VOLKSWAGEN TOURAN 2003 (01) PDF Document

The VOLKSWAGEN TOURAN 2003 with 1.9 liter engine has the following specifications: Bore is 79.5 mm, stroke is 95.5 mm, there are 2 valves per cylinder, the firing order is 1-3-4-2, it is equipped with a catalytic converter, and it has an exhaust gas recirculation system.

For a one-piece engine cover on the VOLKSWAGEN TOURAN 2003, pull the engine cover abruptly upwards at the front and right, then pull it forwards out of the rear fastening. For a two-piece engine cover, first pull the outer engine cover abruptly upwards at the arrows, then pull the inner engine cover abruptly upwards at the arrows.

When working on the fuel supply system of a VOLKSWAGEN TOURAN 2003, remember that fuel and fuel lines can become very hot, creating a danger of scalding. The fuel system is under pressure, so place cloths around connections before carefully loosening them to release pressure. Always wear eye and hand protection. Additionally, ensure the work area is well-ventilated and prevent skin contact with fuel by wearing fuel-resistant gloves.

To check the engine oil level in a VOLKSWAGEN TOURAN 2003, verify the dipstick markings. The area of the min. mark means to top-up with a maximum of 0.5 liters of engine oil. If the oil level is in the middle range, it can be topped up. If the oil level is in the area of the max. mark, do not add engine oil.

First, open the cap on the coolant expansion tank. If a drain plug is fitted, open it to drain the coolant. If no drain plug is fitted, pull off the lower coolant hose retaining clip and remove the coolant hose from the quick-release connection of the radiator. Additionally, remove the coolant hose from the engine oil cooler to drain coolant from the engine. Always observe environmental regulations for disposal.

Ensure the engine is at operating temperature. Open the cap on the coolant expansion tank. Attach the cooling system tester and the appropriate adapter to the expansion tank. Use the hand pump on the tester to create a pressure of about 1.0 bar. If the pressure drops on the gauge, find the leaks and rectify them.

Attach the cooling system tester with the appropriate adapter to the cap. Use the hand pump to create a pressure of maximum 1.6 bar. The pressure relief valve must not open. Increase the pressure to over 1.6 bar; the pressure relief valve must open. If it fails to open or opens prematurely, renew the sealing cap.

Remove the noise insulation and the lower part of the front right wheel housing liner. Pull the fuel filter out of the bracket and place it with hoses to one side. Mark the direction of rotation of the poly V-belt. Swing the tensioning element in the direction of the arrow to remove tension from the belt and lock the tensioning element using a locking pin. Remove the poly V-belt.

Ensure the engine oil temperature is at least 30 degrees Celsius. Pull off the central connector for the unit injectors. Remove all glow plugs or ceramic glow plugs. Screw in the adapter in place of the glow plugs. Check compression using a compression tester by operating the starter until the tester shows no further pressure increase. The compression pressure for a new engine is 25 to 31 bar, with a wear limit of 19 bar. The maximum permissible difference between all cylinders is 5 bar.