Touareg Body Manual

Student Reference

Volkswagen of America, Inc. Service Training Printed in U.S.A. Printed 5/2003 2003 Volkswagen of America, Inc. All rights reserved. All information contained in this manual is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, nor may these materials be modified or reposted to other sites without the prior expressed written permission of the publisher. All requests for permission to copy and redistribute information should be referred to Volkswagen of America, Inc. Always check Technical Bulletins and the Volkswagen Worldwide Repair Information System for information that may supersede any information included in this booklet. Trademarks: All brand names and product names used in this manual are trade names, service marks, trademarks, or registered trademarks; and are the property of their respective owners.

Table of Contents
Specifications ................................................................................................ 1 Front Bumper and Grille ............................................................................... 2 Front Fenders ................................................................................................ 3 Hood ............................................................................................................... 4 Front Doors .................................................................................................... 5 Rear Doors ..................................................................................................... 6 Tailgate ........................................................................................................... 7 Fuel Filler Lid ................................................................................................. 8 Rear Bumper .................................................................................................. 9 Exterior Lights ............................................................................................. 10 Glass ............................................................................................................. 11 Exterior Trim ................................................................................................ 12 Roof Rack ..................................................................................................... 13 Sunroof ........................................................................................................ 14 Instrument Panel ......................................................................................... 15 Interior Trim ................................................................................................. 17 Airbags ......................................................................................................... 18 Seat Belts ..................................................................................................... 19 Front Seats .................................................................................................. 20 Rear Seats .................................................................................................... 21 Vehicle Identification Number Plate .......................................................... 22 Bonded Joints ............................................................................................. 23 Body Insulation ........................................................................................... 24 Body Cavity Sealing .................................................................................... 25 Body Repair ................................................................................................. 26

New!

Important/Note!
The Service Training Student Reference provides you with information regarding designs and functions. The Service Training Student Reference is not a Repair Manual! For maintenance and repair work, always refer to the current technical literature

Specifications
The illustration shows the dimensions of the Touareg with a V6 engine.

SSP297/005

Length 187.17 inches (4754 mm) Width 75.91 inches (1928 mm) Height 67.05 67.95 inches (1703 1726 mm) (depending on the engine) Roof load capacity 220 pounds (100 kg) Towing capacity 7716 pounds (3500 kg) Fuel tank volume 26.4 gallons (100 liters) Front track width 64.76 65.28 inches (1645 1658 mm) (depending on the engine)

Rear track width 65.24 65.53 inches (1657 1664.5 mm) (depending on the engine) Permitted gross vehicle weight 6283 6790 pounds (2850 3080 kg) (depending on the engine) Curb weight 4881 5564 pounds (2214 2524 kg) (depending on the engine) Cargo load space Except V10 TDI: 19.6 55.4 cubic feet (555 1570 liters) V10 TDI: 19.4 53.8 cubic feet (550 1525 liters) Drag coefficient 0.38 to 0.42 CD (depending on the engine)

Front Bumper and Grille

VOA884/004a

The radiator grille has an additional bolted attachment point.

The front end and bumper components are plastic. They are attached in the conventional manner.

VOA884/004b

Front Fenders

The front fenders are plastic.

15 14

17 16

Front fenders are not repairable. If damaged, they must be replaced.

13

12

When installing front fenders, it is important to follow the bolt tightening sequence indicated by the numbers in the illustration.

Refer to ELSA for repair instructions.

10 11 7

8 9
VOA884/005

Hood

The hood is aluminum.

Hood height can be adjusted using the stop bolts at the hinges.

The hood release cable is a two-part design.

The inside hood release lever is similar to the Volkswagen Golf design, and is maintained the same way.

VOA884/006

Front Doors
Doors are comprised of a steel outer panel and a subframe to which all the operating elements of the door are attached.

The lock system is the same as the Volkswagen Passat design.

VOA884/007a

Hinges are bolted from inside and outside and can be replaced.

Doors are sealed at the body openings three ways.

Wiring harnesses can be disconnected from outside the door assemblies at the A-pillars.

VOA884/007b

VOA884/007c

VOA884/007d

The keyless access and start authorization locking system requires door subframe removal for door handle replacement.

Rear Doors

Hinges are bolted from inside and outside and can be replaced.

VOA884/008a

VOA884/008b

Doors are comprised of a steel outer panel and a subframe to which all the operating elements of the door are attached.

Doors are sealed at the body openings three ways.

Wiring harnesses can be disconnected from outside the door assemblies at the B-pillars.

The lock system is the same as the Volkswagen Passat design.

VOA884/008d

The keyless access and start authorization locking system requires door subframe removal for door handle replacement.
VOA884/008c

Tailgate
Gas-filled struts assist tailgate opening. The tailgate is hinged at the top and opens in the conventional manner. The rear window can be opened separately to quickly load small items.

An emergency release behind the tailgate interior trim enables opening the tailgate from inside the vehicle.

VOA884/021

Fuel Filler Lid

VOA884/022a

The fuel filler lid locking mechanism is controlled by the Motor for Fuel Tank Lid Unlock V155.

In the event of an electrical fault, an integrated rubber strap can be used to release the fuel filler lid mechanically. The strap is accessed from inside the vehicle behind the interior trim panel.

VOA884/022b

Rear Bumper

Rear bumper components are similar to those found on other Volkswagen vehicles. They are attached in the conventional manner.

VOA884/009

Exterior Lights
Depending upon optional equipment installed, the headlights are available with halogen or xenon bulbs.

A special key is provided in the vehicle tool kit for headlight assembly removal.

Headlight bulb replacement is simplified by a drawer-type mechanism that provides easy access.

The rear window washer jet is integrated into the third brake light, which is mounted above the rear window.

VOA884/023

10

Glass
The Touareg windshield is made of acoustic glass and does not require PUR pre-coating during installation. A heated windshield is available as an option. A new clip attachment eases removal and installation of the interior rearview mirror. The flip-up rear window is not bonded and can be opened separately from the tailgate. The rear window module consists of the glass and a sheet metal frame.

VOA884/013a

The rear side window modules are complete with C-pillar trim and mounting studs, and are fastened to the body with nuts. The glass is connected to the panels and trim strips by plastic extrusion coating.

VOA884/013b

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Exterior Trim

The roof molding and lower rubber protective molding are fastened with clips.

VOA884/014a

Additional trim may be installed on the doors depending upon Touareg model and optional equipment.
VOA884/014b

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Roof Rack

VOA884/015a

Four bonded protective moldings protect the paint on the roof from damage.

The carriers and supports can be moved forward or rearward in the rails, or removed.

VOA884/015c

VOA884/015d

VOA884/015b

The roof rack carrier supports are inserted into openings in the centers of the rails.

To avoid damage to the paint, the key for unlocking the carrier supports should be removed before moving the carriers.

The two roof rack guide rails are aluminum chamfered C-rails.

VOA884/015e

The rails are attached to the roof with screws and captured-nut fasteners.

VOA884/015f

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Sunroof

A tilt and slide sunroof is available on the Touareg. This sunroof is like the one used on the Volkswagen Passat. 0 + 1 mm 0 - 1 mm

VOA884/016a

VOA884/016b

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Instrument Panel

The instrument panel is fastened to the carrier subframe with screws.

The instrument cluster trim is fastened to the instrument panel with screws.

VOA884/010

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Instrument Panel

VOA884/011a

The center and right side lower instrument panel trim with the assembled glove box is fastened to the carrier subframe and the instrument panel with screws.

VOA884/011b

The left side lower instrument panel trim is fastened to the carrier subframe and the instrument panel with screws.

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Interior Trim

The headliner and all other interior trim panels are fastened with a combination of clips and screws.

New insulating elements are installed behind the B-pillar and C-pillar trim.

G BA AIR

AIRBAG AIRBAG

VOA884/012

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Airbags
The steering wheel used on the Touareg is the same as is used on the Volkswagen Phaeton.

A AIRB

VOA884/017a

The front passenger airbag is installed under a seamless cover in the instrument panel. If the front passenger airbag has been activated, the instrument panel must be replaced.

VOA884/017b

Side airbags are attached to the outboard sides of the front seatbacks.

Curtain airbags are mounted along the entire length of the vehicle seating area.

VOA884/017c

VOA884/017c

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Seat Belts

Front seat belt tensioners are mounted to the B-pillars.

The center rear seat belt tensioner is installed in the rear seatback.

VOA884/018a

All seat belt tensioners are electrically activated.

VOA884/018b

Outboard rear seat belt tensioners are mounted to the C-pillars.

VOA884/018c

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Front Seats
Front seats are available in 8-way and 12-way adjustable versions.

The optional 12-way front seat has four additional adjustment features. All adjustments except headrest height are electrically controlled.

VOA884/019a

The 8-way front seat adjustments are manually controlled. The front passenger seat includes child seat fasteners.

Fronts seats are attached to a seat frame that is fastened to the floor panel with screws.
VOA884/019b

There is a new attachment and removal method for the seat belts at the seats.

VOA884/019c

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Rear Seats

The rear seat cushion hinges are fastened directly to the floor panel with screws.

VOA884/020a

The rear seatback sections hinge on pins mounted to the body on the outboard sides.
2

The folding rear seatback is comprised of two unequal sections.

VOA884/020b

On the inboard sides the rear seatback sections rest in slots in a common central bracket, where they are retained by a metal clip and fastener.

VOA884/020c

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Vehicle Identification Number Plate

WVGZZZ7LZ3DZ000441

VOA884/024

In addition to the VIN located on the front left edge of the instrument panel that is visible through the windshield, a vehicle identification number plate is attached to the body in the spare wheel well.

22

Bonded Joints

Additional welds and bonds are made at high-stress areas of the body to ensure rigidity.

VOA884/025

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Body Insulation

Body insulation is used to reduce noise levels in the Touareg. While most body insulation is applied during final vehicle assembly stages, some is installed during body shell assembly.

VOA884/026a

VOA884/026b

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Body Cavity Sealing

Because of its fording capability, the body cavities on the Touareg are thoroughly sealed to prevent the intrusion of water.

VOA884/027

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Body Repair

VOA884/028a

VOA884/028b

The Touareg body structure is a new self-supporting design, incorporating as much static and dynamic rigidity as possible. Integrated longitudinal load-bearing members run the length of the vehicle. Tailored blanks with varying thicknesses depending on load forces and high-strength sheet metals are used.

Laser welds at stress points supplement spot welds. Laser brazing is used in the roof area. The body shell is fully galvanized and is covered by a 12-year limited warranty against perforation caused by corrosion.

The alignment bracket attachment set VAS 6215 and portal gauge accessory VAS 5007/16 are required for body repair, straightening, and welding.

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Body Repair

VOA884/029

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Body Repair

VOA884/030

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Body Repair

VOA884/031

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Body Repair

VOA884/032

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Body Repair

VOA884/033

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Body Repair

VOA884/034

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Body Repair

VOA884/035

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Notes

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Volkswagen of America, Inc. 3800 Hamlin Road Auburn Hills, MI 48326 Printed in U.S.A. May 2003