. Leaking electrolyte can cause skin burns and vehicle corrosion.

• Explosive Gas: Batteries produce an explosive gas when charging. Do not cause sparks through grinding, welding, naked lights, or smoking near the battery. Always touch the vehicle body to discharge static electricity before touching the battery.

• Untrained Personnel: Untrained personnel should only work on batteries under the supervision of a qualified vehicle mechanic or electrician.

• Damaged Batteries: Batteries with a colorless or light yellow magic eye must be renewed. Do not check, charge, or jump start them due to explosion risk.

• Ventilation: Only work on batteries in well-ventilated rooms.

Safety Markings on the Battery:

1. Fires, sparks, naked flames, and smoking are prohibited. Avoid short circuits; never lay a tool on a battery.

2. Wear eye protection.

3. Keep children away from acid and batteries.

4. Dispose of old batteries as hazardous waste through a suitable collection center.

5. Never dispose of old batteries in household waste.

6. Danger of explosion. Highly explosive gas is produced when charging.

7. Always follow instructions on the battery and in the owner’s manual.

To prevent damage to the battery clamps and terminals on your VOLKSWAGEN TOUAREG 2003, follow these steps for connection:

Caution:

• The battery clamps should only be fitted by hand and without using force.

• Battery terminals should not be coated with grease.

• The battery clamps should be fitted so that the battery terminal is either flush with the clamp or protruding from it.

• Once the battery clamps have been tightened to the specified torque, the threaded connections should not be tightened any further.

A visual inspection is essential to check the external condition, terminals, and proper attachment of the battery in your VOLKSWAGEN TOUAREG 2003 before performing more extensive tests.

Caution:

• The battery will be damaged if it is not secured correctly.

• Vibrations shorten the life of the battery and can cause damage to the battery housing and cell plates, creating an explosion risk.

• Check that the battery is securely seated. If necessary, tighten the securing bolt to the specified torque.

Performing the visual check establishes:

• Damaged Housing: Check if the battery housing is damaged. If electrolyte has leaked, it can cause serious damage to the vehicle. Treat affected components immediately with an acid neutralizer or a soap solution.

• Damaged Terminals: Check if the battery terminals are damaged. Proper contact cannot be guaranteed with damaged terminals. When connecting the battery clamps, tighten them to the torque specified in the workshop manual. If not correctly seated, wiring may burn and cause electrical system malfunctions.

The magic eye provides information about the electrolyte level and charge state of the battery in your VOLKSWAGEN TOUAREG 2003. Before checking, lightly and carefully tap the magic eye with a screwdriver handle to dissipate any air bubbles that could distort the display.

“3-Colour” Magic Eye Display:

• Green: Battery is sufficiently charged.

• Black: Battery is partly discharged (charge state < 65%) or completely discharged.

• Colourless or light yellow: Battery must be renewed.

“2-Colour” Magic Eye Display (Later models):

• Black: Electrolyte level is OK.

• Colourless or light yellow: Electrolyte level is too low. The battery must be renewed.

WARNING: Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle! There is a danger of explosion. These batteries must be renewed.

Note: The magic eye only reflects the condition of one battery cell. An exact determination of the battery’s overall condition is only possible through a battery load test.

After performing a battery load test on your VOLKSWAGEN TOUAREG 2003 using the VAS 5097 A tester, use the following table to determine the next steps based on the printout:

To test the battery in your VOLKSWAGEN TOUAREG 2003 with the VAS 6161 tester, follow these steps:

WARNING: Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle. Danger of explosion. These batteries must be renewed.

1. Switch off the ignition and all electrical consumers.

2. Check the magic eye on batteries that have one.

3. Switch on the VAS 6161 unit.

4. Connect the red terminal “+” of the tester to the positive terminal of the battery.

5. Connect the black terminal “-” of the tester to the negative terminal of the battery.

Note: Ensure the test clamps have a good contact.

6. Select one of the following functions on the tester:

• Maintenance test: (Only for new cars before registration or in stationary/stock maintenance programs).

• Service test

• Guarantee test

7. Follow the on-screen prompts for the selected test. This may include scanning a vehicle VIN or battery barcode, selecting battery type, and measuring temperature by holding the sensor about 5 cm above a battery terminal until the temperature stabilizes.

8. Start the test. The test completes in about 10 seconds and the result is printed out by the printer.

When assessing the battery test results for your VOLKSWAGEN TOUAREG 2003 from the VAS 6161 tester, use the following guidelines for guarantee and service tests.

For maintenance tests, follow this table:

A current draw test helps to quickly ascertain the state of a discharged battery in your VOLKSWAGEN TOUAREG 2003 to determine if it must be replaced or can be fully recharged. This test is performed while the battery is charging.

Test Requirements:

• Battery temperature must be at least +10 °C.

• The charger must be capable of outputting a charge current of at least 30 A (e.g., VAS 5095A, VAS 5900, VAS 5903).

• The battery’s current draw must be measured with a current pick-up clamp.

Procedure:

1. Connect the battery to a suitable battery charger and start the charging sequence.

2. Measure the charging current of the battery after 5 minutes.

Test Result:

• If the current draw (in Amperes) is higher than 10% of the nominal capacity (e.g., > 6.1 A for a 61 Ah battery), the battery is likely serviceable. Fully charge the battery and perform a battery load test again after allowing it to rest for two hours.

• If the current draw is below 10% of the nominal capacity after 5 minutes, the battery must be renewed.

This test is used to assess the condition of the battery on stock and stored vehicles as part of prescribed maintenance to determine if recharging is needed.

Test Conditions:

• The battery must not have been charged or discharged within the last 2 days.

Procedure:

• Using a hand multimeter (e.g., V.A.G 1526 B), check the battery’s no-load voltage.

Interpreting the Results:

A no-load voltage of 11.60 V indicates a 0% charge, meaning the battery is discharged and has no capacity.

To activate or deactivate the cruise control system (CCS) on your VOLKSWAGEN TOUAREG 2003, you will need to use a vehicle diagnostic tester.

1. Connect the vehicle diagnostic tester to your vehicle.

2. Select “Guided fault finding” mode on the diagnostic tester.

3. Using the “GoTo” button, select “Functions/component”.

4. Navigate through the following menu options in succession:

• Drive

• Engine code

• 01 – On Board Diagnostic capable systems

• Engine management/diesel direct injection and glow plug system

• Functions

• Activating and deactivating cruise control system (CCS)

Follow the on-screen instructions to complete the process.

Your VOLKSWAGEN TOUAREG 2003 uses several types of hose couplings for the washer system. Here is how to handle them:

Type 1 (Simple Push-Fit):

• To loosen: Pull the two coupling sections apart (no securing device).

• To secure: Push the two coupling sections together until you hear and feel them engage.

Type 2 (Rotating Lock Ring):

• To loosen: Rotate the lock ring -1- through 90° and pull off the hose connection.

• To secure: Push on the hose connection and rotate the lock ring -1- until it engages.

Type 3 (Pull-Up Lock Ring):

• To loosen: Pull up the lock ring -1- by approx. 1 mm and pull off the hose connection.

• To secure: Attach the hose connection and press in the clip -1- until it engages.

Headlight Washer System Coupling (Push Lock Ring):

• To loosen: Push the lock ring -1- and pull off the hose connection.

• To secure: Push and hold the lock ring and push on the hose connection. Check that the securing clip has correctly engaged by trying to pull it off without the clip.

You can repair both smooth and corrugated washer hoses on your VOLKSWAGEN TOUAREG 2003 using available replacement parts.

Repairing Smooth Pipe (5×1 mm or 6×1 mm):

1. Cut the damaged section squarely out of the smooth pipe.

2. Select the appropriate EPDM hose and cable ties from the electronic parts catalogue (ETKA).

3. Cut the EPDM hose so that the ends of the smooth pipe can each be pushed about 10 mm into the EPDM hose.

4. Secure the repair joints with cable ties.

Repairing Corrugated Pipe:

Note: Repair points must not be subjected to pulling or bending forces. If the damaged section is longer than 20 mm, a new piece of corrugated pipe must be used.

1. Cut the damaged section squarely out of the corrugated pipe.

2. Select suitable end pieces and the correct sized heat-shrink piping from the ETKA.

3. Heat the end of the corrugated pipe.

4. Push the appropriate connector into the heated pipe end.

5. Repeat for the other end of the pipe (or the new piece of pipe).

6. Cut the heat-shrink hose so that the ends of the corrugated pipe are each covered by about 20 mm.

7. Push the heat-shrink hose over the corrugated pipe, join the connectors, and secure the repair joints with the heat-shrink hose using a hot air blower.

Gas discharge bulbs operate with lethally high voltage and require strict safety precautions. Before working on the headlights of your VOLKSWAGEN TOUAREG 2003, observe the following:

WARNING: High Voltage Danger

• Disconnect Power: It is absolutely necessary to disconnect the battery earth strap before working on any parts of the gas discharge headlights (marked with yellow high voltage symbols).

• Discharge Residual Voltage: After disconnecting the battery, switch the dipped beam on and off again. This will eliminate any possible residual voltage in the system.

• Never operate components separately: The gas discharge lamp control unit must never be operated without a gas discharge lamp installed. The bulb must only be operated inside the headlight housing due to high ignition voltage (above 28,000 V) and high temperatures.

WARNING: Physical Hazards

• Pressurized Bulbs: H7 and gas discharge bulbs are under pressure and can explode while being changed, causing injury. Always wear protective goggles and gloves when removing and installing them.

• Hot Surfaces: The glass of the bulbs can be very hot, creating a danger of burns.

• UV Radiation and Glare: Avoid looking directly into the beam. The UV rays are about 2.5 times greater than normal halogen bulbs, and the glare can impair vision for a substantial time.

• Do not touch the glass: Do not touch the bulb glass with bare fingers. Use clean cloth gloves. Oils from fingerprints can vaporize and settle on the reflector, impairing brightness.

Disposal:

• Gas discharge bulbs must be disposed of as hazardous waste. They contain metallic mercury (Hg) and traces of thallium. Never destroy these bulbs or dispose of them as conventional waste. Use an authorized collection point.

The procedure for the cigarette lighter and 12V sockets in your VOLKSWAGEN TOUAREG 2003 is the same.

Caution: Only illuminated sockets can be removed with the puller T 40148. Sockets without illumination usually cannot be removed without being damaged, as the puller cannot release their locking lugs.

Removing the Socket:

1. If present, remove the cigarette lighter or dummy plug from the socket.

2. Push the puller (T 40148) into the socket so that its locking lugs -1- engage in the recesses -2- inside the socket.

3. Pull the grip -3- of the puller to release the locking lugs of the outer retaining sleeve.

4. Pull the socket out of the retaining sleeve using the puller.

Caution: Take care not to stretch the wiring when pulling out the socket.

5. Pull off the socket connector.

Removing the Illumination Bulb (L28/L42):

Note: On some vehicles, illumination is by an LED that is permanently attached and cannot be renewed separately. On others, the bulb may or may not be replaceable separately from the bulb carrier.

1. Remove the socket first.

2. Press the retaining lugs and remove the retaining sleeve together with the bulb carrier.

3. Unclip the bulb carrier from the retaining sleeve.

4. Separate the bulb carrier in areas -A- and -B- as shown in diagrams.

5. Open part -B- of the bulb carrier.

6. Remove the light bulb in the direction of the arrow.

Installing:

Installation is carried out in the reverse order of removal.

When performing repairs on the vehicle electrical system of your VOLKSWAGEN TOUAREG 2003, always follow these general rules:

• Disconnect the Battery: Always disconnect the battery earth strap before working on the electrical system to ensure a safe working environment.

• Identify the Cause: Before starting a repair, identify and rectify the cause of the damage (e.g., sharp edges, corrosion, defective components).

• No Soldering: Soldering is not permitted for repairs to vehicle wiring.

• Use Approved Repair Sets: Wiring harness and connector repairs should be carried out using the approved wiring harness repair set (e.g., VAS 1978 B). Use only yellow wires from this set for repairs.

• Mark Repairs: Wiring harness repairs should not be integrated into the vehicle’s own wiring harness but marked with yellow adhesive tape to indicate a previous repair.

• Crimp Connectors: Crimp connectors may never be repaired. If needed, lay a new wire parallel to the defective one. After crimping, they must be shrink-fitted using a hot air blower to prevent moisture ingress.

• Heat-Resistant Wiring: In high-temperature areas like the engine compartment, only use heat-resistant wiring (identifiable by its slightly matt and softer insulation) for repairs.

• Screened Wires: Screened wires must not be repaired. If damaged, they must be replaced completely.

• Function Test: Carry out a function test after every repair. It may be necessary to interrogate and erase the fault memory.

WARNING: Faulty repairs to the airbag and seat belt tensioning system can cause malfunctions in the passenger protection system, potentially preventing them from deploying or causing them to fail. Only use contacts, connectors, and wiring designed specifically for this purpose.

In addition to the general wiring repair notes, observe the following for your VOLKSWAGEN TOUAREG 2003:

• Maximum Two Repairs: A maximum of two repairs may be performed on the wiring in the airbag and belt tensioner system. More repairs increase resistance and can trigger faults in the self-diagnosis system.

• Repair Location: Repairs should be no more than 30 cm from the next contact housing.

• Marking: Mark the area of repair clearly with yellow insulating tape.

• Wire Twisting: The wires to the triggering units are twisted as standard with a twine spacing of A = 20 mm ± 5. This must be adhered to on repair lengths. There must not be any section of wiring longer than B = 100 mm that is not twisted (e.g., around crimp connectors).

• Wire Length: During repairs, the wires to the triggering units must have the same length.

• Shrink-Fit Connectors: To avoid corrosion, crimp connectors must always be shrink-fitted.

The CAN bus uses an unshielded two-wire line with a cross-section of 0.35 mm² or 0.5 mm². When repairing this wiring on your VOLKSWAGEN TOUAREG 2003, follow these rules:

• Wire Colors: The color codes for the CAN bus wires are as follows:

• Wire Length: When performing repairs, both bus wires must have the same length.

• Wire Twisting: When twisting the two wires together, the length of each complete twist must be A = 20 mm.

• Untwisted Sections: There must not be any section of wiring longer than B = 50 mm that is not twisted, for example, in the vicinity of crimp connectors.

• Marking: Mark the area of repair with yellow insulation tape to make it easy to identify.

Aerial wires on your VOLKSWAGEN TOUAREG 2003 must not be repaired. If damaged, the defective section must be replaced using a new repair concept involving adapter and connecting wires.

General Description:

• Aerial wires must be replaced, not repaired, using genuine connecting wires and adapter cables.

• Note: Do not kink or excessively bend aerial wires. The bending radius must not be below 50 mm.

Installing a New Aerial Cable Section:

The goal is to replace a defective section (e.g., between the radio and the aerial) with a set of new cables: an adapter cable for the radio, a connecting wire of the appropriate length, and an adapter cable for the aerial.

1. Pull the defective aerial wire connections off the units (e.g., radio, amplifier, aerial).

2. Determine the routing of the defective wire and measure its total length to be replaced.

3. To find the required length of the new central connecting wire, subtract 60 cm (for the two 30 cm adapter cables) from the total measured length.

4. Obtain the two required adapter cables and the connecting wire of the calculated length.

5. Cut off the connectors from the old, defective aerial wire. The remainder of the wire can stay in the vehicle.

6. Connect the new adapter cables to the equipment in the vehicle (e.g., radio and aerial).

7. Route and attach the new connecting wire in the immediate vicinity of the original factory routing.

8. Connect the new connecting wire to the adapter cables.

9. Perform a functional test.

To release individual contacts (terminals) from their plastic housings on your VOLKSWAGEN TOUAREG 2003, you must use the correct release tools and follow this procedure:

Note: Always use the correct release tool. Never pull contacts out by force. Damaged contact housings must be replaced.

1. Disengage Secondary Lock: If the connector has a secondary locking mechanism (often a different colored plastic piece like a flap, slide, or toothed element), it must be opened, removed, or disengaged first. This secures all the wires in the housing. Use an appropriate tool or small screwdriver if necessary.

2. Disengage Primary Lock: The primary lock is the mechanism that holds each individual contact in place.

• Insert the appropriate release tool for the specific contact type into the release port of the contact housing.

• Grab the wire of the contact you want to remove and gently push it slightly further into the contact housing. This action helps lift the locking tab(s) off the housing edge, allowing the release tool to disengage them.

• While pushing the contact in, simultaneously push the release tool into the housing to disengage the lock.

• Pull the released contact and its wire out from the back of the contact housing.

3. Remove Tool: Once the contact is out, the release tool can be removed from the housing.

The VAS 6410 set allows for proper cleaning of high-current electrical connections (starting and charging circuits) on your VOLKSWAGEN TOUAREG 2003. Note: Do not use penetrating fluid, contact spray, or grease, as this can cause improper torque and connection failure. Use grey sanding pads for light dirt and red pads for heavy dirt.

Cleaning a Ring Terminal:

1. Disconnect the battery.

2. Loosen the cap nut and remove the ring terminal.

3. Check for corrosion and dirt.

4. Select a suitable adapter and sanding pad.

5. Insert the adapter into the ring terminal and grind off corrosion with circular movements. Caution: Do not abrade excessively, and ensure the underlying copper does not appear, as this can cause a faulty repair.

6. If necessary, use the deburrer to remove any punching burr.

Cleaning a Threaded Connection (Stud):

1. Disconnect the battery and remove the ring terminal.

2. Check the threaded connection for corrosion.

3. Select a suitable adapter and sanding pad.

4. Set the adapter on the threaded connection and grind off corrosion with circular movements.

Cleaning Battery Clamps and Terminals:

1. Disconnect the battery.

2. Using the appropriate wire brush tool (e.g., VAG 1331), clean the inside of the battery clamp and the outside of the battery terminal post with circular movements.

After Cleaning (All Types):

1. Reconnect the components and tighten to the specified torque. This ensures optimum contact.

2. Apply a suitable anti-corrosion treatment.

3. Reconnect the battery and, if necessary, teach-in windows, enter the radio code, and set the clock.

Note: Do not repair Lambda probe wires, as this can result in malfunctions. The wires should not be crimped or cut.

The general procedure for replacing both LSF (4-pin) and LSU (6-pin) Lambda probes on your VOLKSWAGEN TOUAREG 2003 is as follows:

1. Remove the defective Lambda probe from the vehicle.

2. Place the old probe and the new uniform probe next to each other so that the sensor housings are at the same height.

3. Tie back any excess length in the new uniform probe’s cable (approx. 50-250 mm) to match the length of the defective probe. Secure the excess cable with cable ties.

4. Check that the connector housing of the new Lambda probe is compatible with the onboard supply side connector. On new vehicles, the coding should match.

5. If necessary (on older vehicles), replace the onboard supply system connector with the new connector housing supplied with the probe. Observe the pin assignment carefully; the pins in the new housing have color markings for clarity.

6. Install the new Lambda probe in the vehicle.

In addition to the part number, you can identify the type of Lambda probe on your VOLKSWAGEN TOUAREG 2003 by the design of its protective tube:

• Type D1: Has 6 openings, each 3.5 mm. This type is only used on 4-pin LSF Lambda probes.

• Type D2: Has 6 openings, each 2 mm. This type is used on 4-pin LSF Lambda probes.

• Type D4: Has 12 openings, each 1.4 mm. This type is used on 4-pin LSF Lambda probes and 6-pin LSU Lambda probes.