VW Tech Tips

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TT 20-07-88
2004 – 2007 Touareg – Main/Primary Fuel Pump Location
Feb 22, 2008 - UPDATE
The main/primary fuel pump location depends on the type of engine the vehicle is equipped with. On the 3.2L V6 engine, the primary pump is located on the left (driver’s) side of the fuel tank. On the V8 engine, the primary pump is located on the right (passenger’s) side of the fuel tank. Location of the main fuel pump can also be determined by restarting the engine (if possible) then checking to see which pump continues to run after 30 seconds. The secondary pump will shut off after 30 seconds and will not run until needed. Regardless of main pump location, the fuel filter is located on the left side assembly and the pressure regulator on the right side. For the 2007 model with the 3.6L V6, there is only one pump. It is located on the right side of the tank and the filter is on the left

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TT 90-08-01
2004> Touareg - Mileage Adaptation on New Clusters
If during the replacement of an instrument cluster on a Touareg an error occurs, please back out of the test plan. During the test plan the mileage is converted to an adaptation value. If an error occurs and the “continue” or “retest” button is pressed, the conversion will start again with the already converted number as the entered value. This will result in the wrong mileage being set into the cluster. It is recommended to back out of the test plan and enter the mileage into adaptation channel 9 in the cluster. The value entered should be the vehicle mileage with the last digit dropped off and a 0 added to the front (i.e.- the mileage is 12500 miles so the value entered should be 01250).

TT 37-08-01
All Models - Transmission Replacements
If the transmission is replaced for any reason, before installation, ensure the trans code on the replacement unit matches the original or is a valid supersession. Installing the wrong unit may cause symptoms such as cruise control shut off and shifting concerns due to gear rations to be exhibited


TT 96-08-04
2004> Touareg with Kessy Max System – Antenna Test Procedure
For diagnosis of the antennas for the Kessy system, it is recommended to use the output test in Guided Fault Finding.
The test will go through each antenna and flash the light on the remote once signal is received.

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Warnings and Cautions

WARNINGS-

• Some repairs may be beyond your capability. If you lack the skills, tools and equipment, or a suitable workplace for any procedure described in this manual, we suggest you leave such repairs to an authorized dealer service department or other qualified shop.
• Do not re-use any fasteners that are worn or deformed in normal use. Many fasteners are designed to be used only once and become unreliable and may fail when used a second time. This includes, but is not limited to, nuts, bolts, washers, self-locking nuts or bolts, circlips and cotter pins. Always replace these fasteners with new parts.
• Never work under a lifted car unless it is solidly supported on stands designed for the purpose. Do not support a car on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a car that is supported solely by a jack. Never work under the car while the engine is running.
• If you are going to work under a car on the ground, make sure that the ground is level. Block the wheels to keep the car from rolling. Disconnect the battery negative (-) terminal (ground strap) to prevent others from starting the car while you are under it.
• Never run the engine unless the work area is well ventilated. Carbon monoxide kills.
• Rings, bracelets and other jewelry should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be crushed by heavy parts.
• Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe injury could result.
• Do not attempt to work on your car if you do not feel well. You increase the danger of injury to yourself and others if you are tired, upset or have taken medication or any other substance that may keep you from being fully alert.
• Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the car. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel, vapors or oil.
• Catch draining fuel, oil, or brake fluid in suitable containers. Do not use food or beverage containers that might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at once, but do not store the oily rags, which can ignite and burn spontaneously.
• Always observe good workshop practices. Wear goggles when you operate machine tools or work with battery acid. Gloves or other protective clothing should be worn whenever the job requires working with harmful substances.
• Greases, lubricants and other automotive chemicals contain toxic substances, many of which are absorbed directly through the skin. Read the manufacturer's instructions and warnings carefully. Use hand and eye protection. Avoid direct skin contact
• Disconnect the battery negative (-) terminal (ground strap) whenever you work on the fuel system or the electrical system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
• Friction materials (such as brake pads or shoes or clutch discs) contain asbestos fibers or other friction materials. Do not create dust by grinding, sanding, or by cleaning with compressed air. Avoid breathing dust. Breathing any friction material dust can lead to serious diseases and may result in death.
• Batteries give off explosive hydrogen gas during charging. Keep sparks, lighted matches and open flame away from the top of the battery. If hydrogen gas escaping from the cap vents is ignited, it will ignite gas trapped in the cells and cause the battery to explode.
• Connect and disconnect battery cables, jumper cables or a battery charger only with the ignition switched off. Do not disconnect the battery while the engine is running.
• Do not quick-charge the battery (for boost starting) for longer than one minute. Wait at least one minute before boosting the battery a second time.
• Do not allow battery charging voltage to exceed 16.5 volts. If the battery begins producing gas or boiling violently, reduce the charging rate. Boosting a sulfated battery at a high charging rate can cause an explosion.
• The air conditioning system is filled with chemical refrigerant, which is hazardous. The A/C system should be serviced only by trained technicians using approved refrigerant recovery/recycling equipment, trained in related safety precautions, and familiar with regulations governing the discharging and disposal of automotive chemical refrigerants.
• Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase system pressure and may cause the system to burst.
• Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the tire from the rim before attempting any repair.
• Some cars are equipped with a supplemental restraint system (SRS), that automatically deploys airbags and pyrotechnic seat belt tensioners in the event of a frontal or side impact. These are explosive devices. Handled improperly or without adequate safeguards, they can be accidently activated and cause serious injury.
• The ignition system produces high voltages that can be fatal. Avoid contact with exposed terminals and use extreme care when working on a car with the engine running or the ignition switched on.
• Place jack stands only at locations specified by manufacturer. The vehicle lifting jack supplied with the vehicle is intended for tire changes only. A heavy duty floor jack should be used to lift vehicle before installing jack stands. See 010 General.
• Battery acid (electrolyte) can cause severe burns. Flush contact area with water, seek medical attention.
• Aerosol cleaners and solvents may contain hazardous or deadly vapors and are highly flammable. Use only in a well ventilated area. Do not use on hot surfaces (engines, brakes, etc.).
• Do not remove coolant reservoir or radiator cap with the engine hot. Danger of burns and engine damage.

CAUTIONS-

• If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we suggest you leave such repairs to an authorized dealer or other qualified shop.
• Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the instructions thoroughly, and do not attempt shortcuts. Use tools appropriate to the work and use only replacement parts meeting original specifications. Makeshift tools, parts and procedures will not make good repairs.
• Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque specification listed.
• Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond or lake. Dispose of in accordance with Federal, State and Local laws.
• The control module for the anti-lock brake system (ABS) cannot withstand temperatures from a paint-drying booth or a heat lamp in excess of 203��F (95��C) and should not be subjected to temperatures in excess of 185��F (85��C) for more than two hours.
• Before doing any electrical welding on cars equipped with ABS, disconnect the battery negative (-) terminal (ground strap) and the ABS control module connector.
• Always make sure ignition is off before disconnecting battery.
• Label battery cables before disconnecting. On some models, battery cables are not color coded.
• Disconnecting the battery may erase fault code(s) stored in control module memory. Check for fault codes prior to disconnecting the battery cables.
• If a normal or rapid charger is used to charge battery, the battery must be disconnected and removed from the vehicle in order to avoid damaging paint and upholstery.
• Do not quick-charge the battery (for boost starting) for longer than one minute. Wait at least one minute before boosting the battery a second time.
• Connect and disconnect a battery charger only with the battery charger switched off.
• Sealed or "maintenance free" batteries should be slow-charged only, at an amperage rate that is approximately 10% of the battery's ampere-hour (Ah) rating.
• Do not allow battery charging voltage to exceed 16.5 volts. If the battery begins producing gas or boiling violently, reduce the charging rate. Boosting a sulfated battery at a high charging rate can cause an explosion.

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TT 42-08-01
2004> Touareg - Clicking Noise from Rear End
For a complaint of “clicking noise when backing up and then braking”, be sure to check the lower outboard control in the rear end for any play in the bushing. The noise could be mistaken for a differential noise if using chassis ears because of the noise transferring through the rear axle. The bushing is available separately and part number (7L0 407 183 A) can be used as reference. Check with the parts department for the latest numbers

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TT 01-08-01
All Models - Control Module Software Updates
If, during a software update, you encounter a problem, before replacing the ECM check to see if the MIL will come on.
To do this, cycle the key to ON, to OFF then back to ON again. Observe the MIL on the MFI display. If the MIL comes on, the ECM is not damaged. Disconnect the ECM or the battery for 30 minutes, then attempt the software update again.

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TT 94-08-03
2008 Touareg DRL’s will not activate using GFF or Guided Functions.
When attempting to activate the Daytime Running Lights (DRL) function during the PDI
inspection, the scan tool may read out ERROR ARGUMENT 1 using VAS 5051/52 Brand V12.83.
To bypass this error, log into vehicle self diagnosis and follow the steps below:

• From the main screen select Vehicle Self Diagnosis
• Select On Board Diagnostic (OBD)
• Select 09 – Electronic central electronics
• Select 007 - Coding (Service1A)
• Highlight byte index 0 it should read Hex value 22
• On the keypad select Hex button and press 23
• Press the Q button to enter and press the forward arrow key.
• The screen will ask to definitely perform coding?
• Select yes and the DRL’s will be active.

TT 00-07-88
All Models - Software Update Reference Page
April 18, 2008 - UPDATE: Locationchange
For your convenience, VW Service & Quality provides a list of available software updates in an easy to use format.
Follow this path to find the list:
1. Go to VW ServiceNet.
2. Click on "Technical Information" in the Library.
3. In category Technical Information, click on "All Systems".
4. Click on “Re-Flash Update Quick Reference”.
This list is updated often, therefore it is recommended to always refer to it electronically rather than printing out a copy.


TT 00-07-91
All Models - On Car Analysis Requests
April 18, 2008 - UPDATE
Volkswagen of America is requesting dealers to call in with certain customer complaints. For a list of these complaints, go to:
·The VW Hub (www.vwhub.com).
·Select the “Service” tab from the top menu.
·In the Documents section, click on “Service and Repair”.
·Locate the document title “On-car Analysis at Dealerships” dated 04/14/2008. (See screen-shot below.)

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TT 10-08-01
2006> Vehicles with 3.6L FSI Engine - Engine Replacement Tip
If the engine is replaced for any reason, make sure the roller lifter for the high pressure pump is transferred from the original engine. A new roller is not included with the new assembly and should be inspected and transferred if the condition is ok.

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TT 19-08-02
2006> Passat, Touareg with 3.6L Engine - Thermostat Replacement Tip
When diagnosis leads to the replacement of a thermostat, ensure all components of the old thermostat have been removed. The top hat shaped section of the thermostat rod may become dislodged upon removal and remain inside the housing.



TT 43-08-01
2004-2007 Touareg - Air Suspension Pressure Valve
For a customer concern regarding the suspension dropping down overnight, the leak may be traced to the residual pressure valve. The valve is available separately through ETKA, so a complete strut replacement is not necessary.
Part number 7L0 616 813 B can be found in ETKA under the strut breakdown page. Always check with parts department for latest part number information.

TT 96-08-05
2008> Touareg - Diagnostic Bus Activation With Loss of 15 Power
In order to activate the Can – Bus on a new Touareg when 15 power has been lost, you will need to pull the turn signal stalk to flash to pass at a rate of once every 20 seconds. This will allow communication with the access/start module to check DTC memory and perform immobilizer functions

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TT 00-08-03
All Models - Tip for Replacing a Control Module
If any vehicle control module is replaced for any concern, it is recommended to code that module according to guided fault finding before testing if the repair was successful. For example, if a door module was replaced for a battery drain, then that module must be coded before retest of the system. It is also recommended to recode the gateway module when another module is replaced to reset the communication system. Even if the coding seems to be correct, entering the code anew will force a reset of the system.


TT 27-08-01
All Models - Battery discharged, Low voltage faults, Instrument cluster display shows low voltage.
During a Battery/Charging system check, the MCR-340 may indicate the system has a low charging voltage problem.

Before replacing any parts, it is important a complete voltage drop test of the battery cables and fasteners be performed. A poorly connected or loose positive/negative cable connection or chassis attachment can cause the generator to not charge properly. The engine/transmission assembly MUST be properly grounded through the chassis for the generator to function properly.
1) Test Requirements:
·Make sure the battery is fully charged
·Voltage drop should be no more than 0.2 volts per connection
·Voltage drop should be performed with engine running and electrical system loaded(Lights,wipers,blower,etc.)
·Use a Fluke 87 or equivalent voltmeter
2) To measure a “positive cable” voltage drop:
Connect voltmeter between B+ Positive post and Generator B+ output post.
3) To measure a “negative cable” voltage drop:
Connect voltmeter between Negative battery post and alligator clamp on generator case.
4) Inspect all cable connections including:
·Positive connection at generator B+ post to fuse block connections, fuse block connection to B+ battery post
·Ground circuit - Engine/Trans assembly to Chassis and Chassis to negative battery post

TT 96-07-53
2004-2007 Touareg - “Key Symbol” Displayed After Access/Start Module Replacement
May 23, 2008 – REMOVED - Refer to TB 57-08-04 (2017104).

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TT 87-08-01
2008 Touareg - Rattle Noise From Engine Compartment
For complaints regarding a rattle or knocking noise while under load coming from the engine compartment or pedal mounting bracket area, check the A/C low pressure refrigerant pipe retaining clamp. The clamp’s rubber bushing may not be positioned correctly in the center of the clamp allowing the pipe to come in contact with the vehicle body resulting in the noise as described.
To repair:
(1) Remove the clamp.
(2) Cut a piece of Flock tape (part # 847 201) from
rattle kit (part #W-42SQK) to a dimension of
30mm x 90mm ( approx. 1 3/16 in x 3 ½ in)
(3) Slide the rubber bushing up the low pressure
pipe and wrap the Flock tape around the rubber
bushing.
(4) Clean the area where the low pressure pipe
contacted the vehicle body and apply clear
lacquer touch-up paint pen (part# LST 100)
to prevent corrosion.
(5) Reinstall the low pressure pipe clamp, centering
the rubber bushing within the clamp and securing
it to the body with the original retaining screw.