Touareg Body

8/3/2019 Touareg Body

http://slidepdf.com/reader/full/touareg-body 1/39

TouaregB ody M a nua l

S t u d e n t R e f e r e n ce



Volkswagen of America, Inc.Service TrainingPrinted 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 latestinformation available at the time of printingand is subject to the copyright and otherintellectual property rights of Volkswagen ofAmerica, Inc., its affiliated companies and itslicensors. All rights are reserved to makechanges at any time without notice. No partof this document may be reproduced,stored in a retrieval system, or transmittedin any form or by any means, electronic,mechanical, photocopying, recording or

otherwise, nor may these materials bemodified or reposted to other sites withoutthe prior expressed written permission ofthe publisher.

All requests for permission to copy andredistribute information should be referredto Volkswagen of America, Inc.

Always check Technical Bulletins and theVolkswagen Worldwide Repair Information

System for information that may supersedeany information included in this booklet.

Trademarks: All brand names and productnames used in this manual are trade names,service marks, trademarks, or registeredtrademarks; and are the property of theirrespective owners.


http://slidepdf.com/reader/full/touareg-body 3/39i

Table of Contents

The Service Training Student Reference provides youwith information regarding designs and functions.

The Service Training Student Reference is not a

Repair Manual!

For maintenance and repair work, always refer tothe current technical literature

Important/ Note!

New!

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





Specifications

1

SSP297/005

• Length187.17 inches (4754 mm)

• Width75.91 inches (1928 mm)

• Height67.05 – 67.95 inches (1703 – 1726 mm)(depending on the engine)

• Roof load capacity220 pounds (100 kg)

• Towing capacity7716 pounds (3500 kg)

• Fuel tank volume26.4 gallons (100 liters)

• Front track width64.76 – 65.28 inches (1645 – 1658 mm)(depending on the engine)

The illustration shows thedimensions of the Touaregwith a V6 engine.

• Rear track width65.24 – 65.53 inches (1657 – 1664.5 mm)(depending on the engine)

• Permitted gross vehicle weight6283 – 6790 pounds (2850 – 3080 kg)(depending on the engine)

• Curb weight4881 – 5564 pounds (2214 – 2524 kg)(depending on the engine)

• Cargo load spaceExcept V10 TDI:19.6 – 55.4 cubic feet (555 – 1570 liters)V10 TDI:19.4 – 53.8 cubic feet (550 – 1525 liters)

• Drag coefficient0.38 to 0.42 C

D

(depending on the engine)



Front Bumper and Grille

2

The front end and bumper

components are plastic.They are attached in theconventional manner.

The radiator grille has an additionalbolted attachment point.

VOA884/004a

VOA884/004b



Front Fenders

3

The front fenders are plastic.

Front fenders are notrepairable. If damaged,

they must be replaced.

When installing front fenders, it isimportant to follow the bolt tighteningsequence indicated by the numbers

in the illustration.

Refer to ELSA for

repair instructions.

VOA884/005

16

15

14

13

12

1

2

3

4

5

6

7

8

9

17

11

10



Hood

The hood is aluminum.

The inside hood release

lever is similar to theVolkswagen Golf design,

and is maintainedthe same way.

The hood release cable

is a two-part design.

Hood height can

be adjusted usingthe stop bolts

at the hinges.

VOA884/006



Front Doors

Doors are comprised of a steel outer paneland a subframe to which all the operating

elements of the door are attached.

Doors are sealed at

the body openingsthree ways.

The keyless access and start

authorization locking systemrequires door subframe removalfor door handle replacement.

Wiring harnesses canbe disconnected from

outside the doorassemblies at the A-pillars.

Hinges are bolted from

inside and outside andcan be replaced.

The lock system is the

same as the VolkswagenPassat design.

VOA884/007a

VOA884/007b

VOA884/007c

VOA884/007d



Rear Doors

Doors are comprisedof a steel outer panel

and a subframe towhich all the operatingelements of the door

are attached.

Doors are sealedat the body openings

three ways.

The keyless access andstart authorization

locking system requiresdoor subframe removal

for door handlereplacement.

Hinges are bolted frominside and outside and

can be replaced.

The lock system

is the same asthe Volkswagen

Passat design.

Wiring harnessescan be disconnected

from outside thedoor assemblies at

the B-pillars.

VOA884/008a

VOA884/008b

VOA884/008d

VOA884/008c



Tailgate

The tailgate is hinged at

the top and opens in theconventional manner.

An emergency release behindthe tailgate interior trim enables

opening the tailgate from insidethe vehicle.

Gas-filled struts assisttailgate opening.

The rear window

can be openedseparately to quicklyload small items.

VOA884/021



Fuel Filler Lid

The fuel filler lid lockingmechanism is controlled by

the Motor for Fuel TankLid Unlock V155.

In the event of an electrical fault,an integrated rubber st rap can be

used to release the fuel f iller lidmechanically. The strap isaccessed from inside the vehicle

behind the interior trim panel.

VOA884/022a

VOA884/022b



Rear Bumper

Rear bumper components are similar tothose found on other Volkswagen vehicles.

They are attached in the conventional manner.

VOA884/009



Exterior Lights

Headlight bulb replacement

is simplified by a drawer-typemechanism that provideseasy access.

The rear w indow washer jet

is integrated into the thirdbrake light, which is mountedabove the rear window.

Depending upon optional

equipment installed, the

headlights are available w ithhalogen or xenon bulbs.

A special key isprovided in the vehicle

tool kit for headlightassembly removal.

VOA884/023



Glass

The Touareg windshield is made ofacoustic glass and does not requirePUR pre-coating during installation.

A heated w indshield is availableas an option.

A new clip attachmenteases removal and

installation of the interiorrearview mirror.

The rear side window modules

are complete with C-pillar trimand mounting studs, and are fastened

to the body with nuts. The glass isconnected to the panels and trim strips

by plastic extrusion coating.

The flip-up rear window is not bonded andcan be opened separately from the tailgate.The rear window module consists of the

glass and a sheet metal frame.

VOA884/013a

VOA884/013b



Exterior Trim

The roof molding andlower rubber protective molding

are fastened with clips.

Additional t rim may

be installed on thedoors depending upon

Touareg model andoptional equipment.

VOA884/014a

VOA884/014b



Roof Rack

Four bondedprotective moldings

protect the paint onthe roof from damage.

To avoid damage to the paint,the key for unlocking the carrier

supports should be removedbefore moving the carriers.

The carriers and supportscan be moved forwardor rearward in the rails,

or removed.

The roof rack carrier supportsare inserted into openings in thecenters of the rails.

The rails are attached to

the roof with screws andcaptured-nut fasteners.

The two roof rackguide rails are aluminum

chamfered C-rails.

VOA884/015a

VOA884/015b

VOA884/015c VOA884/015d

VOA884/015e

VOA884/015f



Sunroof

A tilt and slide sunroof is available onthe Touareg.

This sunroof is like the one used on the

Volkswagen Passat.

0 - 1 mm0 + 1 mm

VOA884/016a

VOA884/016b



Instrument Panel

The instrument panel is fastened tothe carrier subframe w ith screws.

The instrument cluster trim is fastened

to the instrument panel with screws.

VOA884/010



Instrument Panel

The center and right side lowerinstrument panel trim with the

assembled glove box is fastenedto the carrier subframe and the

instrument panel with screws.

The left side lowerinstrument panel trim

is fastened to thecarrier subframe andthe instrument panel

with screws.

VOA884/011a

VOA884/011b



A IR B A G AIR

BAG

A IR B A G

17

Interior Trim

The headliner and all otherinterior trim panels are fastened

with a combination of clipsand screws.

New insulating elements

are installed behind theB-pillar and C-pillar trim.

VOA884/012



Airbags

18

The steering wheel used on the

Touareg is the same as is used onthe Volkswagen Phaeton.

Curtain airbags are mountedalong the entire length of

the vehicle seating area.

Side airbags are attached

to the outboard sides ofthe front seatbacks.

The front passenger airbag is

installed under a seamless coverin the instrument panel.

If the front passengerairbag has been activated,

the instrument panelmust be replaced.

A I R BA G

VOA884/017a

VOA884/017b

VOA884/017cVOA884/017c



Seat Belts

19

Front seat belt tensionersare mounted to the B-pillars.

All seat belt tensioners

are electrically activated.

The center rear seat belttensioner is installed inthe rear seatback.

Outboard rear seat belt tensioners

are mounted to the C-pillars.

VOA884/018a

VOA884/018b

VOA884/018c



Front Seats

Front seats are available in 8-way

and 12-way adjustable versions.

There is a new attachmentand removal method for

the seat belts at the seats.

Fronts seats are attached

to a seat frame that isfastened to the floor panel

with screws.

The front passenger seatincludes child seat fasteners.

The 8-way front

seat adjustments aremanually controlled.

The optional 12-way front seat

has four additional adjustmentfeatures. All adjustments

except headrest heightare electrically controlled.

VOA884/019a

VOA884/019b

VOA884/019c



Rear Seats

The rear seat cushion hinges

are fastened directly to thefloor panel with screws.

On the inboard sidesthe rear seatbacksections rest in slots

in a common centralbracket, where they

are retained by ametal clip and fastener.

The rear seatbacksections hinge on

pins mounted to

the body on theoutboard sides.

The folding rear seatbackis comprised of two

unequal sections.

1

5

2

VOA884/020a

VOA884/020b

VOA884/020c



WVGZZZ7LZ3DZ000441

22

Vehicle Identification Number Plate

In addition to the VIN located on thefront left edge of the instrument panelthat is visible through the w indshield,

a vehicle identification number plateis attached to the body in the

spare wheel well.

VOA884/024



Bonded Joints

Additional w elds and bonds are made athigh-stress areas of the body to ensure rigidity.

VOA884/025



Body Insulation

Body insulation is used to reduce

noise levels in the Touareg.

While most body insulation is

applied during final vehicle assemblystages, some is installed during

body shell assembly.

VOA884/026a

VOA884/026b



Body Cavity Sealing

Because of its fording capability, the body cavitieson the Touareg are thoroughly sealed to prevent theintrusion of w ater.

VOA884/027



Body Repair

The Touareg body structure is a new self-supporting

design, incorporating as much static and dynamicrigidity as possible.

Integrated longitudinal load-bearing members runthe length of the vehicle.

Tailored blanks w ith varying thicknessesdepending on load forces and high-strength sheet

metals are used.

Laser welds at stress points supplement spot w elds.

Laser brazing is used in the roof area.

The body shell is fully galvanized and is covered by a

12-year limited w arranty against perforation causedby corrosion.

The alignment bracket attachment set

VAS 6215 and portal gauge accessoryVAS 5007/16 are required for bodyrepair, straightening, and w elding.

VOA884/028a

VOA884/028b



Body Repair

VOA884/029



Body Repair

VOA884/030



Body Repair

VOA884/031



Body Repair

VOA884/032



Body Repair

VOA884/033



Body Repair

VOA884/034



Body Repair

VOA884/035



Notes



Volkswagen of America, Inc.

Documents

Touareg Body