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General body repairs, exterior

For Touareg

Original Volkswagen repair manual


27,39 €7% VAT incl.

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Language: English

Digital PDF file

8.358 KB

356 Sites

Detailed technical data

Immediately readable

This repair manual contains: Lock carrier, Wing, Noise insulation, Underbody cladding, Plenum chamber bulkhead, Bonnet, Rear lid, Sunroof with glass panel, Front bumper > 10.2006, Flush bonded windows, Windows having threaded connections, Exterior mirror, Roof rack and Spare wheel carrier for rear lid. Show more
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Repair manual Touareg General body repairs, exterior PDF download has the following content:

Chapter overview

  • Body - front
    1
  • 1 Lock carrier
    1
  • 1.1 Tools
    1
  • 1.2 Electrical and electronic components and fitting locations
    2
  • 1.3 Assembly overview - lock carrier, service position
    3
  • 1.4 Assembly overview - lock carrier service position, W12 petrol engine
    4
  • 1.5 Service position
    5
  • 1.6 Assembly overview - lock carrier with add-on parts
    8
  • 1.7 Removing and installing lock carrier with add-on parts
    9
  • 2 Wing
    11
  • 2.1 Tools
    11
  • 2.2 Assembly overview - front wing
    11
  • 2.3 Removing and installing front wing
    12
  • 2.4 Front wing - bolting sequence
    14
  • 3 Noise insulation
    16
  • 3.1 Tools
    16
  • 3.2 Assembly overview - noise insulation
    16
  • 4 Underbody cladding
    18
  • 4.1 Tools
    18
  • 4.2 Assembly overview - underbody panel
    18
  • 5 Plenum chamber bulkhead
    20
  • 5.1 Tools
    20
  • 5.2 Assembly overview - plenum chamber bulkhead
    20
  • 6 Skid plate
    21
  • 6.1 Tools
    21
  • 6.2 Assembly overview - skid plate
    21
  • 6.3 Assembly overview - engine skid plate
    23
  • 6.4 Removing and installing engine skid plate
    24
  • 6.5 Assembly overview - gearbox skid plate
    26
  • 6.6 Removing and installing gearbox skid plate
    27
  • 6.7 Assembly overview - rear differential skid plate
    29
  • 6.8 Removing and installing rear differential skid plate
    30
  • 6.9 Assembly overview - fuel tank underride guard
    32
  • 6.10 Assembly overview - wishbone skid plate
    33
  • 6.11 Assembly overview - sill guard
    34
  • Bonnet, rear lid
    35
  • 1 Contact corrosion!
    35
  • 2 Bonnet
    36
  • 2.1 Tools
    36
  • 2.2 Assembly overview - bonnet
    36
  • 2.3 Removing and installing bonnet
    38
  • 2.4 Removing gas strut
    39
  • 2.5 Releasing gas from gas strut
    39
  • 2.6 Removing and installing insulation
    40
  • 2.7 Assembly overview - locking and release components
    40
  • 2.8 Removing and installing bonnet lock
    41
  • 2.9 Adjusting bonnet
    43
  • 2.10 Separating Bowden cable
    45
  • 2.11 Removing and installing release lever
    45
  • 3 Rear lid
    48
  • 3.1 Tools
    48
  • 3.2 Assembly overview - rear lid
    48
  • 3.3 Removing and installing rear lid
    50
  • 3.4 Adjusting rear lid
    51
  • 3.5 Assembly overview - guide pins and guide wedges
    53
  • 3.6 Adjusting guide wedge and guide pin
    55
  • 3.7 Assembly overview - rear lid hinge
    56
  • 3.8 Removing and installing rear lid hinges
    56
  • 3.9 Removing and installing gas strut cover > 15.06
    58
  • 3.10 Removing and installing gas strut cover 16.06 >
    58
  • 3.11 Assembly overview - gas strut for rear lid opening window
    59
  • 3.12 Removing and installing gas strut for rear lid opening window
    60
  • 3.13 Assembly overview - rear lid gas strut
    62
  • 3.14 Removing and installing rear lid gas strut
    63
  • 3.15 Releasing gas from gas strut
    65
  • 3.16 Assembly overview - hydraulic rear lid drive
    65
  • 3.17 Removing and installing hydraulic pump for hydraulic rear lid drive
    67
  • 3.18 Removing and installing hydraulic cylinder for hydraulic rear lid drive
    69
  • 3.19 Filling with hydraulic fluid and checking fluid level
    73
  • 3.20 Removing and installing control unit
    75
  • 3.21 Removing and installing angle sensor
    76
  • 3.22 Basic setting of rear lid electronics
    78
  • 3.23 Assembly overview - locking and release components
    79
  • 3.24 Removing and installing locking and release components
    80
  • 3.25 Removing and installing rear lid lock
    81
  • 3.26 Removing and installing striker pin with power latching system
    81
  • 3.27 Removing and installing rear lid release motor
    82
  • 3.28 Removing and installing rear lid opening window lock
    82
  • 3.29 Removing and installing rear lid window release unit
    83
  • 3.30 Assembly overview - handle for vehicles with spare wheel carrier on rear lid
    83
  • 3.31 Removing and installing handle for vehicles with spare wheel carrier on rear lid
    85
  • 3.32 Rear lid seal
    86
  • 3.33 Removing and installing rear lid seal
    86
  • 4 Rear spoiler
    89
  • 4.1 Tools
    89
  • 4.2 Assembly overview - rear spoiler
    89
  • 4.3 Removing and installing rear spoiler
    90
  • 5 Tank flap unit
    92
  • 5.1 Tools
    92
  • 5.2 Assembly overview - tank flap unit
    92
  • 5.3 Removing and installing fuel tank filler cap locking and release components
    94
  • Front doors, door components, central locking
    96
  • 1 Front door
    96
  • 1.1 Tools
    96
  • 1.2 Assembly overview - front door
    97
  • 1.3 Assembly overview - fittings carrier individual parts
    99
  • 1.4 Assembly overview - door hinges
    100
  • 1.5 Greasing new door hinges
    102
  • 1.6 Removing and installing door
    103
  • 1.7 Door adjustment
    103
  • 1.8 Adjusting striker pin
    104
  • 1.9 Assembly overview - door handle and door lock
    105
  • 1.10 Removing and installing lock cylinder housing
    106
  • 1.11 Removing and installing door handle
    107
  • 1.12 Door handle with (Kessy) cable routing
    109
  • 1.13 Removing and installing door lock
    109
  • 1.14 Door seals
    114
  • 1.15 Removing and installing inner door seal
    115
  • 1.16 Removing and installing outer door seal
    115
  • 1.17 Removing and installing door seal
    117
  • 2 Central locking
    118
  • 2.1 Assembly overview - central locking and convenience system
    118
  • 2.2 Adapting keys with remote control
    120
  • 2.3 Assembly overview - batteries for main key (foldable) with remote control
    121
  • 2.4 Removing and installing batteries for folding main key with remote control system
    122
  • Rear doors, door components
    123
  • 1 Rear door
    123
  • 1.1 Tools
    123
  • 1.2 Assembly overview - rear door
    124
  • 1.3 Assembly overview - fittings carrier individual parts
    126
  • 1.4 Assembly overview - door hinges
    127
  • 1.5 Greasing new door hinges
    129
  • 1.6 Removing and installing door
    130
  • 1.7 Adjusting door
    130
  • 1.8 Adjusting striker pin
    131
  • 1.9 Assembly overview - door handle and door lock
    132
  • 1.10 Removing and installing lock cylinder housing
    133
  • 1.11 Removing and installing door handle
    134
  • 1.12 Door handle with (Kessy) cable routing
    136
  • 1.13 Removing and installing door lock
    136
  • 1.14 Door seals
    141
  • 1.15 Removing and installing inner door seal
    141
  • 1.16 Removing and installing outer door seal
    141
  • 1.17 Removing and installing door seal
    143
  • Sunroof
    144
  • 1 Sunroof with glass panel
    144
  • 1.1 Tools
    144
  • 1.2 Function
    144
  • 1.3 Assembly overview
    145
  • 1.4 Removing sliding/tilting sunroof glass panel
    147
  • 1.5 Installing sliding/tilting sunroof glass panel
    147
  • 1.6 Adjusting height of sliding/tilting sunroof glass panel
    148
  • 1.7 Checking parallel running of glass panel
    149
  • 1.8 Adjusting parallel running of glass panel
    149
  • 1.9 Adjusting panel seal
    150
  • 1.10 Renewing panel seal
    150
  • 1.11 Removing wind deflector
    151
  • 1.12 Removing sliding headliner
    151
  • 1.13 Removing drive for sliding/tilting sunroof
    152
  • 1.14 Adjusting drive for sunroof (zero position)
    152
  • 1.15 Removing pre-selector control for sliding/tilting sunroof
    153
  • 1.16 Removing and installing carrier unit
    153
  • 1.17 Removing coulisse guide
    155
  • 1.18 Operating without current
    155
  • 1.19 Cleaning water drain hoses
    156
  • 2 Remove sliding/tilting sunroof with solar panel
    158
  • 2.1 Tools
    158
  • 2.2 Function
    158
  • 2.3 Assembly overview
    159
  • 2.4 Removing sliding/tilting sunroof solar panel
    160
  • 2.5 Installing sliding/tilting sunroof solar panel
    161
  • 2.6 Adjusting sliding/tilting sunroof solar panel height
    161
  • 2.7 Checking parallel running of solar panel
    162
  • 2.8 Adjusting parallel running of solar panel
    163
  • 2.9 Renewing panel seal
    163
  • 2.10 Removing wind deflector
    163
  • 2.11 Removing solar panel trim
    164
  • 2.12 Removing sliding/tilting sunroof drive
    164
  • 2.13 Adjusting drive for sliding/tilting sunroof (zero position)
    165
  • 2.14 Removing preselection control for sliding/tilting sunroof
    166
  • 2.15 Removing and installing DC converter
    166
  • 2.16 Removing and installing solar contact in solar panel
    166
  • 2.17 Removing and installing solar contact in carrier unit
    167
  • 2.18 Removing and installing carrier unit
    167
  • 2.19 Operating without current
    169
  • 2.20 Cleaning water drain hoses
    170
  • Bumpers
    172
  • 1 Front bumper > 10.2006
    172
  • 1.1 Tools
    172
  • 1.2 Repairing bumper cover
    172
  • 1.3 Assembly overview - bumper cover
    172
  • 1.4 Removing and installing bumper cover
    173
  • 1.5 Front bumper add-on parts
    175
  • 1.6 Front bumper cover - preparation for vehicles with skid plate
    176
  • 1.7 Front bumper cover - preparation for vehicles with cable winch
    177
  • 1.8 Front bumper substructure
    181
  • 1.9 Assembly overview - bumper carrier
    182
  • 1.10 Removing and installing bumper carrier
    182
  • 1.11 Bumper carrier with cable winch mounting bracket
    183
  • 2 Front bumper 11.2006 >
    187
  • 2.1 Tools
    187
  • 2.2 Repairing bumper cover
    187
  • 2.3 Assembly overview - bumper cover
    187
  • 2.4 Removing and installing bumper cover
    188
  • 2.5 Front bumper add-on parts
    191
  • 2.6 Front bumper substructure
    192
  • 2.7 Assembly overview - bumper carrier
    193
  • 2.8 Removing and installing bumper carrier
    193
  • 3 Rear bumper
    195
  • 3.1 Tools
    195
  • 3.2 Repairing bumper cover
    195
  • 3.3 Assembly overview - bumper cover
    195
  • 3.4 Removing and installing bumper cover
    196
  • 3.5 Rear bumper add-on parts
    199
  • 3.6 Rear bumper substructure
    202
  • 3.7 Assembly overview - bumper carrier
    203
  • 3.8 Assembly overview - towing bracket
    204
  • 3.9 Electrically retractable towing bracket
    205
  • 3.11 Assembly overview - USA towing bracket
    210
  • 3.12 USA towing bracket - bolting sequence
    211
  • Glazing
    212
  • 1 Flush bonded windows
    212
  • 1.1 Tools
    212
  • 1.2 Materials
    214
  • 1.3 Repairing windscreen
    214
  • 1.4 Assembly overview - windscreen
    214
  • 1.5 Removing and installing plenum chamber cover
    216
  • 1.6 Removing windscreen
    218
  • 1.7 Installing windscreen
    220
  • 1.9 Preparing a removed windscreen for glazing
    220
  • 1.10 Preparing new window for glazing
    223
  • 1.11 Preparing body flange for glazing
    227
  • 1.12 Installation instructions
    228
  • 1.13 Minimum curing time
    228
  • 1.14 Touching up paint damage
    229
  • 1.15 Cleaning off excess adhesive sealing material
    229
  • 2 Windows having threaded connections
    230
  • 2.1 Tools
    230
  • 2.2 Assembly overview - side windows
    230
  • 2.3 Removing and installing side window
    232
  • 2.4 Assembly overview - rear lid opening window
    234
  • 2.5 Removing and installing rear lid opening window
    234
  • 2.6 Adjusting rear lid opening window
    235
  • 2.7 Adjusting striker pin
    235
  • 2.8 Assembly overview - rear lid opening window button and striker pin
    235
  • 2.9 Window seal
    237
  • 3 Front door windows
    238
  • 3.1 Tools
    238
  • 3.2 Assembly overview - front door
    238
  • 3.3 Assembly overview - window frame parts
    240
  • 3.4 Removing and installing door window
    241
  • 3.5 Repairing window regulators
    244
  • 3.6 Removing and installing window regulator motor
    245
  • 4 Rear door windows
    246
  • 4.1 Tools
    246
  • 4.2 Assembly overview - rear door
    246
  • 4.3 Assembly overview - window frame parts
    248
  • 4.4 Removing and installing door window
    248
  • 4.5 Repairing window regulators
    252
  • 4.6 Removing and installing window regulator motor
    253
  • Exterior equipment
    254
  • 1 Wheel housing liners
    254
  • 1.1 Tools
    254
  • 1.2 Assembly overview - front wheel housing liner
    254
  • 1.3 Assembly overview - rear wheel housing liner
    256
  • 2 Exterior mirror
    257
  • 2.1 Exterior mirror > 10.2006
    257
  • 2.2 Exterior mirror 11.2006 >
    261
  • 2.3 Assembly overview - exterior mirror
    268
  • 2.4 Removing and installing exterior mirror
    268
  • 3 Radiator grille
    270
  • 3.1 Tools
    270
  • 3.2 Assembly overview - radiator grille > 10.2006
    270
  • 3.3 Removing and installing radiator grille > 10.2006
    271
  • 3.4 Removing and installing chrome grille > 10.2006
    272
  • 3.5 Assembly overview - radiator grille 11.2006 >
    272
  • 3.6 Removing and installing radiator grille 11.2006 >
    274
  • 3.7 Removing and installing emblem 11.2006 >
    276
  • 3.8 Installing number plate carrier 11.2006 >
    278
  • 3.9 Installing number plate carrier, USA 11.2006 >
    279
  • 4 Mouldings and trims
    280
  • 4.1 Tools
    280
  • 4.2 Drip channel
    281
  • 4.3 B-pillar trim
    284
  • 4.4 Removing and installing side window trim
    286
  • 4.5 Assembly overview - water deflector
    286
  • 4.6 Front wing trim panel
    288
  • 4.7 Front door trim panel
    290
  • 4.8 Rear door trim panel
    292
  • 4.9 Side member protective strips
    294
  • 4.10 Renewing roof trim strips
    296
  • 4.11 Door trim strips
    297
  • 4.12 Protective film and trim film
    300
  • 5 Wheel housing, wing and side member extensions
    301
  • 5.1 Tools
    301
  • 5.2 Materials
    301
  • 5.3 Safety requirements
    302
  • 5.4 Fitting notes for extensions
    302
  • 5.5 Overview - components
    303
  • 5.6 Front wheel housing extension
    304
  • 5.7 Rear wheel housing extension
    306
  • 5.8 Side member extension “R50”
    308
  • 5.9 Side member extension “R Line”
    311
  • 5.10 Preparing add-on parts for bonding
    313
  • 5.11 Preparing new part for bonding
    313
  • 5.12 Preparing body part for bonding
    313
  • 5.13 Installation instructions
    313
  • 5.14 Cleaning guidelines
    314
  • 5.15 Minimum curing time
    314
  • 5.16 Touching up paint damage
    314
  • 5.17 Cleaning off excess adhesive sealing material
    314
  • 6 Roof rack
    315
  • 6.1 Tools
    315
  • 6.2 Assembly overview - guide rail
    315
  • 6.3 Removing and installing guide rail
    316
  • 6.4 Guide rail - bolting sequence
    318
  • 6.5 Assembly overview - roof rack
    319
  • 6.6 Removing roof rack
    319
  • 6.7 Assembly overview - roof rack repair kit
    322
  • 6.8 Removing and installing roof rack repair kit
    322
  • 6.9 Removing and installing roof rack lock cylinder
    324
  • 6.10 Assembly overview - roof railing
    325
  • 6.11 Removing and installing roof railing
    326
  • 6.12 Assembly overview - roof-mounted luggage basket
    331
  • 6.13 Removing and installing roof-mounted luggage basket
    332
  • 7 Spare wheel carrier for rear lid
    334
  • 7.1 Tools
    334
  • 7.2 Assembly overview - spare wheel carrier for rear lid
    334
  • 7.3 Removing and installing spare wheel
    336
  • 7.4 Removing and installing spare wheel carrier
    336
  • 7.5 Removing and installing lock carrier
    338
  • 7.6 Removing and installing lock
    339
  • 7.7 Removing and installing emergency release
    340
  • 7.8 Adjusting guide for spare wheel carrier
    341
  • 8 Lettering
    342
  • 8.1 Tools
    342
  • 8.2 Attachment notes for lettering
    342
  • 8.3 Rear lettering dimensions
    342
  • 8.4 Wing lettering dimensions - Individual
    344
  • 8.5 Wing lettering dimensions – R-Line
    345
Manufacturer's designation General body repairs, exterior
Manufacturer Volkswagen
Suitable for Touareg (2003 - 2007)
Suitable car types 7L
Category Reparaturanleitung

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