Get Exhaust system Guide for Volkswagen Touareg SUV First Generation (2002-2010)

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

26 – Exhaust system

1

Removing and installing parts of ex‐

haust system

Assembly overview - exhaust manifold with starter catalytic con‐

verters and attachments ⇒ page 148

Assembly overview - silencers with mountings ⇒ page 153

Note

After working on the exhaust system, ensure that the system has

sufficient clearance to the bodywork. If necessary, loosen flange

on catalytic converter and realign silencers and exhaust pipes

⇒ page 154 .

Special tools and workshop equipment required

♦ Lambda probe open ring spanner set -3337-

lk

♦ Torque wrench -V.A.G 1332-

1. Removing and installing parts of exhaust system

147

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

1.1

Assembly overview - exhaust manifold with starter catalytic converters and

attachments

1 - Nut, 25 Nm

2 - Nut, 25 Nm

3 - Exhaust manifold

❑ For cylinder bank 1.

❑ Removal only possible

with engine removed.

4 - M8 25 Nm, M10 40 Nm

5 - Lambda probe -G39- 50 Nm

❑ Bank 1, probe 1.

❑ Installed in exhaust gas

stream of cylinders 1, 2,

3 and 4.

❑ Removing and installing

⇒ page 149

6 - Starter catalytic converter

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❑ Installed in exhaust gas

stream of cylinder bank

1.

7 - Lambda probe after catalyt‐

ic converter -G130- 50 Nm

❑ Bank 1, probe 2.

❑ Removing and installing

⇒ page 149

8 - Catalytic converter

9 - Mounting

❑ Installation position

⇒ page 154 .

10 - 25 Nm

11 - To centre silencer

12 - Mounting

13 - To centre silencer

14 - Gasket

❑ Renew.

15 - M8 25 Nm, M10 40 Nm

16 - Bracket

❑ For supporting gearbox on right.

17 - Lambda probe 2 after catalytic converter -G131- , 50 Nm

❑ Bank 2, probe 2.

❑ Removing and installing ⇒ page 149

18 - Lambda probe 2 -G108- 50 Nm

❑ Bank 2, probe 1

❑ Installed in exhaust gas stream of cylinders 5, 6, 7 and 8.

❑ Removing and installing ⇒ page 149

148

Rep. gr.26 - Exhaust system

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

lk

19 - Catalytic converter

20 - Starter catalytic converter

❑ Installed in exhaust gas stream of cylinder bank 2.

21 - 25 Nm

22 - Bracket

❑ For supporting gearbox on left.

23 - 25 Nm

24 - Exhaust manifold

❑ For cylinder bank 2.

❑ Removal only possible with engine removed.

❑ Removing ⇒ page 149

25 - Gasket

❑ Renew.

❑ Note installation position.

Removing and installing exhaust manifold

– Oil dipstick guide tube retainer -1- must be removed to enable

removal of cylinder bank 2 exhaust manifold.

– Then disconnect refrigerant line -2- and seal connections with

a clean cloth.

– Now unscrew securing nuts -arrows-.

1.2

Removing and installing Lambda

probes

Special tools and workshop equipment required

1. Removing and installing parts of exhaust system

149

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

♦ Open ring spanner with 3/8" drive (flared spanner)

♦ Lambda probe open ring spanner set -3337-

Removing:

– Remove cover for engine and inta^lk^ke manifold.

– Remove intake hoses -1- and -2-. Loosen hose clip for crank‐

case breather valve -3- and pull crankcase breather valve off

hose connection.

– Remove intake air duct to throttle valve module -J338- .

– Disconnect connector for respective Lambda probe and lay

cable to Lambda probe aside.

1 - Lambda probe after catalytic converter -G130-

2 - Lambda probe -G39-

3 - Lambda probe 2 after catalytic converter -G131-

4 - Lambda probe 2 -G108-

Note

Connector for cylinder bank 1 = black, connector for cylinder bank

2 = brown

150

Rep. gr.26 - Exhaust system

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

Lambda probe 2 -G108- (bank 2, probe 1):

– Unscrew Lambda probe 2 -G108- -item 1-.

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Lambda probe -G39- (bank 1, probe 1):

– Unscrew Lambda probe -G39- -item 2-.

Lambda probe 2 after catalytic converter -G131- (bank 2, probe

2) and Lambda probe after catalytic converter -G130- (bank 1,

probe 2):

– Unscrew bolts and remove rear noise insulation tray -2-.

Lambda probe 2 after catalytic converter -G131- (bank 2, probe

2):

– Unscrew Lambda probe 2 after catalytic converter -G131-

-item 2-.

1. Removing and installing parts of exhaust system

151

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

Lambda probe after catalytic converter -G130- (bank 1, probe 2):

– Unbolt heat shield for front propshaft -arrows-.

– Unscrew Lambda probe after catalytic converter -G130-

-item 1-.

Installing:

– If reusing Lambda probe, lubricate threads with high temper‐

ature paste -G 052 112 A3- . Paste may not come into contact

with slots on probe body.

– Restore wiring to original position.

Further installation is carried out in the reverse order.

Note

♦ Threads of new Lambda probes are already coated with as‐

sembly paste; the paste must not get into the slots on the probe

body.

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♦ When installing, the Lambda probe electrical wiring must al‐

ways be reattached at the same locations to prevent the

Lambda probe wiring from coming into contact with the ex‐

haust pipe.

♦ Fit all cable ties in the original position when installing.

Specified torques

Component

Nm

50

9

Lambda probe in exhaust pipe

Heat shield to final drive

Air pipe to bracket

9

152

Rep. gr.26 - Exhaust system

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Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

1.3

Assembly overview - silencers with mountings

1 - Exhaust tailpipe

2 - Rear silencer

❑ Centre and rear silenc‐

ers are installed as a

single component dur‐

ing production. In case

of repair, the centre and

rear silencers are sup‐

plied separately, with a

double repair clamp for

connecting.

❑ In case of repair, align

rear silencer free of

stress.

3 - Mounting

❑ Installation position

⇒ page 154 .

❑ Renew if damaged.

4 - 25 Nm

5 - Exhaust tailpipe

6 - Separating point

❑ For repair cases

❑ Marked by impressions

on exhaust pipe.

❑ Centre and rear silenc‐

ers are installed as a

single component dur‐

ing production. In case

of repair, the centre and

rear silencers are sup‐

plied separately, with a

double repair clamp for

connecting.

❑ Cut through connecting

pipe at right angles at

separating point using e.g. pneumatic sabre saw -V.A.G 1523A- .

❑ The notches to the left and right of the separating points must be visible following the installation of the

double clamp.

7 - Mounting

❑ Installation position ⇒ page 154 .

❑ Renew if damaged.

8 - 25 Nm

9 - Mounting

❑ Installation position ⇒ page 154 .

10 - Double clamp

❑ Must be slid to its mid-point on forward exhaust pipe.

❑ Note installation position: Securing bolt ends must not project beyond lower edge of clamp.

11 - Mounting

❑ Installation position ⇒ page 154 .

12 - Double clamp, 40 Nm

❑ Must be slid to its mid-point on forward exhaust pipe.

1. Removing and installing parts of exhaust system

153

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Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

13 - To exhaust manifold

14 - Centre silencer

❑ Centre and rear silencers are installed as a single component during production. In case of repair, the

centre and rear silencers are supplied separately, with a double repair clamp for connecting.

15 - Double clamp

❑ For repair cases

❑ Installation position ⇒ page 154 .

Installation position, double repair clamp in direction of travel

– The end of bolt -1- must not project beyond lower edge of

double clamp.

– The angle -2- must be 10° + 5°.

Aligning exhaust system

Exhaust system cold

•

– Push exhaust system in direction of travel -1- and tighten dou‐

ble clamps until dimension -a- is attained at the mountings.

Centre silencer: dimension a = 10 mm; Rear silencer: dimen‐

sion a = 15 mm

154

Rep. gr.26 - Exhaust system

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

2

Secondary air system

Function

The secondary air system blows air in behind the exhaust valves

for max. 65 seconds after a cold start (+15°C … +35°C coolant _lk

temperature). This produces an oxygen rich exhaust gas, causing

afterburning and reducing the heat-up phase of the catalytic con‐

verter. The engine control unit activates the system via the sec‐

ondary air pump relay -J299- to the secondary air inlet valve -

N112- and combination valve. Additionally, after each

subsequent engine start (up to max. 80 C engine temperature),

the secondary air system will, after a 20 second delay, switch in

for 5 seconds during idling and will be checked by the self-diag‐

nosis.

Assembly overview - removing and installing parts of secondary

air system ⇒ page 155

2.1

Assembly overview - removing and in‐

stalling parts of secondary air system

Note

Secondary air pump relay -J299- ⇒ page 156

2. Secondary air system

155

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

1 - Combination valve

❑ For cylinder bank 1.

2 - 10 Nm

3 - To secondary air inlet valve

-N112-

4 - Combination valve

❑ For cylinder bank 2.

5 - Gasket

6 - Connecting hose

❑ From cylinder bank 1 to

cylinder bank 2.

7 - Secondary air inlet valve -

N112-

lk

8 - 10 Nm

9 - Bracket

10 - Vacuum reservoir

11 - Hose coupling

❑ Press together at front

to release.

12 - Pressure hose

❑ Check for secure seat‐

ing.

❑ Press together at front

to release.

13 - Secondary air pump motor

-V101-

14 - From air filter.

15 - Pressure pipe

❑ Bolted to cylinder head

cover.

16 - 8 Nm

17 - 10 Nm

18 - To secondary air inlet valve -N112-

Secondary air pump relay -J299-

Note

♦ The secondary air pump relay -1- is in socket A4.

♦ If tools are necessary to pull relays or control units out of the

relay plate, first disconnect battery earth strap ⇒ Electrical

system; Rep. gr. 27 ; Disconnecting and reconnecting batter‐

ies.

156

Rep. gr.26 - Exhaust system

Exhaust system for Your Volkswagen Touareg SUV First Generation (2002-2010)

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