Service
ServiceTouareg V8 O-ring Replacement Procedure
Tip:
If coolant is found to be leaking from either the inlet or outlet coolant hose at generator, both O-rings are to be replaced during service with part No.: N90783401 ONLY.
^ Disconnect battery, see Repair Manual, Electrical Equipment Group 27- Battery, Starter, Generator, Cruise control, "Battery, removing and installing".
^ Drain coolant, see Repair Manual, Engine, Group 19-Cooling system, Engine coolant, draining and refilling.
^ Remove engine trim cover from right side, if applicable.
^ Remove right front wheel.
^ Remove right front wheel well liner, see Repair Manual, Body Exterior, Group 66-Exterior equipment, Front wheel housing liner, assembly overview.
^ Remove engine compartment trim covers (if applicable).
^ Remove right side engine compartment trim cover clip (if applicable).
^ Remove Air Box, see Repair Manual, Multiport Fuel Injection, Group 24- Air filter, assembly overview.
^ Remove bolt securing outlet coolant pipe. Remove U shaped pipe.
^ Remove bolt securing inlet coolant pipe from back of generator (arrow).
^ Remove bolt securing pipe to oil filter housing.
^ Remove pipe and discard 0-rings.
Tip:
All O-rings MUST be replaced.
Installation
^ Lubricate replacement O-rings -4- with silicone lubricant spray, VW Part Number: D 007 000 A2 , install 0-rings on coolant pipes.
^ Install inlet coolant pipe first by inserting pipe end into block and then rotate pipe slightly inserting other end of pipe into generator.
^ Install fastener to generator, tighten to 10 Nm (88.5 in. lbs.).
^ Install fastener securing pipe bracket to engine block tighten to 25 Nm (221 in. lbs.).
^ Install outlet coolant pipe by inserting into generator and tighten fastener to 10 Nm (88.5 in. lbs.).
^ Install Air Box, see Repair Manual, Multiport Fuel Injection, Group 24- Air filter, assembly overview.
^ Install engine compartment trim cover clip (if applicable).
^ Install engine compartment trim covers (if applicable).
^ Fill cooling system with coolant, see Repair Manual, Engine, Group 19- Cooling system, Engine coolant, draining and refilling.
^ Pressure test cooling system, see Repair Manual, Engine, Group 19- Engine Cooling system, checking for proper seal.
^ Inspect for any leaks.
^ Install wheel well liner, see Repair Manual, Body Exterior, Group 66- Exterior equipment, Front wheel housing liner, assembly overview.
^ Install sound insulation.
^ Install right front wheel.
^ Reconnect battery, see Repair Manual, Electrical Equipment Group 27- Battery, Starter, Generator, Cruise control, "Battery, removing and installing".
^ Using 5051/5052, scan for DTCs and erase codes.
^ Perform Post Procedure Component Reset/Relearn.
Post Procedure Component Reset/Relearn
Access Start Module
Before starting vehicle, Access Start Module must be reset:
^ Turn ignition switch to left most position.
^ Let ignition switch return to zero position (at rest when key is in ignition switch).
^ Turn ignition switch to the right position to start the engine.
With vehicle idling:
^ Fully open both front windows.
^ Fully close both front windows.
Electronic front seat (if equipped) "Soft stop function"
With vehicle idling:
^ Hold seat "forward/backward" switch in forward position until front seat moves fully forward and seat stops.
^ Release switch.
^ Hold seat "forward/backward" switch in forward position to ensure front seat is in fully forward position.
Release switch. Forward soft stop position is learned.
^ Hold seat "forward/backward" switch in backward position until front seat moves fully backward and seat stops.
^ Release switch.
^ Hold seat "forward/backward" switch in backward position to ensure front seat is in fully backward position.
^ Release switch. Backward soft stop position is learned.
^ Repeat steps for other front seat.
Electronic steering column (if equipped)
With vehicle idling:
^ Operate steering column adjustment switch in each direction (up, down, forward and backward) until steering column stops in that direction.
Steering angle sensor & Air suspension
Steering angle sensor will temporarily lose calibration (light will illuminate) and must relearn its position.
Air suspension will temporarily lose communication with the steering wheel angle sensor (light will illuminate).
^ Drive vehicle forward with wheels in the straight ahead position for approx. 45 ft. (13.7 meters).
Touareg V10 - O-ring Replacement Procedure
applicable Model Years: 2004 and 2005
^ Replace O-rings only.
Tip:
Applicable part numbers of O-rings -3- which insert into generator: N 907 834 01. This part number is for both inlet and outlet coolant pipes.
Removal
^ Disconnect both batteries, see Repair Manual, Electrical Equipment Group 27-Battery, Starter, Generator, Cruise control, "Battery, removing and installing".
^ Remove engine trim panels (if applicable).
^ Remove engine trim cover (if applicable).
^ Remove fastener securing oil fill tube to oil filter housing.
^ Unclip wiring harness from intake manifold and position aside.
^ Remove fasteners securing oil filter housing, and remove housing.
^ Clamp off coolant hoses for generator.
^ Remove coolant line retaining bracket bolt at the back of the generator, remove retaining bracket, and remove coolant hoses from generator.
^ Remove O-rings from coolant tubes, and discard.
Installation
^ Lubricate replacement O-rings -3- with silicone lubricant spray, VW Part Number: D 007 000 A2 , install O-rings on coolant pipes.
^ Insert coolant pipes into generator, secure with retaining bracket and tighten fastener to torque to 9 Nm (80 in.-lbs)
^ Unclamp coolant hoses to generator.
^ Replace O-ring on oil filter housing. Install oil filter housing and tighten fasteners to 10 N.m (88.5 in. lbs.).
^ Secure engine wiring harness to intake manifold.
^ Secure oil fill tube to oil filter housing and tighten fastener to 10 N.m (88.5 in. lbs.).
^ Fill cooling system to proper level, see Repair Manual, Engine, Group 19-Cooling system, Engine coolant, draining and refilling.
^ Connect both batteries, see Repair Manual, Electrical Equipment Group 27-Battery, Starter, Generator, Cruise control, "Battery, removing and installing".
^ Install engine cover and trim panels (if applicable).
^ Clear all DTCs using VAS 5051/5052.
^ Perform Post Procedure Component Reset/Relearn.
Post Procedure Component Reset / Relearn
Access Start Module
Before starting vehicle, Access Start Module must be reset:
^ Turn ignition switch to left most position.
^ Let ignition switch return to zero position (at rest when key is in ignition switch).
^ Turn ignition switch to the right position to start the engine.
With vehicle idling:
^ Fully open both front windows.
^ Fully close both front windows.
Electronic front seat (if equipped) "Soft stop function"
With vehicle idling:
^ Hold seat "forward/backward" switch in forward position until front seat moves fully forward and seat stops.
^ Release switch.
^ Hold seat "forward/backward" switch in forward position to ensure front seat is in fully forward position.
^ Release switch. Forward soft stop position is learned.
^ Hold seat "forward/backward" switch in backward position until front seat moves fully backward and seat stops.
^ Release switch.
^ Hold seat "forward/backward" switch in backward position to ensure front seat is in fully backward position.
^ Release switch. Backward soft stop position is learned.
^ Repeat steps for other front seat.
Electronic Steering column (if equipped)
With vehicle idling:
^ Operate steering column adjustment switch in each direction (up, down, forward and backward) until steering column stops in that direction.
Steering angle sensor & Air suspension
Steering angle sensor will temporarily lose calibration (light will illuminate) and must relearn its position.
Air suspension will temporarily lose communication with the steering wheel angle sensor (light will illuminate).
^ Drive vehicle forward with wheels in the straight ahead position for approx. 45 ft. (13.7 meters).
^ Pressure test cooling system to verify no leaks at generator coolant tubes, see Repair Manual, Engine, Group 19-Engine Cooling system, checking for proper seal.
^ Install engine trim cover.
^ Install engine trim panels.
Phaeton W12 O-ring Replacement Procedure
Tip
Applicable part numbers of O-ring -4- which insert into generator: N 907 834 01. This part number is for both inlet and outlet coolant pipes.
Applicable Model Years: 2004 and 2005
Removal
^ Disconnect batteries, see Repair Manual, Electrical Equipment Group 27-Battery, Starter, Generator, Cruise control, "Battery, removing and installing".
^ Drain coolant, see Repair Manual, Engine, Group 19-Cooling system, Engine coolant, draining and refilling.
^ Remove engine trim cover from right side, if applicable.
^ Remove right front wheel.
^ Remove right front wheel well liner, see Repair Manual, Body Exterior, Group 66-Exterior equipment, Front wheel housing liner, assembly overview.
^ Remove front bumper cover, see Repair Manual, Body Exterior Group, 63-Bumper, Front Bumper cover, removing and installing.
^ Remove windshield washer solvent reservoir.
^ Remove the fasteners mounting the auxiliary radiator (if equipped) and position aside. DO NOT disconnect radiator from vehicle.
^ Remove fasteners securing engine oil cooler bracket to body/frame and position aside. DO NOT disconnect cooler from vehicle.
^ Remove coolant pipe to generator bracket.
^ Remove outlet coolant pipe from generator, DO NOT disconnect other end of pipe from cooling system.
^ Remove inlet coolant pipe from generator, DO NOT disconnect other end of pipe from cooling system.
Installation
^ Lubricate replacement O-rings -4- with silicone lubricant spray, VW Part Number: D 007 000 A2 , install 0-rings on coolant pipes.
^ Insert coolant pipes into generator, secure with retaining bracket and tighten fastener to 9 Nm (80 in. lbs.).
^ Position oil cooler and install fasteners securing engine oil cooler bracket to body/frame and tighten 9Nm (80 in.-lbs).
^ Position auxiliary radiator and install fasteners. Tighten fasteners to 20 N.m (177 in. lbs.).
^ Install windshield washer solvent reservoir.
^ Install front bumper cover, see Repair Manual, Body Exterior Group, 63-Bumper, Front Bumper cover, removing and installing.
^ Install right front wheel well liner, see Repair Manual, Body Exterior, Group 66-Exterior equipment, Front wheel housing liner, assembly overview.
^ Install right front wheel.
^ Fill cooling system to proper level, see Repair Manual, Engine, Group 19-Cooling system, Engine coolant, draining and refilling.
^ Connect both batteries, see Repair Manual, Electrical Equipment Group 27-Battery, Starter, Generator, Cruise control, "Battery, removing and installing".
^ Clear all DTCs using VAS 5051/5052.
^ Pressure test cooling system to verify no leaks at generator coolant tubes, see Repair Manual, Engine, Group 19-Engine Cooling system, checking for proper seal.