2004 Volkswagen Touareg Service and Repair Manual

This factory service and repair manual for the 2004 Volkswagen Touareg covers a 4-door sport utility with three very different engines. The data lists a 3.2L V6 and a 4.2L V8, both DOHC, naturally aspirated and gasoline, and a 4.9L V10 turbodiesel with single overhead cams. Four trims match those choices: V6, V6 Premium, V8 and TDI. The manual provides procedures, specifications and torque values for the gasoline and diesel engines, fuel systems and drivetrain, with wiring diagrams and diagnostics for the electrical system.

Engines covered

• 3.2L V6 (195 cu in) — DOHC, naturally aspirated, gasoline
• 4.2L V8 — DOHC, naturally aspirated, gasoline
• 4.9L V10 (300 cu in) — SOHC, turbocharged, diesel

Body styles covered

• 4-door sport utility

Trims covered

• TDI
• V6
• V6 Premium
• V8

Known issues on the 2004 Touareg. There are 4 recalls on the federal record for the 2004 Touareg. On certain gasoline-powered vehicles, the fuel filter flange could crack and leak fuel, raising fire risk. Certain vehicles, 24,269 of them, may have had the rear seat belt latch bolt poorly riveted, so an occupant might not be held properly. On certain others, 670 in number, the tire pressure monitoring harness could be routed against the parking brake cable spring, disabling the monitor and possibly shorting to ground. Owners filed 231 complaints, led by power train (50), electrical system (49) and tires (36); 9 reported a crash, 5 a fire and 6 an injury. Fuel system and electrical wiring diagrams, procedures and torque values apply.