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Contents
1 Engine list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Information on LongLife service and time or distance dependent service . . . . . . . . . . . . . . 3
2.2 Service tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Raising vehicle with lifting platform or trolley jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Connecting vehicle diagnosis tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.5 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.6 Countries with elevated sulphur content in diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.7 Engine code and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.8 Severe operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.9 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.10 Jacking up mode: Switching self-levelling suspension off and on . . . . . . . . . . . . . . . . . . . . 19
4 Descriptions of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1 Swivel joints, axle bearings, coupling rod bearings and anti-roll bar rubber mountings: Visual
check for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2 Automatic headlight control and static cornering light: Perform functional check . . . . . . . . 24
4.3 Battery: Check charge status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.4 Battery beneath driver seat: Visual check and checking using battery tester with printer, VAS
5097A or VAS 6161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.5 Checking tyres: Condition, wear pattern, tyre pressure, tread depth and age of tyres . . . . 26
4.6 Front passenger front airbag: Check key switch and „On/Off function“ . . . . . . . . . . . . . . . . 28
4.7 Brake system and shock absorbers: Perform visual check for leaks and damage . . . . . . 29
4.8 Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.9 Brake fluid level (depending on lining/pad wear): Check . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.10 Thickness of brake pads/linings and condition of brake discs, front and rear: Check . . . . 36
4.11 Diesel particulate filter: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.12 Window regulators: Check positioning (open and close functions) . . . . . . . . . . . . . . . . . . 38
4.13 Reading fault memory of all systems with vehicle diagnosis tester , correcting possible faults
according to repair guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.14 Gearbox, final drive and drive shaft bellows: Visual check for leaks and damage . . . . . . . . 39
4.15 Hybrid components: Perform visual check for damage on high-voltage components and
wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.16 Interior and exterior body: Performing visual check for corrosion when doors and flaps are
open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.17 Poly V-belt: Check condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.18 Poly V-belt for compressor: Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.19 Diesel fuel filter: Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.20 Diesel fuel filter: Renew (Diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.21 Cooling system: Check frost protection and coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.22 Air suspension: Checking for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.23 Air filter: Clean housing and renew filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.24 Engine oil level: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.25 Engine oil: Drain or extract; renew oil filter and replenish engine oil . . . . . . . . . . . . . . . . . . 61
4.26 Engine and designer cover -top-: Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . 70
4.27 Removing and installing engine cover -bottom- (noise insulation) . . . . . . . . . . . . . . . . . . . . 73
4.28 Engine and components in engine compartment (from above and below): Perform visual
check for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.29 Panoramic sliding roof: Check function, if necessary clean guide rails, lubricate with special
grease and clean wind deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.30 Performing road test (driving behaviour, noises, air conditioner etc.) . . . . . . . . . . . . . . . . 75
4.31 Wheel securing bolts: Tighten to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.32 Reducing agent (AdBlue®): Replenish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Touareg 2010 ➤
Maintenance - Edition 11.2011
Contents i
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