Maintenance

Service
Maintenance
Touran 2003 ➤
Edition 01.2019
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Service Department. Technical Information

Service
Maintenance
Heading
1. Engine list
2. Service work
3. General information
4. Descriptions of work:
5. Exhaust emissions test
6. Glossary
7. ---Change history---
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Technical information should always be available to the foremen and mechanics, because their
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Touran 2003 ➤
Maintenance - Edition 01.2019
Contents
1 Engine list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Information about flexible or fixed service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Service tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.1 Raising vehicle with lifting platform or trolley jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.2 Stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.3 Entries in service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.4 Connecting vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.5 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.6 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.7 Countries with hot climate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.8 Country overview for diesel not compliant with EN 590 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.9 Country overview for petrol not compliant with EN 228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.10 Engine code and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.11 RME fuel (biodiesel) for vehicles to ►2006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.12 Severe operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.13 Countries with high levels of dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.14 Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.15 Shortened intervals for spark plug replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4 Descriptions of work: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.1 Removable towing bracket: checking and cleaning if necessary . . . . . . . . . . . . . . . . . . . . 40
4.2 Swivel joints and suspension G. Volkswageinspecting
alink mountings: .......................... 42
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4.3 Driving light assist and bycornering
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light: checking function gua. . . . . . . . . . . . . . . . . . . . . . . . . . 43
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4.4 Automatic gearbox ho
ris09G: checking ATF level . . . . . . . . . . . n.te.e. . . . . . . . . . . . . . . . . . . . . . . 45
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4.5 Automatic gearbox
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4.6 Battery: checking battery terminal clamps for secure seating . . . . . . . . . . . . . . . . . . . . . . 45
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4.7 Battery: checking with battery tester and printer VAS 6161 . . . . . . . . . . . . . . . . . . . . . . . . 48
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4.8 Status of battery: reading, sending diagnosis protocol online . . . . . . . . . . . . . . . . . . . . . . 48

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4.9 Tyres: checking condition, wear pattern, tyre pressure and tread depth . . . . . . . . . . . . . . 48
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4.10 Brake and clutch system: changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

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4.11 Brake fluid level: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

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4.12 Brake system and shock absorbers: inspecting for leaks and damage . . . . . . . . . . . . . . . . 62
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4.13 Brakes, front and rear: checking thickness of brake pads and condition of brake discs . . 63
4.14 Diesel particulate filter: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.15 Dual clutch gearbox 02E: changing gear oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
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4.16 Electric windows: checking positioning (open and close functions) . . . . . . . . . . . . . . . . . . 66

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4.17 Fault memory of all systems: reading with vehicle diagnostic tester , correcting possible faults
according to repair guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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4.18 Front passenger airbag: checking key switch and “On/Off function” . . . . . . . . . . . . . . . . . . 67
4.19 Bonnet catch hook: grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
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4.20 Boots: inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

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4.21 Interior and exterior body: inspecting for corrosion with doors and flaps open . . . . . . . . . . 70
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4.22 Poly V-belt: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

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4.23 Poly V-belt: check condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

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4.24 Poly V-belt: adjusting tension on engines without automatic tensioning roller . . . . . . . . . . 71
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4.25 Cooling system: checking frost protection and coolant level . . . . . . . . . . . . . . . . . . . . . . . . 72
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4.26 Diesel fuel filter: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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4.27 Air filter: cleaning housing and renewing filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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4.28 Multi-purpose additive for diesel fuel: adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.29 Multi-purpose additive for petrol fuel: adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.30 Engine cover panel -top-: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.31 Engine compartment cover -bottom- (noise insulation): removing and installing . . . . . . . . 95
Contents i
Touran 2003 ➤
4.32 Engine and components in engine compartment: inspecting for leaks and damage (from
above and below) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.33 Engine oil level: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.34 Engine oil: draining or extracting, renewing oil filter and replenishing engine oil . . . . . . . . 96
4.35 Engine oil: capacities and specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.36 Panorama tilting/sliding roof with rear panorama roof: checking function, cleaning and
greasing guide rails, and cleaning wind deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.37 Road test: performing (driving behaviour, noises, air conditioner etc.) . . . . . . . . . . . . . . . . 112
4.38 Wheel securing bolts: tightening to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.39 Radio/navigation system: reading code using vehicle diagnostic tester . . . . . . . . . . . . . . 116
4.40 Radio/navigation system: entering PIN of anti-theft coding and storing local radio stations to
station buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.41 Tyre pressure loss indicator: performing basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.42 Tyre repair set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.43 Dust and pollen filter: cleaning housing and renewing filter element . . . . . . . . . . . . . . . . . . 119
4.44 Headlight adjustment: checking halogen headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.45 Headlight adjustment: checking gas discharge headlights without DLA . . . . . . . . . . . . . . 125
4.46 Headlight adjustment: checking gas discharge headlights with DLA . . . . . . . . . . . . . . . . . . 130
4.47 Headlight adjustment: checking fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4.48 Service interval display: resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
4.49 Service interval display: recoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.50 Sunroof: checking function, cleaning guide rails and greasing with special grease . . . . . . 142
4.51 Sliding sunroof drains: checking for blockage, cleaning if necessary . . . . . . . . . . . . . . . . 143
4.52 Windscreen wash/wipe system and headlight washer system: checking function and
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4.53 Wiper blade protection: removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
4.54 Track rod ends: checking clearance, firm seating and boots . . . . . . . . . . . . . . . . . . . . . . . . 154
4.55 Auxiliary heater: setting weekday in menu of dash panel insert . . . . . . . . . . . . . . . . . . . . . . 154
4.56 Door arrester: grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
4.57 Transportation mode: switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
4.58 Transportation devices: removing blocking pieces from springs on front axle . . . . . . . . . . 157
4.59 Underbody: inspecting for damage to underbody sealant, underbody panels, routing of lines,
plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .V.o.lk.sw. a. . . . . . . . . . . . . . . . 158
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4.60 Clock and date: setting . . . . . . . . . . . . . . . . . . . . . . . .lk.sw. a.g.en. . . . . . . . . . . . G . .do. e.s.no. . . . . . . 158
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4.61 Toothed belt and toothed belt tensioning roller: renewing db
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4.62 Camshaft drive toothed belt: renewing (only 2.0 ho l FSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . .e o 160
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4.63 Camshaft drive toothed belt: checking (4-cylinder ss
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4.64 Spark plugs: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

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4.65 Driving instructor pedals: greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

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4.66 Natural gas system: inspecting natural gas tank for corrosion and leakage. . . . . . . . . . . . . 172
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4.67 Natural gas system: checking wax layer between natural gas fuel tank and fuel tank shut-off
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4.68 Natural gas filler connection: checking condition, cleaning if necessary and checking seal
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4.69 Natural gas tank: renew. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
5 Exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
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5.1 Exhaust emissions test for petrol engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

5.2 Exhaust emissions test for diesel engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
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6 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
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7 ---Change history--- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

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Contents Prote
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Touran 2003 ➤
1 Engine list
(VIGG001259; Edition 01.2019)
This chapter provides information on the following subjects:
♦ Petrol engines ⇒ page 1
♦ Diesel engines ⇒ page 3
Note
To ease the search for an engine, the engine codes are listed in
alphabetical order.
Petrol engines
Engines ⇒ Petrol engine Petrol engine Petrol engine Petrol engine
Displacement I 2,0 1,6 1,6 1,6
Engine code AXW BAG BGU BLF
No. of cylinders/valves per cylin‐ 4/4 4/4 4/2 4/4
der
Power kW at rpm 110/6000 85/6000 75/5600 85/5800
Torque Nm at rpm 200/3500 155/4000 148/3800 155/4000
Bore ∅ mm 82,5 76,5 81,0 76,5
Stroke mm 92,8 86,9 77,4 86,9
Compression ratio 11,5 11,5 10,5 12,0
Injection/ignition Motronic MED Motronic MED Simos
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Engine code BLG BLP BLR BLX

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Power kW at rpm 125/6000 85/5800 110/6000 110/6000
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Torque Nm at rpm 240/1750 155/4000 200/3500 200/3500

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Bore ∅ mm 76,5 76,5 82,5 82,5

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Stroke mm 75,6 86,9 92,8 92,8

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Injection/ignition Motronic MED Motronic MED Motronic MED Motronic MED

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1. Engine list 1
Touran 2003 ➤

Engine code BLY BMY BSE BSF
No. of cylinders/valves per cylinder 4/4 4/4 4/2 4/2
Power kW at rpm 110/6000 103/5600 75/5600 75/5600
Torque Nm at rpm 200/3500 220/2000 to 148/3800 148/3800
4000
Bore ∅ mm 82,5 76,5 81,0 81,0
Stroke mm 92,8 75,6 77,4 77,4
Compression ratio 11,5 10 10,5 10,5
Injection/ignition Motronic MED Motronic MED Simos 7.1 Simos 7.1
09/05/2010 9.5.10 (17.5.1) manifold inj. manifold inj.
FSI TSI twin charger
RON unleaded, at least 95 95 95 95
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Engines ⇒ Natural gas/pet‐s Petrol engine Petrol engine Petrol engine
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Engine code BSX BVY BVZ CAVB
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Power kW at rpm 80/5400 110/6000 110/6000 125/6000
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Torque Nm at rpm 160/3500 200/3500 200/3500 240/1500 to
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4500
Bore ∅ mm 82,5 82,5 82,5 76,5
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Stroke mm 92,8 92,8 92,8 75,6
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CNG/PFI FSI FSI TSI twin charger
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RON unleaded, at least Natural gas and 95 95 95

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Engines ⇒ Petrol engine Petrol engine
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Engine code CAVC CBZB CDGA CTHB
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Power kW at rpm 103/5600 77/5000 110/5500 125/6000
Torque Nm at rpm 220/1250 to 175/1550 to 4100 220/1500 to 240/1500 to
4000 4500 4500
Bore ∅ mm 76,5 71 76,5 76,5
Stroke mm 75,6 75,6 75,6 75,6
Compression ratio 10 10,0 10,0 9,7
Injection/ignition Motronic MED Simos 10.1 Motronic MED Motronic MED
9.5.10 (17.5.1) TSI turbocharger 17.1 17.5
TSI twin charger CNG/TSI twin‐ TSI twin charger
charger
2 1. Engine list
Touran 2003 ➤

Engine code CAVC CBZB CDGA CTHB
RON unleaded, at least 95 95 Natural gas and 95
95
Camshaft drive Chain Chain Chain Chain
Engines ⇒ Petrol engine

Displacement I 1,4
Engine code CTHC
No. of cylinders/valves per cylinder 4/4
Power kW at rpm 103/5600
Torque Nm at rpm 220/1250 to 4000
Bore ∅ mm 76,5
Stroke mm 75,6
Compression ratio 9,7
Injection/ignition Motronic MED 17.5
TSI twin charger
RON unleaded, at least 95
Camshaft drive Chain
Diesel engines
Engines ⇒ Diesel engine Diesel engine G. VoDiesel
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Displacement I 1,9 o2,0
lksw 1,9 not g 2,0
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Engine code AVQ rise AZV BKC BKD
ran
tee
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No. of cylinders/valves per cylin‐ 4/2 ss au 4/4 4/2 4/4r ac
der
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Power kW at rpm 74/4000 103/4000 77/4000 103/4000
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Torque Nm at rpm 250/1900 320/1750 to 250/1900 320/1750 to

ab
pe
2500 2500 ility

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Bore ∅ mm 79,5 81,0 79,5 81,0 h re

hole
spec
Stroke mm 95,5 95,5 95,5 95,5
es, in part or in w

t to the co
Injection/ignition TDI TDI TDI TDI

unit injector unit injector unit injector unit injector
rrectness of i
Diesel particle filters No No No No

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Camshaft drive Toothed belt Toothed belt Toothed belt Toothed belt
nform
mercia
Engines ⇒ Diesel engine Diesel engine Diesel engine Diesel engine

com
tion in

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Engine code BLS BMM BMN BRU

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Power kW at rpm 77/4000 103/4000 125/4200 66/4000
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Torque Nm at rpm 250/1900 320/1750 to 350/1800 to 210/1800 to
co Vo
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2500 2500 2500
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Bore ∅ mm 79,5 81,0 81,0 79,5
1. Engine list 3
Touran 2003 ➤
. Volkswagen AG
swa
gen AG does
k not
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Engines ris ⇒ Diesel engine Diesel engine nteeDiesel engine Diesel engine
utho or
Displacement ss
a I 1,9 2,0 ac 2,0 1,9
ce
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Engine code BLS BMM BMN BRU
un
pt
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Stroke mm 95,5 95,5 95,5 95,5
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ility
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unit injector unit injector unit injector unit injector
spec
Diesel particle filters Yes Yes Yes No
t to the co
rrectne
ss
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cial p
f in
Engine code BXE BXF BXJ CAYB
form
mer
atio
om
der
n
c
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or
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Power kW at rpm 77/4000 66/4000 66/4000 66/4200
te
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Torque Nm at rpm 250/1900 210/1900 210/1800 230/1500 to

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2500
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Bore ∅ mm 79,5 79,5 79,5 79,5
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mm 95,5 95,5 95,5 80,5
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Compression ratio cted
18,5 18,5 19,0 16,5
agen
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unit injector unit injector unit injector common rail
Diesel particle filters No No Yes Yes

Engine code CAYC CFHC CFHF CFJA
Power kW at rpm 77/4400 103/4200 81/4200 125/4200
Torque Nm at rpm 250/1500 to 320/1750 to 280/1750 to 350/1750 to
2500 2500 2750 2500
Bore ∅ mm 79,5 81,0 81,0 81,0
Stroke mm 80,5 95,5 95,5 95,5
common rail common rail common rail common rail
Diesel particle filters yes/no1) Yes Yes Yes
1) Vehicles with diesel particulate filter (factory-fitted) can be iden‐
tified by PR No. 7GG, 7MB, 7MG, 7GA or 7MQ on the vehicle
data sticker.
2) PMS: particulate reduction system
4 1. Engine list
Touran 2003 ➤
Engines ⇒ Diesel engine Diesel engine

Displacement I 2,0 2,0
Engine code CFJB CLCA
No. of cylinders/valves per cylinder 4/4 4/4
Power kW at rpm 130/4200 81/4200
Torque Nm at rpm 380/1750 to 2500 250/1500 to 2500
Bore ∅ mm 81,0 81,0
Stroke mm 95,5 95,5
Compression ratio 16,0 16,5
Injection/ignition TDI TDI
common rail common rail
Diesel particle filters Yes no
PMS2)
Camshaft drive Toothed nbelt
AG. Volkswagen AG Toothed belt
wage does
1) Vehicles with diesel particulate filter (factory-fitted) can be iden‐ olks not
byV gu
ara
d
tified by PR No. 7GG, 7MB, 7MG, 7GA or 7MQ on the hvehicle ise nte
or eo
data sticker. au
t ra
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ss
2) PMS: particulate reduction system
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un
pt
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ab
pe
ility
ot
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
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com
tion in
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Cop py
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by
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Prote AG.
1. Engine list 5
Touran 2003 ➤
2 Service work
Information reference flexible or fixed service ⇒ page 6
Service tables ⇒ page 8
2.1 Information about flexible or fixed serv‐

ice
Service identification ⇒ page 6
Flexible service ⇒ page 6
Fixed service ⇒ page 7
Service interval display ⇒ page 7
2.1.1 Service identification

– Referring to vehicle data sticker ⇒ page 27 , check if vehicle
is equipped with following PR numbers:
The PR number is decisive for the service intervals
⇒ page 8 .
Vehicle IDs with the following PR number
Model year PR number Service
► 2012 QG1 Flexible service
► 2012 QG0, QG2, QG3 Fixed service
2013 ► QI6 Flexible service
2013 ► QI1, QI2, QI3, QI4, QI7 Fixed service
In the past, the PR numbers QG0, QG1 and QG2 determined the
type of service. n AG. Volkswagen A ge G do
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With immediate effect, these PR numbers denote by only whether
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an engine oil level sensor is installed or not riand
sed no longer have ran
tee
an influence on the oil change interval. utho or
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2.1.2 Flexible service
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The flexible service enables long service intervals, depending on

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individual driving style and the conditions under which the vehicle
pe
ility
is used.
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hole
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Note
es, in part or in w
t to the co
For the flexible service a special LongLife engine oil is required

⇒ page 8 .
rrectness of i
Vehicles with PR number “QG1” or “QI6” are set up for flexible

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service when they leave the factory. This means that these vehi‐
cles have a flexible service interval display and are fitted with the
nform
following components:
mercia
♦ Flexible service interval display in dash panel insert

a
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tion in
♦ Engine oil level sensor

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♦ Brake pad wear indicator (if fitted)

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For vehicles with flexible service the service interval is determined

en
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t.
by the control unit and is indicated on service interval display
yi Co
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(SID) ⇒ page 7 .
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6 2. Service work
AG. Volkswagen AG d
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Therefore the service intervals are flexible. ss c
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2.1.3 Fixed service
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For vehicles with a fixed service, fixed services are calculated.
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Volkswagen. For normal operating conditions achieving these
h re
service intervals is technically assured.
hole
spec
es, in part or in w
Therefore the service intervals are fixed.
t to the co
For vehicles
♦ Which have not been delivered with extended servicing inter‐
rrectness of i
vals (ESI) (PR numbers “QG0”, “QG2”, “QI1”, “QI2”, “QI3”,
l purpos
“QI4”, “QI7”.
♦ or for which the extended servicing interval (ESI) was stopped
nform
ercia
♦ or for which no LongLife engine oil was used

m
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fixed service applies.
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These non-flexible service intervals apply to all types of service
his
ate
including an engine oil change.
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Vehicles with PR number “QG0”

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The vehicles are “not” factory-fitted with components for flexible C py
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Vehicles with PR number “QG2” cted agen
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The PR number is valid only to ►2012.

For these vehicles the flexible service is not factory-activated.
Therefore, these vehicles have a fixed service interval display
⇒ page 7 and for maintenance the fixed service intervals (rigid
service intervals) apply. These vehicles are fitted with the follow‐
ing components:
♦ Fixed service interval display in dash panel insert
Vehicles with PR number “QG3”
The PR number is valid only to ►2012.
For these vehicles the flexible service is not factory-activated.
Therefore, these vehicles have a fixed service interval display
⇒ page 7 and for maintenance the fixed service intervals apply.
These vehicles are fitted with the following components:
♦ Fixed service interval display in dash panel insert
2.1.4 Service interval display

Introduction of extended servicing intervals (ESI) ⇒ page 8
Flexible service interval display (only vehicles with a flexible serv‐
ice) ⇒ page 8
Fixed service interval display (only vehicles with a fixed service)
⇒ page 8
Service interval display: resetting ⇒ page 138
Service interval display: recoding ⇒ page 141
2. Service work 7
Touran 2003 ➤
Introduction of extended servicing intervals (ESI)

Ask your importer if the extended servicing interval (ESI) is avail‐
able for your country.
Flexible service interval display (only vehicles with a flexible serv‐
ice)
Calculation of service intervals:
♦ The service intervals on vehicles with a flexible service is cal‐
culated. Input values such as, distance travelled, fuel con‐
sumption, oil temperature and loading on diesel particulate
filter are evaluated by the control unit.
♦ The result of the evaluation is a value for the deterioration of
the oil due to thermal loading.
♦ The oil deterioration is the deciding factor concerning the dis‐
tance that can still be driven to the next service.
Note
For vehicles with a flexible service but which are serviced ac‐
cording to fixed service intervals, the service interval display must
be recoded to “non-flexible” ⇒ page 141 .
Fixed service interval display (only vehicles with a fixed service)

Calculation of service intervals:
♦ The service interval for vehicles with a fixed service is calcu‐
AG. Volkswagen AG d
lated in fixed service intervals. This means that wthe
agenmileage or oes
time values have been previously determined olks not
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♦ For normal operating conditionsssachieving
a these service in‐ ra
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tervals is technically assured.
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2.2 Service tables

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Note
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spec
♦ The service tables apply in general with differences depending

es, in part or in w
t to the co
on the vehicle model and equipment level. There is no relation

between individual vehicles and identified vehicle identifica‐
tion numbers.
rrectness of i
♦ Vehicle-specific time and mileage dependent additional work

can only be found in the ⇒ maintenance tables .
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2.2.1 Delivery inspection

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Scope of work
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– Battery: check battery terminal clamps for secure seating.

thi
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– Transportation mode: switch off.

iv
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– Service interval display: reset.

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– Status of battery: read. ht. Cop py
rig
– Event memories of all systems: read.
rig ht
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co Vo
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– Radio/radio navigation system: store local radio stations to station buttons. cted agen
Prote AG.
– Time and date: set.
– All switches, electrical consumers, sockets, gauges and other controls: check function.
– Front passenger airbag: check key switch and ON/OFF function.
– Window regulators: initialise (activate).
8 2. Service work
Touran 2003 ➤
Scope of work
– Vehicle interior: check for cleanliness.
– Protective seat covers and protective carpet film: remove.
– All equipment which has been packed inside vehicle (if part of original equipment): install.
– Two safety hammers: install according to installation instructions.
– Edge protection on doors (plastic film): remove.
– Vehicle exterior: check for cleanliness.
– Tyre pressure: check.
– Wheel bolts: tighten to specified torque.
– Wiper blade protection: remove.
– Tyre Pressure Loss Indicator: calibrate after tyre pressure has been corrected.
– Vehicle: inspect for leaks and damage from above and below.
– Brake system: inspect for leaks and damage.
– Transportation devices: remove (if fitted).
– Vehicle underside (underbody): inspect for damage.
– Windscreen wash/wipe system and headlight washer system: check function and settings.
– Engine oil level: check; observe oil specification when topping up.
– Coolant level: check.
– Brake fluid: renew, if vehicle is older than 6 months.
AG. Volkswagen AG d
– Brake fluid level: check that it is at maximum. lkswagen oes
not
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– Keys: check number, operation and cleanliness. ed b ara
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– Service Schedule / Digital Service aSchedule:
uth enter pre-delivery inspection. eo
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– Owner's literature: check that literature is complete and prepare for delivery to customer.
ce
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un
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– Carry out road test.
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– Warning stickers: check that they are present.
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– Charging cable: check that cable is present and check its condition.
wit
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• Applies only to BEV and PHEV
spec
– High-voltage battery: charging t to the co
• Applies only to BEV and PHEV

rrectne
– Special rubber care set: hang on interior rear view mirror.

s
– Stowage compartments for roof side member, felt in rear longitudinal members and hydraulic pump noise
s o
insulation: check for dampness.

cial p
f inform
– Dash panel insert: adapt language version (not applicable for German speaking countries).
mer
atio
– Onboard computer: reset using front information display and control unit.
om
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Cop py
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Prote AG.
2. Service work 9
Touran 2003 ➤
2.2.2 Scopes of service
Note
♦ Depending on the time elapsed and the mileage since the last
service, service events may be combined (inspection with oil
change).
♦ An extended scope of inspection is carried out in combination
with an inspection.
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♦ The scopes of service work are generally
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olks applicable and differ ot g
according to vehicle model andiseequipment level. There is no
d b ua
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relation between individual vehicles
ut
hor
and identified vehicle tee
or
identification numbers. ss a ac
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♦ Scopes of service work for individual vehicles can be found

un
pt
an
d
only in the maintenance tables. ⇒ Maintenance tables

itte
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Oil Inspec‐ Exten‐ Scope of work
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change tion ded
h re
service scope of
hole
spec
inspec‐
es, in part or in w
tion
t to the co
(applies
only in
addition
rrectness of i
to regu‐
l purpos
lar in‐
spec‐
tion)
nform
ercia
Vehicle interior
m
a
com
X – Interior lights: check function of headliner, luggage compartment and tion in
glove compartment lights.

r
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X – Horn: check function.

iva
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X – Charging cable: check that cable is present and check its condition.
fo
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• Applies only to BEV
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X – High-voltage battery: check charge level, charge as necessary.
co Vo
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cted agen
Prote AG.
X – Sliding/tilting sunroof: check function.

Vehicle exterior
X – Headlight washer system: check function.
X – Front lighting: check function.
X – Static cornering light (cornering light): check function.
X – Automatic headlight control: check function.
X – Rear lighting: check function.
X – Windscreen wash/wipe system: check function and spray jet settings and
adjust if necessary; check for damage.
X – Wiper blades: move blades to service position and check for damage;
check park position.
X – Interior and exterior of body: inspect for corrosion.
X – Windscreen: inspect for damage.
X – High-voltage charging socket in radiator grille: inspect for soiling and
damage.
• Applies only to PHEV
10 2. Service work
AG. Volkswagen AG d
agen oes
olksw not
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d by ara Touran 2003 ➤
ise nte
r eMaintenance
ut
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or - Edition 01.2019
s a ac
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change tion ded
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service scope of
erm
ab
inspec‐
ility
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tion
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(applies
h re
hole
only in
spec
addition
es, in part or in w
t to the co
to regu‐
lar in‐
spec‐
rrectness of i
tion)
X – High-voltage charging socket in radiator grille and tank cap: inspect for
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soiling and damage.
nform
ercia

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X – Reducing agent (AdBlue®): replenish only if customer requests.
ion
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• If part of equipment
at
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X – CSC roof: check for damage and function, clean wind deflector and seals
f
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t.
and apply special lubricant to rubber seals.
Cop
yi Co
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t. rig
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• Applies only to EOS
ht
pyri by
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cted agen
X – Sliding/tilting roof: clean and grease guide rails of glass panel and sliding
Prote AG.
headliner.
• Applies only to EOS
X – Bonnet catch hook: grease.
• Does NOT apply to: Polo 6C1, up!, e-up!, Passat (NMS-US) A32, Golf
5G1, Golf estate BA5, Golf SV AM1, e-Golf, Beetle, Jetta or Scirocco
X – Door arrester: grease.
• Applies only to Touran 1T, EOS, Golf Cabriolet, CC and Phaeton
X – Convertible top: clean and lubricate locking element.

• Applies only to Golf Cabriolet and Beetle Cabriolet
X – Convertible top: perform water test.
• Applies only to Golf Cabriolet and Beetle Cabriolet
X – Sunroof seal: regrease.
• Applies only to Phaeton
X – Sliding sunroof drains: check for blockage, clean if necessary.
• Applies only to Touareg and Passat (NMS-US)
Underside of vehicle
X – Drain engine oil and renew oil filter.
X – Engine and components in engine compartment: inspect for leaks and
damage (from below).
X – Gearbox, final drive and drive shaft boots: inspect for leaks and damage.
X – Brakes, front and rear: check thickness of pads/linings and condition of
brake discs.
X – Poly V-belt: check condition.
2. Service work 11
Touran 2003 ➤

change tion ded
service scope of
inspec‐
tion
(applies
only in
addition
to regu‐
lar in‐
spec‐
tion)
X – Swivel joints, axle mountings, coupling rod bearings and anti-roll bar rub‐
ber mounting: inspect for damage.
X – Track rod ball joints: check clearance, firm seating and boots.
X – Brake system and shock absorbers: inspecting for leaks and damage
X – Exhaust system: inspect for leaks, firm seating and damage.
X – Underbody: inspect for damage to undercoating, underbody cladding,
routing of lines, plugs.
X – Front and rear coil springs and rubber buffers: inspect for damage.
X – Warning stickers: check that they are present.
• Applies only to high-voltage vehicles
X – Removable towing bracket: check.
• If part of equipment
X – Air suspension: check for leaks and damage.
• Applies only to Touareg and Phaeton

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X – Sunroof:
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check function, cleansguide
ot g rails and
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lubricate with special
ir se grease.
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X au – Automatic gearbox: checking ATF level or a
th
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• Applies only to Phaeton

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Tyres
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X – Tyre pressure: check.

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X – Tyre mobility set: check for damage and use.

h re
hole
spec
X – Tyres: check condition and wear pattern of tyre; enter tread depth.
es, in part or in w
t to the co
Engine compartment
X – Engine oil: replenish.
X – Oil level: check.
rrectness of i
X – Battery and, if fitted, second battery: check with battery tester.

l purpos
X – Engine and components in engine compartment: inspect for leaks and

damage (from above).
nform
ercia
X – Brake fluid level (dependent upon brake pad/lining wear): checking

m
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om
X – Cooling system: check frost protection and coolant level.

ion
c
in t
or
X – Window wash/wipe system: check anti-freeze protection; replenish wash‐

his
te
er fluid.
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X – Hybrid components: inspect for damage to high-voltage components and

for
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wires.
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•
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Applies only to HEV and PHEV
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Prote AG.
12 2. Service work
Touran 2003 ➤

change tion ded
service scope of
inspec‐
tion
(applies
only in
addition
to regu‐
lar in‐
spec‐
tion)
G. Volkswagen
X – High-voltage components landksw high-voltage cables: e
agen
A AG do
inspect
s no for damage
and correct routing andbysecuring
Vo of lines. t gu
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• Applies only to aBEV
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ac
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X – Power assisted steering: checking fluid level e
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• Applies only to Touareg and Phaeton
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X – Plenum chamber: check for soiling.
wit
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• Applies only to up!
spec
es, in part or in w
t to the co
X – Plenum chamber: check for soiling.
• Applicable for e-up! only
rrectness of i
Final checks
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X – Service interval display: resetting
nf
ercia
X – Headlight adjustment: check and adjust as necessary.
orm
X – Tyre Pressure Loss Indicator: calibrate after tyre pressure has been cor‐
m
atio
m
rected.
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X – Carry out road test.
thi
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X – High-voltage battery: charge.
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• Applies only to PHEV

t.
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Cop py
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Prote AG.
2.2.3 Service intervals to model year ►2013
Caution
Applies only to diesel engines

• In some countries, diesel has a higher sulphur content.
• The high sulphur content leads to excessive wear of cyl‐
inders and it considerably reduces the cleanliness of pis‐
tons.
♦ Therefore change engine oil every 7,500 km in countries
where the diesel has a high sulphur content.
2. Service work 13
Touran 2003 ➤
Note
♦ For extremely uneconomical driving style or use under ex‐

treme conditions , the shortest interval for an oil change serv‐
ice is “7,500 km or 1 year”.
♦ However, other intervals apply for other countries. Your im‐
porter will inform you about this.
lkswage es n
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TOURAN d b ua
ran
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Service intervals ►2007
auth or
ac
ss
from-to Engine/Engine code/ Service/intervals Indicated on
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PR No./Remarks service interval display SID
pt
du
an
(includes oil change)
itte
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Since intro‐ Diesel, in countries Oil change service YES
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duction where the sulphur con‐ every 7,500 km or 1 year
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tent in fuel is high
h re
hole
spec
Since intro‐ QG0/QG2/QG3 or Oil change service YES
es, in part or in w
duction QG1 vehicles coded to every 15,000 km or 1 year
t to the co
non-flexible interval
►2004 QG1 vehicles Oil change service YES
flexible from 15,000 km to max.
rrectness of i
30,000 km or 2 years
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►2004 For all vehicles Inspection service NO

every 60,000 km or 4 years
nf
ercia
2005►2007 QG0/QG2/QG3 or Interval service YES
orm
QG1 vehicles coded to every 30,000 km or 2 years
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2005►2007 QG1 vehicles Interval service YES
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flexible from 15,000 km to max.
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2005►2007 For all vehicles Interval service inspection YES

t.
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every 60,000 km or 4 years Cop py
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Caution
Only applicable for natural gas vehicles with engine code

CDGA.
Vehicles with natural gas engine and engine code CDGA can
be identified by PR No. QG1 on vehicle data sticker.
Flexible interval services and use of LongLife engine oil are not
approved for engine code CDGA and must therefore not be
used. Failure to observe this may result in damage to the en‐
gine.
The service interval display is coded/needs to be coded to fixed
intervals. Only engine oils according to VW standard 502 00
must be used.
14 2. Service work
n AG. Volkswagen AG do Touran 2003 ➤
wage es n
yV
olks ot g Maintenance - Edition 01.2019
d b ua
ran
ir se tee
ho TOURAN 2008►2012
aut or
ac
ss
Service intervals
ce
e
nl
pt
du
from-to Engine/Engine code/ Service/intervals Indicated on
an
itte
y li
PR No./Remarks erm
service interval display SID
ab
ility
ot p
wit
2008►2012 Diesel, in countries Oil change service YES
, is n
h re
where the sulphur con‐ every 7,500 km or 1 year
hole
spec
tent in fuel is high
es, in part or in w
t to the co
Petrol and diesel: Oil change service YES
QG0/QG2/QG3 or every 15,000 km or 1 year
QG1 vehicles coded to Interval service: YES
rrectness of i
l purpos
Petrol and diesel: Interval service: YES

QG1 vehicles flexible according to SID from
15,000 km or 1 year up to max.
nform
ercia
m
at
Petrol and diesel: Inspection service: NO
om
io
all vehicles after 60,000 km or 3 years, then
n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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t. Cop TOURAN 2013 py
rig
Service intervals
gh ht
pyri by
Vo
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by
From - to PR No. Prote
cted Service events:
AG.
agen Indicated on
Intervals service interval display
2013 QI1 Oil change service (fixed): YES
every 5,000 km or 1 year
QI2 Oil change service (fixed): YES
every 10,000 mi or 1 year
QI1, QI2, QI3, QI4, QI7 Interval service (fixed): YES
QI6 Interval service (flexible): YES
from 15,000 km or 1 year up to
max. 30,000 km or 2 years
QI1, QI2, QI3, QI4, QI6, QI7 Inspection service: NO
after 3 years or max 60,000
km, then every 2 years or
60,000 km
2.2.4 Service intervals as of model year 2014►

Scope of work Climate and traffic condi‐ For operation with fuels that are »NOT« compliant with
tions usual for passenger standards EN 228 ⇒ page 30 or EN 590
vehicles operated on fuels ⇒ page 29
compliant with EN 228 or
EN 590
Oil change service --- QI1
every 5,000 km or 1 year (fixed) 1)
2. Service work 15
Touran 2003 ➤
EN 590
QI2 ---
--- QI3
QI4
QI6 ---
max. 30,000 km or 2 years
(flexible) 1)
QI7 ---
every 10,000 mi or 1 year
(fixed) 1)
1) Whichever occurs first. AG. Volkswagen AG d
agen oes
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d by ara
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Scope of work Climate and trafficaut condi‐ For operation with fuels that are »NOT« r acompliant with
s c
tions usual for passenger
s standards EN 228 ⇒ page 30 or EN 590
ce
le

un
pt
an
d

itte
y li
EN 590
erm
ab
ility
ot p
Inspection --- QI1
wit
is n
every 10,000 km or 1 year 1)
h re
ole,
spec
--- QI2
t to the co
--- QI3
rrectne
QI4 QI4
30,000 km or 2 years every 15,000 km or 1 year 1)
s
then every 30,000 km or
s o
cial p
1 year 1) f inform
QI6 ---
mer
atio
om
then every 30,000 km or

n
c
i
or
1 year 1)
thi
te
sd
va
QI7 ---
i
o
pr
cum
r
Every 20,000 mi or 2 years

fo
en
ng
1)
t.
yi Co
Cop py
t. rig
gh
1)
ht
Whichever occurs first. yri
p by
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Prote AG.
EN 590
Inspection with expanded After 60,000 km or 3 years After 30,000 km or 2 years or
scope then every 60,000 km or after 20,000 km or 2 years 1)
• Applies only in con‐ 2 years 1)
junction with regular in‐
spection
16 2. Service work
Touran 2003 ➤
1) Whichever occurs first.
2.2.5 Air filter n AG. Volkswagen AG do

lkswage es n
o ot g
Scope of work d b Climate
yV and traffic conditions usual
ua Countries with high levels
ran
of dust
o
ir se for passenger vehicles tee ⇒ page 32
th or
u
Air filter: cleaning housing
ss and re‐
a Every 60,000 km ac Every 30,000 km
newing filter element or 4 years 1) or 2 years 1)
ce
e
nl
pt
• Applies only to Polo (except for
du
an
itte
1.0 TSI) and up! with PFI
y li
erm
ab
ility
ot p
Air filter: cleaning housing and re‐ Every 90,000 km Every 30,000 km
wit
, is n
newing filter element or 6 years 1) or 2 years 1)
h re
hole
spec
es, in part or in w
t to the co
2.2.6 Dust and pollen filter
rrectness of i
l purpos
Scope of work Climate and traffic conditions usual Countries with high levels of dust
for passenger vehicles ⇒ page 32
nform
ercia
Dust and pollen filter (cabin filter): Every 30,000 km Max. 1 year
renew. or 2 years 1) or 30,000 km 1)
m
at
om
• Applies only to Polo (6R1 and
ion
c
6C1) and up!
in t
or
his
ate
do
riv
Dust and pollen filter (cabin filter): Every 60,000 km Max. 1 year
p
cum
or
renew. or 2 years 1) or 30,000 km 1)

f
en
ng
t.
yi Co
op
C py
t. rig
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pyri by
Vo
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cted agen
Prote AG.
2.2.7 Panoramic sliding sunroof

Panoramic sliding sunroof After 60,000 km or 3 years Max. 1 year
• If the lubricating paste is grey, then every 60,000 km or 2 years 1) or 15,000 km 1)
clean and grease guide rails
and clean wind deflector.
2.2.8 Toothed belt

Camshaft drive toothed belt: re‐ Every 120,000 km
new.
• Applies only to TDI UIS up to
►2006
Tensioning roller: renew. Every 240,000 km

• Applies only to TDI UIS up to
►2006
2. Service work 17
Touran 2003 ➤
Camshaft drive toothed belt: re‐ Every
agen 150,000 kmAG does
AG. Volkswagen
new. Volksw not
gu
• Applies to TDI UIS as of 2007► d by ara
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Tensioning roller: renew. ss a Every 300,000 km c
• Applies to TDI UIS as of 2007►
ce
le
un
pt
an
d
itte
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Toothed belt and camshaft drive Every 210,000 km Every 120,000 km
erm
ab
tensioning roller: renew.
ility
• Applies only to CR TDI ot p
wit
is n
h re
ole,
Camshaft drive toothed belt: re‐ Every 180,000 km
spec
new.
t to the co
• Applies to 2.0 l petrol engines
rrectness o
2.2.9 Poly V-belt
cial p
f inform
mer
atio
m

o
n
c
i
or
n
Poly V-belt: renewing --- Every 60,000 km
thi
te
sd
va
Poly V-belt for compressor: renew. Every 90,000 km Every 60,000 km

i
o
pr
cum
r
• Applies only to Touareg

fo
en
ng
t.
yi Co
Cop py
t. rig
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by
2.2.10 Diesel fuel filter
cted agen
Prote AG.
Scope of work Diesel compliant with EN 590 Diesel not compliant with EN 590
⇒ page 29
Diesel fuel filter: renewing Every 60,000 km Every 30,000 km
• Applies only to Polo (6R1 &
6C1) and Touareg
Diesel fuel filter: renewing Every 90,000 km Every 30,000 km
2.2.11 Spark plugs

Scope of work Petrol engine compliant E100 Petrol engine not compli‐
with EN 228 ant with EN 228
⇒ page 34
Spark plugs: renewing Every 60,000 km Every 40,000 km Every 30,000 km /
or 4 years 1) or 4 years 1) 20,000 km
Spark plugs: renewing Every 90,000 km or 2 years 1)
• Applies for all 6-cylin‐ and
or 6 years 1) every 15,000 km /
der engines
10,000 km
or 1 year 1)
18 2. Service work
Touran 2003 ➤
2.2.12 Brake fluid

Scope of work Climate and traffic conditions usual Only for markets outside Europe
for passenger vehicles and with fixed oil change intervals
Brake and clutch system: chang‐ Every 2 years
ing brake fluid
• Applies only to vehicles to
►2007
Brake and clutch system: chang‐ 3 years after initial registration, Every 2 years
ing brake fluid then every 2 years
• Applies to vehicles as of 2008►
AG. Volkswagen AG d
agen oes
olksw not
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2.2.13 author
Natural gas system eo
ra
ss c
Scope of work Interval
ce
le
un
pt
an
d
Natural gas system: inspect natural gas tank for cor‐ 4 years after initial registration,
itte
y li
erm
rosion and leakage. then every 2 years
ab
ility
• Italy only
ot p
wit
is n
h re
Natural gas filler connection and sealing cap: check 4 years after initial registration,
ole,
spec
condition, clean if necessary and check seal. then every 2 years
• Italy only
t to the co
rrectne
2.2.14 Time and mileage-dependent additional

s
work for the markets Russia and USA to

s o
cial p
model year ►2013

inform
mer
atio
om
n
c
Note
i
or
n thi
te
sd
va
♦ This chapter contains only the time or mileage-dependent ad‐

i
o
pr
cum
r
ditional work up to model year ►2013 for Russian and USA

fo
en
ng
markets.
t.
yi Co
Cop py
♦ For information for other markets, refer to the chapter “Service
t. rig
gh ht
yri by
tables”. ⇒ page 8
cop Vo
by lksw
cted agen
Prote AG.
Russian market
Applies up to ►2013 Interval Description of work
Interval service (fixed) Every → Maintenance ta‐
♦ (QG0/QG2/QG3) 2) 15,000 km bles
or 1 year 1)
♦ QI4
(appears on service interval display)
Inspection service every → Maintenance ta‐
(does not appears on service interval display) 30,000 km bles
or 2 years 1)
– Multi-purpose additive for petrol fuel: adding At every serv‐ ⇒ page 87
ice.
– Dust and pollen filter (cabin filter): renew. Every ⇒ page 119
15,000 km
or 1 year 1)
– Spark plugs: renewing every ⇒ page 161
30,000 km
or 2 years 1)
2. Service work 19
Touran 2003 ➤
Applies up to ►2013 Interval Description of work

– Diesel fuel filter: renewing Every ⇒ page 74
30,000 km
– Air filter element: renew and clean housing. every ⇒ page 81
30,000 km
or 2 years 1)
– Panorama tilting/sliding roof with rear panorama roof: checking every ⇒ page 109
function, cleaning and greasing guide rails, and cleaning wind de‐ 30,000 km
flector or 2 years 1)
– Camshaft drive toothed belt: renew. Every ⇒ page 160
90,000 km
• Only valid for 2.0 l FSI engine
– Camshaft drive toothed belt: renew. Every ⇒ page 160

120,000 km
• Only valid for 1.6 l TDI and 2.0 l TDI Common Rail engines

2)Oil change service has been omitted in the Russian market.
The interval service is carried out as a substitute. Changing the
engine oil is an integral part of the interval service.
North American market
AG. Volkswagen AG d Interval Description of work

agen oes
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Sliding sunroof drains: checking – forby Vblockage,
ol cleaning if necessarynot
gu Every ⇒ page 143
rised 60,000
ara
ntee km
utho or
a ac
ss
ce
le
un
pt
2.2.15 Country-specific additional work dependent on time and mileage

an
d
itte
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rm
ab
Scope of work Interval

pe
ility
ot
wit
, is n
Automatic gearbox: change ATF. Every 60,000 km

h re
• Only applicable for countries with hot climate

hole
spec
es, in part or in w
Automatic gearbox: change ATF. Every 80,000 mi

t to the co
• Only applicable for NAR
Dual clutch gearbox (DSG) 02E and 0D9: change gear Every 60,000 km
rrectness of i
oil and filter.

l purpos
Dual clutch gearboxes (DSG) 0DD, 0DL and 0BH: Every 60,000 km
change gear oil.
nform
ercia
– Camshaft drive toothed belt: check. At 90,000 km,

then every 30,000 km
m
a
com
• Only applicable for engine codes BGU, BSE, BSF,

ion in
BSX
r
te o
thi
s
iva
do
Diesel particulate filter: check. At 150,000 km/180,000 km/210,000 km,

r
rp
cum
fo
then every 30,000 km

en
ng
t.
yi Co
Natural gas system: inspect natural gas tank for cor‐ Cop 3 years after initial registration,
py
rosion and leakage. then every 2 years
t. rig
gh ht
yri
• Europe only (except for Italy)
p by
co Vo
by lksw
cted agen
Prote AG.
Natural gas filler connection and sealing cap: check 3 years after initial registration,
condition, clean if necessary and check seal. then every 2 years
• Europe only (except for Italy)
Natural gas tank: renew. Every 20 years
20 2. Service work
Touran 2003 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
by
21
copy Vo
by lksw
cted agen 2. Service work
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
Touran 2003 ➤ d by
V gu
ara
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Maintenance - Editionhoris
01.2019 eo
aut ra
ss c
ce
e
3 General information
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Raising vehicle with lifting platform or trolley jack ⇒ page 22
wit
, is n
h re
hole
Sticker ⇒ page 23
spec
es, in part or in w
Entries in service schedule ⇒ page 25
t to the co
Connecting vehicle diagnosis tester ⇒ page 25
Vehicle identification number ⇒ page 26
rrectness of i
Vehicle data sticker ⇒ page 27
l purpos
Countries with hot climate ⇒ page 28
nform
ercia
Country overview for diesel not compliant with EN 590

m
⇒ page 29
at
om
ion
c
Country overview for petrol not compliant with EN 228
in t
or
⇒ page 30
his
ate
do
priv
c
Engine code and engine number ⇒ page 31
um
for
en
ng
t.
RME fuel (biodiesel) for vehicles to ►2006 ⇒ page 31
yi Co
Cop py
t. rig
Severe operating conditions ⇒ page 32
gh ht
pyri by
Vo
o
by c lksw
Countries with high levels of dust ⇒ page 32 Prote
cted AG.
agen
Type plate ⇒ page 33

Shortened intervals for spark plug replacement ⇒ page 34
3.1 Raising vehicle with lifting platform or

trolley jack
3.1.1 Safety notes:
WARNING
♦ Before driving onto a lifting platform, ensure that there is

sufficient clearance between low-lying components and
lifting platform.
♦ Before driving a vehicle onto a lifting platform it must be
ensured that the vehicle weight does not exceed the per‐
missible lifting capacity of the platform.
♦ Vehicle may be lifted only at points indicated in figure to
avoid damaging vehicle underbody or tipping vehicle.
♦ Never start engine and engage a gear with vehicle lifted
as long as even one driven wheel has contact with the
floor! Disregarding these warnings risks the danger of an
accident!
♦ If work is to be performed under vehicle, it must be sup‐
ported by suitable jack stands.
22 3. General information
Touran 2003 ➤
3.1.2 Lifting points for lifting platform or trolley

jack
Front lifting point:
– Position support plate in area of side member marking, at ver‐
tical reinforcement of floor pan -arrow-.
WARNING
Ensure that side member reinforcement seats centrally on

support plate of hoist mounting.
lkswage es n
o ot g
byV ua
Rear lifting point: ir se
d ran
tee
tho
or
– Position support plate
au in area of side member marking, at ver‐ ac
ss
tical reinforcement of floor pan -arrow-.
ce
le
un
pt
an
d
itte
y li
WARNING
erm
ab
ility
ot p
Ensure that side member reinforcement seats centrally on wit

is n
support plate of hoist mounting. h re

ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m
3.2 Stickers
o
n
c
i
or
n thi
te
sd
a
In this chapter there are stickers which apply for the German
iv
o
r
market. The stickers determined for your country can be obtained

p
cum
r
fo
from your importer.

en
ng
t.
yi Co
op
Attach “Your next service” sticker. ⇒ page 23
C py
t. rig
gh ht
yri by
Attach “vehicle data sticker” in customer service schedule. cop Vo
by lksw
⇒ page 24
cted agen
Prote AG.
Attach “Long-life engine oil sticker” ⇒ page 24
3.2.1 Attaching “Your next service” sticker
Note
For vehicles from model year 2014►, no service sticker needs to

be attached.
3. General information 23
Touran 2003 ➤
Service sticker valid for vehicles to model year ►2013

– Service sticker “Your next service”: Enter a cross in position
for next oil change service or inspection service or legal check
such as legislative inspection or gas system check (next serv‐
ice due) and enter date and mileage.
Service intervals ⇒ page 8
– Attach sticker to driver side door pillar (B-pillar) -arrow-.
3.2.2 Attaching “vehicle data sticker” in cus‐

tomer service schedule: wage
e
olks s no
t gu
– Apply the lower of the two vehicle data stickers
db
y V -arrow- in the ara
service schedule. rise nte
ho t eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
3.2.3 Attaching “LongLife engine oil” sticker

t to the co
– For vehicles with LongLife service (PR number QG1), the

sticker must be attached as shown below.
rrectness of i
– Attach sticker -arrow- as shown on left side of lock carrier (from

l purpos
driver perspective).
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
24
cop Vo
by lksw
3. General information Prote
cted AG.
agen
Touran 2003 ➤
3.3 Entries in service schedule

If a component is changed which has a change interval prescribed
by the manufacturer, e.g. the toothed belt, the new change inter‐
val begins at the time the component is changed.
• Therefore it is very important, every time a component is
changed, to document this in the service schedule.
• This also applies to components which were changed before
the regular change interval.
3.4 Connecting vehicle diagnostic tester

Special tools and workshop equipment required
♦ Diagnosis system - VAS 6160 A-
AG. Volkswagen AG d
agen oes
olksw not
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pt
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♦ Diagnosis system VCI - VAS 6150 C-

h re
hole
spec
es, in part or in w
Note
t to the co
Ensure that the selected vehicle diagnostic tester is used only

with the respective diagnostic cable.
rrectness of i
l purpos
WARNING
nform
ercia
♦ During a road test, you must always secure testing and

m
measuring equipment on the back seat.

com
tion in
r
♦ Only a passenger may operate these devices while the

te o
thi
s
vehicle is in motion.
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
– Carry out following procedure: t. Cop py
rig
gh ht
– Pull storage compartment cover -1- in direction of arrow and pyri by
Vo
co
remove it.
by lksw
cted agen
Prote AG.
– Connect diagnosis cable connector to diagnostic connection
-2-.
– Switch on vehicle diagnostic tester .
– Switch on ignition.
Now follow information given on screen to start desired functions.
Touran 2003 ➤
AG. Volkswagen AG d
Maintenance - Edition 01.2019 agen oes
olksw not
y V gu
d b ara
ise
3.5 Vehicle identification number r nte
tho eo
au ra
ss c
ce
le
un
pt
Note
an
d
itte
y li
rm
ab
Depending on vehicle equipment, the vehicle identification num‐
pe
ility
ot
ber can be found at different places in the vehicle.
wit
, is n
h re
hole
spec
♦ Vehicle identification number on lower edge of windscreen
es, in part or in w
⇒ page 26
t to the co
♦ Vehicle identification number in vehicle interior ⇒ page 26
♦ Vehicle identification number on body, front ⇒ page 27
rrectness of i
♦ Significance of vehicle identification number ⇒ page 27
l purpos
3.5.1 Vehicle identification number on lower
nform
ercia
edge of windscreen
m
a
com
ti
The vehicle identification number -arrow- is located on the left-
on in
hand side of the vehicle in the windscreen near the wiper mount‐
r
te o
thi
ing. It is visible from the outside.
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3.5.2 Vehicle identification number in vehicle

interior
The vehicle identification number -arrow- is found on right from
driver perspective, behind the right seat, in area of outer longitu‐
dinal member of seat. It can be seen when opening a flap in the
floor covering.
Touran 2003 ➤
3.5.3 Vehicle identification number on body,

front
The vehicle identification number is located on suspension strut
mounting, front right -arrow-.
AG. Volkswagen AG d
agen oes
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byV gu
ara
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nl
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ab
3.5.4 Significance of vehicle identification number
ility
ot p
wit
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WVG ZZZ 1T Z 4 8 000 234
hole
spec
Manufacturer Filler charac‐ Model Filler charac‐ Model year Production lo‐ Serial number
es, in part or in w
code ters ters 2004 cation
t to the co
rrectness of i
3.6 Vehicle data sticker
l purpos
The vehicle data sticker -arrow- is attached to the luggage com‐

partment floor near the spare wheel recess, on the left in direction
nform
ercia
of travel.
m
at
The vehicle data sticker is also found in the service schedule for
om
ion
the customer.
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
The sticker contains the following data of the vehicle

1 - Vehicle identification number (chassis number)
2 - Vehicle type, engine output, gearbox
3 - Engine and gearbox codes, paint number, interior equipment
4 - Optional equipment, PR numbers
Touran 2003 ➤
The sticker in service schedule includes the same data. The leg‐
end can be found below the sticker.
3.7 Countries with hot climate

♦ Countries with hot and super hot climates have elevated peak
temperatures (50°C) compared with the European average
(25°C).
♦ Locally high ambient temperatures have an influence on the
longevity of the engine, gearbox and coolant circuit, such as
journeys uphill and at higher speeds as well as start/stop op‐
eration.
Australia Qatar Thailand
Abu Dhabi Lebanon Tunisia
Algeria Libya Togo
Egypt Lesotho Tanzania
Afghanistan Liberia Chad
Angola Mexico Uganda
Equatorial Guinea Malaysia USA
Ethiopia Mauritius United Arab Emirates
Bahrain lkswageMorocco es n West Sahara
o ot g
byV ua
Brunei ir se
d
Madagascar ran
tee Zimbabwe
tho
or
Benin au Mali ac Central African Republic
ss
Burkina Faso Mozambique
ce
e
nl
pt
du
an
Botswana Malawi
itte
y li
erm
ab
Burundi Mauritania
ility
ot p
China Nigeria
wit
, is n
h re
Dubai Namibia
hole
spec
Democratic Republic of the Congo Niger

es, in part or in w
t to the co
Djibouti Oman
Ivory Coast Puerto Rico
rrectness of i
Eritrea Palestine
l purpos
Gabon Pakistan
Gambia Republic of Congo
nform
ercia
Ghana Rwanda
m
at
Guinea South Africa

om
ion
c
Guinea-Bissau Saudi Arabia

in t
or
his
te
Iran Singapore
a
do
priv
cum
India Senegal
for
en
ng
t.
yi
Indonesia Sudan
Co
Cop py
t. rig
Iraq Zambia opyri
gh by
Vo
ht
Israel South Sudan

c by lksw
cted agen
Prote AG.
Touran 2003 ➤
Yemen Sierra Leone

Jordan Somalia
Kuwait Swaziland
Cameroon Syria
Kenya
3.8 Country overview for diesel not compli‐

ant with EN 590
Examples in fuel inadequacies that can lead to shortened main‐
tenance / exchange intervals:
♦ High sulphur content
♦ Elevated amount of biodiesel
♦ Contaminants in diesel
♦ Elevated amount of water in diesel
Abu Dhabi Gambia Sierra Leone Malawi
Afghanistan Georgia Zimbabwe Malaysia
Egypt Ghana Singapore Mali
Algeria Guatemala Somalia Morocco
Angola Guinea Sri Lanka and the Mal‐ Mauritania
dives
Equatorial Guinea Guinea-Bissau Mauritius
wage
nAG. Volkswagen AG do South Africa
es n
olks ot g
Argentina Guyana d b Macedonia
y V Sudan ua
ran
e
ris
Armenia Haiti utho Mexico South Sudan
tee
or
a ac
Azerbaijan Honduras ss Moldova Surinam
ce
le
un
Ethiopia India Mongolia Swaziland
pt
an
d
itte
y li
Bahamas Indonesia Mozambique Syria
erm
ab
ility
Bahrain Iraq Myanmar Tajikistan
ot p
wit
is n
Bangladesh Iran Namibia Tanzania

h re
ole,
spec
Belize Jamaica Nepal Thailand
Benin Yemen New Caledonia Togo t to the co
Bermudas Jordan Nicaragua Trinidad and Tobago

Bhutan Cambodia Dutch Overseas Territo‐ Chad
rrectne
ries
Bolivia Cameroon Niger Tunisia
ss o
cial p
Botswana Canada Nigeria Turkey

f inform
Brazil Cape Verde North Korea Turkmenistan

mer
atio
Brunei Caribbean driving on the Oman Uganda

om
left
c
i
or
n thi
e
Burkina Faso Kazakhstan Pakistan Ukraine

t
sd
iva
o
pr
Burundi Qatar Panama Uruguay

um
r
fo
en
ng
t.
Cayman Islands Kenya Papua New Guinea USA Cop
yi Co
py
China Kyrgyz Republic Paraguay Uzbekistan
t. rig
gh ht
pyri by
Costa Rica Columbia Peru Venezuela
o Vo
by c lksw
cted agen
Prote AG.
Democratic Republic of Cuba Philippines United Arab Emirates
the Congo
Djibouti Kuwait Puerto Rico Vietnam
Dominican Republic Laos Republic of Congo West Sahara
Touran 2003 ➤
Dubai Lesotho Rwanda Central African Republic

Ecuador Lebanon Russia Ivory Coast
El Salvador Liberia Zambia
Eritrea Libya Saudi Arabia
Fiji Macao Senegal
Gabon Madagascar Seychelles
n AG. Volkswagen A
age G do
ksw es n
y Vol ot g
ua
b
ed ran
oris tee
3.9 Country overview for petrol not compli‐ th or
au ac
ss
ant with EN 228
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
♦ Petrol contaminated with diesel
, is n
h re
hole
spec
es, in part or in w
♦ Poor boiling point / evaporation
t to the co
♦ Metallic components / Octane Booster Additive
rrectness of i
♦ Contaminants in petrol
l purpos
Abu Dhabi Malaysia Gabon South Africa

Afghanistan Mali Gambia South Sudan
nf
ercia
Egypt Morocco Georgia Zimbabwe
orm
m
atio
Algeria Mauritania Ghana Sudan
om
n in
c
Angola Mauritius Guatemala Suriname

or
thi
te
sd
a
Equatorial Guinea Mexico Guinea Syria

iv
o
r
rp
cu
Argentina Mongolia Guinea-Bissau Swaziland

o
m
f
en
ng
t.
yi
Armenia Mozambique Haiti Tajikistan
Co
Cop py
t. rig
Azerbaijan Myanmar (Burma) Honduras gh
Taiwan
ht
pyri by
Vo
co
Ethiopia Namibia India Tanzania
by lksw
cted agen
Prote AG.
Australia Nepal (Indian subconti‐ Indonesia Thailand
nent)
Bahamas Iraq New Caledonia Togo
Bahrain Iran Nicaragua Trinidad and Tobago
Bangladesh Jamaica Dutch Overseas Territo‐ Chad
ries
Belize Yemen Niger Tunisia
Benin (Dahomey) Jordan Nigeria Turkey
Bermudas Cayman Islands North Korea Turkmenistan
Bhutan Cambodia Oman Uganda
Bolivia Cameroon Pakistan Ukraine
Botswana Cape Verde Panama Uruguay
Brunei Caribbean, left-hand traf‐ Papua New Guinea Uzbekistan
fic
Burkina Faso (Upper Vol‐ Kazakhstan Paraguay Venezuela
ta)
Burundi Qatar Peru United Arab Emirates
Chile Kenya Philippines Vietnam
China Kyrgyz Republic Republic of Congo Belarus
Costa Rica Columbia Rwanda West Sahara
Touran 2003 ➤
Democratic Republic of Cuba Russian Federation Central African Republic

the Congo
Djibouti Kuwait Zambia Macao
Dominican Republic Laos Saudi Arabia
Dubai Lesotho Senegal
Ecuador Lebanon Seychelles
El Salvador Liberia Sierra Leone
Ivory Coast Libya Singapore
Eritrea Madagascar Somalia
Fiji Malawi Sri Lanka
3.10 Engine code and engine number

Engine code and engine number are located:
♦ ⇒ Rep. gr. 00 ; Technical data
♦ On vehicle data sticker ⇒ page 27 .
Note
For technical reasons it is possible that several cross references

are not directed to the correct chapter. In this case select the pro‐
cedure manually in the information.
3.11 RME fuel (biodiesel) for vehicles to

►2006 en AG. V
olkswagen AG
wag does
olks not
byV gu
ara
ed
Note ho
ris nte
eo
t
au ra
c
ss
The RME compatibility does not apply to vehicles as of 2007►.
ce
e
nl
pt
du
an
itte
y li
RME fuel may be used only in vehicles which have been approved
erm
ab
for this purpose by Volkswagen - either in the standard version or

ility
ot p
in vehicles which have had special equipment (PR No. 2G0) for
wit
, is n
this purpose.
h re
hole
spec
es, in part or in w
Caution
t to the co
♦ When RME fuel is used and your vehicle is not suitable for
this, the fuel system can be damaged.
rrectness of i
♦ When filling the tank with biodiesel, only use RME fuel
l purpos
conforming to EN 14214 (FAME)!

♦ When biodiesel is used which does not conform to the re‐
nf
ercia
quired standard, the fuel filter can become blocked.

rm
m
atio
om
n in
or c
RME fuel must conform to EN 14214 (FAME).

thi
te
sd
iva
♦ RME means “Rapeseed Methyl Ester”.

r
rp
cu
o
m
f
en
ng
♦ EN means “Euro standard”.

t.
yi Co
Cop py
♦ FAME means “Fatty Acid Methyl Ester”.
t. rig
gh ht
pyri by
Vo
o
Vehicles which are factory-fitted for RME can be identified by the
c by lksw
cted agen
PR No. 2GO on vehicle data sticker ⇒ page 27 .
Prote AG.
Touran 2003 ➤
Characteristics of RME fuel

♦ Performance can slightly be lower when using biodiesel.
♦ Fuel consumption can slightly be higher when using biodiesel.
♦ RME can be used in winter at temperatures to approx. -10 °C
♦ At ambient temperatures below -10℃ we recommend using
winter diesel fuel.
Note
♦ When using biodiesel observe the changed intervals for

changing the fuel filter ⇒ page 13 .
♦ If it is planned not to use the vehicle for approx. two weeks, it
is recommended to fill the tank with conventional diesel be‐
forehand and drive approx. 50 km to prevent damage to the
fuel injection system.
. Volkswagen AG
gen AG
3.12 Severe ooperating conditions
a oes d
lksw not
yV b gu
ara
ed
If the vehicle is
tho
used
ris under severe operating conditions some
nte
e
work will have
sa
u to be performed before the next service is dueor aor
c
at shorter service intervals.
s
ce
le
un
pt
• Regular short trips or stop and go operation in urban traffic

an
d
itte
y li
erm
ab
• High percentage of cold starts

ility
ot p
wit
• Vehicle is used in areas with winter temperatures over a long

is n
h re
period
ole,
spec
• Regular long periods of idling (e.g. taxis)

t to the co
• Vehicle is often driven at full throttle with high payload or whilst

towing a trailer
rrectne
• Using diesel with elevated sulphur content

• Regular operation in areas with high levels of dust
ss o
cial p
• Countries with generally poor road conditions such as high

f in
number of potholes, protrusions, high elevations in the road/

form
mer
deep “tramlines”.
atio
om
• High number of gravel roads with poor surface quality, such

n
c
i
or
as irregularities/bumps, elevations, protruding stones, waves.

thi
te
sd
iva
• Subtropical climates (combination of high ambient tempera‐

pr
cum
r
fo
ture and high air humidity)

en
ng
t.
yi Co
op
3.13 Countries with high levels of dust
C py
t. rig
gh ht
pyri by
Vo
♦ High dust content in the air due to road and environmental
co lksw
by
cted agen
conditions. Prote AG.
♦ Dust is categorised according to particle size or type of dust

(organic and inorganic material) such as e.g. pollen, bacteria,
fungal spores or rock dust, mineral fibres.
Abu Dhabi Gabon Macau Somalia
Afghanistan Gambia Madagascar Sri Lanka
Egypt Georgia Malawi South Africa
Algeria Ghana Maldives Seychelles
Angola Guatemala Mali South Sudan
Equatorial Guinea Guinea Morocco Sudan
Argentina Guinea-Bissau Mauritania Suriname
Touran 2003 ➤
Armenia Guyana Mauritius Swaziland

Azerbaijan Honduras Mexico Syria
Ethiopia Hong Kong Mongolia Tajikistan
Australia India Mozambique Tanzania
Bahrain Indonesia Myanmar (Burma) Thailand
Volkswagen AG
Bangladesh Iraq swagen AG. doNamibia
es n Togo
k
Vol ot g
Belize ed byIsrael Nepal u(Indian
ara subconti‐ Chad
horis nent) nte
e
ut or
Benin (Dahomey) ss a Yemen Nicaragua ac Tunisia
ce
le
Bhutan Jordan Niger Turkey

un
pt
an
d
itte
Bolivia Cambodia Nigeria Turkmenistan
y li
rm
ab
Botswana
pe
Cameroon North Korea Uganda
ility
ot
wit
, is n
Brazil Cape Verde Oman Uruguay
h re
hole
Brunei Kazakhstan Pakistan Ukraine
spec
es, in part or in w
Burkina Faso (Upper Vol‐ Qatar Palestine Uzbekistan
t to the co
ta)
Chile Kenya Panama Venezuela
rrectness of i
China Kyrgyz Republic Papua New Guinea United Arab Emirates
l purpos
Costa Rica Columbia Paraguay Vietnam

Democratic Republic of Cuba Peru Belarus
nform
the Congo
ercia
Djibouti Kuwait Puerto Rico West Sahara

m
a
com
tio
Dominican Republic Laos Rwanda Central African Republic
n in
r
te o
thi
Dubai Lesotho Russian Federation
s
iva
do
r
Ecuador Lebanon Zambia

rp
cum
fo
en
g
El Salvador Liberia Saudi Arabia

n
t.
yi Co
op py
Ivory Coast Libya Senegal t. C rig
gh ht
yri by
Eritrea Philippines Sierra Leone
op Vo
by c lksw
cted agen
French Guyana Burundi Zimbabwe
Prote AG.
Fiji
3.14 Identification plate
Note
Vehicles for certain export countries have no type plate.
Type plate -arrow- is visible in lower area of B-pillar when front

left door is opened.
The type plate includes the following vehicle data:
A - Vehicle identification number
B - Variable indications e.g. axle loads, gross vehicle weight rat‐
ing, gross combination weight
C - Model identification number
D - Engine code
Touran 2003 ➤
3.15 Shortened intervals for spark plug re‐

placement
Shortened spark plug replacement intervals are necessary if fuel
not compliant with DIN EN 228 are used.
♦ Petrol contaminated with diesel
♦ Poor boiling point / evaporation
♦ Metallic components / Octane Booster Additive
♦ Contaminants in petrol
Country
30,000 km / 2 years 20,000 km / 2 years 15,000 km /1 year 10,000 km /1 year
Abu Dhabi X
Afghanistan X
Egypt X
Algeria X
Angola X
Equatorial Guinea X
Armenia X
Azerbaijan X
Ethiopia X
Australia X
Bahamas X
Bahrain X
Bangladesh X AG. Volkswagen AG d
agen oes
ksw
Belize by Vol
Xnot gua
ed ran
Benin (Dahomey) horis tee X
ut or
Bermudas X ss
a ac
ce
le
Bhutan X
un
pt
an
d
itte
Bolivia X
y li
erm
ab
Botswana X
ility
ot p
wit
is n
Brunei X
h re
ole,
Burkina Faso (Upper X

spec
Volta)
t to the co
Burundi X
Chile X
rrectne
China X
Costa Rica X
ss o
Democratic Republic X
cial p
f in
of the Congo
form
mer
Djibouti X
atio
om
Dominican Republic X
n
c
i
or
n thi
Dubai X
te
sd
iva
o
r
Ecuador X
p
cum
r
fo
en
ng
El Salvador X
t.
yi Co
op py
Ivory Coast X
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
34
Prote AG.
3. General information
Touran 2003 ➤
Country
Eritrea X
Fiji X
Gabon AG. Volkswagen AG d X
agen oes
ksw
Gambia by Vol not
gu
ara
X
d
Georgia rise X nte
tho eo
u ra
Ghana ss a c X
ce
e
Guatemala X
nl
pt
du
an
itte
Guinea X
y li
erm
ab
Guinea-Bissau X
ility
ot p
wit
, is n
Haiti X
h re
hole
Honduras X
spec
es, in part or in w
India X
t to the co
Indonesia X
Iraq X
rrectness of i
Iran X
l purpos
Jamaica X
Yemen X
nf
ercia
o
Jordan X
rm
m
atio
m
Cayman Islands X
o
n in
or c
Cambodia X
thi
te
sd
iva
Cameroon X
o
r
rp
cu
o
m
Cape Verde X
f
en
ng
t.
yi Co
Caribbean, left-hand X
Cop py
t. rig
traffic (Grenada, An‐ yri
gh by
ht
tigua and Barbuda, cop Vo
by lksw
Barbados, Domini‐ cted agen
Prote AG.
ca)
Kazakhstan X
Qatar X
Kenya X
Kyrgyz Republic X
Columbia X
Cuba X
Kuwait X
Laos X
Lesotho X
Lebanon X
Liberia X
Libya X
Macao X
Madagascar X
Malawi X
Malaysia X
Mali X
Morocco X
Mauritania X
Mauritius X
Touran 2003 ➤
Country
Mexico X
Mongolia X
Mozambique X
Myanmar (Burma) X
Namibia X
Nepal (Indian sub‐ X
continent)
New Caledonia X
Nicaragua X
Netherlands over‐ X
seas territories Aru‐
ba, Curacao, Sint-
Maarten (Dutch)
Niger X
Nigeria X
North Korea X
Oman X
Pakistan n AG. Volkswagen AG do X
swage es n
Panama X byV
olk ot g
ua
d ran
Papua New Guinea X ir se tee
tho
u or
Paraguay X ss
a ac
ce
le
Peru X
un
pt
an
d
itte
Philippines X
y li
erm
ab
Republic of Congo X
ility
ot p
wit
is n
Rwanda X
h re
ole,
Russian Federation X
spec
Zambia t to the co X
Saudi Arabia X
Senegal X
rrectne
Seychelles X
Sierra Leone X
ss o
cial p
Singapore X
inform
Somalia X
mer
atio
m
Sri Lanka X
o
n
c
i
or
South Africa X
thi
te
sd
a
South Sudan X
iv
o
pr
cum
r
fo
Sudan X
en
ng
t.
yi Co
Suriname t. Cop py
rig X
gh
Syria X
ht
pyri by
Vo
co lksw
by
Swaziland X cted agen
Prote AG.
Tajikistan X
Taiwan X
Tanzania X
Thailand X
Togo X
Trinidad and Tobago X
Chad X
Touran 2003 ➤
Country
Tunisia X
Turkey X
Turkmenistan X
Uganda X
Ukraine X
Uruguay X
Uzbekistan X
Venezuela X
United Arab Emi‐ X
rates
Vietnam X
Belarus X
West Sahara X
Central African Re‐ X
public
Zimbabwe X
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Touran 2003 ➤
4 Descriptions of work:
♦ Removable towing bracket: checking and cleaning if neces‐
sary ⇒ page 40
♦ Swivel joints and axle mountings: inspecting ⇒ page 42
♦ Front passenger front airbag: checking key switch and “ON/
OFF function” ⇒ page 67
♦ Driving light assist and cornering light: checking function
⇒ page 43
♦ Automatic gearbox 09G: checking ATF level ⇒ page 45
♦ Automatic gearbox 09G: changing ATF ⇒ page 45
♦ Battery: checking battery terminal clamps for secure seating
⇒ page 45
♦ Battery: checking using battery tester with printer VAS 6161
⇒ page 48
♦ Status of battery: reading, sending diagnosis protocol via on‐
line connection ⇒ page 48
♦ Tyres: checking condition, wear pattern, tyre pressure and
tread depth ⇒ page 48
♦ Brake and clutch system: changing brake fluid ⇒ page 57
♦ Brake fluid level: checking ⇒ page 61
♦ Brake system and shock absorbers: inspecting for leaks and
damage ⇒ page 62
♦ Brakes, front and rear: checking thickness of brake pads and
condition of brake discs ⇒ page 63
AG. Volkswagen AG d
agen oes
♦ Diesel fuel filter: renewing ⇒ page 74 Volksw not
gu
d by ara
e
♦ Diesel particulate filter: checking ⇒ page 65 horis nte
eo
aut ra
♦ Dual clutch gearbox 02E: changing gear oil s and filter
s c
⇒ page 65
ce
e
nl
pt
du
an
itte
♦ Window regulators: checking positioning (open and close

y li
erm
ab
functions) ⇒ page 66
ility
ot p
♦ CNG tank: renewing ⇒ page 178

wit
, is n
h re
hole
♦ Natural gas system: inspecting natural gas tank for corrosion

spec
and leakage ⇒ page 172

es, in part or in w
t to the co
♦ Natural gas system: checking wax layer between natural gas

fuel tank and fuel tank shut-off valve ⇒ page 177
rrectness of i
♦ Fault memories of all systems: reading with vehicle diagnostic

tester and correcting possible faults according to repair guide‐
l purpos
lines ⇒ page 66
♦ Driver instructor pedals: lubricating ⇒ page 170
nform
ercia
♦ Bonnet: greasing catch hook ⇒ page 69

m
at
om
io
♦ Protective bellows: inspecting ⇒ page 69

n
c
in t
or
his
e
♦ Interior and exterior body: inspecting for corrosion when doors

at
do
riv
and flaps are open ⇒ page 70

p
cum
for
en
g
♦ Poly V-belt: renewing ⇒ page 70

n
t.
yi Co
Cop py
♦ Poly V-belt: checking condition ⇒ page 70
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
38 4. Descriptions of work:
Touran 2003 ➤
♦ Poly V-belt: adjusting tension on engines without automatic

belt tensioner ⇒ page 71
♦ Cooling system: checking frost protection and coolant level
⇒ page 72
♦ Air filter: cleaning housing and renewing filter element
⇒ page 81
♦ Multi-purpose additive for diesel fuel: adding ⇒ page 85
♦ Multi-purpose additive for petrol fuels: adding ⇒ page 87
♦ Engine cover panel -top-: removing and installing
⇒ page 88
♦ Engine compartment cover -bottom- (noise insulation): remov‐
ing and installing ⇒ page 95
♦ Engine and components in engine compartment: inspecting
for leaks and damage (from above and below) ⇒ page 95
♦ Oil level: checking ⇒ page 95
♦ Engine oil: draining or extracting; renewing oil filter and re‐
plenishing engine oil ⇒ page 96
♦ Engine oil: capacities and specifications ⇒ page 107
♦ Panorama tilting/sliding roof with rear panorama roof: check‐
ing function, cleaning and greasingVoguide rails, and cleaning
. lkswagen AG
wind deflector ⇒ page 109 swagen AG does
k not
y Vol g
♦ Road test (performance,
db handling, noises, air conditioner
ua
etc.):
ran
ise
carrying out ⇒thpage
or 112 tee
o
au ra
c
♦ Wheel securing
ss bolts: tightening to specified torque
ce
le
⇒ page 113
un
pt
an
d
itte
y li
♦ Radio/navigation system: reading code using vehicle diag‐

erm
ab
nostic tester ⇒ page 116

ility
ot p
wit
♦ Radio/navigation system: activating anti-theft coding

is n
h re
⇒ page 117
ole,
spec
♦ Tyre Pressure Loss Indicator: performing basic setting

t to the co
⇒ page 117
♦ Tyre repair set ⇒ page 118
rrectne
♦ Dust and pollen filter: cleaning housing and renewing filter el‐
ement ⇒ page 119
ss
♦ Headlight adjustment: checking halogen headlights

o
cial p
f i
⇒ page 119
nform
mer
♦ Headlight adjustment: checking gas discharge headlights

atio
m
without DLA ⇒ page 125

o
n
c
i
or
n thi
♦ Headlight adjustment: checking gas discharge headlights with

te
sd
a
DLA ⇒ page 130

iv
o
pr
cum
r
fo
♦ Headlight adjustment: checking fog lights ⇒ page 136

en
ng
t.
yi Co
op
♦ Service interval display: resetting ⇒ page 138
C py
ht. rig
rig ht
py by
♦ Service interval display: recoding ⇒ page 141 co Vo
by lksw
cted agen
Prote
♦ Sunroof: checking function, cleaning guide rails and greasing
AG.
with special grease ⇒ page 142

♦ Sliding sunroof drains: checking for blockage, cleaning if nec‐
essary ⇒ page 143
♦ Window wash/wipe system and headlight washer system:
checking function ⇒ page 146
♦ Wiper blade protection: removing ⇒ page 151
4. Descriptions of work: 39
Touran 2003 ➤
♦ Track rod ends: checking clearance, security and boots

⇒ page 154
♦ Auxiliary heater: setting weekday in menu of dash panel insert
⇒ page 154
♦ Door arrester: lubricating ⇒ page 156
♦ Transportation mode: switching off ⇒ page 156
♦ Transportation devices: removing blocking pieces from
springs on front axle ⇒ page 157
♦ Underbody: inspecting for damage to underbody sealant, un‐
derbody panels, routing of lines, plugs
wage
n⇒Apage
G. Volk158
swagen AG
doe
ks s no
Vol t gu
♦ Clock and date: setting ⇒ page
ed
by 158 ara
is nte
or
♦ Toothed belt and toothed
au belt tensioning roller: renewing
th (die‐ eo
ra
sel) ⇒ page 160 ss c
ce
le
un
pt
♦ Camshaft drive toothed belt: renewing (only 2.0 l FSI)
an
d
itte
⇒ page 160
y li
erm
ab
ility
♦ Camshaft drive toothed belt: checking (4-cylinder petrol en‐
ot p
wit
gines) ⇒ page 160
is n
h re
ole,
♦ Spark plugs: renewing ⇒ page 161
spec
4.1 Removable towing bracket: checking
t to the co
and cleaning if necessary
rrectne
This chapter describes how to check and repair a removable tow‐
ing bracket.
ss o
cial p
f in
Note
form
mer
atio
m
Note that checking towing bracket is included in the respective

o
n
c
service. However, a repair is charged separately and must be re‐

i
or
n thi
quired by the customer.

te
sd
iva
o
pr
cum
r
fo
Check procedure
en
ng
t.
yi Co
op
– Remove cover -1-. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Touran 2003 ➤
– Pull off protective cap -1- from ball head mounting -2-.
– Insert ball head into mounting.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
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ss c
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un
pt
an
d
itte
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rm
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pe
ility
ot
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
After ball head has been inserted, green mark on hand wheel
must be aligned with white mark on ball head. Hand wheel must
nform
ercia
be entirely in contact. Afterwards, it must be possible to close the

towing bracket lock by removing the key. If this is not possible,
m
a
the following repair procedure must be performed.
com
tion in
r
te o
thi
s
iva
Note
do
r
rp
cum
fo
en
g
If a repair has to be performed, it has only to be in agreement with

n
t.
yi Co
op
the customer. A repair must be charged separately. C py
t. rig
gh ht
pyri by
Vo
co
Repair procedure:
by lksw
cted agen
Prote AG.
– Check contact surfaces -arrows- of ball head mounting for

corrosion.
– If contact surfaces are corroded, eliminate corrosion with a tri‐
angular scraper and clean the treated areas with silicone
remover.
– Apply a thin coat of lubricating paste G 000 650 or G 000 150
on cleaned surfaces.
– Check contact surfaces -arrows- of ball head for corrosion.

– If contact surfaces are corroded, eliminate corrosion with a tri‐
angular scraper and clean the treated areas with silicone
remover.
– Apply a thin coat of lubricating paste G 000 650 or G 000 150
on cleaned surfaces.
– Check again ball head seat in mounting ⇒ page 40 .
Touran 2003 ➤
– After checking, fit protective cap -1- into ball head mounting
-2-.
Note
If protective cap is damaged or not available, a new protective

cap must be fitted to protect ball head mounting against corrosion.
⇒ ETKA
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
– Insert cover -1-.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
4.2 Swivel joints and suspension link
atio
om
mountings: inspecting
n
c
i
or
n thi
te
sd
a
– Check swivel joint boots -arrow- for leaks and damage.

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Touran 2003 ➤
– Check also suspension link mountings -arrow- for following

damage:
♦ Large cracks, perforating cracks or cuts in rubber material.
♦ Complete separation of rubber and metal parts.
♦ Large play between mounting and suspension link, which has
a considerably negative effect on the function of the mounting.
Note
♦ Superficial cracks and cuts as well as minor separations of the

rubber element from the metal part do not significantly affect
the operation of the elasto-kinematic mounting and do not
constitute a basis for a complaint.
♦ Damage to the thin rubber skin over cavities due to construc‐
tion is also permissible.
♦ Play between bearing and axle component is permissible as
long as there is no negative effect on the function of the bear‐
ing.
– Check sealing boots of coupling rod -arrows- for damage.

♦ There must be no clearance.
AG. Volkswagen AG d
– Check anti-roll bar bearing -arrow- for damage.
olks
wage
n oes
not
yV gu
♦ There must be no clearance. db ara
rise nte
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
4.3 Driving light assist and cornering light:

rrectness of i
checking function
l purpos
♦ Checking driving light assist ⇒ page 44

♦ Checking cornering light (static cornering light) ⇒ page 44
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
43
co Vo
by lksw
cted
agen
Prote AG.
Touran 2003 ➤
4.3.1 Driving light assist: checking
Note
The driving light assist is also called automatic headlight control

(AHC).
wage
• Vehicle must be in natural daylight. yV
olks es n
ot g
d b ua
ran
Checking in daylight or brightness ir se tee
tho
u or
a ac
– Switch on ignition. ss
ce
e
nl
pt
– Turn light switch -4- to position -2- for driving light assist.
du
an
itte
y li
The headlights may not light in brightness.
erm
ab
ility
ot p
Checking at night or in darkness
wit
, is n
h re
• Ignition is switched on.
hole
spec
es, in part or in w
• Light switch is in position for driving light assist
t to the co
rrectness of i
l purpos
nform
ercia
The rain and light sensor is secured on the interior mirror retainer.
m
The rain and light sensor is located centrally at top of windscreen
at
om
io
-arrow-.
n
c
in t
or
his
e
– Cover the securing area for interior mirror from outside of

at
do
riv
windscreen by hand or with a suitable object -arrow-.

p
cum
for
This measures the light incidence and the headlights are switched
en
ng
t.
yi Co
on. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
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cted agen
Prote AG.
– Turn light switch -4- to position 0 -1- and switch off ignition.
4.3.2 Cornering light (static cornering light):

checking
There are 2 different types of static corning light. With gas dis‐
charge headlights: integrated in headlight. With halogen head‐
lights: integrated in fog light. The procedure for both is basically
the same.
Touran 2003 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
Note orised
nte
h eo
aut ra
♦ If necessary, check activation of the cornering light in the mul‐ ss c
ce
e
tifunction display of the dash panel insert.
nl
pt
du
an
itte
♦ Switch on turn signal.
y li
erm
ab
ility
♦ If necessary, mask off rain and light sensor.
ot p
wit
, is n
h re
• Vehicle stationary, steering in straight-ahead position hole
spec
es, in part or in w
– Switch on ignition and dipped beam or driving light assist.
t to the co
– Turn steering wheel one full turn from centre position in clock‐
wise direction and check if right cornering light lights up.
rrectness of i
– Switch on turn signal if necessary.
l purpos
When the steering wheel is in straight-ahead position the corner‐

ing light must not light.
nf
ercia
o
– Repeat this work step for the left-hand side.
rm
m
atio
m
4.4 Automatic gearbox 09G: checking ATF

o
n in
or c
thi
level
te
sd
iva
o
r
rp
cu
Procedure
o
m
f
en
ng
t.
yi
– Power transmission ⇒ Rep. gr. 37 → Checking ATF level and
Co
Cop py
topping up ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note

4.5 Automatic gearbox 09G: changing ATF
Note
In particularly hot climates ⇒ page 28 , a transmission fluid change

of the 09G gearbox must be performed. The deterioration of
transmission fluid in these climatic conditions is especially high.
Procedure
– Power transmission/automatic gearbox ⇒ Rep. gr. 37 →
Checking ATF level and topping up/Draining and filling ATF
4.6 Battery: checking battery terminal

clamps for secure seating
Touran 2003 ➤
♦ Torque wrench - V.A.G 1331-
AG. Volkswagen AG d
agen
Note Volksw
oes
not
gu
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♦ A securely seated battery terminal clamp ensuresuthor
trouble free eo
ra
function and long service life of the battery.
ss a c
ce
e
♦ When securing the terminal clamp, ensure it is located fully on

nl
pt
du
an
the battery terminal.
itte
y li
erm
ab
ility
ot p
Battery in engine compartment
wit
, is n
h re
Carry out following procedure:
hole
spec
– Open battery cover, if fitted.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
– Check whether battery terminal clamps are secure on battery

f
en
ng
terminals by moving battery negative clamp and battery posi‐

t.
yi Co
op
tive clamp back and forth. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
WARNING cted agen
Prote AG.
If the battery terminal clamp is not seated securely on the bat‐

tery positive terminal, first disconnect battery terminal clamp
on battery negative terminal to prevent possible accidents.
If the battery terminal clamp is NOT seated securely on positive

terminal:
Touran 2003 ➤
– Loosen the -NEGATIVE- battery terminal clamp and remove.
– Tighten -POSITIVE- terminalwaclamp

gen AG to 6 Nm using
. Volkswagen AG torque
doe
wrench - V.A.G 1331- and
yV
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s
- V.A.G. 1331/1- .s not gu
b ara
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oris e
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Reconnect -NEGATIVE- terminal clamp and tighten it to 6 Nm
using torque wrench - V.A.G 1331- and ratchet - V.A.G.
rrectness of i
1331/1- .
l purpos
If battery terminal clamp is NOT seated securely on negative ter‐

minal:
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
– Tighten -NEGATIVE- terminal clamp on battery terminal to
t. rig
gh ht
yri
6 Nm using torque wrench - V.A.G 1331- and ratchet - V.A.G. p by
co Vo
lksw
1331/1- .
by
cted agen
Prote AG.
Touran 2003 ➤
– Reinstall cover, if fitted.

After connecting battery perform the following work steps:
Procedure
Vehicle electrics → Electrical system ⇒ Rep. gr. 27 → Discon‐
necting and connecting battery → Connecting battery → Work
steps after connecting battery
cedure manually in the information. gen AG
. Volkswagen AG
wa does
olks not
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ris
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4.7 Battery: checking with battery tester and au ra
ss c
ce
printer VAS 6161
le
un
pt
an
d
itte
y li
Procedure
erm
ab
ility
ot p
Vehicle electrics → Electrical system, General information ⇒ Rep.
wit
is n
gr. 27 → Checking battery
h re
ole,
spec
Note
t to the co
rrectne
ss o
4.8 Status of battery: reading, sending diag‐
cial p
f inform
nosis protocol online
mer
atio
om
n
c
i
or
n thi
Note
te
sd
iva
o
pr
cum
r
Applies only to vehicles with start/stop and energy recovery sys‐

fo
en
ng
tem
t.
yi Co
Cop py
ht. rig
rig ht
Procedure py by
co Vo
by lksw
cted agen
The battery status is read while the transportation mode is being Prote AG.
switched off ⇒ page 156 .
4.9 Tyres: checking condition, wear pattern,

tyre pressure and tread depth
Checking condition of tyre ⇒ page 49 .
Checking wear pattern ⇒ page 49
Tread depth (including spare wheel): check ⇒ page 50 .
General notes ⇒ page 50
Tyre pressures for Touran ⇒ page 51
Tyre pressures for Touran "Cross" ⇒ page 56
Touran 2003 ➤
♦ Tyre inflator - VAS 5216-
AG. Volkswagen AG d
agen oes
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ility
ot
wit
4.9.1 Tyres: checking condition
, is n
h re
hole
spec
es, in part or in w
WARNING
t to the co
If damage is determined, always check to see if a new tyre
should be fitted.
rrectness of i
l purpos
Tests at delivery inspection
nform
ercia
– Check tyre side walls and treads for damage and foreign bod‐
ies such as, for example, nails or glass splinters.
m
a
com
tion in
Tests at service
r
te o
thi
– Check tyre side walls and treads for damage and foreign bod‐
s
iva
do
ies such as, for example, nails or glass splinters.
r
rp
cum
fo
en
g
– Check tyres for cupping, one-sided wear, porous side walls,

n
t.
yi Co
op
cuts and punctures. C py
ht. rig
rig ht
by
– Check for appropriate direction of rotation, or make sure that copy Vo
by lksw
the inner and outer sides have not been interchanged. cted agen
Prote AG.
4.9.2 Wear pattern: checking

The wear pattern on the front tyres will indicate, for example, if
toe and camber settings should be checked:
♦ Feathering on tread indicates incorrect toe setting.
♦ One-sided tread wear is mainly attributed to incorrect camber.
When wear of this nature is detected, determine cause by check‐
ing alignment (repair measure).
Touran 2003 ➤
4.9.3 Tyre tread depth (including spare

wheel): checking
– Check tyre tread depth.
Minimum tread depth: 1.6 mm
Note
♦ This figure may vary according to legislation in individual coun‐

tries.
♦ The minimum tread depth is reached when the tyres have
worn down level with the 1.6 mm high tread wear indicators
-arrows- positioned at intervals around the tyre.
♦ If the tread depth is approaching the minimum allowed depth,
inform the customer.
4.9.4 General information
WARNING AG. Volkswagen AG d

agen oes
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V gu
♦ For safety reasons, only tyres of same type d b and tread pat‐
y ara
ise nte
tern should be fitted on a vehicle! Approved
thor wheel and tyre eo
combinations, e.g. ⇒ Running gear; s a Rep. gr. 44 ; Touran
u ra
c
as of model year 2003 s
ce
le
un
pt
♦ On four-wheel drive vehicles, tyres of the same type and
an
d
itte
y li
tread pattern must be used. Otherwise the centre differ‐
erm
ab
ential may be damaged.
ility
ot p
wit
is n
h re
ole,
spec
Note
t to the co
♦ Tyre pressures for the relevant model can also be found on a
sticker. It is attached to the inside of tank flap or to B-pillar.
rrectne
♦ The pressures on the sticker apply to cold tyres. Do not reduce

s
increased pressures of warm tyres.

s o
cial p
f i
♦ Depending on the vehicle, the sticker may also contain infor‐

nform
mation on the comfort tyre pressure. The comfort tyre pressure

mer
facilitates improved driving comfort.

atio
om
n
c
♦ Driving with comfort tyre pressure may result in an increased

or
n thi
e
fuel consumption.
t
sd
iva
o
pr
♦ Adjust the tyre pressure to suit the vehicle load. For delivery
um
r
fo
en
ng
inspections or repairs, the partial load tyre pressure is to be

t.
yi Co
used. Cop py
t. rig
gh ht
yri
♦ If no inflation pressure is shown for the spare wheel, then in‐ p by
co Vo
flate the spare wheel to the highest inflation pressure for the
by lksw
cted agen
Prote
vehicle.
AG.
♦ Please note that basic setting should be performed on vehicles

with Tyre Pressure Loss Indicator after every pressure change
⇒ page 117 .
Touran 2003 ➤
M+S tyres
Note
♦ Important information on recommended winter tyres can be

found in Wheels and Tyres Guide - Standard → ⇒ Running
gear; Rep. gr. 44 ; Recommended winter tyres → Recom‐
mended winter tyres.
♦ If winter tyres are fitted, a sticker, visible for the customer and
indicating the speed limit, must be applied in the interior of the
vehicle.
♦ For winter tyres, the tyre pressure does not have be increased.
However, this only applies if the winter tyre used corresponds
exactly to the standard summer tyre size and the speed index
is no higher than “H”. If this is not the case, please refer to the
recommendation of the tyre manufacturer.
Note

cedure manually in the information. olkswage es n
o
yV t gu
db ara
ise nte
4.9.5 Tyre pressures for Touran
r
tho eo
au ra
c
ss
ce
e
nl
pt
du
Note
an
itte
y li
erm
ab
ility
♦ During delivery inspection, check that tyre inflation pressure
ot p
sticker is fitted. If the sticker is missing, order a new sticker wit

, is n
through ETKA. h re
hole
spec
♦ The mandatory tyre pressures for the respective model can be
es, in part or in w
t to the co
found on a sticker attached to the inside of tank flap or to the

B-pillar.
♦ If the inflation pressure sticker is missing, proceed as follows:
rrectness of i
♦ Locate correct part number for respective vehicle in ETKA.

l purpos
♦ Using part number, determine respective inflation pressures

in tyre inflation table.
nf
ercia
orm
♦ Uniform pressure: if tyre sizes are not shown for a part number,
m
atio
m
then a uniform pressure is valid for all authorised wheel/tyre

o
n in
c
combinations. ⇒ Wheels and Tyres Guide - Standard; Rep.

or
thi
gr. 44
te
sd
iva
o
r
rp
cu
o
Check tyre pressure using tyre inflator - VAS 5216- , correct if

f
en
ng
t.
necessary.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Touran 2003 ➤
Part number - 1T0 010 742- Touran

. Volkswagen AG
Part number - 1T0 010 741 G- agen AG does
olksw not
V gu
Part number - 1T0 010 756 A- d by ara
rise nte
o
Part number - 1T0 010 808 P- auth eo
ra
s c
Part number - 1T0 010 000- s
ce
e
nl
pt
du
Part number - 1T0 010 000 G-
an
itte
y li
Part number - 1T0 010 644 E-
erm
ab
ility
ot p
Part number - 1T0 010 000 P-
wit
, is n
h re
Half payload Full payload
hole
kPa/bar/psi kPa/bar/psi
spec
es, in part or in w
Tyre size Front Rear Front Rear
t to the co
All 1) 230/2.3/33 230/2.3/33 250/2.5/36 300/3.0/44
rrectness of i
1) Valid for all authorised wheel/tyre combinations. ⇒ Wheels and
Tyres Guide - Standard; Rep. gr. 44
l purpos
nform
ercia
Part number - 1T0 010 742 A- Touran

m
at
om
i
Part number - 1T0 010 741 H-
on
c
in t
or
his
ate
do
priv
cum
or

f
en
ng
t.
yi
250/2.5/36 250/2.5/36 270/2.7/39 300/3.0/44
Co
All 1) t. Cop py
rig
gh ht
yri by
cop Vo
by lksw
cted agen
Prote AG.
Part number - 1T0 010 742 C- Touran

All 1) 270/2.7/39 270/2.7/39 290/2.9/42 300/3.0/44
Part number - 1T0 010 742 E- Touran

All 1) 280/2.8/41 280/2.8/41 280/2.8/41 300/3.0/44
Touran 2003 ➤
Part number - 1T0 010 741 S- Touran

All 1) 270/2.7/39 270/2.7/39 290/2.9/42 300/3.0/44
1) Valid for all authorised wheel/tyre combinations. AG. Volkswagen AG d
ksw ⇒ Wheels and
agen oes
l not
Tyres Guide - Standard; Rep. gr. 44 by Vo gu
ara
d
rise nte
tho eo
au ra
ss c
Part number - 1T0 010 764 L- Touran
ce
e
nl
pt
du
an
Part number - 1T0 010 764 R-
itte
y li
erm
ab
ility
ot p
Part number - 1T0 010 000 D-
wit
, is n
h re
Part number - 1T0 010 000 L-
hole
spec
Part number - 1T0 010 000 S-
es, in part or in w
t to the co
rrectness of i
All 1) 250/2.5/36 250/2.5/36 270/2.7/39 310/3.1/45
l purpos
nform
ercia

m
at
om
ion
c
in t
or
his
e
Part number - 1T0 010 749 L- Touran

at
do
riv
Part number - 1T0 010 742 F-

p
cum
for
en
g

n
t.
yi Co
op py
Part number - 1T0 010 808 S- t. C rig
gh ht
yri by
Part number - 1T0 010 000 A- cop Vo
by lksw
cted agen
Prote AG.
Part number - 1T0 010 000 Q-

All 1) 240/2.4/35 240/2.4/35 260/2.6/38 300/3.0/44
Part number - 1T0 010 764 M- Touran

Part number - 1T0 010 764 T-
Part number - 1T0 010 809-
Part number - 1T0 010 000 B-
Part number - 1T0 010 000 J-
Part number - 1T0 010 000 AB-
All 1) 250/2.5/36 250/2.5/36 280/2.8/41 320/3.2/46
Touran 2003 ➤

Part number - 1T0 010 764 N- Touran

Part number - 1T0 010 808 M-
All 1) 270/2.7/39 270/2.7/39 290/2.9/42 320/3.2/46
Part number - 1T0 010 742 D- Touran

Part number - 1T0 010 808 Q-
AG. Volkswagen AG d
agen oes
All 1) 260/2.6/38 260/2.6/38
Volksw 260/2.6/38not
gu
300/3.0/44
d by ara
ise nte
1) Valid for all authorised wheel/tyre combinations.
hor
⇒ Wheels and eo
ut ra
Tyres Guide - Standard; Rep. gr. 44 ss a c
ce
e
nl
pt
du
an
itte
y li
erm
ab
Part number - 1T0 010 764 P- Touran
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
Tyre size Front Rear Front Rear t to the co
All 1) 270/2.7/39 270/2.7/39 270/2.7/39 300/3.0/44

rrectness of i

l purpos
nform
ercia
Part number - 1T0 010 764 Q- Touran

m
at
om
io
Part number - 1T0 010 808 N-

n
c
in t
or

his
ate
do
priv
cum
or

f
en
ng
t.
yi Co
1) 280/2.8/41 280/2.8/41 280/2.8/41 320/3.2/46
op
All C py
t. rig
gh ht
yri by
1) Valid for all authorised wheel/tyre combinations. ⇒
p
Wheels and
o Vo
by c lksw
cted
agen
Prote AG.
Part number - 1T0 010 391 G- Touran

All 1) 260/2.6/38 260/2.6/38 290/2.9/42 300/3.0/44
Touran 2003 ➤
wage es n
Part number - 1T0 010 391 G- yV
olks
Touran
ot g
ua
b
ed ran
Halfor payload
is Full
tee payload
ukPa/bar/psi kPa/bar/psi
th or
a ac
ss
ce
le
un
pt
an
Emergency spare 415/4.2/61
d
itte
y li
tyre
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Part number - 1T0 010 000 C- Touran
Part number - 1T0 010 000 K-
rrectness of i
l purpos

nform
ercia

m
a
All 1) 260/2.6/38 260/2.6/38 280/2.8/41 320/3.2/46
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
Part number - 1T0 010 000 E- gh
Touran
ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
All 1) 260/2.6/38 260/2.6/38 290/2.9/42 330/3.3/48
Part number - 1T0 010 000 F- Touran

Part number - 1T0 010 000 AA-
All 1) 280/2.8/41 280/2.8/41 300/3.0/44 340/3.4/49
Touran 2003 ➤
4.9.6 Tyre pressures for Touran "Cross"
Note
♦ During delivery inspection, check that tyre inflation pressure

sticker is fitted. If the sticker is missing, order a new sticker
through ETKA.
♦ The mandatory tyre pressures for the respective model can be
found on a sticker attached to the inside of tank flap or to the
B-pillar.
♦ If the inflation pressure sticker is missing, proceed as follows:
♦ Locate correct part number for respective vehicle in ETKA.
♦ Using part number, determine respective inflation pressures
in tyre inflation table. AG. Volkswagen AG d
agen oes
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Uniform pressure: if tyre sizes are notbshown for a part number,
l not
♦ yV
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ara
then a uniform pressure is valid ofor
ris all authorised wheel/tyre
ed
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combinations. ⇒ Wheels andauTyresth Guide - Standard; Rep. eo
ra
gr. 44 ss c
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nl
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an
Check tyre pressure using tyre inflator - VAS 5216- , correct if
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Part number - 1T0 010 741 T- Touran "Cross"
wit
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spec
es, in part or in w
t to the co
rrectness of i
All 1) 230/2.3/33 230/2.3/33 250/2.5/36 300/3.0/44
l purpos

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Part number - 1T0 010 749 J- Touran "Cross"

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Tyre size Front cted
Rear Front Rear
agen
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All 1) 250/2.5/36 250/2.5/36 270/2.7/39 300/3.0/44

Part number - 1T0 010 749 K- Touran "Cross"

All 1) 270/2.7/39 270/2.7/39 290/2.9/42 300/3.0/44
Touran 2003 ➤

Part number - 1T0 010 749 L- Touran "Cross"

Part number - 1T0 010 811 A- n AG. Volkswagen AG do
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Half payloady Volks oFull
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kPa/bar/psi ed
b
kPa/bar/psi
ara
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Tyre size Front au
th
Rear Front ra Rear
ss c
All 1) 240/2.4/35 240/2.4/35 260/2.6/38 300/3.0/44
ce
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1) Valid for all authorised wheel/tyre combinations. ⇒ itte
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Wheels and
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spec
4.10 Brake and clutch system: changing
t to the co
brake fluid
rrectne
♦ Torque wrench - VAS 6854-
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
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cted agen
Prote
♦ Brake filling and bleeding equipment - VAS 5234-
AG.
Touran 2003 ➤
♦ Brake filling and bleeding equipment - VAS 6860-
♦ Brake bleeding tool - VAS 6564-
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WARNINGutho
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♦ Never allow brake fluid to come into contact with fluids that
ce
le
un
pt
contain mineral oils (e.g. oil, petrol, cleaning agents). Min‐

an
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eral oils will damage seals and rubber grommets of brake

rm
ab
system.
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ility
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♦ Brake fluid is poisonous. In addition, due to its corrosive

h re
nature, it must not come into contact with paint.

hole
spec
♦ Brake fluid is hygroscopic, which means it absorbs mois‐

es, in part or in w
t to the co
ture from the ambient air and should therefore always be

stored in air-tight containers.
♦ Rinse off spilled brake fluid using plenty of water.
rrectness of i
♦ Do not reuse extracted (used) brake fluid!

l purpos
♦ Observe relevant disposal regulations.

nform
mercia
Extracting brake fluid

com
tion in
r
– Unscrew cap -1- from brake fluid reservoir.

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Touran 2003 ➤
– Using the suction hose from brake filling and bleeding unit ,
extract as much brake fluid -2- from the brake fluid reservoir
as possible through the strainer -1-.
Note
♦ The strainer in brake fluid reservoir must remain in place.

♦ Ensure that no brake fluid runs through the strainer after com‐
pleting the extraction (the brake fluid level in the reservoir must
be even with the lower edge of the strainer).
Connecting brake filling and bleeding equipment
– Screw adapter -1- ontoGbrake fluid reservoir.

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nA n AG d
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– Connect filler Vohose
lks from brake filling ands bleeding
not
gu unit to
by
adapterise-1-.
d ara
n
r tee
tho
– Set
sa
ucorrect pressure on brake filling and bleeding equipment
or
ac
⇒ Operating Manual , and switch on brake filling and bleeding
s
ce
le
equipment .
un
pt
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♦ The bleeder hose must be firmly seated on bleeder valve so
hole
spec
that no air can enter the brake system.

es, in part or in w
t to the co
♦ There must always be sufficient brake fluid in the brake res‐

ervoir so that no air can enter the brake system through the
reservoir.
rrectness of i
Front axle
l purpos
– Remove cover cap -1- from bleeder valve of front left brake
nform
ercia
caliper.
m
a
com
tion in
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Cop py
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cted agen
Prote AG.
– Push collector bottle bleeder hose -1- onto front left bleeder
valve, open bleeder valve and let appropriate quantity of brake
fluid run out (see table). Close bleeder valve. Torque: Running
gear → Brake systems ⇒ Rep. gr. 47 → Repairing front brake
caliper.
– Fit again cover cap on bleeder valve of front left brake caliper.
Repeat procedure on right-hand side of vehicle at front.
Rear axle
– If necessary, remove both wheels on rear axle to reach the
bleed screw.
Touran 2003 ➤
– Remove cover cap -1- from bleeder valve of rear left brake
caliper.
– Push collector bottle bleeder hose -1- onto rear left bleeder
valve.
– Open bleeder valve and let appropriate quantity of brake fluid
run out (see table). Close bleeder valve. Torque: Running gear
→ Brake systems ⇒ Rep. gr. 47 → Repairing rear brake caliper.
– Fit again cover cap on bleeder valve of rear left brake caliper.
– Repeat procedure on right-hand side of vehicle at rear.
Bleeding clutch slave cylinder
AG. Volkswagen AG d
agen oes
ksw
Note byV
ol not
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ara
ed
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Applies only ato
ut vehicles with manual gearbox.
h
ra
ss c
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nl
Remove air filter housing if necessary.

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Procedure
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ility
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– Power unit ⇒ Rep. gr. 23 → Diesel direct injection system →

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Assembly overview - air filter

h re
hole
spec
Or
es, in part or in w
t to the co
– Power unit ⇒ Rep. gr. 24 → Injection system → Removing and

installing air filter.
rrectness of i
Note
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ercia
or

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– Push bleeder hose onto bleeder valve -arrow- of clutch slave

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sd
a
cylinder -1-.
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– Open valve and allow approx. 50 ml of brake fluid to flow out.

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– Close valve and depress clutch pedal 10 to 15 times quickly
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in succession. rig ht
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by lksw
– Open valve again and allow approx. 50 ml of brake fluid to flow cted agen
Prote AG.
out.
– Close valve, remove bleeder hose and depress clutch pedal
several times.
– Install air filter housing accordingly in reverse order.
Sequence and quantity of brake fluid
Touran 2003 ➤
Sequence Brake fluid quantity

bleeder valves: which must flow out of bleeder valves:
Brake caliper agen

AG. Volkswagen AG d
oes
olksw not
d by
V Front left gu
ara 0.20 l
ise nte
ut
hor
Front right eo 0.20 l
a ra
Wheel brake cylinder/brake caliper ss c
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un
Rear left 0.30 l
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Rear right 0.30 l
rm
ab
pe
ility
Clutch slave cylinder 0.15 l
ot
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Total quantity for automatic gearbox including approx. 1.00 l
h re
hole
the quantity extracted from the brake fluid res‐
spec
ervoir
es, in part or in w
t to the co
Total quantity for manual gearbox including the approx. 1.15 l
quantity extracted from the brake fluid reservoir
rrectness of i
l purpos
– Switch off brake filling and bleeding unit .

– Take filler hose off adapter.
nform
ercia
– Unscrew adapter from brake fluid reservoir.

m
a
com
tio
– Check brake fluid level and correct if necessary. It must be
n in
r
between position -1- and -2-.

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Prote AG.
– Screw on cap -1- of brake fluid reservoir.

– Reinstall rear wheels, if removed previously ⇒ page 113 .
– Perform functional check during road test.
4.11 Brake fluid level: checking
WARNING
If fluid level is below MIN. marking -2-, the brake system should
be checked before fluid is topped up “Repair measure”
Operation and safety notes ⇒ page 57
Touran 2003 ➤
Brake fluid specification. ⇒ page 57

Procedure, brake fluid level (dependent upon lining/pad wear):
checking ⇒ page 62
4.11.1 Procedure, brake fluid level (dependent

upon lining/pad wear): checking
Brake fluid level at delivery inspection:
– For the delivery inspection the fluid level must be at MAX.
marking -1-.
Note
In order that brake fluid does not overflow the reservoir, MAX
marking -1- must not be exceeded.
Brake fluid level at inspection service

The fluid level must always be judged in conjunction with lining/
pad wear.
When vehicle is in use, fluid level tends to drop slightly due to
lining/pad wear and automatic adjustment.
• Recommended brake fluid level, if brake pads are almost at
wear limit:
“At MIN marking or just above” -2-, “REPLENISHING IS NOT

REQUIRED”.
• Recommended brake fluid level when brake pads are new or
well within pad wear limit:
“Between MIN and MAX marking”.
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nl
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erm
4.12 Brake system and shock absorbers: in‐

ab
ility
ot p
specting for leaks and damage

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hole
Check following components for leaks and damage:

spec
es, in part or in w
♦ Brake master cylinder

t to the co
♦ Brake servo (for anti-lock brake system: hydraulic unit)

rrectness of i
♦ Brake pressure regulator and

l purpos
♦ Brake caliper
♦ Shock absorbers (during inspection only)
nform
ercia
♦ Presence of dust caps on brake fluid bleeder screws

m
at
om
♦ Presence of caps on guide bushes

on
c
in t
or
– Ensure that brake hoses are not twisted.

his
ate
do
riv
– Additionally ensure that brake hoses do not touch any vehicle

p
cum
or
components when steering is at full lock.

f
en
ng
t.
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op
– Check brake hoses for abrasion, porosity and brittleness.
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– Check brake lines for corrosion. cop Vo
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Prote AG.
Touran 2003 ➤
AG . Volkswage
– Check brake connections and fastenings
ksw
agen for correct seating,
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ise
– Check brake lines and brake
ut
ho
r
hoses for correct seating and tee
or
attachment in retainers.
ss a ac
ce
e
nl
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an
WARNING itte
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erm
ab
ility
Faults found must always be rectified (repair measure).
ot p
wit
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hole
spec
4.13 Brakes, front and rear: checking thick‐
es, in part or in w
t to the co
ness of brake pads and condition of
brake discs
rrectness of i
Front disc brake pads: checking thickness ⇒ page 63
l purpos
Rear disc brake pads: checking thickness ⇒ page 64

Brake discs: checking condition ⇒ page 65
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ercia
orm
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or c
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Cop py
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cted agen
Prote AG.
♦ Electric hand torch and mirror

The adapter to loosen and tighten the anti-theft wheel bolts can
be found in the vehicle tool kit ⇒ page 113 .
4.13.1 Front disc brake pads: checking thick‐

ness
– For better evaluation of remaining pad thickness, use a test
mirror and, if necessary, remove the wheel on the side where
the brake pad wear indicator is installed.
– Pull off wheel bolt covers if necessary ⇒ page 113 .
– Mark position of wheel relative to brake disc.
– Unbolt wheel bolts and remove wheel.
Touran 2003 ➤
– Measure thickness of inner and outer pads.

a - Pad thickness “without” backplate
Wear dimension: 2 mm
The brake pads have reached their wear limit at a pad thickness
of 2 mm (without backplate) and must be renewed (repair meas‐
ure). Inform customer!
Note
. Volkswagen AG
gen AG does
swa
♦ When replacing brake pads, always yV
olk check brake discs as well not
gu
for wear! ised b ara
nte
or eo
h
♦ Checking and if necessary
s aut replacing the brake discs is a repair ra
c
measure. s
ce
le
un
pt
an
d
itte
– Check brake disc for wear. Procedure: Brake systems ⇒
y li
erm
ab
Brake systems; Rep. gr. 46 ; Repairing front brakes → Re‐
ility
ot p
pairing front brakes
wit
is n
h re
ole,
spec
Note
t to the co
rrectne
– Install wheel in marked position.
ss o
cial p
f
– Tighten wheel bolts diagonally and alternately, specified tor‐
que ⇒ page 113 . inform
mer
atio
m
– Place adapter in vehicle tool kit after completing work.

o
n
c
i
or
– Fit wheel bolt covers if necessary .

thi
te
sd
iva
o
pr
cum
r
4.13.2 Rear disc brake pads: checking thick‐

fo
en
ng
t.
yi
ness
Co
Cop py
ht. rig
rig ht
– Illuminate area behind hole in rim using an electric hand torch.
py by
co Vo
by lksw
cted agen
– Inspect outer pad to determine thickness.
Prote AG.
– Illuminate inner pad with an electric hand torch and mirror.

– Inspect inner pad to determine thickness.
a - Inner and outer pad thickness without backplate
Permissible brake pad thickness (only rear axle)

Mileage for brake pads in km 30,000 60,000 90,000
Brake pad thickness at mm 6,0 5,0 4,0
least
If brake pad thickness (without backplate) is below the values

shown in the table, renew brake pads (repair measure). In this
Touran 2003 ➤
case it can be assumed, that the brake pad thickness is below the
permissible value at a further mileage of max. 30,000 km. Inform
the customer of this, because it can be prevented to take the ve‐
hicle to the workshop between the inspections.
Note
When replacing brake pads, always check brake discs as well for
wear! Checking and if necessary replacing the brake discs is a
repair measure.
– Check brake disc for wear. Procedure: Brake systems ⇒

Brake systems; Rep. gr. 46 ; Repairing rear brakes → Repair‐
ing rear brakes
Note

cedure manually in the information. en AG. Volkswagen AG
ag does
ksw not
y Vol gu
4.13.3 Brake discs: checking condition
b ara
ed nte
oris eo
th
au ra
Check all brake discsssfor the following damage pattern: c
ce
e
nl
♦ Cracks
pt
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♦ Scoring
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ility
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♦ Rust (no surface rust)

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♦ Burrs on circumference of brake disc h re

hole
spec
es, in part or in w
t to the co
Note
Inform customer if brake disc damage is similar to these damage

rrectness of i
patterns. Renewing the brake discs is a repair measure.

l purpos
4.14 Diesel particulate filter: checking

nf
ercia
or
– Check ash loading ⇒ Vehicle diagnostic tester.

m
m
atio
m
4.15 Dual clutch gearbox 02E: changing gear

o
n in
or c
thi
oil and filter

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Procedure
o
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f
en
ng
t.
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Power transmission ⇒ Rep. gr. 34 t. Cop py
rig
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Note cted agen
Prote AG.

Touran 2003 ➤
4.16 Electric windows: checking positioning

(open and close functions)
Note n AG. Volkswagen AG do

lks wage es n
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byV ua
ed ran
The automatic opening and closing features for the or electric win‐
is tee
dows do not function after disconnecting and reconnecting the
th or
au ac
battery. Therefore, with immediate effect, before a new vehicle is
ss
ce
le
delivered, the window regulators must be reactivated. Once the
un
pt
windows have been reactivated, the battery must not be discon‐
an
d
itte
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nected again. erm
ab
ility
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WARNING
ole,
spec
After batteries have been disconnected and reconnected the
t to the co
roll-back function of the electric window regulators is disabled.
Severe pinching injuries could result!
rrectne
Carry out the following procedure to reactivate the automatic
ss
functions of the window regulators:
o
cial p
f inform
mer
Note
atio
om
n
c
i
or
n
The following work description applies to the front left window
thi
te
regulator. Reactivate the other window automatic functions in the
sd
iva
o
r
same manner by operating the respective switch in the driver

p
cum
r
fo
door.
en
ng
t.
yi Co
Cop py
. rig
t
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pyri by
Vo
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– Close all doors and windows completely.
by
cted agen
Prote AG.
– Hold the front left side window in “closed” position, by pulling
and holding switch (for longer than 1 second).
– Pull switch again for 1 second. The side window must now go
up or down by itself when switch is briefly pulled or pressed.
– Switch off ignition.
4.17 Fault memory of all systems: reading

with vehicle diagnostic tester , correct‐
ing possible faults according to repair
guidelines
– Read event memory ⇒ Vehicle diagnostic tester.
– Repair all faults according to repair guidelines.
Caution
The vehicle must always be delivered to the customer with

event memory cleared.
Static faults
If one or more static faults are found in the event memory, we
recommend seeking agreement from the customer to rectify
these faults using Guided Fault Finding.
lkswage es n
o ot g
byV ua Touran 2003 ➤
d ran
ir se
tho tee
or Maintenance - Edition 01.2019
au ac
ss
Sporadic faults
ce
le
un
pt
an
d
If only sporadic faults or notes are stored in the event memory
itte
y li
rm
and the customer has no complaints regarding the electronic ve‐
ab
pe
ility
hicle system, erase event memory.
ot
wit
, is n
4.18 Front passenger airbag: checking key
h re
hole
spec
switch and “On/Off function”
es, in part or in w
t to the co
Note
rrectness of i
The “Airbag ON/OFF” switch is located in the glove compartment.
l purpos
Front passenger front airbag: checking key switch and “ON/OFF
nform
ercia
function” version 1 ⇒ page 67

m
a
Front passenger front airbag: checking key switch and “ON/OFF
com
tion in
function” version 2 ⇒ page 68
r
te o
thi
4.18.1 Front passenger front airbag: checking
s
iva
do
r
rp
cum
key switch and “ON/OFF function”, ver‐
fo
en
ng
t.
yi
sion 1
Co
Cop py
t. rig
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Front passenger front airbag: check key switch and “ON/OFF
p by
co Vo
lksw
function”
by
cted agen
Prote AG.
– Using ignition key, turn key switch to position “Airbag Off”

-arrow-. The key slot must point in the direction of travel (for‐
wards).
– Switch on ignition. Warning lamp “passenger airbag off”

-arrow- must also light up after self-test (passenger airbag de‐
activated).
Touran 2003 ➤
– Using ignition key -arrow-, turn key switch to position “Airbag

ON”. The key slot must be horizontal (point to sides of vehicle).
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
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un
pt
an
d
itte
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rm
ab
pe
ility
– Switch on ignition. Warning lamp “Passenger Airbag Off”
ot
wit
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-arrow- goes out after self-test (passenger airbag activated).
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
4.18.2 Front passenger front airbag: checking

r
te o
thi
key switch and “ON/OFF function”, ver‐

s
iva
do
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sion 2
um
fo
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ng
t.
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op
Front passenger front airbag: check key switch and “ON/OFF C py
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– Using ignition key, turn switch to “AIRBAG OFF” position. The
Prote
cted AG.
agen
key slot must point in the “OFF” position.
– Switch on ignition. Warning lamp “passenger airbag off”

-arrow- must also light up after self-test (passenger airbag de‐
activated).
Touran 2003 ➤
– Turn switch to “AIRBAG ON” position using ignition key. The

key slot must point in the “ON” position.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
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itte
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– Switch on ignition. Warning lamp “Passenger Airbag Off”
erm
ab
-arrow- goes out after self-test (passenger airbag activated).
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
4.19 Bonnet catch hook: grease.

atio
om
n
c
i
or

thi
te
sd
va
♦ Universal oil spray G 000 115 A2

i
o
pr
cum
r
fo
en
ng
t.
yi Co
op
Note
C py
t. rig
gh ht
pyri by
Vo
o
by c
Vehicle must be at least at room temperature.
lksw
cted agen
Prote AG.
Applies only to vehicles up to ► 2010

– Lubricate bonnet arrester with universal oil spray G 000 115
A2 at points marked with -arrows-.
– Operate moving parts several times so that universal oil is able
to penetrate.
– Remove any excess lubricant using a lint-free cloth.
4.20 Boots: inspecting

– Check outer and inner boots -arrows- for leaks and damage.
Touran 2003 ➤
– Ensure clamps -1- are fitted on boots.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
4.21 Interior and exterior body: inspecting for ss aut ra
c
corrosion with doors and flaps open
ce
e
nl
pt
du
an
itte
y li
Test locations
erm
ab
ility
ot p
♦ Sliding roof frame
wit
, is n
♦ Inner and outer door frame
h re
hole
spec
♦ Area around trim strips
es, in part or in w
t to the co
♦ Windscreen roof edge
♦ Outer and inner A-pillar
rrectness of i
♦ Bonnet
l purpos
♦ Wheel arches
♦ Inner and outer tailgate
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ercia
orm
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o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh
4.22 Poly V-belt: renewing
ht
pyri by
Vo
o
by c lksw
cted agen
Procedure
Prote AG.
⇒ Rep. gr. 13 ; Cylinder block belt pulley end; Removing and

installing poly V-belt
Note

4.23 Poly V-belt: check condition

– Remove engine cover panel if necessary ⇒ page 88 .
– Crank engine at vibration damper on pulley using a socket.
Touran 2003 ➤
Check poly V-belt -1- for:

♦ Sub-surface cracks (cracks, core ruptures, cross sectional
breaks)
♦ Layer separation (top layer, cord strands)
♦ Base break-up
♦ Frayed cord strands
♦ Flank wear (material wear, frayed flanks, flank brittleness -
glassy flanks-, surface cracks)
♦ Traces of oil and grease
Note
If faults are found, it is essential for the poly V-belt to be renewed.

This can avoid breakdowns and malfunctions. The replacement
of a poly V-belt is a repair measure.
4.24 Poly V-belt: lkswagadjusting

en AG. V tension
olkswagen AG
does on en‐
not
gines
ise
d bwithout
y Vo
automatic tensioning gu
ara roller
n
r tee
ho
Special toolsaand
ut workshop equipment required or
ac
ss
♦ Tensioning arm - 3297-
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Loosen securing bolts -1 + 2-.

nform
ercia
3 - Alternator
m
at
om
ion
4 - Mounting
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Touran 2003 ➤ n AG. Volkswagen AG do
wage es n
yV
olks ot g
b ua
ed ran
ris tee
– Fit tensioning lever, secure th with pin -arrow- and swing
o alter‐ or
au
nator downwards (use torque
ss wrench, for example, as drive ac
for 3297).
ce
le
un
pt
an
d
– Press alternator with tensioning lever to stop of tensioning arm
itte
y li
rm
at least three times, to ensure optimum ease of movement.
ab
pe
ility
ot
– First tighten lower and then upper alternator bolt to 25 Nm.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
4.25 Cooling system: checking frost protec‐
l purpos
tion and coolant level
nform
mercia
a
com
Note
tion in
r
te o
thi
♦ The water used for mixing has a major influence on the effec‐
s
iva
do
tiveness of the coolant. Because the water quality differs from
r
rp
cum
country to country and even from region to region, the quality
fo
en
g
of the water to be used in the cooling system has been speci‐

n
t.
yi Co
op
fied by Volkswagen. Distilled water fulfils all requirements. C py
t. rig
Therefore, only ever use distilled water when mixing coolant
gh ht
yri by
for topping up or renewing coolant.
cop Vo
by lksw
cted agen
Prote AG.
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic parts catalogue (ETKA) . Other coolant additives may
reduce corrosion protection substantially. The resulting dam‐
age could lead to loss of coolant and subsequent severe
damage to the motor.
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
rosion damage as well as scaling. Such additives also raise
the boiling point of the coolant. Therefore, the cooling system
must be filled all year round with a coolant additive.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ Use ONLY refractometer - T10007A- for determining current
anti-freeze value.
♦ Frost protection must be guaranteed down to -25°C as a min‐
imum and, in countries with arctic conditions, down to approx.
-36°C. Increasing the frost protection is permissible only if cli‐
matic conditions require stronger frost protection. It may, how‐
ever, be increased only to a maximum of -48°C. Otherwise,
the cooling effect will be impaired.
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. Frost
protection must be guaranteed down to at least -25°C.
♦ Read off anti-freeze figures for respective replenished coolant
additives.
♦ The temperature read off the refractometer - T10007A- corre‐
sponds the »ice flocculation point«. Flakes of ice may start
forming in the coolant below this temperature.
♦ Never reuse old coolant.
♦ Use only a water/coolant additive mixture as a slip agent for
coolant hoses.
Touran 2003 ➤
4.25.1 Frost protection: checking, replenishing

coolant additive if necessary
♦ Refractometer - T10007 A-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
Read precise value for the following tests at light/dark boundary.
wit
, is n
Using a pipette, place a drop of water on the glass to improve the
h re
hole
readability of the light/dark boundary. The light-dark border can
spec
be clearly recognised on the “WATERLINE”.
es, in part or in w
t to the co
– Check concentration of coolant additive using refractometer -
T10007 A- (refer to operating instructions).
rrectness of i
The scale -1- of the refractometer is calibrated for coolant addi‐
l purpos
tives G12; G12 Plus, G12 Plus Plus and G11.

The scale -2- is only calibrated for coolant additive G13.
nform
ercia
– If frost protection is too low, drain some coolant and add cool‐
m
ant additive. at
om
ion
c
in t
or
his
ate
do
riv
Note
p
cum
for
en
ng
♦ If the currently used coolant additive cannot be determined

t.
yi Co
op
precisely, use the scale -2- for coolant additive G13. C py
t. rig
gh ht
yri by
♦ Please observe disposal instructions! cop Vo
by lksw
cted agen
Prote AG.
– Check coolant additive concentration after road test again.
4.25.2 Coolant level: checking, replenishing

coolant if necessary
– Check coolant level in expansion tank with engine cold.
Touran 2003 ➤
♦ Delivery inspection: coolant level is at least at “MAX marking”.

♦ At delivery inspection, coolant level above “MAX marking”
n AG. Volkis
swagen AG
permissible as well. lkswage does
not
Vo y gu
db ara
♦ The excessive amount of coolant does ris not need to be extrac‐
e nte
utho will decrease after the
ted as the coolant level in new vehicles eo
ra
a
system has been bled. ss c
ce
le
un
pt
♦ Inspection service or inspection: coolant level above “MIN
an
d
marking”. itte
y li
rm
ab
pe
ility
– If coolant is too low, add required amount according to mixture
ot
wit
ratio.
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
If fluid loss is greater than can be expected through normal use,
determine source and rectify (repair measure).
rrectness of i
l purpos
4.25.3 Mixing ratio:
nform
ercia
Caution
m
a
com
tion in
r
Use only distilled water for mixing coolant additives. The use
te o
thi
of distilled water ensures optimum protection against corro‐
s
iva
do
sion.
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
.
Frost protection to Coolant additive Distilled water
t rig
gh ht
yri by
portion
cop Vo
by lksw
cted agen
Prote
-25 °C approx. 40% approx. 60 %
AG.
-36 °C approx. 50 % approx. 50 %
4.26 Diesel fuel filter: renewing
Touran 2003 ➤
Note
♦ There are two different fuel filter systems.

♦ System 1 is fitted with a water extraction plug -1-
⇒ page 75 .
♦ System 2 is “not” fitted with a water extraction plug
⇒ page 77 .
AG. Volkswagen AG d
agen oes
olksw not
4.26.1 Diesel fuel filter: renewing, fuel filter sys‐
V gu
d by ara
ise nte
r
aut
ho
tem with water extraction plug eo
ra
c
ss
ce
e
nl
pt
du
an
itte
♦ Diesel extractor - VAS 5226-
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
♦ Angled screwdriver - VAS 6543-

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
After the diesel fuel filter has been changed, the fuel system must
be bled.
Remove engine cover panel ⇒ page 88 .
Touran 2003 ➤
Removing:
Caution
Do NOT pull fuel hoses off fuel filter cover and do NOT lever gen AG. Volkswagen AG d
at connection. Leaks could occur and the fuel filter upperVopart
lksw
a oes
not
can be damaged. ed by gu
ara
is nte
or
Ensure that no diesel fuel contacts other components in the
th eo
au ra
engine compartment. Clean immediately, if necessary.
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
Please observe disposal instructions!
hole
spec
es, in part or in w
t to the co
Carry out the following procedure:
– Remove water extraction plug -1-.
rrectness of i
– Fit hose of diesel extractor - VAS 5226- onto connector.
l purpos
– Extract about 100 ml diesel fuel using diesel extractor - VAS

5226- .
nform
ercia
– Renew seal of water extraction plug.

m
a
com
t
– Tighten water extraction plug to 3 Nm.
ion in
r
te o
– Remove all securing screws of fuel filter upper part and re‐
thi
s
iva
move fuel filter upper part.
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
Note
by lksw
cted agen
Prote AG.
If upper part of fuel filter is stuck, loosen it as follows:
The fuel filter upper part can be raised at assembly groove

-arrow A- using angled screwdriver - VAS 6543- .
♦ The assembly groove can be of different size, depending on
the type of upper part.
– Insert appropriate side of angled screwdriver - VAS 6543- in
assembly groove -arrow A- and turn angled screwdriver - VAS
6543- .
This will lift the upper part of the fuel filter.
– Remove easy change filter -1- and seal -2- from fuel filter lower
part -4-.
– Renew seal -3-.
Note
Touran 2003 ➤
– Insert new easy change filter into fuel filter lower part.
Caution
Always moisten new seal -1- slightly with diesel fuel to avoid
malfunctions!
– Insert new seal -1- into upper part of diesel fuel filter
-arrows-.
– Place fuel filter upper part with seal properly onto fuel filter
lower part, press on firmly and evenly until the fuel filter upper
part is correctly seated.
Caution
Do NOT tighten bolts for upper part, before it is correctly seated

onto lower part.
– Screw all bolts into fuel filter lower part and tighten hand-tight.
– Then tighten bolts to specified torque of 5 Nm in sequence n AG. Volkswagen AG do
wage
shown. Volks es n
ot g
y ua
db ran
This procedure prevents the seal from being damaged.
ho
ris
e
tee
t or
au ac
Bleeding fuel system ss
ce
e
nl
• There must be sufficient fuel in the tank.

pt
du
an
itte
y li
– Activate fuel pump ⇒ Vehicle diagnostic tester.

erm
ab
ility
ot p
– After the fuel system has been bled, start engine.

wit
, is n
h re
– Allow engine to run for several minutes at mid revs, then switch
hole
spec
engine off again.

es, in part or in w
t to the co
– Read event memory and erase if necessary.

– Carry out a leakage test of the fuel system.
rrectness of i
l purpos
Note
If there is still air in the fuel system, the engine can change to
nform
ercia
emergency running mode during road test. In this case, switch

m
engine off and erase fault memory. Then continue with a road test.
at
om
ion
c
in t
or
his
ate
4.26.2 Diesel fuel filter: renewing, fuel filter sys‐

do
priv
cum
or
tem without water extraction plug

f
en
ng
t.
yi Co
op
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
77
Prote AG.
Touran 2003 ➤
♦ Diesel extractor - VAS 5226-
♦ Angled screwdriver - VAS 6543-
Note
After the diesel fuel filter has been changed, athe fuel
gen AG. Vsystem
olkswagemust
n AG d
oes
be bled. olksw not
yV bgu
ara
ed nte
oris e
Remove engine cover panel ⇒au page 88
th . or
ac
ss
Removing:
ce
e
nl
pt
du
an
itte
y li
erm
Caution
ab
ility
ot p
wit
, is n
♦ Do NOT pull fuel hoses off fuel filter cover and do NOT
h re
lever at connection. Leaks could occur and the fuel filter

hole
spec
upper part can be damaged.

es, in part or in w
t to the co
♦ Ensure that no diesel fuel contacts other components in

the engine compartment. Clean immediately, if necessa‐
ry.
rrectness of i
l purpos
Note
nform
mercia

at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen ATouran 2003 ➤
agen G do
es n
olksw Maintenance - Edition o01.2019
t
y V gu
db ara
rise nte
Carry out the following procedure: aut
ho eo
ra
ss c
– Unscrew all bolts -arrows- from fuel filter upper part and re‐
ce
le
un
move fuel filter upper part.
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Note l purpos
nform
ercia
If upper part of fuel filter is stuck, loosen it as follows:

m
a
com
tion in
The fuel filter upper part can be raised at assembly groove
r
te o
thi
-arrow A- using angled screwdriver - VAS 6543- .
s
iva
do
r
rp
c
♦ The assembly groove can be of different size, depending on
um
fo
the type of upper part.
en
ng
t.
yi Co
op py
– Insert appropriate side of angled screwdriver - VAS 6543- in
. C rig
ht ht
assembly groove -arrow A-, and turn angled screwdriver - VAS
rig by
opy Vo
6543- .
by c lksw
cted agen
Prote AG.
This will lift the upper part of the fuel filter.
– Take filter -3- out of fuel filter lower part.
Touran 2003 ➤
– Remove old seal -2- from fuel filter upper part -1- by levering
seal out of respective groove -arrow-.
Caution
Remove all diesel, dirt and water residues from fuel filter lower
part using diesel extractor - VAS 5226- .
Note
Installing:
– Insert new filter into fuel filter lower part.
AG. Volkswagen AG d
agen oes
olksw not
yV gu
Caution ised b ara
nte
or eo
h
ut ra
Always moisten new seal -1- slightly with diesel fuel to avoid
ss a c
malfunctions!
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
– Insert new seal -1- into upper part of diesel fuel filter
ot
wit
, is n
-arrows-.
h re
hole
spec
– Place fuel filter upper part with seal properly onto fuel filter
es, in part or in w
lower part, press on firmly and evenly until the fuel filter upper
t to the co
part is correctly seated.
Caution
rrectness of i
l purpos
Do NOT tighten bolts for upper part, before it is correctly seated

onto lower part.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Touran 2003 ➤
– Screw all bolts into fuel filter lower part and tighten hand-tight.
– Then tighten bolts to 5 Nm according to sequence shown in
illustration -arrows-.
Caution
This procedure prevents the seal from being damaged.

kswage es n
Bleeding fuel system byV
ol ot g
ua
d ran
ir se
• There must be sufficient fuel tin
h the tank.
o tee
or
au ac
– Activate fuel pump ⇒ Vehicle diagnostic tester. ss
ce
le
un
pt
– After the fuel system has been bled, start engine.
an
d
itte
y li
rm
ab
– Allow engine to run for several minutes at mid revs, then switch
pe
ility
engine off again.
ot
wit
, is n
h re
– Read event memory and erase if necessary.
hole
spec
– Carry out a leakage test of the fuel system.
es, in part or in w
t to the co
Note
rrectness of i
If there is still air in the fuel system, the engine can change to
l purpos
emergency running mode during road test. In this case, switch

engine off and erase fault memory. Then continue with a road test.
nform
mercia
a
4.27 Air filter: cleaning housing and renewing
com
tion in
filter element
r
te o
thi
s
iva
Air filter element: removing and installing, 1.6 l engines do

r
rp
cum
fo
⇒ page 81 .
en
ng
t.
yi Co
op
Air filter element: removing and installing, 2.0 l FSI engines C py
t. rig
⇒ page 83 . gh ht
pyri by
Vo
co lksw
by
Air filter element: removing and installing for vehicles with diesel Prote
cted AG.
agen
engine or 1.4 l TSI engine ⇒ page 83 .
♦ Torque screwdriver - VAS 6494-
4.27.1 Air filter element: removing and instal‐

ling, 1.6 l engine
Removing
– Remove engine cover panel ⇒ page 88 .
Touran 2003 ➤
– Remove bolts -arrow-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
– Remove lower part of air filter -1- and air filter element -2-.
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos
– Clean upper part of air filter.
nform
ercia
Installing
m
at
om
ion
c
in t
or
his
ate
do
riv
– Insert new filter element -3- into lower part of air filter -2-.
p
cum
for
en
ng
t.
yi Co
op py
Note t. C rig
gh ht
pyri by
Vo
co lksw
by
♦ Self-tapping bolts are the standard means of fastening the up‐ Prote
cted AG.
agen
per part of air filter to the lower part of air filter and to the intake
connection. If these bolts are loosened or tightened with a
cordless screwdriver, it is possible that the thread in the upper
part of air filter will be damaged.
♦ For this reason it is only permitted to use a power screwdriver,
if the following prerequisites are fulfilled:
♦ The speed of power screwdriver must be max. 200 rpm.
♦ It must be possible to set a maximum specified torque of 3 Nm.
– Fit lower part of air filter onto upper part of air filter.
– Tighten bolts -arrows- to max. 3 Nm.
Touran 2003 ➤

ling, 2.0 l FSI engines
– Remove the 4 screws -arrows- and remove cover.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
– Pull off retainer -2-.
itte
y li
erm
ab
– Take out used filter element -3-.
ility
ot p
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
– Clean filter housing and install new filter element.
rrectness of i
– Tighten bolt -1- of retainer to 2 Nm and bolts of cover to 3 Nm.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
C py
t. rig
gh ht
yri
ling for vehicles with diesel engine or 1.4
p by
o Vo
by c lksw
cted
l TSI engine
agen
Prote AG.
– Unscrew bolts -arrows-.
– Pull vacuum hose off air filter housing.
Caution
To prevent damage to the connection and to vacuum hose, do

not use sharp-edged tools when pulling hose off.
Touran 2003 ➤
– Remove air filter upper part and take out air filter element -1-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
Checking position of warm air flap le
un
pt
an
d
itte
y li
– Check position of warm air flap -1- in lower part of air filter. The
erm
ab
warm air flap must close completely at temperatures above
ility
ot p
+12°C.
wit
is n
h re
ole,
spec
Note
t to the co
The warm air flap is not installed in all vehicles.
rrectne
– Clean upper part of air filter.
s
– Insert new air filter element and install air filter upper part.
s o
cial p
f inform
– Tighten air filter upper part with bolts -arrows- to 1.6 Nm.
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Touran 2003 ➤
4.28 Multi-purpose additive for diesel fuel:

adding
4.28.1 Specification for using multi-purpose ad‐

ditive for diesel fuel
Note
♦ In the three markets mentioned below there is a particularly

high risk of deposits forming on the injectors and inlet valves
owing to the quality of the fuel.
♦ To counteract the formation of deposits, a multi-purpose ad‐
ditive for diesel fuel must be added.
♦ Only additives compliant with VW 505 26 (multi-purpose ad‐
ditive G 001 790 M3) may be used.
♦ After adding the additive, it is extremely important to fully refuel
the vehicle to achieve optimal effectiveness of the additive.
– During each change oil service, fill entire bottle of multi-pur‐

pose additive for diesel fuel into regular fuel tank.
Country
China India Russia
4.28.2 Recommendation for using multi-pur‐

pose additive for diesel fuel
Note agen
AG. Volkswagen AG d
oes
olksw not
V gu
by ar
In the followingis markets with a high risk of coke and adeposit
d
♦ or
e nte
formation,aut the addition of a multi-purpose additive is recom‐
h eo
ra
mended s owing to the lower concentration of additives in the
s c
diesel fuel.
ce
le
un
pt
an
d
itte
♦ Only additives compliant with VW 505 26 (multi-purpose ad‐

y li
erm
ab

ility
ot p

wit
is n
h re
the vehicle to achieve optimal effectiveness of the additive.

ole,
spec
♦ The multi-purpose additive can also be used in all other mar‐

t to the co
kets that are not listed in the table.
– During each change oil service, fill entire bottle of multi-pur‐

rrectne
pose additive for diesel fuel into regular fuel tank.

Country
ss o
cial p
Afghanistan Mali
inform
mer
Egypt Morocco
atio
m
Albania Mauritania
o
n
c
i
or
Equatorial Guinea Macedonia

thi
te
sd
va
Argentina Moldova
i
o
pr
cum
r
fo
Azerbaijan Myanmar
en
ng
t.
yi Co
Belize Dutch Overseas Territories
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
85
agen
Prote AG.
Touran 2003 ➤
Country
Benin Nigeria
Bhutan Pakistan
Brazil Panama
lkswage es n
o ot g
byV ua
Brunei ir se Paraguay
d ran
tee
tho
or
Burkina Faso au Saudi Arabia ac
ss
Cayman Islands Senegal
ce
e
nl
pt
du
an
Democratic Republic of the Congo Sierra Leone
itte
y li
erm
ab
Dominican Republic Zimbabwe
ility
ot p
El Salvador Sri Lanka and the Maldives
wit
, is n
h re
Ivory Coast South Africa
hole
spec
Fiji Sudan
es, in part or in w
t to the co
Gambia South Sudan
Georgia Surinam
rrectness of i
Ghana Syria
l purpos
Guatemala Thailand
Guinea Togo
nf
ercia
Guinea-Bissau Trinidad and Tobago
orm
m
atio
Guyana Chad
om
n in
c
Haiti Turkmenistan
or
thi
te
sd
Honduras Ukraine
iva
o
r
rp
cu
Indonesia USA
o
m
f
en
ng
t.
yi
Iraq Central African Republic
Co
Cop py
t. rig
Jamaica opyri
gh
Venezuela by
Vo
ht
Jordan Zimbabwe
c by lksw
cted agen
Prote AG.
Cambodia
Cameroon
Canada
Cape Verde
Caribbean, left-hand traffic
Columbia
Laos
Lebanon
Liberia
Touran 2003 ➤
4.29 Multi-purpose additive for petrol fuel:

adding
4.29.1 Specification for using multi-purpose ad‐

ditive for petrol fuel
Note
♦ In the three markets mentioned below there is a particularly

high risk of deposits forming on the injectors and inlet valves
owing to the quality of the fuel.
♦ To counteract the formation of deposits, a multi-purpose ad‐
ditive for petrol fuel must be added.
♦ Only additives compliant with VW 507 53 B (multi-purpose ad‐
♦ Observe the dosing instructions on the additive container.
. Volkswagen AG
gen AG
♦ After adding the additive, it is extremely important
ksw to fully refuel
a does
not
Vol
the vehicle to achieve optimal effectiveness ed by of the additive. gu
ara
ris nte
ho eo
ut ra
– Fill multi-purpose additive for petrol
ss a fuels into regular fuel tank c
during each oil change service.
ce
e
nl
pt
du
an
itte
Country
y li
erm
ab
China India Russia
ility
ot p
wit
, is n
h re
hole
spec
4.29.2 Recommendation for using multi-pur‐
es, in part or in w
t to the co
pose additive for petrol fuel
rrectness of i
Note
l purpos
♦ In the following markets with a high risk of coke and deposit

nform
formation, the addition of a multi-purpose additive is recom‐

ercia
mended owing to the elevated olefin content and aromatics in

m
at
the petrol.
om
ion
c
in t
♦ Only additives compliant with VW 507 53 B (multi-purpose ad‐

or
his
e

at
do
priv
cum
♦ Observe the dosing instructions on the additive container.

for
en
ng
t.
yi
Co
Cop py
the vehicle to achieve optimal effectiveness of the additive. ht. rig
rig ht
py by
o Vo
♦ The multi-purpose additive can also be used in all other mar‐
by c lksw
cted agen
kets that are not listed in the table.
Prote AG.
– Fill multi-purpose additive for petrol fuels into regular fuel tank
during each oil change service.
Country
Algeria
Bahrain
Bolivia
Brazil
Ghana
Touran 2003 ➤
Country
Indonesia
Iraq
Iran
Japan
Yemen
Jordan
Cambodia
Qatar
Columbia
Kuwait
Lebanon
AG. Volkswagen AG d
agen
Malaysia Volksw
oes
not
by gu
ara
Mauritius rise
d
nte
tho eo
Niger s au ra
c
s
Nigeria
ce
le
un
pt
an
d
Oman
itte
y li
rm
ab
Pakistan
pe
ility
ot
Peru
wit
, is n
h re
Philippines
hole
spec
Saudi Arabia
es, in part or in w
t to the co
Senegal
Singapore
rrectness of i
Surinam
l purpos
Syria
Chad
nform
ercia
Uzbekistan
m
United Arab Emirates

com
tion in
Vietnam
r
te o
thi
s
iva
do
r
rp
cum
fo
en
g
4.30 Engine cover panel -top-: removing and

n
t.
yi Co
op py
installing
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
Caution
AG.
♦ Do not push with the fist or a tool on the engine cover panel
when it is installed or engaged at securing points, it could
be damaged.
Engine cover panel: removing and installing, 1.4 l TSI engines

⇒ page 89
Engine cover panel: removing and installing, 1.6 l FSI petrol direct
injection engines ⇒ page 90 .
Engine cover panel: removing and installing, 1.6 l injection en‐
gines ⇒ page 91 .
Engine cover panel: removing and installing, 2.0 l FSI petrol direct
injection engines ⇒ page 92 .
Touran 2003 ➤
Engine cover panel: removing and installing, 1.9 l UIS diesel en‐
gines ⇒ page 92
Engine cover panel: removing and installing, 2.0 l UIS diesel en‐
gines ⇒ page 94
Engine cover panel: removing and
agen
installing,
AG. Volkswa1.6 l/2.0
gen A G do l CR diesel
engines ⇒ page 94 Volksw es n
ot g
y ua
db ran
se
4.30.1 Engineut
ho cover panel: removing and in‐
ri tee
or
stalling, 1.4 l TSI engines
a ac
ss
ce
e
nl
pt
du
Removing:
an
itte
y li
erm
ab
– If fitted, pull hose off connection -arrow A -.
ility
ot p
– Disengage engine cover panel at securing points -arrows B-
wit
, is n
h re
and raise.
hole
spec
– Then pull out of bracket -arrow C-.
es, in part or in w
t to the co
Installing:
rrectness of i
l purpos
nf
ercia
– Push engine cover panel -1- with lug -arrow A- at securing
orm
point -2- into bracket -arrow B-.
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Then fit engine cover panel at the other securing points

-arrows B- and press on, until they noticeably engage.
– If fitted, connect hose at connection -arrow A-.
Touran 2003 ➤
4.30.2 Engine cover panel: removing and in‐

stalling, 1.6 l FSI petrol direct injection
olkswagen AG
en AG. V
engines Volks wag does
not
by gu
ara
Removing: ed nte
oris eo
th
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Pull out oil dipstick -1-.
es, in part or in w
t to the co
– Pull off connector -C- and hose connection -B-.
– Loosen clip -A- and pull off hose.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
– Disengage engine cover panel at the securing points -2- and

o
m
f
remove upwards.
en
ng
t.
yi Co
op py
Installing: t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Fit engine cover panel at securing points -2- and press on until
it engages.
– Fit connector -C- and hose connection -B-.
– Connect hose and tighten clip -A-.
Touran 2003 ➤
– Slide oil dipstick -1- into guide tube.

stalling, 1.6 l injection engines
Removing
– Unclip engine cover panel at the securing points -2- and re‐
move upwards.
Installing
AG. Volkswagen AG d
agen oes
olksw not
y V gu
– Fit engine icoverse
d b panel -arrows A- to securing pins ara-arrows
nte B-
first. thor eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Then fit to remaining securing points -2- and press on until it

can be felt to engage.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
Touran 2003 ➤ d by
V gu
ara
e nte
Maintenance - Edition
horis
01.2019 eo
aut ra
ss c
ce
e
nl
pt
du
stalling, 2.0 l FSI petrol direct injection
an
itte
y li
erm
ab
engines
ility
ot p
wit
, is n
Removing
h re
hole
spec
– Unclip engine cover panel at securing points -arrows- and re‐
es, in part or in w
move upwards.
t to the co
Installing
Install in reverse order.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
stalling, 1.9 l UIS diesel engines

p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
Note opyri
gh by
Vo
ht
by c lksw
cted
♦ There are different versions of engine cover panels:
agen
Prote AG.
♦ 1. One-piece engine cover panel

♦ 2. Two-piece engine cover panel
One-piece engine cover panel:

Removing:
– Disengage engine cover panel -arrow 2- and lift.
– Then pull off forwards -arrow 3-.
Installing:
– Position engine cover panel over front retainers then press on
until the cover engages.
– Slide oil dipstick -1- into guide tube.
Two-piece engine cover panel:
Touran 2003 ➤
AG. Volkswagen AG d
agen oes
Removing: olksw not
y V gu
d b ara
rise nte
tho eo
u ra
Note ss a c
ce
le
un
pt
The engine cover panel consists of two individual parts.
an
d
itte
y li
rm
ab
pe
ility
♦ 1. The outer part -A-, here shaded in illustration
ot
wit
, is n
♦ 2. The centre part -B-, here not shaded in illustration
h re
hole
spec
es, in part or in w
– Disengage engine cover panel carefully at individual securing
t to the co
points and raise as follows.
♦ -1-, -3-, -2-, -4-.
rrectness of i
– Remove outer part -1-.
l purpos
– Disengage centre part -2- also carefully and remove.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Installing:
– Fit engine cover panel onto securing points -arrows- and press
on.
– Then fit outer part -1- over retaining points -arrows- and press
on, so that cover engages.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
Touran 2003 ➤ oris nte
eo
th
s au ra
c
s
ce
le
un
pt
an
d
itte
y li
stalling, 2.0 l UIS diesel engines
rm
ab
pe
ility
ot
wit
Removing:
, is n
h re
– Pull out oil dipstick. hole
spec
es, in part or in w
– Disengage engine cover panel -A- at securing points
t to the co
-arrows 1 to 4- and raise.
– Then pull off forwards -upper arrow in illustration-.
rrectness of i
Installing:
l purpos
– First fit engine cover panel -A- at securing point

-upper arrow in illustration-.
nform
ercia
– Then fit engine cover panel -A- at the other securing points
m
a
-arrows 1 to 4- and press on, until it noticeably engages.
com
tion in
r
te o
thi
s
iva
do
r
stalling, 1.6 l/2.0 l CR diesel engines

rp
cum
fo
en
ng
t.
yi Co
Removing: . Cop py
rig
ht ht
rig
– Disengage engine cover panel at securing points -arrow- and py by
o Vo
raise.
by c lksw
cted agen
Prote AG.
Installing:
Caution
Before installing engine cover panel, check the 4 securing el‐

ements (ball sockets) in the correct positions. Reset to correct
position, if necessary. Otherwise the engine cover panel will
be damaged.
– Push ball sockets of engine cover panel to correct installation

position, if necessary.
– Fit engine cover panel onto securing points and press on at
edges to engage.
Touran 2003 ➤
4.31 Engine compartment cover -bottom-

(noise insulation): removing and instal‐
ling
Procedure
The procedure of removing the engine cover panel -bottom-
(noise insulation) can be found in Workshop Manual under:
»General body repairs, exterior« ⇒ General body repairs, exte‐
rior; Rep. gr. 50 ; Noise insulation »Noise insulation«
Note

4.32 Engine and components in engine com‐

partment: inspecting for leaks and dam‐
age (from above and below)
Inspect as follows:
– Check engine and components in engine compartment
n AG. Volfor
kswagen AG
leaks and damage. wage does
olks no t gu
yV
db ara
– Lines, hoses and connections rise nte
tho eo
♦ Fuel system s au ra
c
s
ce
le
♦ Cooling and heating system

un
pt
an
d
itte
y li
♦ Lubrication system
erm
ab
ility
ot p
♦ Air conditioning system
wit
is n
h re
♦ Intake system
ole,
spec
♦ And brake system t to the co
Check for leaks, abrasion, porousness, cracks, correct seating

and attachment in retainers.
rrectne
Note
ss o
cial p
♦ Arrange for defects to be rectified as repair measures.

inform
mer
♦ If fluid loss is greater than can be expected through normal

atio
m
use, determine source and rectify (repair measure).

o
n
c
i
or
n thi
te
4.33 Engine oil level: checking

sd
iva
o
pr
cum
r
fo
Note the following:

en
ng
t.
yi Co
op
– After shutting off engine, wait at least 3 minutes so that the oil
C py
t. rig
gh
can flow back into the sump.
ht
pyri by
Vo
co lksw
by
– Pull out dipstick, wipe with a clean cloth and push dipstick in
cted agen
Prote AG.
again to limit stop.
– Pull dipstick out again and read oil level.
Touran 2003 ➤
Note
♦ Oil level must always be in area A for the delivery inspection.

This way, you will achieve the greatest possible customer sat‐
isfaction.
♦ The oil-change quantity in the service table was determined
experimentally and is sufficient for the technical functionality
of the engine in all operating conditions. During all other serv‐
ice events, the oil level must be checked and corrected as
necessary if the customer requests this. This enables an ad‐
ditional topping-up to the specified oil quantity to the upper limit
of the dip stick. Due to tolerances, the oil temperature and the
drip time, various quantities may be required for topping up.
A - Do not top up oil.

B - Oil can be replenished up to area -A-.
C - Oil must be replenished. The oil level must then be at least in
the upper half of the measuring area -B-.
AG. Volkswagen AG d
agen oes
– If oil level is above -A- marking, drain or extract excess
yV
olkoil
sw in not
gu
order to avoid damage to catalytic converter. ised b ara
nte
r
ho eo
– If the oil level is below marking -C- replenishauat sufficient ra
c
amount of oil (at least 0.5 l) ⇒ page 8 . ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
4.34 Engine oil: draining or extracting, renew‐
ot
wit
, is n
ing oil filter and replenishing engine oil
h re
hole
spec
es, in part or in w
Engine oil: Draining or extracting and replenishing ⇒ page 96 .
t to the co
Renew oil filter ⇒ page 97 .
Replenishing engine oil ⇒ page 107 .
rrectness of i
4.34.1 Engine oil: draining or extracting
l purpos
Special tools and workshop equipment required nform

ercia
♦ Used oil collection and extraction unit - VAS 6622A-

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Oil spill cloth

Engine oil: draining or extracting
Touran 2003 ➤
Note
♦ For engines with standing oil filter, the oil filter must be re‐
newed before changing the engine oil ⇒ page 97 . When
removing the filter element a valve is opened, the oil in the filter
housing automatically flows into crankcase.
♦ If engine oil is drained rather than being extracted with the
used oil collection and extraction unit, replace oil drain plug.
This prevents leaks.
♦ Please observe disposal instructions!
– Extract engine oil using used oil collection and extraction unit
- VAS 6622A- .
Or
– Remove oil drain plug.
– Let engine oil drain.
Note
♦ The oil drain plug is fitted with a secure seal, therefore the oil
drain plug must always be renewed.
– Screw in oil drain plug together with

gen AG. Voseal
lkswahand-tight
gen AG
does and then
swa
tighten to specified torque.
y Volk not
gu b ara
ed
– Replenish engine
tho
risoil. nte
e or
au ac
Engine oil capacity:
ss
ce
e
nl
pt
♦ ⇒ Maintenance tables
du
an
itte
y li
erm
♦ Engine oil: capacities and specifications ⇒ page 107

ab
ility
ot p
Specified torques for oil drain plug:

wit
, is n
h re
♦ Oil drain plug M14: 30 Nm

hole
spec
es, in part or in w
♦ Oil drain plug M24: 50 Nm

t to the co
WARNING
rrectness of i
♦ Torque specifications must not be exceeded.

l purpos
♦ Excessive torque can cause leaks in the area of the oil

drain plug or even damage.
nform
mercia
at
om
io
4.34.2 Oil filter: renewing

n
c
in t
or
his
ate
Oil filter: renewing, 1.2 l TSI engines ⇒ page 98

do
priv
cum
or
Oil filter: renewing, 1.4 l TSI engines ⇒ page 99 .

f
en
ng
t.
yi Co
op
Oil filter: renewing, 1.6 l FSI engines ⇒ page 102 . C py
ht. rig
rig ht
Renewing oil filter, 1.6 l injection engines ⇒ page 103 .
py by
co Vo
by lksw
cted agen
Oil filter: renewing, 2.0 l FSI engines ⇒ page 103 .
Prote AG.
Oil filter: renewing, UIS diesel engines ⇒ page 105 .

Oil filter: renewing, CR diesel engines ⇒ page 106
AG. Volkswagen AG d
agen oes
olksw not
b yV gu
ara
ed
Touran 2003oris ➤ nte
eo
th
Maintenance
s au - Edition 01.2019 ra
c
s
ce
e
nl
pt
4.34.3 Oil filter: renewing, 1.2 l TSI engines
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Oil new O-rings before installing.
♦ Prevent engine oil from dripping onto components.
rrectness of i
l purpos
♦ Oil filter tool - 3417-
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing
Note

♦ Cover alternator with cloth before removing.
Touran 2003 ➤
– Loosen oil filter -arrow- first, using a strap or oil filter tool -
3417- before removing oil filter completely.
– Wait a few minutes, so that engine oil can flow back from filter
into engine.
– Then remove oil filter.
Caution
When removing oil filter, make certain that the old seal is also
removed and is not stuck to the valve timing housing.
Ensure that no engine oil drips onto poly V-belt or alternator.
Installing
Note
♦ Observe fitting instructions on oil filter.

– Clean oil filter sealing surface on valve timing housing.

– Lightly oil seal on new filter.
– Screw new oil filter -arrow- in by hand.

– Then tighten to 20 Nm.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
4.34.4 Oil filter: renewing, 1.4 l TSI engines

un
pt
an
d
itte
y li
Type 1
erm
ab
ility
ot p
wit
is n
h re
Note
ole,
spec

t to the co

rrectne
Removing
ss o
cial p
Remove engine cover panel, see ⇒ page 88 .

inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
99
by c lksw
cted
agen
Prote AG.
Touran 2003 ➤
– Unscrew oil filter cover -arrow- using e.g. 36 mm socket insert.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Remove oil filter cover -1- with oil filter element -4- and valve
wit
, is n
h re
-5-.
hole
spec
Installing
es, in part or in w
t to the co
– Renew O-ring -2- of oil filter cover and O-ring -3- of valve.
– Renew used oil filter element by new filter element -4-.
rrectness of i
l purpos
Note
nform
ercia

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
– Tighten oil filter cover -arrow- to 25 Nm.
cted agen
Prote AG.
Further assembly is basically a reverse of the dismantling se‐

quence.
Type 2


Touran 2003 ➤
Removing
Note

♦ Cover alternator with cloth before removing.
– Loosen oil filter -arrow- first, using a strap or oil filter tool -
3417- before removing oil filter completely.
– Wait a few minutes, so that engine oil can flow back from filter
into engine.
– Then remove oil filter.
Caution AG. Volkswagen AG d

agen oes
olksw not
yV
When removing oil filter, make certainsethat the old seal is also
b gu
d ara
nte
removed and is not stuck to the valve hori
timing housing. eo
aut ra
Ensure that no engine oil drips onto
ss
poly V-belt or alternator. c
ce
le
un
pt
an
d
itte
y li
Installing
erm
ab
ility
ot p
wit
is n
h re
Note
ole,
spec
♦ Observe fitting instructions on oil filter.

t to the co

rrectne
– Clean oil filter sealing surface on valve timing housing.

– Lightly oil seal on new filter.
ss o
cial p
f inform
– Screw new oil filter -arrow- in by hand.

mer
atio
– Then tighten to 20 Nm.

om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touran 2003 ➤
AG. Volkswagen AG d
agen
4.34.5 Oil filter: renewing, 1.6 Vlol FSI engines
oes
ksw not
by gu
ara
ed nte
Special tools and workshop equipment oris required eo
th
au ra
c
♦ Torque wrench - V.A.G 1331- ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
Note
mer
atio
m

o
n
c
i
or
n thi
e

t
sd
iva
o
pr
c
♦ Prevent engine oil from dripping onto subframe.
um
r
fo
en
ng
t.
yi Co
op
Removing
C py
t. rig
gh ht
yri by
Remove engine cover panel ⇒ page 88 . cop Vo
by lksw
cted agen
Prote
– Loosen sealing cap -arrow- on hexagonal flats and remove.
AG.
– Take oil filter -4- out of oil filter cover -1-.

– Clean sealing surfaces on oil filter cover and on oil filter hous‐
ing.

Touran 2003 ➤
Installing
– Insert new filter element -4- in oil filter cover.
– Renew seal -2-.
– Lightly oil seal.
– Clean thread -3- and lightly moisten with oil.
– Tighten oil filter cover -arrow- to 25 Nm. agen

AG. Volkswagen AG d
oes
olksw not
V
Further assembly is basically a reverse ed byof the dismantling se‐ gu
ara
quence. horis nte
eo
aut ra
ss c
ce
le
un
pt
an
d
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rm
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pe
ility
ot
wit
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spec
es, in part or in w
t to the co
4.34.6 Oil filter: renewing, 1.6 l injection en‐
gines
rrectness of i
l purpos

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Loosen oil filter -arrow A- from below using a strap or oil filter
tool - 3417- .
Note
– Clean oil cooler sealing surface.

– Oil rubber seal lightly on new filter. This ensures best possible
sealing when the filter is tightened.
– Tighten filter by hand.
4.34.7 Oil filter: renewing, 2.0 l FSI engines


Touran 2003 ➤
♦ Oil drain adapter - T40057-
AG. Volkswagen AG d
agen oes
olksw not
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au ra
ss c
ce
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r

rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Carry out the following procedure:

– Remove dust cap -arrow- from oil filter housing.
Before removing the oil filter housing, it must be drained.

AG. Volkswagen AG d
agen oes
ksw
by
Vol Touran
not
gu 2003 ➤
d ara
orise Maintenance - Edition 01.2019
nte
h eo
aut ra
c
– Insert oil drain adapter - T40057- into oil filter housing
ss
and hold
ce
le
hose in oil drip tray.
un
pt
an
d
itte
y li
erm
ab
ility
Note
ot p
wit
is n
h re
When the oil drain adapter - T40057- is screwed in, a valve is
ole,
spec
opened in oil filter housing. When the oil drain adapter - T40057-
is removed again, the valve closes automatically.
t to the co
– Drain engine oil.
rrectne
– Unscrew oil drain adapter - T40057- again.
– Unscrew oil filter housing using oil filter tool - 3417- .
ss o
cial p
f in
– Renew oil filter element -4- and seal -3-.
form
mer
atio
om
n
c
Note
i
or
n thi
te
sd
va

i
o
pr
cum
r
fo
en
ng
t.
yi
– Tighten oil filter housing -2- to 25 Nm.
Co
Cop py
t. rig
gh
– Insert dust cap -1- into oil filter housing -2- hand-tight.
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
4.34.8 Oil filter: renewing, UIS diesel engines

Removing
Note

– Unbolt retainer on intake manifold -1-.

– If necessary, unclip cable to create more space for removing
the oil filter sealing cap.

Touran 2003 ➤
Loosen cover cap -arrow-.
Note
Before draining or extracting release sealing cap, so that the en‐

gine oil can flow out of filter housing.
– Clean sealing surfaces on threaded cap and oil filter housing.
Installing
– Renew filter element -3-.
– Renew O-rings -2 and 4-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
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e
nl
pt
du
an
itte
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erm
ab
ility
ot p
– Install threaded cap -arrow- and tighten to 25 Nm.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
4.34.9 Oil filter: renewing, CR diesel engines

in t
or
his
ate
do
riv

p
cum
for
en
♦ Socket insert - SW 32- .

ng
t.
yi Co
op py
Removing
. C rig
ht ht
rig by
py
co Vo
by lksw
cted agen
Prote AG.
Note


Touran 2003 ➤
– Unscrew bolt -1-.

– Place bracket -2- on one side together with the switch-over
solenoid valve -3-. AG. Volkswagen
agen AG do
ksw es n
y Vol ot g
ua
b
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
– Loosen filler cap -2- e.g. using an appropriate combination
spec
spanner or socket.
es, in part or in w
t to the co
Note
rrectness of i
Before draining or extracting, release sealing cap so that the en‐
l purpos
gine oil can flow out of filter housing.
nform
ercia
– Clean sealing surfaces on threaded cap and oil filter housing.

m
at
om
ion
c
in t
or
his
ate
do
riv
Installing
p
cum
for
en
g
– Renew filter element -3-.

n
t.
yi Co
Cop py
– Renew O-rings -2 and 4-.
t. rig
gh ht
pyri by
Vo
co
– Install threaded cap and tighten to 25 Nm.
by lksw
cted agen
Prote AG.
– Further assembly is basically a reverse of the dismantling se‐
quence.
– Fit engine cover panel ⇒ page 88 .
4.34.10 Engine oil: replenishing

Engine oil: capacities and specifications ⇒ page 107
Oil level: checking ⇒ page 95
4.35 Engine oil: capacities and specifications

Touran
Petrol engines Oil quantity with filter VW engine oil standards
Engine code Capacity / output (I) With flexible service With fixed service
AXW 2.0 l 110kW 4,6 504 00 / 503 00 502 00 / 501 01
BAG 1.6 l 85kW 3,6 504 00 / 503 00 502 00 / 501 01
BGU 1.6 l 75kW 4,5 504 00 / 503 00 502 00 / 501 01

Touran 2003 ➤
Touran
Petrol engines Oil quantity with filter VW engine oil standards
olksw
AG. V agen AG
agen does
BLF 1.6 l 75kW Volksw 3,6 504
not 00 / 503 00 502 00 / 501 01
by gu
ara
BLG 1.4 l 125kW ris
ed 3,6 504 00 n/te503 00 502 00 / 501 01
tho eo
BLP 1.6s alu85kW 3,6 504 00 / 503 r a 00
c 502 00 / 501 01
s
BLR 2.0 l 110kW 4,6 504 00 / 503 00 502 00 / 501 01
ce
le
un
pt
an
d
BLX 2.0 l 110kW 4,6 504 00 / 503 00 502 00 / 501 01

itte
y li
rm
ab
BLY 2.0 l 110kW 4,6 504 00 / 503 00 502 00 / 501 01
pe
ility
ot
BMY 1.4 l 103kW 3,6 504 00 / 503 00 502 00 / 501 01
wit
, is n
h re
BSE 1.6 l 75kW 4,5 504 00 / 503 00 502 00 / 501 01
hole
spec
BSF 1.6 l 75kW 4,5 504 00 / 503 00 502 00 / 501 01
es, in part or in w
t to the co
BSX 2.0 l 80kW 4,0 504 00 / 503 00 502 00 / 501 01
BVY 2.0 l 110kW 4,6 504 00 / 503 00 502 00 / 501 01
rrectness of i
BVZ 2.0 l 110kW 4,6 504 00 / 503 00 502 00 / 501 01
l purpos
CAVB 1.4 l 125kW 3,6 504 00 502 00

CAVC 1.4 l 103kW 3,6 504 00 502 00
nform
ercia
CBZB 1) 1.2 l 77kW 3,6 504 00 502 00

m
a
CBZB 2) 1.2 l 77kW 3,9 504 00 502 00
com
tion in
r
CDGA 1.4 l 110kW 3,6 --- 502 00

te o
thi
s
iva
CTHB 1.4 l 125kW 3,6 504 00 502 00
do
r
rp
cum
fo
CTHC 1.4 l 103kW 3,6 504 00 en 502 00

ng
t.
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op
1)
py
Applies up to model year ►2011 t. C rig
gh ht
pyri by
2)
Vo
Applies as of model year 2012►
co lksw
by
cted agen
Prote AG.
Touran
Diesel engines Oil quantity with filter VW engine oil standards
AVQ 1.9 l 74kW 3,8 507 00 / 506 01 505 01
AZV 2.0 l 100kW 3,8 507 00 / 506 01 505 01
BKC 1.9 l 77kW 3,8 507 00 / 506 01 505 01
BKD 2.0 l 103kW 3,8 507 00 / 506 01 505 01
BLS 1.9 l 77kW 4,3 507 00 507 00
BMM 2.0 l 103kW 4,3 507 00 507 00
BMN 2.0 l 125kW 4,3 507 00 507 00
BRU 1.9 l 66kW 3,8 507 00 / 506 01 505 01
BXE 1.9 l 77kW 3,8 507 00 / 506 01 505 01
BXF 1.9 l 66kW 3,8 507 00 / 506 01 505 01
BXJ 1.9 l 66kW 4,3 507 00 507 00
CAYB 1.6 l 66kW 4,3 507 00 507 00
CAYC 1.6 l 77kW 4,3 507 00 507 00
CFHC 2.0 l 103kW 4,3 507 00 507 00
CFHF 2.0 l 81kW 4,3 507 00 507 00
CFJA 2.0 l 125kW 4,3 507 00 507 00
CFJB 2.0 l 130kW 4,3 507 00 507 00

Touran 2003 ➤
Touran
Diesel engines Oil quantity
AG. Volwith
kswagfilter
en AG VW engine oil standards
agen (I) does
Engine code Capacity / output olksw With noflexible
t service With fixed service
yV gu b ara
ed
CLCA 2.0 l 81kWris 4,3 ---ntee 505 01
tho or
au ac
ss
ce
le
un
pt
an
d
4.36 Panorama tilting/sliding roof with rear itte
y li
erm
ab
panorama roof: checking function,
ility
ot p
cleaning and greasing guide rails, and
wit
is n
h re
ole,
cleaning wind deflector
spec
t to the co
♦ Lint-free cloth
rrectne
♦ Wet and dry vacuum cleaner
♦ Lubricating paste G 060 751 A2
ss o
♦ Hand cartridge gun - V.A.G 1628-
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Grease stone - VAS 6621-
4.36.1 Sunroof: checking function, cleaning

and lubricating guide rails
– Check roof system for damage.
– Check function of roof system, i.e. open and close glass panel
and sliding headliner/roller blind completely.
– Open roof system and remove any excessive dirt.
• Only grease stone - VAS 6621- is allowed to be used for
cleaning and lubricating.

Touran 2003 ➤
Caution
In order to prevent the vehicle interior from being soiled hold a

cloth under the respective work area.
Cleaning
– Open glass panel completely.
– Insert -VAS 6621- in rear part of guide rail -1- and turn by 90°
-2-.
– Move grease stone -VAS 6621- as far as centre of guide rail
in -direction of arrow 3-.
– Turn -VAS 6621- by 90° -4- and remove tool -5-.
– Remove residual grease and dirt from inner area of guide rail
using a lint-free cloth. (if necessary, remove sand and dust
from the guide rail using a workshop vacuum cleaner).
– The described procedure can be repeated several times, de‐
pending on the degree of soiling.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
– Insert -VAS 6621- in front part of guide rail (near wind deflec‐
erm
ab
tor) -1- and turn it by 90° -2-.
ility
ot p
wit
, is n
– Move grease stone -VAS 6621- as far as centre of guide rail
h re
in -direction of arrow 3-.
hole
spec
es, in part or in w
– Turn -VAS 6621- by 90° -4- and remove tool -5-.
t to the co
– Remove residual grease and dirt from inner area of guide rail
using a lint-free cloth. (if necessary, remove sand and dust
rrectness of i
from the guide rail using a workshop vacuum cleaner).
l purpos
– The described procedure can be repeated several times, de‐

pending on the degree of soiling.
nf
ercia
– Repeat the process on the other side of the vehicle.

orm
m
atio
Grease
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
lkswage es n
o ot g
– Screw grease ed
by V stone - VAS 6621- -1- onto thread ua of lubricant
ran -
G 060h751 oris A2- for guide rails -2- in direction of -arrow- tee and
insertau in hand-cartridge gun - V.A.G 1628- -3-.
t or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
– Insert hand-cartridge gun with -VAS 6621- at rear end of guide
c
in t
or
rail -1- and turn it by 90° -2-.
his
ate
do
riv
– Apply lubricant - G 060 751 A2- for guide rails in direction of

p
cum
or
-arrow 3- towards front of guide rail, applying uniform pressure

f
en
ng
t.
yi
while operating hand-cartridge gun .
Co
Cop py
t. rig
gh
– Turn hand-cartridge gun with -VAS 6621- by 90° -4- and re‐
ht
pyri by
move it -5-.
co Vo
by lksw
cted agen
Prote AG.
– After lubricating, open and close panoramic sliding roof once,
then remove excess grease.
Ensure that no other components or the inside of the vehicle are
soiled.
– Repeat the process on the other side of the vehicle.
Caution
Faults found must always be rectified (repair measure).

Touran 2003 ➤
4.36.2 Panorama sliding roof: cleaning wind

deflector
– Check the wind deflector -1- for dirt. Especially check lower
part of wind deflector for dirt -arrows-.
– Remove dirt deposits using wet and dry cleaner, for example.
Note
AG. Volkswagen AG d
♦ To remove insects and particles from the net and wind deflec‐
lksw
agen oes
not
tor frame, use a sponge and a soapy solution. d by Vo gu
ara
e nte
ris
♦ Mixing ratio for soapy solution: 3 drops of washing-up
tho liquid to eo
1 litre of water. au ra
c
ss
ce
le
un
pt
an
d
itte
y li
Caution
erm
ab
ility
ot p
Do not use a commercially available insect remover or other
wit
is n
h re
solvents, because these products have not been tested and
ole,
approved.
spec
t to the co
– Then remove loose insects and particles using a vacuum
cleaner with a suitable nozzle.
rrectne
Caution
ss o
cial p
f i
Use a suitable nozzle for the wind deflector so that the net is
nform
not damaged!
mer
atio
m
When doing this, ensure that no dirt drops into vehicle interior.
o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
4.37 Road test: performing (driving behav‐

fo
en
ng
t.
yi Co
iour, noises, air conditioner etc.) Cop py
t. rig
gh ht
yri by
Which of the following can be checked depends on vehicle equip‐
op Vo
by c lksw
ment and local conditions (urban/country). cted agen
Prote AG.
Check the following during a road test:

– Engine: output, misfiring, idling speed, acceleration
– Clutch: pulling away, pedal pressure, odours
– Gear selection: ease of operation, stick position
– Automatic gearbox: selector lever position, shift lock/ignition
key removal lock, shift behaviour, dash panel insert display.
– Foot brake and handbrake: function, free travel and effective‐
ness, pulling to one side, juddering, squeal
– ABS function: pulsing must be felt at the brake pedal during
ABS-regulated braking
– Steering: function, steering free clearance, steering wheel
centred when vehicle is travelling straight ahead
– Sliding sunroof/panoramic sliding roof: function
– Radio/radio navigation system: function, reception, GALA, in‐
terference noise
– Multi-function indicator (MFI): functions

Touran 2003 ➤
– Air conditioning system: check function. (At low temperatures

the function of air conditioner must be checked in a workshop).
– Vehicle: pulls to one side when travelling straight ahead (level
road).
– Imbalance: Wheels, drive shafts
– Wheel bearings: noises
– Engine: hot starting behaviour
4.38 Wheel securing bolts: tightening to

specified torque
♦ Pulling off wheel hub trim: ⇒ page 113
AG. Volkswagen AG d
agen oes
♦ Pulling off wheel trim ⇒ page 114Volksw not
gu
y
db ara
♦ Pulling off wheel bolt caps: r se page 114
i⇒ nte
tho eo
au ra
♦ Loosening/tightening anti-theft
ss wheel bolts ⇒ page 114 c
ce
le
un
♦ Tightening wheel bolts ⇒ page 115
pt
an
d
itte
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♦ Installing wheel centre cover, wheel bolt cover caps and wheel
erm
ab
cover ⇒ page 115
ility
ot p
wit
is n
Pulling off wheel hub trim
h re
ole,
spec
Caution
t to the co
On vehicles with light alloy wheels do not lever wheel hub trim
off with screwdriver, only use the special tool for this purpose
rrectne
(puller hook in vehicle tool kit).
ss o
cial p
f
The puller hook -1- to remove the cover caps is located with the
vehicle tool kit. inform
mer
atio
m
– Hook puller hook into one drilling of wheel hub trim and pull off
o
n
c
in -direction of arrow-.
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touran 2003 ➤ AG. Volkswagen AG d
agen
Maintenance - Edition 01.2019 Volksw
oes
not
by gu
d ara
ise nte
Pulling off wheel trim ut
hor eo
a ra
s c
– On vehicles with wheel trim, loosen wheel trim all around as s
ce
le
shown, e.g. using puller hook and wheel brace from vehicle
un
pt
an
d
tool kit -A- and pull off -arrow B-.
itte
y li
rm
ab
Pulling cover caps off wheel bolts
pe
ility
ot
wit
, is n
h re
Caution
hole
spec
es, in part or in w
On vehicles with light alloy wheels do not lever wheel bolt caps
t to the co
off with screwdriver, only use the special tool for this purpose
(puller hook in vehicle tool kit).
rrectness of i
l purpos
Note
nform
ercia
Before loosening or tightening the wheel bolts, remove the cover

m
a
com
caps.
tion in
r
te o
thi
s
iva
do
The puller hook to remove the cover caps is located with the ve‐
r
rp
cum
hicle tool kit.
fo
en
ng
t.
yi Co
– Place the puller hook through opening in cover cap. t. Cop py
rig
gh ht
– Pull off cap using the puller hook. yri
p by
o Vo
by c lksw
cted agen
Prote AG.
Loosening/tightening anti-theft wheel bolts
Note
♦ To loosen/tighten the anti-theft wheel bolts a special adapter,

located in vehicle tool kit, is required.
♦ To loosen the anti-theft wheel bolts (lockable wheel bolts) do
not use an impact screwdriver.
♦ If the adapter to loosen or tighten the anti-theft wheel bolts is
not available in the vehicle, use the corresponding adapter set
for tamper-proof wheel bolts.

Touran 2003 ➤
♦ Adapter set for tamper-proof wheel bolts - T10101-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
♦ Adapter set for tamper-proof wheel bolts - T10313-
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m

o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Slide adapter -2- into anti-theft wheel bolt -1- onto stop.
– Slide the wheel bolt wrench onto adapter -2- onto stop.
Tightening wheel bolts
– Tighten the wheel bolts diagonally and alternately to the fol‐
lowing torque setting:
♦ 120 Nm
WARNING
Never use an impact screwdriver to tighten the wheel bolts!
Installing wheel centre cover, wheel bolt cover caps and wheel
cover

Touran 2003 ➤
– Push wheel hub trim into opening of wheel hub. Ensure that
-A and B- are accurately fitted on rim.
AG. Volkswagen AG d
agen
Fit cover caps on wheel bolts. Volksw
oes
not
by gu
d ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Install wheel trim by inserting trim evenly into steel wheel. Ensure
rrectness of i
that valve -B- seats in cut-out -A- of wheel trim.
l purpos
Note nform
ercia
Place adapter and puller hooks properly in vehicle tool kit after
m
at
completing work.
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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4.39 Radio/navigation system: reading code pyri by
Vo
o
by c lksw
using vehicle diagnostic tester
cted agen
Prote AG.
Authorization prerequisites for vehicle diagnostic tester

• The vehicle diagnostic tester is connected via the Central
Partner Network (CPN) with the central database (Carport,
Fazit).
• Available access for the user of the system “GeKo” (secrecy
and component protection)
Note
♦ The radio codes can be read in the central database and can
be displayed on vehicle diagnostic tester .
♦ For radio activation the codes must be entered via radio but‐
tons, as previously ⇒ page 117 .
– Read radio code ⇒ Vehicle diagnostic tester.

Touran 2003 ➤
4.40 Radio/navigation system: entering PIN

of anti-theft coding and storing local ra‐
dio stations to station buttons
The anti-theft coding electronically prevents unauthorized per‐
sons from operating the unit after it has been removed from
vehicle. The anti-theft codes are also called radio codes or se‐
curity codes. Security code means that each unit with an anti-theft
coding is programmed with its own code number. This security
code is not active when leaving the factory. The security code is
found on the unit card, if fitted. If the unit card is not fitted, the
security code can be read using vehicle diagnostic tester of a
central database ⇒ page 116 .
Note
. Volkswagen AG
gen AG does
If an incorrect code number is entered when releasingVthe olks elec‐
wa not
tronic lock, the whole procedure can be repeated sonce.ed by If an gu
ara
incorrect code number is entered again, the unit thois locked for
ri nte
eo
about one hour. That means, it cannot be used. au After one hour, ra
c
ss
during which time the unit must remain switched on, the display
ce
le
extinguishes. The electronic lock can be released as described

un
pt
an
d
above. The cycle two attempts, one hour lock applies again.
itte
y li
rm
ab
pe
ility
Procedure
ot
wit
, is n
h re
Vehicle electrics → Communication ⇒ Rep. gr. 91 → e.g. radio
hole
spec
system "RCD 500" → Electronic anti-theft coding → Deactivating
es, in part or in w
electronic anti-theft coding.
t to the co
rrectness of i
l purpos
4.41 Tyre pressure loss indicator: performing

basic setting
nform
mercia
a
com
t
Note
ion in
r
te o
thi
♦ The basic setting of the tyre pressure monitoring - K220- must
s
iva
do
only be performed after the tyre pressure has been corrected

r
rp
cum
fo
to the prescribed values.

en
ng
t.
yi Co
op
♦ If no pressure loss and tyre damage are found after a tyre C py
t. rig
pressure warning, the incorrect warning can be rectified by a
gh ht
yri by
basic setting.
op Vo
by c lksw
cted agen
Prote AG.
The tyre pressure monitoring system is part of the software in the

ABS control unit - J104- .
The ABS control unit compares the speed and the rolling circum‐
ference of the individual wheels via the ABS speed sensors.
When the rolling circumference of one wheel is changed this is
displayed by the tyre pressure monitoring. The rolling circumfer‐
ence of tyre can change if:
♦ The tyre pressure is too low.
♦ The tyre has structural damage.
♦ The vehicle is loaded more heavily on one side.
♦ The wheels on one axle are loaded more heavily (e.g. when
towing a trailer or when driving in mountains).
♦ Snow chains are fitted.

Touran 2003 ➤
♦ The temporary spare wheel is fitted.

♦ One wheel per axle has been changed.
The tyre pressure monitoring warning lamp - K220- has a yellow
warning lamp in the dash panel insert -arrow-.
♦ “FLASHING LIGHT” means that the “INITIAL BASIC SET‐
TING” has not been performed.
♦ “PERMANENT LIGHT” in conjunction with a warning tone
means “WARNING”, pressure loss has been recognised,
check tyre pressure, perform system basic setting.
Perform “INITIAL” basic setting
– Press button ESP and button SET in centre console simulta‐

neously and for longer than 2 seconds. lkswage es n
o ot
yV gu
db ara
If the SET button is not in the centre console,oriitsewill be located in nte
eo
the glove compartment. au
th ra
ss c
– If ESP is not fitted, press TCS button.
ce
le
un
pt
an
d
itte
The start of basic setting will be confirmed by an acoustic signal.
y li
rm
ab
pe
– When switching on ignition again, no warning is shown.
ility
ot
wit
, is n
Perform basic settings
h re
hole
spec
es, in part or in w
t to the co
– Press the SET button in the centre console or in the glove
compartment for longer than 2 seconds.
rrectness of i
The tyre pressure monitoring warning lamp in dash panel insert
l purpos
-arrow- lights up as long as the button is pressed.

The start of basic setting will be confirmed by an acoustic signal.
nform
ercia
When switching on ignition again, no warning is indicated.

m
a
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tion in
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thi
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Cop py
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Vo
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4.42 Tyre repair set
cted agen
Prote AG.
Note
♦ The tyre repair set (breakdown kit) is located under the floor
covering in the luggage compartment.
♦ The tyre repair set also contains a filler bottle with tyre sealant.

Touran 2003 ➤
4.42.1 Expiry date: checking

– Check the expiry date.
The expiry date is printed on a sticker on the tyre sealant container
-arrow-.
– Enter the expiry date in maintenance table.
– Renew tyre sealant if the expiry date has been reached. (The
tyre sealant must not be more than 4 years old).
Note
♦ If the tyre sealant has been used, the container must be re‐
newed.
AG. Volkswagen n AG do
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Volks ot g
by ua
ed ran
4.43 Dust and pollen filter: cleaning housing
thoris tee
or
au
ss and renewing filter element ac
ce
e
nl
pt
Procedure
du
an
itte
y li
erm
Heating, ventilation, air conditioning system ⇒ Rep. gr. 80 →
ab
ility
Repairing heating system → Removing and installing dust and
ot p
wit
pollen filter
, is n
h re
hole
spec
es, in part or in w
Note t to the co

rrectness of i

l purpos
4.44 Headlight adjustment: checking halogen

nf
ercia
headlights
orm
m
atio
om
n in
or c
Note
thi
te
sd
iva
o
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rp
cu
♦ Additional weights are no longer used.

o
m
f
en
ng
t.
♦ Instead, a different inclination setting on the headlight adjust‐
yi Co
op py
ment unit is used. t. C rig
gh ht
pyri by
♦ If the maintenance tables are used, the settings are displayed
co Vo
by lksw
cted
in the vehicle-specific maintenance list as of model year 2014.
agen
Prote AG.
♦ In the US, Canadian and Mexican markets SAE-compliant

headlights are used.
♦ As of model year 2014 the headlight adjustment is subject to
a separate charge.
Test and adjustment prerequisites ⇒ page 119

Check headlight adjustment (ECE). ⇒ page 120
Check headlight adjustment (SAE). ⇒ page 121
Halogen headlights: adjusting ⇒ page 122 .
4.44.1 Test and adjustment conditions

• Tyre pressure OK

Touran 2003 ➤
• Lenses must not be damaged or dirty.

• Reflectors and bulbs OK.
• The vehicle must be rolled forward and backward several me‐
tres or front and rear springs must be bounced fully several
times so that springs settle.
• Vehicle and headlight adjuster must be on a level surface.
• Vehicle and headlight adjuster must be aligned.
• Inclination must be set.
• Refer to the ⇒ operating instructions for headlight adjustment
units .
4.44.2 Headlight adjustment (ECE): adjusting

. Volkswagen AG
gen AG does
♦ Headlight adjustment unit
Vol
ks-w VAS 5046 A-
a
not
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♦ Headlight adjustment
or
ise unit - VAS 5047 A- nte
h eo
ut ra
♦ Headlight adjustment
ss
a unit - VAS 621 001- c
ce
e
nl
pt
du
an
itte
Note
y li
erm
ab
ility
ot p
For certain export markets, halogen headlights with manually wit

, is n
regulated headlight range control are not offered. h re

hole
spec
es, in part or in w
– Check headlight height adjustment by setting the maximum

t to the co
level and monitoring the headlights' light.

– If fitted, then set the headlight range control thumb wheel to
rrectness of i
position 0 .
l purpos
The inclination on the headlight adjustment unit is set according

to the fuel level in the fuel tank.
nform
ercia
Inclination setting for ECE-compliant headlights

m
at
Fill level of Inclination

om
ion
fuel gauge
c
in t
or
his
e
0 to 1/2 1.2 %
at
do
priv
1/2 to 1 1.0 %
um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
Inclination for halogen headlights on the ECE CNG-Touran
p by
co Vo
by lksw
cted agen
Prote AG.
Inclination
1.0 %
Test pattern with dipped headlights

Check the following:

Touran 2003 ➤
– Whether, with the dipped beam switched on, the horizontal

bright/dark boundary contacts the dividing line -1- of the test
area and
– Check whether the breaking point -2- between the horizontal
part of the light/dark border on the left and the rising part on
the right lies on the vertical line of the central point -3-. The
bright core of the light beam must be to the right of the vertical
line.
Note
♦ To simplify the determination of the breaking point -2-, cover

and uncover left (from driver perspective) half of the headlight
a few times. Then check dipped beam again.
♦ After correct adjustment of dipped beams, the centre point of
G. Volkswage
the main beam must
lksw
aglie
en Aon the centre mark
n AG d
oes -3-.
n
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edb ran
ris tee
tho
4.44.3ss au Headlight adjustment (SAE): checking or
ac
ce
le

un
pt
an
d
itte
y li
♦ Headlight adjustment unit - VAS 5046 A-
erm
ab
ility
ot p

wit
is n
h re
♦ Headlight adjustment unit - VAS 621 001-
ole,
spec
t to the co
Note
♦ The VOL/VOR marking is visible on the outside the headlight.

rrectne
♦ The lateral adjustment mechanism is sealed on SAE-compli‐

ant headlights.
ss o
cial p
♦ For certain export markets, halogen headlights with manually

inform
regulated headlight range control are not offered.

mer
atio
om
– Check headlight height adjustment by setting the maximum

n
c
i
or
level and monitoring the headlights' light.

thi
te
sd
va
– If fitted, then set the headlight range control thumb wheel to

i
o
pr
cum
r
fo
position 0 .
en
ng
t.
yi Co
op
C py
ht. rig
to the fuel level in the fuel tank. rig ht
py by
co Vo
by lksw
Inclination for SAE VOL halogen headlights
cted agen
Prote AG.

fuel gauge
0 to 1/2 0.9 %
1/2 to 1 0.7 %

Touran 2003 ➤
VOL: Visual Optical Aim Left -1-

– Check whether the left horizontal light-dark border touches
olks
wagthe
e es n
ot g
separating line -1- in the test area of the headlightd badjustment
yV ua
ran
unit. or
ise tee
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Inclination for SAE VOR halogen headlights
rrectne
fuel gauge
0 to 1/2 0.2 %
ss
1/2 to 1 0.0 %
o
cial p
f inform
mer
atio
m
VOR: Visual Optical Aim Right -2-

o
n
c
i
or
n thi
e
– Check whether the right horizontal light-dark border touches

t
sd
va
the separating line -2- in the test area of the headlight adjust‐
i
o
pr
cum
r
ment unit.
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4.44.4 Halogen headlights: adjusting
Note

a separate charge.
♦ If the vehicle is equipped with separate dipped and main
beam, adjust main beam additionally. When adjusting main
beam ensure that the adjustment unit is set to 0%.

Touran 2003 ➤
Adjusting left headlight:

Version 1
The adjustment bolts for the right headlight are a mirror image.
♦ Headlight height adjustment screw -1-
♦ Headlight lateral adjustment screw -2-
olkswagen AG
en AG. V
♦ Vertical adjustment screw -3- for
olks main beam
wag does
not
byV gu
ara
♦ Lateral adjustment screw ris -4- for main beam
ed
nte
ho eo
ut
– Always turn the height
ss a adjustment screws of bright-dark boun‐ ra
c
dary first.
ce
e
nl
pt
du
an
– Then, turn the lateral adjustment screws of light-dark border.
itte
y li
erm
ab
Version 2
ility
ot p
wit
, is n
h re
Overview of halogen headlights:
hole
spec
1- Bulb for front left turn signal - M5- or bulb for front right left
es, in part or in w
t to the co
turn signal - M7-
2- Bulb for left parking light - M1- or bulb for right parking light
- M3-
rrectness of i
3- Bulb for left main beam headlight - M30- and bulb for right
l purpos
main beam headlight - M32- , bulb for left day driving light -
L174- or bulb for right day driving light - L175-
nf
ercia
o
4- Bulb for left dipped beam - M29- or bulb for right dipped
rm
m
beam - M31-
atio
om
n in
c
5-
or
thi
te
sd
iva
Lateral and height adjustment for left headlight:

r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touran 2003 ➤
1 - Lateral adjustment
2 - Height adjustment
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
Note
un
pt
an
d
itte
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In some markets, the adjustment bolt for lateral adjustment is

rm
ab
pe
ility
-1- encapsulated. Lateral adjustment is not permissible here.

ot
wit
, is n
h re
– Turn height adjustment bolt -2- and lateral adjustment bolt

hole
spec
-1- until the correct setting is achieved.

es, in part or in w
t to the co
Note
rrectness of i
♦ Adjustment of the left headlight is carried out in the same se‐

l purpos
quence.
♦ The adjustment bolts for the left headlight are a mirror image.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
124
agen
Prote AG.
Touran 2003 ➤
4.45 Headlight adjustment: checking gas dis‐

charge headlights without DLA
Note

ment unit is used.
a separate charge.

Check headlight adjustment (ECE). ⇒ page 125
Check headlight adjustment (SAE). ⇒ page 126
Gas discharge headlights without “Dynamic Light Assist” dynamic
main beam regulation: adjusting ⇒ page 128

• Headlight lenses must not be damaged or dirty.
• Reflectors and lights OK AG. Volkswagen AG d
agen oes
olksw not
yV gu
• The initialisation of
isethe
d b headlight range control must have abeen
ran
completed. 1) utho
r tee
or
s a ac
s
ce
e

nl
pt
du
an

itte
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erm
ab

ility
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wit
, is n
• Vehicle and headlight adjustment unit must be aligned.

h re
hole
spec

es, in part or in w
t to the co
• Event memory must be cleared.

• If the headlight adjustment unit has an adjustment mode, se‐
lect it.
rrectness of i

l purpos
units .
1) During the initialisation, the step motors for the headlight range
nform
ercia
control are reset to dipped beam position. The initialisation of the

m
headlight range control is performed during vehicle start or after

at
om
io
an "on" signal is applied to terminal 15.

n
c
in t
or
his
e

at
do
priv
cum
or

f
en
ng
t.
yi Co
op
♦ Headlight adjustment unit - VAS 5046 A- C py
t. rig
gh ht
yri
p by
o Vo
by c lksw
cted agen
Prote AG.
♦ Vehicle diagnostic tester

Touran 2003 ➤

Inclination setting for ECE-compliant gas discharge headlights,
LED headlights and DLA headlights
fuel gauge
0 to 1/2 1.0 %
1/2 to 1 1.0 %
Light pattern for dimmed beam, version 1:

– Whether, with the dipped beam switched on, the horizontal
bright/dark boundary contacts the dividing line -1- of the test
area and
– Check whether the breakinggepoint AG. V-2-
olksbetween
wagen AG the horizontal
a n does
part of the light/dark borderVolksw on the left and the risingnot part on
the right lies on the ed bvertical line of the central point -3-.uaThe
y g
ran
bright core of the
tho light beam must be to the right of the vertical
ris tee
or
line. s au ac
s
ce
le
un
pt
an
d
Note
itte
y li
rm
ab
pe
ility
♦ To simplify the determination of the breaking point -2-, cover

ot
wit
, is n
and uncover left (from driver perspective) half of the headlight

h re
a few times. Then check dipped beam again.

hole
spec
es, in part or in w
♦ After correct adjustment of dipped beams, the centre point of

t to the co
the main beam must lie on the centre mark -3-.
Light pattern for dimmed beam, version 2:

rrectness of i

l purpos
– With the dipped beam switched on, the lowest part of the hor‐
nform
ercia
izontal light-dark border must touch the dividing line -1- of the
test area
m
a
com
tion in
– The breaking point -2- between the horizontal part of the light-
r
te o
dark border on the left and the slope on the right should be on
thi
s
iva
the vertical line passing through the centre mark.

do
r
rp
cum
fo
en
ng
t.
yi Co
Note t. Cop py
rig
gh ht
yri by
To simplify the determination of the breaking point -2-, cover and
op Vo
by c lksw
cted
uncover left (from driver perspective) half of the headlight a few
agen
Prote AG.
times. Then check dipped beam again.
4.45.3 Headlight adjustment (SAE): checking


Touran 2003 ➤
Note
♦ The VOL/VOR marking is visible on the outside the headlight.

ant headlights.

Inclination setting for SAE-compliant VOL gas discharge head‐
lights, LED headlights and DLA headlights
fuel gauge
0 to 1/2 0.7 %
1/2 to 1 0.7 %
VOL: Visual Optical Aim Left -1-

– Check whether the left horizontal light-dark border touches the
separating line -1- in the test area of the headlight adjustment
unit. agen
AG. Volkswagen AG d
o w es n
olks ot g
byV ua
ed ran
ris tee
tho or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
Inclination setting for SAE-compliant VOR gas discharge head‐ h re

hole
spec
es, in part or in w
t to the co

fuel gauge
rrectness of i
0 to 1/2 0.0 %
1/2 to 1 0.0 %
l purpos
nform
ercia
VOR: Visual Optical Aim Right -2-

m
at
om
io
– Check whether the right horizontal light-dark border touches

n
c
in t
r
the separating line -2- in the test area of the headlight adjust‐
o
his
te
ment unit.
a
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touran 2003 ➤
4.45.4 Gas discharge headlights without “Dy‐

namic Light Assist” dynamic main beam
regulation: adjusting
Note
As of model year 2014 the headlight Aadjustment

G. VolkswagenisAG
subject to a
separate charge. lksw
agen does
no
o t gu
yV
edb ara
is nte
– Carrying out basic thorsetting of headlight range control ⇒ Vehicle eo
diagnostic tester
s au ra
c
s
ce
le
Headlight ►2006
un
pt
an
d
itte
The adjustment screws for the right headlight are a mirror image.
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
♦ Vertical adjustment screw -3- for main beam
es, in part or in w
t to the co
♦ Lateral adjustment screw -4- for main beam
– Always turn the height adjustment screws of bright-dark boun‐
rrectness of i
dary first.
l purpos
– Then, turn the lateral adjustment screws of light-dark border.
Headlights 2007► nform

ercia
The adjustment bolts for the left headlight are a mirror image.
m
a
com
tion in

r
te o
thi
s

iva
do
r
rp
cum
Headlights 2011►
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Overview of gas discharge headlights without “Dynamic Light As‐

sist” dynamic main beam regulation:
1- Bulb for left cornering light - L148- or bulb for right cornering
light - L149-
turn signal - M7-
3- Left LED module for daytime running light and side light -
L176-
4- Left gas discharge lamp - L13- or right gas discharge lamp
- L14-
– Adjust right headlight as follows:

Touran 2003 ➤
1 - Lateral adjustment
2 - Height adjustment
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Turn height adjustment screw -2- until setting is correct.
Note
In some markets, the adjustment bolt for lateral adjustment is

-1- encapsulated. Lateral adjustment is not permissible here.
– Turn respective lateral adjustment screw -1- until setting is

correct.
Note

quence.

Touran 2003 ➤
4.46 Headlight adjustment: checking gas dis‐

charge headlights with DLA
Note

ment unit is used.
a separate charge.

AG. Volkswagen AG d
agen
Check headlight adjustment (ECE). ⇒ page 130 olksw
oes
not
byV gu
ara
d
Check headlight adjustment (SAE). ⇒ page 132 orise nte
eo
h
ut ra
Gas discharge headlights with “Dynamic Light Assist”
ss a
dynamic c
main beam regulation: adjusting ⇒ page 135
ce
le
un
pt
an
d

itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
• Headlight lenses must not be damaged or dirty.
hole
spec
• Reflectors and lights OK
es, in part or in w
t to the co
• The initialisation of the headlight range control must have been
completed. 1)
rrectness of i
l purpos

nform
ercia
• Vehicle and headlight adjustment unit must be aligned.

m
a
com
tion in

r
te o
thi
s
• Event memory must be cleared.

iva
do
r
rp
cum
• If the headlight adjustment unit has an adjustment mode, se‐

fo
en
ng
lect it.
t.
yi Co
Cop py
. rig
ht ht
rig by
py
units . co Vo
by lksw
cted agen
Prote
1) During the initialisation, the step motors for the headlight range
AG.
control are reset to dipped beam position. The initialisation of the

headlight range control is performed during vehicle start or after
an "on" signal is applied to terminal 15.


AG. Volkswagen AG d
agen oes Touran 2003 ➤
olksw not
d by
V
Maintenance - Edition
gu
ara 01.2019
ise nte
or eo
h
The inclination on the headlight adjustment unit
aut is set according ra
s c
to the fuel level in the fuel tank. s
ce
e
nl
pt
du
Inclination setting for ECE-compliant gas discharge headlights,
an
itte
y li
LED headlights and DLA headlights
erm
ab
ility
ot p
wit
, is n
fuel gauge
h re
hole
spec
0 to 1/2 1.0 %
es, in part or in w
t to the co
1/2 to 1 1.0 %
rrectness of i
Test pattern with dynamic main beam
l purpos
Note
nform
mercia
♦ For dynamic main beam test pattern, headlights need to be
at
om
io
reset to basic settings using vehicle diagnostic tester .
n
c
in t
or
his
e
♦ The basic settings can only be reset using vehicle diagnostic

at
do
riv
tester . After resetting, DLA main beam distribution is actuated

p
cum
or
automatically.
f
en
ng
t.
yi Co
♦ Pay special attention to correct alignment of the adjustment Cop py
t.
sighting device on the headlight adjuster. Only when this has
rig
gh ht
yri by
been done can you adjust the headlights to ensure that they
op Vo
by c lksw
do not dazzle other road users. cted agen
Prote AG.
♦ In vehicles with DLA the dipped headlight setting can be

checked as an alternative. ⇒ page 131

– Whether the horizontal light-dark border touches the separat‐
ing line -1- in the test area when the main beam is on.
– Whether the breaking point -2- between horizontal part of the
light-dark border on the right and the rising part on the left lies
on the vertical line of the central point -3-. The bright core of
the light beam must be to the left of the vertical line.
Note
The setup pattern applies only to the left headlight. The setup
pattern for the right headlight is a mirror image.

Testing may also be carried out with dipped headlights switched
on. Nevertheless, said dynamic main beam test pattern is prefer‐
red.
For checking dipped headlight it is not necessary to use the ve‐
hicle diagnostic tester .
Headlight adjustment, on the other hand, can only be carried out
using the test pattern with dynamic main beam. The controller
only uses the DLA main beam distribution test program.

Touran 2003 ➤
test area
4.46.3 Headlight adjustment (SAE): checking

AG. Volkswagen AG d
agen oes
olksw not
V gu
by
Note rised ara
nte
ho eo
aut ra
♦ The VOL/VOR marking is visible on the outsides the headlight.
s c
ce
le
un
pt
an
d
itte
ant headlights.
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Inclination setting for SAE-compliant VOL gas discharge head‐
t to the co
fuel gauge
rrectne
0 to 1/2 0.7 %
s
1/2 to 1 0.7 %
s o
cial p
f inform
mer
atio

om
n
c
i
or
n thi
te
sd
a
Note
iv
o
pr
cum
r
fo
en
ng
♦ For dynamic main beam test pattern, headlights need to be

t.
yi Co
op
reset to basic settings using vehicle diagnostic tester . C py
t. rig
gh ht
yri by
♦ The basic settings can only be reset using vehicle diagnostic
op Vo
by c lksw
tester . After resetting, DLA main beam distribution is actuated cted agen
Prote AG.
automatically.
♦ Pay special attention to correct alignment of the adjustment
do not dazzle other road users.
♦ DLA: “Dynamic Light Assist”, dynamic high beam regulation.

Touran 2003 ➤

Note
The setup pattern applies only to the left headlight. The setup
pattern for the right headlight is a mirror image.

red.
test area
olkswagen AG
the vertical line passing AG. Vthe
swthrough
agen centre mark.
does
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ility
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Inclination setting for SAE-compliant VOR gas discharge head‐

wit
, is n

h re
hole
spec

es, in part or in w
fuel gauge
t to the co
0 to 1/2 0.0 %
1/2 to 1 0.0 %
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
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or c
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Cop py
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Prote AG.

Touran 2003 ➤
Note
AG. Volkswagen AG d
agen
♦ For dynamic main beam
Vol test pattern, headlights need
ksw
oes
not to be
reset to basic settings
se
db
y
using vehicle diagnostic tester .uaran
g
i tee
or
♦ The basic settings
au
th can only be reset using vehicle diagnosticor a
tester . After
ss resetting, DLA main beam distribution is actuated c
ce
le
automatically.
un
pt
an
d
itte
♦ Pay special attention to correct alignment of the adjustment
y li
erm
ab
ility
ot p
wit
is n
do not dazzle other road users.
h re
ole,
spec
t to the co
♦ DLA: “Dynamic Light Assist”, dynamic high beam regulation.
rrectne
ss
o
cial p
f inform
mer
atio
m
o
n
c

i
or
n thi
te
sd
iva
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pr
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r
Note
fo
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t.
yi Co
op py
The setup pattern applies only to the left headlight. The setup t. C rig
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pattern for the right headlight is a mirror image. yri
p by
o Vo
by c lksw
cted agen
Prote AG.
red.
test area

Touran 2003 ➤
AG. Volkswagen AG d Maintenance - Edition 01.2019
agen oes
olksw not
V gu
by
4.46.4 Gas discharge headlights with “Dynamic orise
d ara
nte
eo
Light Assist” dynamic main beam regu‐ th
au ra
ss c
lation: adjusting
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
h re
As of model year 2014 the headlight adjustment is subject to a
hole
separate charge.
spec
es, in part or in w
t to the co
Identification:
There is no external difference between headlights with “Dynamic
rrectness of i
Light Assist” and headlights without DLA The production control
number 8G3 means that the vehicle is equipped with DLA.
l purpos
Overview of gas discharge headlights and “Dynamic Light Assist”

dynamic main beam regulation 2011►
nf
ercia
orm
1- Bulb for left cornering light - L148- or bulb for right cornering
m
atio
m
light - L149-
o
n in
or c
thi
te
sd
a
turn signal - M7-

iv
o
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rp
cu
o
m
3- Left LED module for daytime running light and side light -
f
en
ng
t.
L176-
yi Co
Cop py
t. rig
4- Left gas discharge lamp - L13- or right gas discharge lamp
gh ht
yri by
- L14-
cop Vo
by lksw
cted agen
Prote AG.
– Carrying out basic setting of headlight range control ⇒ Vehicle
diagnostic tester

Touran 2003 ➤
Adjusting right headlight:

1- Lateral adjustment
2- Height adjustment
– Turn height adjustment screw -2- until setting is correct.
Note lkswage es n
o ot g
byV ua
d ran
ir se
In some markets, the adjustment
tho bolt for lateral adjustment is tee
or
-1- encapsulated. Lateral
ss
au
adjustment is not permissible here. ac
ce
le
un
pt
– Turn lateral adjustment screw -1- until setting is correct.
an
d
itte
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rm
ab
The adjustment bolts for the left headlight are a mirror image.
pe
ility
ot
Subsequent check of right headlight
wit
, is n
h re
hole
spec
Caution
es, in part or in w
t to the co
The subsequent check of the headlight is performed using the
test pattern for the dipped beam headlight.
rrectness of i
It is not permitted to change the lateral setting of the headlight
l purpos
any more during the check. Readjusting the vertical setting is

permissible.
nform
ercia
– Check headlight setting.

m
a
com
tion in
– Adjust height setting of headlight, if necessary.
r
te o
thi
s
iva
do
r
rp
cum
Note
fo
en
ng
t.
yi Co
op
C py
t. rig
gh
quence.
ht
pyri by
Vo
co lksw
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cted agen
Prote AG.
4.47 Headlight adjustment: checking fog

lights
Note

ment unit is used.
a separate charge.

Checking headlight adjustment ⇒ page 137
Adjusting fog lights and other auxiliary lights. ⇒ page 137


AG. Volkswagen AG d
agen oes
Volksw Touran no2003
t gu ➤
y
rised b
ara
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au ra
• Lenses must not be damaged or dirty. ss c
ce
le
un
• Reflectors and bulbs OK.
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
• Vehicle and headlight adjuster must be aligned.
t to the co
rrectness of i
units .
l purpos
4.47.2 Headlight adjustment: checking
nform
ercia
m
a
com
tion in
r

te o
thi
s
iva
do
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rp
cum
fo
en
g

n
t.
yi Co
to the fuel level in the fuel tank. t. Cop py
rig
gh ht
yri
Inclination setting for fog lights p by
co Vo
by lksw
cted agen
Prote
AG.
fuel gauge
0 to 1/2 2.2 %
1/2 to 1 2.0 %
Fog lights:
– Check whether the upper light-dark border touches the setting
line and runs horizontally over the entire width of the test
screen.
Other additional lights:
Additionally retrofitted lights of other systems must be checked
and set according to valid guidelines.
4.47.3 Fog lights and other auxiliary lights: ad‐

justing
Note
As of model year 2014 the headlight adjustment is subject to a

separate charge.
Version 1
Front fog light in headlight:
Adjustment of fog lights is performed automatically when adjust‐
ing headlights ⇒ page 119 .

Touran 2003 ➤
Version 2
Fog light in bumper:
The illustration shows the right fog lamp; the setting screw on the
left fog lamp is on the opposite side.
– Set the appropriate inclination on the headlight adjustment
unit.
– Unclip retaining lugs -arrows- and pull cover off lower part of
bumper.
– To adjust the headlight range turn adjustment bolt -arrow-.

Version 3
Fog light in bumper:
The illustration shows the left fog lamp; the setting screw on the
right fog lamp is on the opposite side.
– Turn height adjustment screw with the help of an Allan key AG. Volkswagen AG d
agen oes
ksw
-arrow- until setting is correct. by Vol not
gu
d ara
ise nte
There is no provision for lateral adjustment. thor eo
au ra
c
Version 4 ss
ce
e
nl
pt
du
Other additional lights:
an
itte
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erm
ab
Additionally retrofitted lights of other systems must be checked
ility
ot p
and set according to valid guidelines.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
4.48 Service interval display: resetting

rrectness of i
Additional information for service interval display ⇒ page 7

l purpos
SID: resetting using vehicle diagnostic tester . ⇒ page 139

SID: resetting without vehicle diagnostic tester . ⇒ page 139
nform
ercia
The service interval display must be reset (adapted) after

m
at
om
ion
♦ delivery inspection
c
in t
or
his
te
♦ Every inspection service (only vehicles as of ►2004)

a
do
priv
cum
or
♦ Every oil change service and interval service.

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en
ng
t.
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♦ each oil change (flexible/fixed) Cop py
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is carried out! p by
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Prote AG.

Touran 2003 ➤
Until now, only service events linked to oil changes could be dis‐ olks
wage es n
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played in the service interval display. Service stickers havedbeen
by
V ua
ran
used for all other service events. or
ise tee
th or
au ac
Model year Service intervalss display for oil Service interval display for inspec‐
ce
change service / interval service tion service (channel 2)
e
nl
pt
du
(channel 1)
an
itte
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erm
ab
►2013 yes no
ility
ot p
wit
, is n
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hole
spec
From model year 2014, a second service channel is provided so
es, in part or in w
that both service events, even those not linked to an oil change,
t to the co
can be conveniently displayed.
Model year Service interval display for oil Service interval display for inspec‐
rrectness of i
change service (flexible/fixed) tion (channel 2)
(channel 1)
l purpos
2014► yes yes
nform
mercia
at
om
ion
c
in t
or
Note
his
ate
do
priv
c
It is also possible to reset the service interval display (SID) man‐
um
for
ually. However, bear in mind that, on vehicles coded to flexible
en
ng
t.
yi Co
interval, the SID needs to be coded to fixed intervals. This also Cop py
modifies the adaptation channel for oil quality.
ht. rig
rig ht
py by
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4.48.1 Resetting SID using vehicle diagnostic
Prote AG.
tester
– Reset service interval display ⇒ Vehicle diagnostic tester.
– Select the respective service which is to be reset.
4.48.2 SID: resetting without vehicle diagnostic

tester
Only up to ►2013 ⇒ page 139
Applies from 2014► ⇒ page 140
Applies only up to ►2013

With rocker switch on windscreen wiper lever or using buttons in
the multifunction steering wheel
– Select menu “Settings” using rocker switch on windscreen
wiper lever or

lkswage es n
o ot g
byV ua
d ran
ir se
Touran 2003 th➤
o tee
or
u
Maintenance
ss - Edition 01.2019
a ac
ce
e
nl
pt
du
– Select menu “Settings” using buttons in the multifunction
an
itte
y li
steering wheel. erm
ab
ility
ot p
– Mark menu option “Reset” in sub-menu “Service” and reset
wit
, is n
service interval display by pressing OK button -1- on wind‐
h re
screen wiper lever or on multifunction steering wheel -5-.
hole
spec
es, in part or in w
– Then confirm the confirmation dialogue with OK button again.
t to the co
With function buttons on dash panel insert
rrectness of i
l purpos
nf
ercia
– With ignition switched off, press button -3- and hold.
orm
m
atio
– Switch ignition on.
om
n in
or c
– Release button -3- and press clock setting button -1- briefly.
thi
te
sd
iva
The service interval display is now in the resetting mode.
o
r
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m
f
en
After a short time the display switches back to the original display.
ng
t.
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op py
Applies as of 2014► t. C rig
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pyri by
Oil change service interval display: resetting
co Vo
by lksw
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Prote AG.
– With ignition switched off, press and hold button -3-.

– Release button -3-.

Touran 2003 ➤
– Reset oil change service information by pressing OK button

-5- on multifunction steering wheel or OK button -1- on wind‐
screen wiper lever.
Inspection service interval display: resetting
– Switch on hazard warning lights. AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
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nl
pt
du
an
itte
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– With ignition switched off, press and hold button -3-.
erm
ab
ility
ot p
wit
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h re
– Release button -3-.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Reset inspection service interval display by pressing OK but‐

ton -5- on multifunction steering wheel or OK button -1- on
windscreen wiper lever.
4.49 Service interval display: recoding

Recoding from flexible to fixed intervals
ODIS Service
– Connect the vehicle diagnostic tester .
– Carry out identification of vehicle.

Touran 2003 ➤
ODIS Service
– Enter task data, or select “Without task”.
– Select “Control units”.
– Select “Dash panel insert”.
– Select “Guided Functions”.
– Select “Change flexible/fixed intervals”.
– Carry out adaptation according to the information of “Guided functions”.
Changing values for maximum distance to be driven (km) until

next oil change service (fixed) during delivery inspection
ODIS Service
– Connect the vehicle diagnostic tester .
– Carry out identification of vehicle.
– Enter task data, or select “Without task”.
– Select “Control units”.
– Select “Dash panel insert”.
AG. Volkswagen AG d
agen
– Select “Guided Functions”. Volksw
oes
not
by gu
ara
– Select “Oil change service (fixed)”.
rised
nte
ho eo
– Follow instructions in “Guided
aut functions” mode. ra
ss c
– Reset “-1- Oil change service (fixed)”. ce
le
un
pt
an
d
– Follow instructions in “Guided functions” mode.

itte
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rm
ab
The current values for maximum distance to be driven (km) until next oil change service are shown in the
pe
ility
display of the vehicle diagnostic tester .

ot
wit
, is n
– Select “No”.
h re
hole
spec
– Select value for maximum distance to be driven until next oil change service, according to specifications
es, in part or in w
valid in your country.

t to the co
– Carry out adaptation according to the information of “Guided functions”.

rrectness of i
l purpos
4.50 Sunroof: checking function, cleaning

guide rails and greasing with special
nform
ercia
grease
m
a
com
tio

n in
r
te o
thi
♦ Lubricating paste G 060 751 A2

s
iva
do
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cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Touran 2003 ➤
Sunroof: checking function, cleaning and greasing guide rails

– Check function of sunroof.
. Volkswagen AG
do gen AG
– Clean guide rails -arrows- and grease
Vol
ksw with special grease G es not
a
060 751 A2. ed
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ara
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ss
ce
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nl
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du
an
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erm
ab
ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
4.51 Sliding sunroof drains: checking for
nform
ercia
blockage, cleaning if necessary

m
at
om
ion
c
in t
or
4.51.1 Sliding sunroof drains, version 1: check‐
his
ate
do
riv
ing for blockage and cleaning if neces‐

p
cum
for
en
g
sary
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
♦ Cleaning and fitting tool - VAS 6620- Prote
cted AG.
agen

– Open sliding sunroof.

Touran 2003 ➤
– Check sliding sunroof drain holes -arrows- for dirt and clean if
necessary.
– Pour tap water into sliding sunroof drains and check if almost
the same quantity of water flows out of the wheel housings.
If this is the case, the test is completed. If only a small quantity of
water or no water at all flows out of the wheel housings, perform
the following procedure:
– Removing plenum chamber cover ⇒ General body repairs,
exterior; Rep. gr. 64 ; Flush bonded windows; Plenum cham‐
ber cover . Volkswage AG n AG d
agen oes
olksw not
yV gu
db ara
Note rise nte
tho eo
s au ra
c
Removal and installation of plenum
s chamber is performed as a
ce
le
separate charge.
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
– If fitted, remove cover -1- by loosening fasteners -A and B-.
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n
– To press out dirt, guide cleaning and fitting tool - VAS 6620-
thi
te
onto drain valves by pushing and pulling it slowly.

sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touran 2003 ➤
– Drains -arrows- are located on the left and right side, inside
the plenum chamber.
lkswage es n
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byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectnes
– Check plenum chamber drains -arrows- for dirt and clean if
s o
necessary.
cial p
f inform
– To check, pour tap water again through the sliding sunroof
mer
atio
drain holes.
om
n
c
i
Install in reverse order.
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
wage es n
olks ot g
4.51.2 Sliding sunroof drains, version 2: check‐
V
by ua
ed ran
ris tee
ing for blockage and cleaning if neces‐
tho
or
au ac
ss
sary
ce
le
un
pt
an
d
Open sliding sunroof completely.

itte
y li
erm
ab
– Check front and rear drain holes for dirt and clean if necessary.
ility
ot p
wit
is n
– Pour tap water from a measuring beaker -1- into sunroof
h re
ole,
drains. Proceed with caution to make sure no water enters the
spec
vehicle interior.
t to the co
– On underside of vehicle, check if water emerges in area of
front and rear wheel housing.
rrectne
– Repeat procedure on other side of vehicle.
– If no water emerges at relevant positions, clean sunroof
s
drains.
s o
cial p
f inform
mer
Note
atio
om
n
c
i
The repair measure is carried out subject to a separate charge.
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op
4.52 Windscreen wash/wipe system and
C py
t. rig
gh ht
yri
headlight washer system: checking
p by
co Vo
by lksw
cted
function and adjusting
agen
Prote AG.
Anti-freeze protection of fluid: check and top up fluid as needed

⇒ page 146 .
Window wash/wipe system: checking spray jet settings and adjust
if necessary ⇒ page 148 .
Headlight washer system: check spray jet settings ⇒ page 150 .
Windscreen wiper blades: check park position ⇒ page 150 .
Rear window wiper blades: checking park position ⇒ page 150
4.52.1 Anti-freeze: checking protection of fluid,

topping up fluid if necessary
♦ Refractometer - T10007 A-

Touran 2003 ➤
Note
In countries and regions where no frost occurs due to the local

climatic conditions, the anti-freeze protection does not need to be
checked.
Read precise value for the following tests at light/dark boundary.

Using a pipette, place a drop of water on the glass to improve the
readability of the light/dark boundary. The light-dark border can
be clearly recognised on the “WATERLINE”.
– Check concentration of anti-freeze additive using refractome‐
ter - T10007 A- .
The scale -4- of the refractometer is applicable for the anti-freeze
protection of the window wash/wipe system.
Mixing ratio:
Frost protection Genuine washer fluid Water

to ⇒ ETKA
-17/-18°C AG. Volkswagen1AG
part 3 parts
agen doe
-22/-23 °C olksw 1 part s not gu 2 part
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b ara
-37/-38 °C ed 1 part nte 1 part
oris eo
th
au ra
ss c
ce
le
un
pt
– Top up fluid in window wash/wipe system (only if customer

an
d
itte
y li
requests to do so).
rm
ab
pe
ility
Use genuine washer fluid ⇒ ETKA throughout all year to fill win‐
ot
wit
, is n
dow wash/wipe system.

h re
hole
Depending on season, a winter product with anti-freeze protection

spec
or a summer product with increased cleaning capabilities should

es, in part or in w
t to the co
be used.
Ready-to-use window cleaner (Ready Mix) does not need to be
mixed with water.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
Note
♦ Genuine washer fluid ⇒ ETKA prevents the spray jets, washer

fluid reservoirs and connecting hoses from freezing.
♦ In vehicles with fan jets, the reservoir must be filled with Gen‐
uine washer fluid, as this fluid has a low viscosity at tempera‐
tures below freezing. Otherwise the complicated spray jet
system can become blocked by the crystallised washer fluid,
which affects the spray pattern of the spray jet. Genuine wash‐
er fluid ensures that the fan jets remain fully functional at low
temperatures.
♦ Genuine washer fluid ⇒ ETKA can also be used in the sum‐
mer. The powerful cleanser easily removes wax and oil resi‐
due from the glass.
♦ Frost protection must be guaranteed to approx. -25°C (approx.
-35°C in countries with an arctic climate) in the windscreen n AG. Volkswagen AG do
wash/wipe system. olkswage es n
ot g
byV ua
d ran
ir se tee
4.52.2 Window wash/wipe system: checking autho
or
ac
spray jet settings and adjusting if nec‐ ss
ce
le
un
pt
essary
an
d
itte
y li
erm
ab
ility
ot p
Note
wit
is n
h re
ole,
spec
♦ If the spray field is uneven due to soiling in the spray jet, re‐
move spray jet, ⇒ Rep. gr. 92 and rinse with water opposite
t to the co
to direction of spray.
♦ Subsequent blowing through with compressed air against the
rrectne
spraying direction is permitted.
ss o
Caution
cial p
f inform
mer
♦ Never use items to clean the spray jets!
atio
om
♦ Never use a needle or a similar object to adjust the spray
n
c
i
or
n
jets, otherwise the water passages in the spray jet will be
thi
te
sd
damaged!
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Spray jets for windscreen wash/wipe system ⇒ page 149 . t. Cop py
rig
gh ht
yri
Rear window spray jet setting ⇒ page 149 . p by
co Vo
by lksw
cted agen
Special tools and workshop equipment required Prote AG.
♦ Adjusting tool - T10564-

Touran 2003 ➤
♦ Adjusting tool - T40187-

Spray jets for windscreen washer system:
The spray jets are preset. However, small differences in height
may be corrected.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– If both spray fields are not at same height, adjust spray direc‐
ility
ot p
tion upwards or downwards as follows:
wit
, is n
h re
– Adjust spray direction at adjuster -arrow- using a screwdriver.
hole
spec
♦ “Clockwise” lower.
es, in part or in w
t to the co
♦ “Anti-clockwise” higher.
Spray jet setting of rear window, version 1
rrectness of i
l purpos
Note nf
ercia
Adjusting the spray jet is only possible vertically, i.e. in direction

orm
of rear window or in opposite direction. A lateral adjustment of

m
atio
m
spray jet in direction of wiper arm must not be performed. The

o
n in
c
spray jet is firmly adjusted in this direction at the factory.

or
thi
te
sd
iva
o
r
rp
cu
o
– Adjust spray jet using adjusting tool - T10564- or adjusting tool

f
en
ng
t.
- T40187- so that the water jet sprays onto the upper third of
yi Co
op
rear window.
C py
t. rig
gh ht
yri by
Spray jet setting of rear window, version 2
op Vo
by c lksw
cted agen
Prote AG.
– Adjust spray jet using adjusting tool - T10564- or adjusting tool

- T40187- so that the water jet sprays onto the upper third of
rear window, as shown.
a - approx. 100 mm
b - approx. 80 mm
Note
If the vehicle is equipped with a fan jet on its rear window, the fan
jet cannot be adjusted.

Touran 2003 ➤
4.52.3 Headlight washer system: checking

spray jet setting, Touran Plus 2003 ►
Caution
Only control function of spray jets but do not adjust them.
Jet adjustment dimensions for the right-hand headlight (left-hand

mirror image).
Washer spray jet: checking settings
– Switch on dipped headlight.
– Operate windscreen washing system.
The headlights are washed if the windscreen wiper lever is held
in “wipe position” for at least 1.5 seconds.
The washer jet must spray to centre of headlights, see -B- and
-C-.
If the spray pattern deviates from the specifications, execute re‐
pair measure ⇒ Electrical system; Rep. gr. 92 ; Headlight washer
system; Removing and installing washer jet lift cylinder .
Note
If the piston rod is pulled out

swa
gby hand,
en AG. Volkthe seal between
swagen AG
does the piston
rod and the lifting cylinder
by
Volk housing will be damaged. not
gu ara
ed nte
ris
tho e or
au
4.52.4 Wiper blades: checking park position
ac
ss
ce
le
un
pt
Vehicles to 07.2010
an
d
itte
y li
rm
ab
⇒ Electrical system up to 07.2010; Rep. gr. 92 ; Windscreen

pe
ility
wiper system (opposed wiper system); Adjusting wiper blade park

ot
wit
, is n
position
h re
hole
Or
spec
es, in part or in w
t to the co
⇒ Electrical system up to 07.2010; Rep. gr. 92 ; Windscreen

wiper system (parallel wiper system); Adjusting front wiper blade
park position
rrectness of i
Vehicles from 08.2010

l purpos
⇒ Electrical system as of 08.2010; Rep. gr. 92 ; Windscreen

wiper system; Adjusting front wiper blade park position
nform
mercia
Note
com
tion in
r
te o
thi
♦ Adjusting the wiper blades is a repair measure.

s
iva
do
r
♦ The repair measure is carried out subject to a separate charge.

rp
cum
fo
en
ng
t.
yi Co
op
4.52.5 Rear window wiper blade: checking park
C py
ht. rig
rig ht
position
py by
co Vo
by lksw
cted agen
Prote AG.
Vehicles to 07.2010
⇒ Electrical system up to 07.2010; Rep. gr. 92 ; Rear window
wiper system; Adjusting rear window wiper park position

Touran 2003 ➤
Vehicles from 08.2010

⇒ Electrical system as of 08.2010; Rep. gr. 92 ; Rear window
wiper system; Adjusting rear window wiper park position
Note
♦ Adjusting the wiper blades is a repair measure.

♦ The repair measure is carried out subject to a separate charge.
4.53 Wiper blade protection: removing
Note
There are 3 different versions of wiper blade protection:
Version 1: blade protector with 2 securing clips

♦ Identification, blade protector with two securing clips
-arrows 1 + 2-.
Wiper blade protection, version 1: removing ⇒ page 152
Version 2: blade protector to slide on

♦ Identification, the blade protector -arrow- is slid on the wiper
blade.
n AG. Volkswagen A
Wiper blade protection, version
olks
wage 2: removing ⇒ page
G do
es n 152
o
yV t gu
db ara
rise nte
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Version 3: transport wiper blade

hole
spec
♦ Identification, the transport wiper blade is fitted without wind

es, in part or in w
t to the co
deflector, it must be replaced by the standard wiper blade.

Changing wiper blade protection, version 3 -transport wiper
blade- ⇒ page 153
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
151
by c lksw
cted
agen
Prote AG.
Touran 2003 ➤
4.53.1 Wiper blade protection, version 1, re‐

moving
– Switch ignition on and off briefly with bonnet closed.
– When engine is switched off move wiper lever down to touch-
wipe function within 10 seconds.
The wiper blades move to the service position.
– Lift the wiper arm away from windscreen.
Caution
When doing this, do not touch the wiper blade to prevent dam‐
age.
AG. Volkswagen AG d
agen oes
olksw not
– Remove upper securing clip upwards and lower securing clip d by V gu
ara
downwards -arrows-. horise nte
eo
ut ra
s a c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Pull blade protector off wiper blade from bottom to top, as
shown in illustration.
s
– Carefully place wiper arm back onto windscreen.
s o
cial p
f in
– Switch ignition on and briefly operate the wiper lever to move
form
mer
the wipers back to park position. Switch ignition off again.
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
4.53.2 Wiper blade protection, version 2, re‐

co Vo
by lksw
cted agen
Prote AG.
moving
Caution
age.

Touran 2003 ➤
– Pull blade protector off wiper blade upwards, as shown in il‐

lustration.
4.53.3 Wiper blade protection, version 3 -trans‐

port wiper blade: changing
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
– Depending on version, turn wiper aut blade with lip upwards and ra
s c
pull off, or release wiper blade
s at joint -3- by pushing locking
ce
le
device -1- into mounting -2- and pull wiper blade out.
un
pt
an
d
itte
y li
– Slide standard wiper blade into mounting and ensure that it
erm
ab
audibly engages, or turn wiper blade with lip down onto stop.
ility
ot p
wit
is n
h re
Caution
ole,
spec
t to the co
age.
rrectne

s

s o
cial p

inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touran 2003 ➤
4.54 Track rod ends: checking clearance,

firm seating and boots
– Check play by moving track rods and wheels with the vehicle
raised (wheels hanging free). Clearance: zero clearance
– Check attachment.
– Check that boots -arrow- are not damaged and are seated
correctly.
4.55 Auxiliary heater: setting weekday in

menu of dash panel insert
As the weekday in the menu for the auxiliary heater is not part of
the time and date setting for the dash panel insert, it must be set
separately.
Auxiliary heater: setting weekday, version 1 ⇒ page 154
Auxiliary heater: setting weekday, version 2 ⇒ page 155
4.55.1 Auxiliary heater: setting weekday, ver‐

sion 1
Setting weekday using buttons on multifunction steering wheel
– Press button -1- until the menu for auxiliaryGheater
. Volkswaappears.
gen
wa oes gen A AG d
– Press button -4- until “Weekday” y V is shown and select using
olks not
gu
button -3-. ris
ed b ara
nt ee
tho or
– Now set weekday using aubuttons -4- and -2-, and confirm with ac
button -3-. ss
ce
le
un
pt
– Exit menu using button -1-.

an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Setting weekday using buttons on windscreen wiper lever

es, in part or in w
t to the co
– Follow same path through menu as followed using buttons on

multifunction steering wheel.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touran 2003 ➤
4.55.2 Auxiliary heater: setting weekday, ver‐

sion 2
Setting weekday using buttons on multifunction steering wheel
Button -5- is used to confirm menu options.
Press arrow buttons -1- -2- and -4- to change the menu.
1. Select main menu:
– Switch ignition on. A vehicle symbol is displayed.
Press OK button -5- in multifunction steering wheel.
– Press appropriate arrow buttons -2- and -4- in multifunction
steering wheel until menu “Auxiliary heater” is displayed.
– Press OK button -5-.
2. Select weekday:
– Press arrow buttons -1- until menu “Setting start time” is dis‐
played.
– Select “Weekday”.
Setting weekday using buttons on windscreen wiper lever

Button -1- is used to confirm menu options.
Rocker lever -2- is used to change the menu.
1. Select main menu:
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
– Switch ignition on. A vehicle symbol is displayed.

pt
du
an
itte
y li
– Press button -1- once.

erm
ab
ility
ot p
– To return to the main menu, press rocker lever -2- and hold for
wit
, is n
about one second. Or select menu option “Back” and press

h re
button -1-.
hole
spec
es, in part or in w
– Press rocker lever -2- up or down to mark a menu option.

t to the co
The marked menu option is found between the two horizontal

lines. Additionally there is a triangle on the right.
rrectness of i
– To confirm, mark menu option “Auxiliary heater” and press

button -1- in windscreen wiper lever.
l purpos
2. Select weekday:
nf
ercia
– Press rocker lever -2- up or down to mark menu option “Setting

rm
m
start time”.
atio
om
n in
c
– Select “Weekday” and confirm with button -1-.

or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touran 2003 ➤
AG. Volkswagen AG d
agen
4.56 Door arrester: grease. yV
olksw
oes
not
gu
d b ara
e
Perform the following procedure: horis nte
eo
aut ra
– Lubricate door arrester at positions -1-, -2-,
s -3- and -4- with
s c
universal oil spray - G 000 115 A2- .
ce
le
un
pt
an
d
itte
Ensure universal oil penetrates by moving door several times over
y li
erm
ab
all detents.
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Wipe off excess universal oil with a cloth.
s
– Then, lubricate door arrester rollers with lubricating paste - G
s o
cial p
f
000 150- at positions marked with an -arrow-.
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
4.57 Transportation mode: switching off
Prote AG.
Note
♦ The transportation mode is responsible for assuring the start‐

ing capability of vehicle.
♦ Battery discharging is reduced by the transportation mode,
because electrical consumers are switched off.
♦ All vehicle functions which are not necessarily used during
vehicle transportation and require no-load voltage or battery
capacity are switched off with the activated transportation
mode, with regard to the service life of battery.
♦ These are especially all functions in the vehicle which can re‐
duce the battery capacity when being misused.
♦ Examples are radios, electronically operated flaps and attach‐
ments and anti-theft alarm systems which can produce faults
during transportation.
Procedure
Note
If the display is not as shown in the procedure: ⇒ Operating in‐

structions for vehicle diagnostic tester
– Switch off transportation mode ⇒ Vehicle diagnostic tester.

Procedure for event entry “Loading mode active P169A00”
– Switch transport mode on again.

Touran 2003 ➤
– Switch ignition off for 10 seconds. AG. Volkswagen AG d

agen oes
lksw not
– Switch transport mode off again. d byV
o gu
ara
ise nte
r
– Switch on ignition again for 10 seconds.utho eo
ra
s a c
After this procedure is carried out the event entry “Loading mode
s
ce
le
active P169A00” is no longer stored.
un
pt
an
d
itte
y li
The vehicle diagnosis tester may need to remain connected for
rm
ab
further procedures or tests.
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
4.58 Transportation devices: removing block‐
ing pieces from springs on front axle
rrectness of i
l purpos
Blocking pieces are fitted to front axle springs of vehicles with

sports running gear. These vehicles can be identified by a label
hanging on the mirror -arrow-.
nform
mercia
a
com
ti
Note
on in
r
te o
thi
The blocking pieces prevent the springs compressing and possi‐
s
iva
do
ble damage to the vehicle when being driven onto a vehicle
r
rp
cum
fo
transporter or railway wagon.
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
by
WARNING copy Vo
by lksw
cted agen
Prote AG.
The blocking pieces must be removed without reservation be‐
fore delivering the vehicle. A sign attached to the interior mirror
reading “Caution!” highlights this point with absolute clarity.
Note
♦ There is no requirement to remove the wheels.

♦ Ensure that the surface of the springs is not damaged.
– Relieve weight on springs by raising vehicle with a hoist.
– Push blocking piece -arrow- off coil spring.

Touran 2003 ➤
4.59 Underbody: inspecting for damage to

underbody sealant, underbody panels,
routing of lines, plugs
Caution
AG. Volkswagen AG d
agen oes
lksw not
• During inspection, also check floor pan, wheel by V housings
o gu
ara
and sills. orise d
nte
h eo
ut
♦ Always ensure that all lines are secured in their mount‐
a ra
ss c
ings, all plugs are available and that there is no visible
ce
e
nl
damage on the underbody.
pt
du
an
itte
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♦ Faults found must always be rectified (repair measure).
erm
ab
This inhibits corrosion and rusting through.
ility
ot p
wit
, is n
h re
hole
spec
4.60 Clock and date: setting
es, in part or in w
t to the co
Time and date: setting, version 1 ⇒ page 158
Time and date: setting, version 2 ⇒ page 159
rrectness of i
4.60.1 Time and date: setting, version 1
l purpos
Setting clock with buttons below rev. counter
nf
ercia
Setting knob -arrow- in dash panel insert.
orm
m
atio
Carry out adjustment as follows:
om
n in
or c
– Turn setting knob -arrow- “anti-clockwise” to set the hours and
thi
te
sd
“clockwise” to set the minutes.
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Setting clock and date using buttons on windscreen wiper lever

– Press button -2- for 2 seconds to open the main menu.
– Press button -2- to select the menu “Settings” and confirm us‐
ing button -1-.
– Press button -2- to select the menu “Time” and confirm using
button -1-.
– Now mark menu item “Hours” by pressing button -1-, set cor‐
rect hour using button -2- and confirm with button -1-.
– For the menu option “Minutes” it is the same procedure.
– The menu “Settings” can be closed via the menu option “back”.
– Now select “MFD” for actual display and confirm this using
button -1-.

Touran 2003 ➤
Setting clock and date using buttons on multifunction steeringAG. Volkswagen AG d

wheel agen oes
olksw not
V gu
by ara
– Switch ignition on. ed nte
oris eo
th
– Press button -1- until the “Settings” menu appears. au ra
c
ss
ce
e
nl
– Then select menu option “Time” with buttons -2- and -4-.
pt
du
an
itte
y li
– Confirm the selection with button -3-.
erm
ab
ility
ot p
– When “Hours” is marked, the marked menu option is found
wit
, is n
between the two horizontal lines, confirm with button -3- and
h re
set the correct hour with buttons -2- and -4-. hole
spec
es, in part or in w
– Press button -3- again and set the minutes, which is the same
t to the co
procedure as for setting the hours.
– The menu can be closed with button -1-.
rrectness of i
l purpos
4.60.2 Time and date: setting, version 2
nf
ercia
o
Clock with buttons in dash panel insert
rm
m
atio
m
The clock can be set when the time is displayed in the dash panel
o
n in
c
insert and is not overlaid with another display.

or
thi
te
sd
iva
The time is set using buttons -1- and -2- in the dash panel insert.
o
r
rp
cu
o
m
f
– Press button -1- to mark the hours on dash panel insert dis‐
en
ng
t.
yi
play.
Co
Cop py
ht. rig
– Press button -3- briefly to advance the time one hour. Keep
rig ht
py by
o Vo
the button pressed to fast-forward through the hours. by c lksw
cted agen
Prote AG.
– Press button -1- again to select minute display.
– Press button -3- briefly to advance the time one hour.
– Keep the button pressed to fast-forward through the minutes.
– Press button -1- again to complete setting the clock.
Setting clock and date with buttons on windscreen wiper lever

– Press button -2- for 2 seconds to open the main menu.
– With button -2-, select then menu “Settings”. Confirm selection
with button -1-.
– Press button -2- to select the menu “Time” and confirm with
button -1-.
– Now mark the menu option “Hours” by pressing button -1-, set
correct hour with button -2- and confirm with button -1-.
– For the menu option “Minutes” it is the same procedure.
– The menu “Settings” can be closed via the menu option “back”.
– Now select “MFD” for actual display and confirm with button
-1-.

Touran 2003 ➤
AG. Volkswagen
Setting clock and date withlksbuttons
wage
n
on multifunction
AG do
essteering
not
wheel d by Vo gu
a
e ran
ris tee
– Switch ignition
ut on.
ho or
sa ac
– Press button
s
-5- until menu “Settings” appears.
ce
le
un
pt
– Select menu option “Time” with buttons -2- and -4-.
an
d
itte
y li
erm
ab
– Confirm selection with button -5-.
ility
ot p
wit
– Press button -5- to confirm “Hours” and set the correct hour
is n
h re
with buttons -2- and -4-.
ole,
spec
– Press button -5- again and set the minutes, which is the same
t to the co
procedure as for setting the hours.
– The menu can be closed with button -1-.
rrectne
ss
4.61 Toothed belt and toothed belt tensioning
o
cial p
f in
roller: renewing (diesel engines)
form
mer
atio
TDI common rail/TDI unit injector engines:
om
n
c
i
or
n
– Removing and installing toothed belt: Power unit ⇒ Rep. gr.
thi
te
15 → Cylinder head, → Valve gear/removing and installing

sd
iva
o
r
toothed belt.
p
cum
r
fo
en
ng
t.
yi Co
op py
Note
t. C rig
gh ht
pyri by
Vo
co lksw
by
For technical reasons it is possible that several cross references cted agen
Prote AG.
4.62 Camshaft drive toothed belt: renewing

(only 2.0 l FSI)
Procedure
– Removing and installing toothed belt: Power unit ⇒ Rep. gr.
15 → Cylinder head, → Valve gear/removing and installing
toothed belt.
Note

4.63 Camshaft drive toothed belt: checking

(4-cylinder petrol engines 1.6 l 75 kW
and 2.0 l 80 kW)
4.63.1 Toothed belt: checking condition

– Remove toothed belt guard ⇒ Rep. gr. 15 .

Touran 2003 ➤
– While turning crankshaft at least one full turn, check toothed

belt condition for:
♦ -A- Cracks, cross-sectional breaks, cracks (coating)
♦ -B- Side contact
♦ -C- Fraying of cord strands
♦ -D- Cracks (in teeth base)
♦ Layer separation (toothed belt body, tensile cords)
♦ Surface cracks (synthetic coating)
♦ Traces of oil and grease
AG. Volkswagen AG d
Note agen oes
olksw not
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d by ara
ise nte
If faults are found, always renew
hor toothed belt. This can avoid eo
ut
breakdowns and malfunctions.
s a The replacement of a toothed belt ra
c
is a repair measure. s
ce
e
nl
pt
du
an
itte
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erm
ab
4.64 Spark plugs: renewing
ility
ot p
wit
, is n
Spark plugs: renewing, 1.2 l TSI engines ⇒ page 163 .
h re
hole
spec
Spark plugs: renewing, 1.4 l TSI engines ⇒ page 163 .
es, in part or in w
t to the co
Spark plugs: renewing, 1.6 l and 2.0 l injection engines
⇒ page 168 .
Spark plugs: renewing, 2.0 l FSI engine ⇒ page 166 .
rrectness of i
Spark plugs: renewing, 1.6 l FSI engine ⇒ page 169 .
l purpos

nf
ercia
♦ Spark plug socket - 3122 B-

orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touran 2003 ➤
♦ Puller - T40039- for 2.0 l direct injection engine
♦ Puller - T10094 A- for 1.4 l TSI engines and 1.6 l direct injection
engines
AG. Volkswagen AG d
agen oes
lksw not
♦ Puller - T10112 A- for 1.2 l TSI engines
d by
Vo
(CBZB) and for 1.6 l gu
ara
injection engine orise nte
eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Assembly tool - T10118- for 1.6 l direct injection engines

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touran 2003 ➤
4.64.1 Spark plugs: renewing, 1.2 l TSI engines

Removing
The spark plugs are located under the spark plug connectors
-arrows-.
– Pull off spark plug connector using puller - T10112 A- .
– Unscrew spark plugs using spark plug socket - 3122 B- .

lkswage es n
o ot g
yV ua
Note ir se
d b ran
o tee
th or
u
♦ Spark plug designation and specified torque:
ss Power unit ⇒
a ac
Rep. gr. 28 → Test data → Spark plugs.
ce
le
un
pt
an
d

itte
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rm
ab
pe
ility
ot
wit
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h re
Note
hole
spec
es, in part or in w
t to the co
rrectness of i
Installing
l purpos
– Screw in new spark plugs using spark plug socket and exten‐
sion - 3122 B- .
nform
ercia
– Fit spark plug connectors by hand onto spark plugs. They must
m
a
be felt to engage.
com
tion in
r
te o
thi
4.64.2 Spark plugs: renewing, 1.4 l TSI engines

s
iva
do
r
rp
cum
Removing:
fo
en
ng
t.
yi Co
– Remove engine cover panel ⇒ page 88 . t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
Note
cted agen
Prote AG.
To simplify removing and installing spark plugs, loosen some

components and place them to side.

Touran 2003 ➤
– Pull off connector -2-.

– Pull off hose end -3-, (press together to release).
– Unscrew bolts -1-.
– Raise hose with bracket and charge pressure control solenoid
valve and place to side.
– Disengage clamps of cable guide -arrows-.
Note
♦ When pulling out the ignition coils with output stages, the wires
or ignition coil connectors can remain connected.
♦ Note installation position of ignition coils with output stages.
Caution
Ensure that the cables are not kinked or damaged.
lkswage es n
ot g
– Seat puller - T10094 A- -1- on ignition coil with output stage. d byV
o
ua
ran
ir se tee
– Pull out ignition coil with output stage and connected wires
uth and
o
or
carefully place to side. ss
a ac
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Unscrew spark plugs using spark plug socket - VAS 3122B- .
rrectne
Installing:
ss o
cial p
f in
Note
form
mer
atio
m
♦ When installing new spark plugs, regrease ignition coils with

o
n
c
output stage using silicone paste ⇒ ETKA .

i
or
n thi
te
sd
a
♦ The applicable silicone paste is stated in the ETKA along with

iv
o
pr
the corresponding ignition coil and/or spark plug.

um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
– Screw in new spark plugs and tighten them to specified torque

using spark plug socket - 3122 B- .
– Apply a thin bead of silicone paste on the circumference of the
sealing hose of the ignition coil with output stage -arrow-.
Note
♦ Spark plug designation and specified torque: Power unit ⇒

Rep. gr. 28 → Repairing ignition system → Test data.
♦ For technical reasons it is possible that several cross referen‐
ces are not directed to the correct chapter. In this case select
the procedure manually in the information.
– Place puller - T10094 A- on ignition coil with output stage.

– Push ignition coil with output stage into cylinder head until they
noticeably engage.
– Route cables properly in cable guide.
AG. Volkswagen AG d
– Engage clamps of cable guide -arrows-.
lksw
agen oes
not
o
byV gu
– Set hose with bracket and rcharge
ised pressure control solenoid ara
nte
valve to original installation
ut
h position.
o eo
ra
s a c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Tighten bolts -1-.

rrectness of i
– Push on connector -2-.

l purpos
– Connect hose end -3-.

– Fit engine cover panel ⇒ page 88 .
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touran 2003 ➤
4.64.3 Spark plugs: renewing, 2.0 l petrol direct

injection engines
Removing:
Note
♦ To pull off spark plugs, fit puller - T40039- on top, thick rib
-arrow- of ignition coils with final output stages.
♦ If the lower ribs are used, they could be damaged.
– Remove engine cover panels ⇒ page 88 .
The spark plugs are located below the ignition coils with output
stages -2-.
Note
Note installation position of ignition coils with output stages.
– Remove the two bolts -1-. lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Pull all ignition coils out of cylinder head approx. 30 mm in rrectness of i
direction of arrow using puller - T40039- .
l purpos
– Press connectors in direction of ignition coils with output

stages, press onto catch by hand and pull connectors
-arrows- off.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
– Unscrew spark plugs using spark plug socket - 3122 B- .
Note
♦ Spark plug designation and torque settings ⇒ Rep. gr. 28 .

Installing
Note

output stage using silicone paste ⇒ ETKA .

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Screw in new spark plugs using spark plug wrench - 3122 B-

and tighten to specified torque.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
– Insert ignition coils with output stages into cylinder head.

– Align ignition coils with output stages in respective recesses
of cylinder head cover.
– Fit all connectors onto ignition coils -arrows-.
AG. Volkswagen AG d
agen oes
– Press ignition coils with output stages Volon spark plugs until stop
ksw not
gu
by hand. They must be felt to engage.
se
d by ara
nte
i
or eo
– Secure cable guides with bolts
au
th -1-. ra
ss c
– Install engine cover panel.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
4.64.4 Spark plugs: renewing, injection en‐
rrectne
gines with 1.6 l and 2.0 l
ss
o
cial p
– Remove engine cover panel ⇒ page 88 . f inform

mer
atio
Removing:
om
n
c
– Pull off injector connectors of first and fourth cylinder.

or
n thi
te
sd
a
– Pull off spark plug connectors using puller - T10112 A- .

iv
o
pr
cum
r
fo
– Remove spark plug with spark plug socket and extension -

en
ng
t.
yi
3122 B- .
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
Note Prote
cted AG.
agen

Installing:
– Screw in new spark plugs using spark plug socket and exten‐
sion - 3122 B- .
– Fit spark plug connectors using puller - T10112 A- .
– Fit connectors of injectors.
– Check that injector connectors, ignition cables and spark plug
connectors are fitted securely.
– Install engine cover panel again.

Touran 2003 ➤
4.64.5 Spark plugs: renewing, 1.6 l petrol direct

injection engines
– Place puller - T10094 A- on ignition coil with output stage
-arrow-.
– Slightly pull out ignition coil with output stage.
. Volkswage
– Fit assembly tool gen AG
-aT10118- as illustrated.
n AG d
oes
ksw n
y Vol ot g
u
– Releaseisconnection
ed
b locking device carefully and
arapull off con‐
nte
nector.
uthor eo
ra
sa c
– Pull
s out ignition coil with output stage.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Unscrew spark plug using spark plug wrench - 3122 B- .
hole
spec
es, in part or in w
t to the co
Note

output stage using silicone paste ⇒ ETKA . rrectness of i
l purpos

nform
mercia
at
om
ion
c
in t
or
his
te
– Screw in new spark plugs and tighten them to specified torque

a
do
riv
using spark plug socket - 3122 B- .

p
cum
for
en
g

n
t.
yi Co
op
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Note Prote AG.


Touran 2003 ➤
– Place puller - T10094 A- on ignition coil with output stage.

– Slide connector on ignition coil with output stage until it audibly
engages.
– Push ignition coil with output stage -arrow- into cylinder head.
– Install engine cover panel ⇒ page 88 .
4.65 Driving instructor pedals: greasing

♦ Universal cloth - VAS 6385-
♦ Non-fibrous lint-free cloths
Caution
The springs of the driving instructor pedals must on no account

be retensioned - danger of breakage.
When driving instructor pedals are stiff/difficult to move, clean
all moving parts of the driving instructor pedals using, for ex‐
ample, a universal cloth - VAS 6385- AGor
. Voalknon-fibrous
swagen AG lint-free
cloth, then grease anew using agen
ksw special lubricant - G e052 not 172
do s
ol
A2- . ed by
V gu
ara
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
Note
an
itte
y li
erm
ab
These work instructions are performed during all service meas‐

ility
ot p
ures.
wit
, is n
h re
hole
spec
Driving instructor pedals, manual gearbox: greasing

es, in part or in w
⇒ page 170
t to the co
4.65.1 Driving instructor pedals, manual gear‐

box: greasing
rrectness of i
l purpos

– Check that driving instructor pedals are free to move and are
nform
ercia
not damaged.
m
– Clean right mountings and bushes and all moving parts

at
om
io
-arrows- of the driving instructor pedals using, for example, a

n
c
in t
r
universal cloth - VAS 6385- or a non-fibrous lint-free cloth, then

o
his
te
grease anew using special lubricant - G 052 172 A2- .

a
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touran 2003 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Clean left mountings and bushes and all moving parts

-arrows- using, for example, a universal cloth - VAS 6385- or
a non-fibrous lint-free cloth, then grease anew using special
lubricant - G 052 172 A2- .

Touran 2003 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4.66 Natural gas system: inspecting natural

gas tank for corrosion and leakage.
♦ Gas leak detector - VAS 523 003-
♦ Mirror
♦ Battery lamp - VAS 6901-
♦ Leak detecting spray

Touran 2003 ➤
WARNING
For reasons of safety, service and maintenance of the natural

gas system may only be meticulously carried out by specially
trained personnel. en AG. V
olkswagen AG
ag does
lksw not
Natural gas is highly flammable and, ind bcombination
yV
o with air, gu
ara
creates a combustible mixture. o
ir se nte
h eo
ut
There must be no open flame or
ss source of ignition near the
a ra
c
natural gas system.
ce
le
un
pt
an
d
Inhaling natural gas can lead to light-headedness and lung
itte
y li
damage. High concentrations may lead to suffocation due to
erm
ab
lack of oxygen.
ility
ot p
wit
is n
Natural gas is NOT odourless because a gas having a strong
h re
ole,
odour is added.
spec
t to the co
Prerequisite for testing
♦ All parts of the natural gas system to be checked must be
rrectne
reached easily.
s
♦ The exhaust gas warning lamp in the dash panel insert must
s o
not light up and there must be no entries concerning natural
cial p
f in
gas in the event memory of the engine control unit.
form
mer
♦ Working environment free of draught
atio
om
n
c
i
or
n thi
te
sd
Note
iva
o
pr
cum
r
fo
♦ Every draught of air above 1.8 km/h (slight gust of wind) will
en
ng
t.
yi Co
result in falsification of the measuring result. Therefore, it is Cop py
essential to work in a draught-free environment.
t. rig
gh ht
pyri by
Vo
co
♦ When working on the natural gas system always ensure for
by lksw
cted agen
Prote
tidiness and cleanliness!
AG.
Inspection
– Remove underbody cladding ⇒ General body repairs, exteri‐
or; Rep. gr. 50 ; Underbody cladding .
– Check underbody cladding from inside for soiling, and clean it
with regular workshop cleaning agents if required.
– Check natural gas system for corrosion and security.
– With the aid of a mirror, inspect complete natural gas tank.
– For German market only: make sure gap between natural gas
fuel tank and fuel tank shut-off valve is sufficiently waxed
⇒ page 177 .
Applicable procedure for assessment of steel and CFRP fuel
tanks: ⇒ Gas engines - general information; Rep. gr. 20 ; Fuel
tanks; Damage assessment catalogue for natural gas fuel tanks
Leak test
– Start engine to set pressures in gas system to operating state.
Engine can be switched off for leakage test.

Touran 2003 ➤
Caution
♦ Pressurised natural gas may escape from natural gas

tanks.
♦ Natural gas is highly flammable and, in combination with
air, creates a combustible mixture.
wage e
♦ Close fuel tank shut-off Volvalves manually. ⇒ Fuel supply
ks s no
t gu
by
system – naturalrisgas
ed engines; Rep. gr. 20 ; Fuel tanks; ara
nte
Closing fuel tank
utho shut-off valves N361/N362 manually eo
r a ac
ss
ce
e
nl
pt
du
– Only valid for engine code BSX: Seal the breather holes (three
an
itte
y li
holes positioned at 120° apart) in engine compartment with
erm
ab
adhesive strips.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
– At indicated test locations -arrows- only, check for leaks using
Co
Cop py
gas leak detector - VAS 523 003- . It is absolutely necessary
t. rig
gh ht
yri
to check all threaded connections of the gas system. p by
co Vo
by lksw
cted agen
Prote AG.
Note
♦ The gas leak detector can only determine whether there is gas
in the ambient air.
♦ Any other result than a green LED for »OK« is not permitted
on the gas leak detector. As soon as a yellow or red LED lights
up, a leak detector spray must be used to prove conclusively
whether the gas is actually escaping from the vehicle system.
When a leak detector spray is used, no bubbles may escape
from the sprayed area within a test period of 3 minutes. Should
leaks occur, these must be repaired, after which the gas sys‐
tem must be retested.
Test locations

Touran 2003 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touran 2003 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touran 2003 ➤
♦ Area of filler connection in wheel housing (measure total con‐

centration, when not OK remove wheel housing liner and
repeat test more carefully)
♦ Coupling point of high-pressure line from natural gas tank 2 to
natural gas tank 3
♦ Tank valves of 4 natural gas tanks with all threaded connec‐
tions
♦ Coupling of high-pressure line on underbody
♦ Only valid for engine code BSX:
♦ High-pressure regulator at all threaded connections
♦ Sealed breather holes on high-pressure regulator
♦ Gas rail with pressure sensor and gas injectors, when installed
(for a better overview it is illustrated when removed)
♦ Only valid for engine code CDGA:
♦ Check electromechanical high-pressure regulator for gas
mode with all connections and threaded connections
-arrows-. Also check whether rubber stopper of pressure relief
valve -1- is fitted as well as condition of low-pressure hose
-2-.
♦ Gas rail with gas injection valve -1- and gas rail sensor -2-
(installed) and without removal of the exhaust gas turbocharg‐
er pressure pipe (see illustration: view when removed)
– Remove adhesive strips on pressure regulator lower part.
– Install underbody cover ⇒ General body repairs, exterior; Rep.
gr. 50 ; Underbody cover .
4.67 Natural gas system: checking wax layer

between natural gas fuel tank and fuel
tank shut-off valve
AG. Volkswagen AG d
agen oes
olksw not
Note d byV gu
ara
ise nte
or eo
th
Applies only
s au to German market. ra
c
s
ce
e
nl
pt

du
an
itte
y li
erm
♦ Wax ⇒ ETKA
ab
ility
ot p
wit
, is n
– Make sure gap between natural gas fuel tank and -1- and fuel
h re
tank shut-off valve -2- is sufficiently waxed.

hole
spec
es, in part or in w
– If necessary, spray wax over entire circumference -arrows-.

t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
by
177
copy Vo
by lksw
cted agen 4. Descriptions of work:
Prote AG.
Touran 2003 ➤
4.68 Natural gas filler connection: checking

condition, cleaning if necessary and
checking seal
– Open tank flap and remove protective cap from natural gas
filler connection.
– Check if O-ring is fitted and its condition -1-.
– Check natural gas filler neck for dirt, damage, and surface
corrosion. Clean natural gas filler neck ONLY from outside.
– If the filler neck is dirty, clean off dirt using compressed air.
The filler neck will not be damaged as a result. agen
AG. Volkswagen AG d
oes
olksw not
– If corrosion is found on the surface of the natural gas fillered byneck,
V gu
ara
remove it using a lint-free cloth. horis nte
eo
aut ra
s s c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
4.69 Natural gas tank: renew.
wit
, is n
h re
hole
spec
WARNING
es, in part or in w
t to the co
Service and maintenance on high-pressure part of the natural
gas system must only be performed by specially trained per‐
rrectness of i
sonnel, which must be trained at regular intervals.
l purpos
Natural gas is highly flammable and, in combination with air,

creates a combustible mixture.
nform
ercia
There must be no open flame or source of ignition near the

natural gas system.
m
at
om
io
Inhaling natural gas can lead to light-headedness and lung
n
c
in t
or
damage. High concentrations may lead to suffocation due to
his
ate
lack of oxygen.
do
priv
cum
or
Natural gas is not odourless because a gas having a strong

f
en
ng
t.
odour is added.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c
Procedure for “power unit” ⇒ Power unit; Rep. gr. 20 ; Removing
lksw
cted agen
Prote
and installing fuel tank “Removing and installing fuel tank”
AG.

Touran 2003 ➤
5 Exhaust emissions test

Exhaust emissions test for petrol engines ⇒ page 179
Exhaust emissions test for diesel engines ⇒ page 181
Note
♦ Please observe the country specific legal regulations.

♦ The exhaust emissions test described below has been created
according to the legal regulations valid in Germany.
5.1 Exhaust emissionslkswtest

agen for petrol en‐
AG. Volkswagen AG d
oes
not
gines
o
byV gu
ara
ed
s i n tee
or
Special tools and workshop
au equipment required
th or
ac
ss
♦ Exhaust gas testing station L - VAS 7320 A-
ce
le
un
pt
an
d
itte
y li
rm
ab
Note
pe
ility
ot
wit
, is n
♦ The following description refers to vehicles fitted with “On‐
h re
hole
board diagnosis” OBD.
spec
es, in part or in w
♦ The OBD monitors all components and part systems influenc‐
t to the co
ing the exhaust emissions quality.
♦ It is possible to carry out an exhaust emissions test only when
rrectness of i
all units of the emissions testing station are connected prop‐
erly and joined to each other according to the operating in‐
l purpos
structions.
♦ All work to be performed is displayed by the emissions testing
nform
ercia
station .
m
a
com
tion in
Conditions for testing

r
te o
thi
• All test conditions and data required for exhaust emissions test
s
iva
do
r
are found on EET data sheet for the respective engine.

rp
cum
fo
en
ng
• For bar code reading the EET data sheet must be printed out.
t.
yi Co
Cop py
.
• Automatic gearbox: selector lever in position “P” or “N”.
ht rig
rig ht
py by
co Vo
• Manual gearbox: gear lever in neutral
by lksw
cted agen
Prote AG.
• Parking brake applied
• 12V battery fully charged (if battery charge is too low, raise
idling speed if necessary).
– Perform exhaust emissions test according to instructions on
display.
Vehicle data input
– Enter the following data:
♦ Registration number
♦ Key numbers
♦ Vehicle identification number
♦ Fuel type
♦ Mileage
5. Exhaust emissions test 179

Touran 2003 ➤
The following vehicle data can be found in the vehicle registration

certificate part 1:
♦ Registration number: “e.g. WOB-HH 1234”
♦ Emission key number “Field 14.1 (code for field 14)”
♦ Vehicle manufacturer: “Field 2”, “Field 2.1 (code for field 2)”
♦ Vehicle identification number “field E”
swage es n
♦ Type and version “Field D2 (type only)”, “Field 2.2 (code y V for
olk ot g
ua
field D.2)” ir se
d b ran
tee
tho
or
Specified data input for EET au ac
ss
ce
e
There are different ways to enter the specified data:
nl
pt
du
an
itte
♦ 1. By manual input
y li
erm
ab
ility
♦ 2. By bar code input from EET data sheet
ot p
wit
, is n
♦ 3. Through ELSA web service
h re
hole
spec
es, in part or in w
t to the co
Note
♦ To use the ELSA web service, the exhaust gas testing station
rrectness of i
L which is used for the exhaust emissions test must be inte‐
grated in the workshop network.
l purpos
♦ The ELSA web service automatically transmits the data for the
specific vehicle via the network to the respective mask.
nform
mercia
at
Manual specified data input for EET:
om
ion
c
in t
or
his
ate
Note
do
priv
cum
for
en
g
All test conditions and data required for exhaust emissions test
n
t.
yi Co
op
can be found in the ⇒ Data sheets for exhaust emissions test for C py
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respective engine.
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– Perform manual data input according to instructions on dis‐
AG.
play.
– Enter displayed values on EET data sheet in column “Test
values for exhaust emissions test” on display as follows:
1- Test speed (idling speed)
2- Warm-up phase for catalytic converter
3- Engine temperature
4- Increased idling speed
5- CO content at increased idling speed
6- Lambda at increased idling speed
7- Idling speed
8- Select regulating probe type; either “Step-type probe” or
“Broad-band probe”.
9- Lambda probe value
Specified data input for EET as bar code:
– If specified data for EET are available as bar code, read bar
code of EET data sheet with bar code reader.
All data required are shown on display.
180 5. Exhaust emissions test

Touran 2003 ➤
Inspection
– Inspect all exhaust emissions relevant components.
– Check if exhaust system is fitted and complete and check for
leaks and damage.
Procedure
– Follow instructions from exhaust gas testing station .
5.2 Exhaust emissions test for diesel en‐

gines
♦ Exhaust gas testing station L - VAS 7320 A-
Note
♦ The following description refers to vehicles fitted with “On‐

board diagnosis” OBD.
♦ The OBD monitors all components and part systems influenc‐
ing the exhaust emissions quality.
♦ It is possible to carry out an exhaust emissions test only when
G. Volkswage
all units of the emissions testing station
lksw
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ise
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♦ All work to be performedssis
a displayed by the emissions testing ra
c
station .
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Conditions for testing
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• All test conditions and data required for exhaust emissions test wit
, is n
are found on EET data sheet for the respective engine. h re

hole
• For bar code reading of specified data for EET, the EET data
spec
es, in part or in w
sheet must be printed out.

t to the co
• Automatic gearbox: selector lever in position “P” or “N”.

• Manual gearbox: gear lever in neutral
rrectness of i
• Parking brake applied

l purpos
• 12V battery fully charged (if battery charge is too low, raise
idling speed if necessary).
nform
ercia
– Perform exhaust emissions test according to instructions on

m
at
om
display.
ion
c
in t
or
Vehicle data input

his
ate
do
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– Enter the following data:

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♦ Registration number
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Cop py
♦ Key numbers
t. rig
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♦ Vehicle identification number
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♦ Fuel type
♦ Mileage
The following vehicle data can be found in the vehicle registration
certificate part 1:
♦ Registration number: “e.g. WOB-HH 1234”
♦ Emission key No. “field 14.1 (code for field 14)”

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♦ Vehicle manufacturer: “Field 2”, “Field 2.1 (code for field 2)”
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erm
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♦ Vehicle identification number “field E”
ility
ot p
wit
♦ Type and version “Field D2 (type only)”, “Field 2.2 (code for
, is n
h re
field D.2)”
hole
spec
♦ Nominal speed “field P4”
es, in part or in w
t to the co
Specified data input for EET
There are different ways to enter the specified data:
rrectness of i
♦ 1. By manual input l purpos
♦ 2. By bar code input from EET data sheet
nf
ercia
♦ 3. Through ELSA web service
orm
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atio
om
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Note
or
thi
te
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iva
♦ If there is no ESP to deactivate the engine speed limiter, the
o
r
rp
cu
rev limit can be measured using the engine speed limited by
o
m
f
en
ng
the control unit. To do this, all the EET specifications must be

t.
yi Co
op
entered manually.
C py
ht. rig
rig ht
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♦ To use the ELSA web service, the exhaust gas testing station co Vo
by lksw
L which is used for the exhaust emissions test must be inte‐ cted agen
Prote AG.
grated in the workshop network.
♦ The ELSA web service automatically transmits the data for the
specific vehicle via the network to the respective mask (ex‐
ception: nominal speed can only be entered manually).
Manual specified data input for EET:
Note
♦ See ⇒ Data sheets for exhaust emissions test of the respective

engine for the requisite test conditions and data for the emis‐
sions test.
♦ The nominal speed is located in field P4 of the registration
certificate part 1 or field 7 of the vehicle document and must
always be entered manually.
♦ If the engine speed limiter cannot be deactivated, enter the
value 2500 ± 200 rpm in the box for rev limit and 2500 in the
box for engine speed for conditioning.
– Perform manual data input according to instructions on dis‐

play.
– Enter displayed values on EET data sheet in column “Test
values for exhaust emissions test” on display as follows:
1- Speed for conditioning
2- Number of throttle bursts for conditioning
3- Engine oil temperature (min. value)
4- Select engine oil temperature measurement procedure
5- Idling speed
6- Governed speed
7- Nominal speed (registration certification part 1, vehicle
document)
8- Governed speed measuring period (1 second)
182 5. Exhaust emissions test

Touran 2003 ➤
9- Type plate value ⇒ page 183

agen
AG. Volkswagen AG d
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10 - Select probe type
ed
by (No. of probe)
V ua
ran
ris tee
11 - Select measuring
au
tho mode or
ac
ss
12 - Measured period portion
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Note
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♦ When performing the exhaust emissions test, the respective
h re
engineer must always use the vehicle-specific exhaust emis‐
hole
spec
sions limit value indicated on the type plate.
es, in part or in w
t to the co
♦ If no value is indicated on the type plate, the opacity figure
specified by the manufacturer and indicated in ELSA must be
used.
rrectness of i
♦ If no value is indicated on the type plate and no opacity figure
l purpos
has been specified by the manufacturer, the statutory opacity

figures (2.5 m -1 or 1.5 m -1, depending on date of initial reg‐
istration) must be used.
nform
mercia
♦ For all Euro-6-vehicles an opacity figure of max. 0.5 m -1 ap‐
a
com
tio
plies.
n in
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te o
thi
s
iva
Specified data input for EET as bar code:
do
r
rp
cum
fo
– If specified data for EET are available as bar code, read bar
en
ng
t.
yi
code of EET data sheet with bar code reader.
Co
Cop py
t. rig
gh
The nominal speed can only be entered manually.
ht
pyri by
Vo
co lksw
by
If the opacity figure on the EET data sheet is different from the
cted agen
Prote AG.
value indicated on the type plate, enter the type plate value man‐
ually.
Inspection
– Inspect all exhaust emissions relevant components.
– Check if exhaust system is fitted and complete and check for
leaks and damage.
Procedure
– Follow instructions from exhaust gas testing station .
Evaluation
Note
If the exhaust emissions test was performed at governed speed,

the log note “governed speed <90 % of the nominal speed (idle
speed control)” is entered in the log.

Touran 2003 ➤
6 Glossary
Term Explanation
ABS (Anti-lock brake system): the ABS is a regulating system in the brake system that prevents
locking when braking. This helps to maintain directional stability and steerability.
All-wheel drive Term to be used in place of “Haldex” with immediate effect. Legal implications make this
coupling step necessary. The term may nevertheless appear in older documents but need not be
replaced.
TCS Traction control system: prevents the wheels from slipping when the vehicle is driven off.
ATF Automatic transmission fluid: gear oil for automatic gearboxes
ATF level Filling level of ATF in gearbox
EET Exhaust emissions test
AUS 32 Abbreviation for “aqueous urea solution” with an urea concentration of 32.5%, see also
(AdBlue®) ⇒ page 184
AdBlue® Is an inventedlksname.wage es n
This fluidd bisy Valso
o
called “NOx reducing agent ot g
AUS
ua 32”, “AUS 32” or “Diesel Exhaust Fluid”
for the o
ir sUSA.
e ran
tee
AdBlue®
au
th is a clear reducing agent which is used foroexhaustra treatment to reduce nitrogen
oxides
ss emissions and particulates. c
AdBlue® is a registered trademark of the VDA (Verband der Automobilindustrie - German
ce
le
un
pt
association of the automotive industry) in the USA, Germany, the European Union and
an
d
itte
y li
other countries.
rm
ab
The AdBlue urea solution is not mixed with diesel fuel, but is carried in a separate tank
pe
ility
in the vehicle.
ot
wit
, is n
h re
BEV Battery Electric Vehicle: vehicle powered by electric energy
hole
CNG Compressed Natural Gas spec

es, in part or in w
t to the co
CO Carbon monoxide: is produced when fuels containing carbon are not combusted com‐
pletely.
Common rail Refers to a common high-pressure injection line “rail”, which supplies all cylinders of the
rrectness of i
“CR” relevant cylinder bank with fuel

l purpos
Diesel exhaust flu‐ Designation in the USA for the NOx reducing agent AUS 32, or (AdBlue®)
id
nform
ercia
DIN Deutsches Institut für Normung e.V. (German Standards Authority)

m
DLA Dynamic Light Assist: a system with variable road illumination allows the vehicle to be
a
com
tio
driven permanently with main beam without dazzling oncoming traffic.

n in
r
te o
thi
DPF Diesel particulate filter

s
iva
do
DS Direct shift
r
rp
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fo
DSP Digital service plan

en
ng
t.
yi Co
op
DSG Dual clutch gearbox
C py
t. rig
gh ht
yri
ATA Anti-theft alarm
p by
co Vo
by lksw
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ECE Economic Commission for Europe Prote AG.
ETKA Electronic parts catalogue

Part no. Abbreviation for part number
EN European standard
EOBD European On-Board Diagnosis
ESP Electronic stabilisation programme (prevents potential vehicle skidding by targeted in‐
tervention in the brake and engine management systems).
FAME Fatty acid methyl ester
HEV Hybrid Electric Vehicle
MM Maintenance manual
LongLife service The LongLife service enables extremely long inspection or oil change intervals, depend‐
ing on individual driving style and conditions under which the vehicle is used. For the
LongLife service a special engine oil is required.
LED Light emitting diode
184 6. Glossary
Touran 2003 ➤
Term Explanation
LPG Liquefied Petroleum Gas
MIL (Malfunction indicator light); American designation for exhaust emissions warning lamp
K83
MPI Multi-point injection
NAR North American region
NSC National Sales Company
NOx reducing Designation of aqueous urea solution according to DIN ISO 22241-1, see also (AdBlue®)
agent AUS 32 ⇒ page 184
NOx reducing Designation of aqueous urea solution according to DIN ISO 22241-1, see also (AdBlue®)
agent AUS 32 ⇒ page 184
OBD (Onboard diagnosis); the OBD monitors all components influencing the exhaust emis‐
sions quality.
OBD-II American onboard diagnosis
PHEV Plug-in Hybrid Electric Vehicle: a vehicle with hybrid drive whose battery can also be
recharged externally using mains electricity.
PR No. Abbreviation for production control number. It identifies among other things optional
equipment, country-specific deviations
PM Particulate matter: soot particulate value for diesel engine emissions
AG. Volkswagen AG d
PMS Particulate reduction system lksw
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QG0 Vehicles are “not” ifactory-fitted
se
d b with components for LongLife
ara service. For maintenance,
nte
the intervals basedthor on time and distance (non-flexible intervals)e o apply.
au ra
QG1 Vehicles are sfactory-fitted with active LongLife service. This means
s c vehicles have a flex‐
ce
ible service interval display and are fitted with the following components:
le
un
pt
♦ Flexible service interval display in dash panel insert
an
d
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ab
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♦ Brake lining wear indicator
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h re
hole
spec
QG2 The LongLife service is not factory-activated. This means vehicles have a non-flexible
es, in part or in w
service interval display (service intervals based on time and distance) and are fitted with
t to the co
the following components:
♦ Non-flexible service interval display in dash panel insert rrectness of i

l purpos
QG3 The LongLife service is not factory-activated. This means vehicles have a non-flexible
nform
ercia
service interval display (service intervals based on time and distance) and are fitted with
the following components:
m
a
com
ti
♦ Non-flexible service interval display in dash panel insert

on in
r
te o
thi

s
iva
do
r
rp
cum
® Registered trademark symbol

fo
en
ng
t.
yi
Readiness code 8-digit binary code which indicates if all exhaust relevant diagnoses have been performed
Co
op py
by the electronic engine management.
t. C rig
gh ht
yri by
RON Research Octane Number Measurement for knock resistance of petrol
cop Vo
by lksw
cted agen
Prote
SPF Particulate filter
AG.
TPMS, TPLI Tyre Pressure Monitoring System, Tyre Pressure Loss Indicator
SAE Society of Automotive Engineers: association which creates proposals/guidelines for im‐
plementing legal requirements (e.g. standards).
SCR With the SCR process (selective catalytic reduction) the noxious nitrogen oxides emis‐
sions are reduced to a great extent and are converted to steam and nitrogen by the urea
solution.
A special urea solution (AdBlue®) is injected into the exhaust system upstream of a spe‐
cial catalytic converter.
PFI Intake manifold injection system (indirect injection system)
6. Glossary 185
Touran 2003 ➤
Term Explanation
SULEV Super Ultra Low Emission Vehicle
TSI TSI turbocharger: charging only with turbocharger
TSI twincharger: charging with turbocharger and compressor
TGI Charging with turbocharger and natural gas injection system
TDI Turbo diesel engine - direct injection
ULEV Ultra low emission vehicle
VDA German association of the automotive industry
VW Volkswagen
ESI Extended service interval
ZEV Zero Emission Vehicle
ASSY Assembly
AG. Volkswagen AG d
agen oes
olksw not
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aut ra
ss c
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ab
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wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
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nform
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com
tion in
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te o
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s
iva
do
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t.
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Cop py
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rig ht
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Prote AG.
186 6. Glossary
Touran 2003 ➤
7 ---Change history---
Date Chapter Scope of modification
24/01/2 Natural gas system: inspecting natural gas tank Chapter updated.
019 for corrosion and leakage ⇒ page 172
23/02/2 Exhaust emissions test ⇒ page 179 Chapter updated.

018
08/12/2 Service tables ⇒ page 8 Chapter updated.

018
Multi-purpose additive for diesel fuel: adding Chapter updated.
⇒ page 85
Multi-purpose additive for petrol fuels: adding Chapter updated.
⇒ page 87
Protective bellows: inspecting ⇒ page 69 "Checking clamps" added to procedure.
Brake system and shock absorbers: inspecting "Checking caps on guide bushes" added to pro‐
for leaks and damage ⇒ page 62 cedure.
AG. Volkswagen AG d
agen oes
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tho eo
au ra
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ab
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, is n
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spec
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rrectness of i
l purpos
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tion in
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do
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7. ---Change history--- 187

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Maintenance

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Service

Service Department. Technical Information

matter of course, be observed.

4.8 Status of battery: reading, sending diagnosis protocol online . . . . . . . . . . . . . . . . . . . . . . 48

4.10 Brake and clutch system: changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

4.11 Brake fluid level: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

4.16 Electric windows: checking positioning (open and close functions) . . . . . . . . . . . . . . . . . . 66

4.20 Boots: inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

4.22 Poly V-belt: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

4.23 Poly V-belt: check condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

4.64 Spark plugs: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

4.65 Driving instructor pedals: greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

5.1 Exhaust emissions test for petrol engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

7 ---Change history--- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Engines ⇒ Petrol engine Petrol engine Petrol engine Petrol engine

Displacement I 1,4 1,6 2,0 2,0

Engine code BLG BLP BLR BLX

No. of cylinders/valves per cylin‐ 4/4 4/4 4/4 4/4

Torque Nm at rpm 240/1750 155/4000 200/3500 200/3500

Bore ∅ mm 76,5 76,5 82,5 82,5

Stroke mm 75,6 86,9 92,8 92,8

Compression ratio 9,7 12,0 11,5 11,5

Injection/ignition Motronic MED Motronic MED Motronic MED Motronic MED

09/05/2010 09/05/2010 09/05/2010 09/05/2010

TSI twincharger FSI FSI FSI

RON unleaded, at least 95 95 95 95

Engines ⇒ Petrol engine Petrol engine Petrol engine Petrol engine

Displacement I 2,0 2,0 2,0 1,4

No. of cylinders/valves per cylinder 4/2 4/4 4/4 4/4

Power kW at rpm 80/5400 110/6000 110/6000 125/6000

Torque Nm at rpm 160/3500 200/3500 200/3500 240/1500 to

CNG/PFI FSI FSI TSI twin charger

RON unleaded, at least Natural gas and 95 95 95

Camshaft drive Toothed belt Toothed belt Toothed belt Chain

Displacement I 1,4 1,2 1,4 1,4

Engines ⇒ Petrol engine Petrol engine Petrol engine Petrol engine

Engines ⇒ Petrol engine

Torque Nm at rpm 250/1900 320/1750 to 250/1900 320/1750 to

2500 2500 ility

Bore ∅ mm 79,5 81,0 79,5 81,0 h re

Compression ratio 19,0 18,5 19,0 18,5

Injection/ignition TDI TDI TDI TDI

Diesel particle filters No No No No

Engines ⇒ Diesel engine Diesel engine Diesel engine Diesel engine

Displacement I 1,9 2,0 2,0 1,9

Engine code BLS BMM BMN BRU

No. of cylinders/valves per cylin‐ 4/2 4/2 4/4 4/2

Bore ∅ mm 79,5 81,0 81,0 79,5

Injection/ignition TDI TDI TDI TDI

unit injector unit injector unit injector unit injector

Diesel particle filters Yes Yes Yes No

Torque Nm at rpm 250/1900 210/1900 210/1800 230/1500 to

Engines ⇒ Diesel engine Diesel engine Diesel engine Diesel engine

Engines ⇒ Diesel engine Diesel engine

2.1 Information about flexible or fixed serv‐

2.1.1 Service identification

The flexible service enables long service intervals, depending on

For the flexible service a special LongLife engine oil is required

Vehicles with PR number “QG1” or “QI6” are set up for flexible

♦ Flexible service interval display in dash panel insert

♦ Engine oil level sensor

♦ Brake pad wear indicator (if fitted)

For vehicles with flexible service the service interval is determined