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8/3/2019 Touareg Body
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TouaregB ody M a nua l
S t u d e n t R e f e r e n ce
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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.
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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
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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)
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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
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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
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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
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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
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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
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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
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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
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Rear Bumper
Rear bumper components are similar tothose found on other Volkswagen vehicles.
They are attached in the conventional manner.
VOA884/009
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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
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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
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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
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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
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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
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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.
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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
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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.
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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
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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
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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
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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
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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.
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Bonded Joints
Additional w elds and bonds are made athigh-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 assemblystages, 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 cavitieson the Touareg are thoroughly sealed to prevent theintrusion of w ater.
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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
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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.
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