VW Touran 2003 Electrical System From 08 2010 Eng

Service
Workshop Manual
Touran 2003 ➤
Electrical system from 08.2010
Edition 06.2011
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
27 - Starter, current supply, CCS
90 - Gauges, instruments
92 - Windscreen wash/wipe system
94 - Lights, bulbs, switches - exterior
96 - Lights, bulbs, switches - interior
97 - Wiring
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Touran 2003 ➤
Electrical system from 08.2010 - Edition 06.2011
Contents
27 - Starter, current supply, CCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Types of battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Warning notices and safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Battery terminal connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Checking battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Charging battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Disconnecting and reconnecting battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.2 Disconnecting battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.3 Reconnecting battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 Removing and installing battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.2 Vehicles with a petrol engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.3 Vehicles with a diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Starter, vehicles with manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.1 Checking starter B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.2 Starter, vehicles with 1.2l, 77 kW injection engine and manual gearbox MQ200-5F . . . . . . 13
6.3 Starter, vehicles with 1.4 l, 103 kW or 110 KW TSI engine and manual gearbox MQ200-6F
........................................................................ 16
6.4 Starter, vehicles with 1.6 l, 66 kW or 77 KW TDI engine and manual gearbox MQ250-6F
........................................................................ 19
6.5 Starter, vehicles with 2.0 l, 103 kW TDI engine and manual gearbox MQ350-6F . . . . . . . . 24
7 Starter, vehicles with dual clutch gearbox (DSG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.1 Starter, vehicles with 1.4 l, 103 kW or 125 kW TSI engine and dual clutch gearbox (DSG)
DQ200-7F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.2 Starter, vehicles with 1.4 l, 110 kW natural gas engine and dual clutch gearbox (DSG)
DQ200-7F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.3 Starter, vehicles with 1.6 l, 77 kW TDI engine and dual clutch gearbox (DSG) DQ250-7F
........................................................................ 36
........................................................................ 40
........................................................................ 45
8 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.1 Securing B+ (battery positive) wire to alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.2 Checking poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.3 Checking alternator C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.4 Alternator, 1.2 l, 77 kW TSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.5 Alternator, 1.4 l, 103 kW/125 kW TSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8.6 Alternator, 1.6 l, 66/77 kW TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8.7 Alternator, 2.0 l, 103/125 kW TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
8.8 Removing and installing poly V-belt pulley on alternator . . . . . . . . . . . . . . . . . . . . . . . . . . 68
8.9 Voltage regulator for alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
9 Cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
10 Start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
10.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
10.2 Start/stop operation switch E693 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
10.3 Voltage stabiliser J532 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
90 - Gauges, instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1 Dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
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Touran 2003 ➤
1.2 Renewing dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

1.3 Removing and installing dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.4 Description of back of dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.5 Warning lamp symbols in dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2 Service interval display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.1 Resetting service interval display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

1 Windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.2 Deactivating APP function of wiper motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.3 Assembly overview - windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.4 Removing and installing windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.5 Removing and installing wiper arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.6 Adjusting windscreen wiper park position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.7 Removing and installing joint-free wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.8 Removing and installing wiper rubber blade of joint-free wiper . . . . . . . . . . . . . . . . . . . . . . 99
1.9 Rain and light sensor G397 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2 Windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2.1 Assembly overview - windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2.2 Removing and installing washer fluid reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.3 Removing and installing windscreen and rear window washer pump V59 . . . . . . . . . . . . 109
2.4 Removing and installing windscreen washer fluid level sender G33 . . . . . . . . . . . . . . . . . . 110
2.5 Removing and installing windscreen washer system spray jets . . . . . . . . . . . . . . . . . . . . . . 110
2.6 Adjusting windscreen washer system spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3 Rear window wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.1 Assembly overview - rear window wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.2 Removing and installing wiper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.3 Removing and installing rear window wiper motor V12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.4 Adjusting rear window wiper park position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.5 Renewing wiper rubber blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.6 Removing and installing joint-free wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4 Rear window washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.1 Assembly overview - rear window washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.2 Renewing spray jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.3 Adjusting spray jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5 Headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.1 Assembly overview - headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.2 Removing and installing headlight washer system pump V11 . . . . . . . . . . . . . . . . . . . . . . 119
5.3 Removing and installing spray jet pop-up cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5.4 Adjusting headlight washer system spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5.5 Bleeding headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
6 Washer fluid line hose couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
7 Hose repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
94 - Lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

1 Headlight with halogen bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.2 Assembly overview - headlights with halogen bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.3 Removing and installing headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.4 Adjusting headlight installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.5 Renewing headlight bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.6 Headlight range control motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.7 Repairing headlight retaining tabs (halogen headlight) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.8 Converting headlights for use when driving on the left or right . . . . . . . . . . . . . . . . . . . . . . 138
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Touran 2003 ➤
1.9 Adjusting headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

2 Headlights with gas discharge bulbs and cornering lights . . . . . . . . . . . . . . . . . . . . . . . . . . 142
2.1 Operation and safety notes for gas discharge bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
2.3 Assembly overview - headlights with gas discharge bulbs and cornering lights . . . . . . . . 146
2.4 Removing and installing headlight with gas discharge bulb and cornering light . . . . . . . . 148
2.5 Adjusting headlight installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2.6 Renewing headlight bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.7 Headlight range control motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
2.8 Control motor for dynamic cornering light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
2.9 Static cornering light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.10 Swivel module position sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
2.11 Dipped beam screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
2.12 Control unit for left gas discharge bulb J343 or control unit for right gas discharge bulb J344
...................................................................... 158
2.13 Output module for left headlight J667 or output module for right headlight J668 . . . . . . . . 160
2.14 Control unit for left daytime running light and side light J860 or control unit for right daytime
running light and side light J861 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
2.15 Cornering light and headlight range control unit J745 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.16 Vehicle level sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2.17 Repairing headlight retaining tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2.18 Converting headlights for use when driving on the left or right . . . . . . . . . . . . . . . . . . . . . . 167
2.19 Adjusting headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3 Fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3.1 Fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3.2 Removing and installing fog light bulb / static cornering light bulb . . . . . . . . . . . . . . . . . . 169
3.3 Adjusting fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
4 Turn signal in exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
4.2 Removing and installing turn signal repeater bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
5 Tail lights (tail light cluster) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
5.1 Tail light cluster in side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
5.2 Tail lights (tail light cluster) in rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
6 Number plate light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
6.1 Removing and installing number plate light X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
7 Additional brake light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
7.1 Removing and installing additional brake light M25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
7.2 Checking additional brake light bulb M25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
8 Steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
8.2 Assembly overview - steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
8.3 Removal and installation sequence of components of steering column switch . . . . . . . . . . 187
8.4 Steering column electronics control unit J527 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
8.5 Steering column combination switch E595 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
8.6 Steering column switch carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
9 Ignition/starter switch and lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
9.1 Removing and installing steering lock housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
9.2 Removing and installing lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
9.3 Removing and installing ignition/starter switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
9.4 Removing and installing ignition key withdrawal lock solenoid N334 . . . . . . . . . . . . . . . . 201
10 Parking aid (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
10.2 Assembly overview - parking aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
10.3 Rear parking aid control unit J446 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
10.4 Rear parking aid senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
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10.5 Parking aid warning buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

10.6 Parking aid button E266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
11 Park assist steering (PAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
11.2 Assembly overview of park assist steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
11.3 Parking aid control unit J446 with park assist steering control unit J791 . . . . . . . . . . . . . . 215
11.4 Parking aid sender and park assist steering sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
11.5 Renewing park assist steering senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
11.6 Park assist steering button E581 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
11.7 Parking aid warning buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
11.8 Renewing holders for parking aid sender and park assist steering sender . . . . . . . . . . . . 226
12 Reverse camera (Rear Assist) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
12.2 Assembly overview - reversing camera system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
12.3 Removing and installing reversing camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
96 - Lights, bulbs, switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

1 Interior lights and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
1.1 Removing and installing interior monitoring deactivation switch . . . . . . . . . . . . . . . . . . . . 233
2 Lights and switches in engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
2.1 Removing and installing bonnet contact switch F266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
3 Lights and switches in dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
3.1 Removing and installing light switch E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
3.2 Removing and installing glove compartment light W6 and glove compartment light switch E26
...................................................................... 237
3.3 Removing and installing headlight range control regulator E102 and switch and instrument
illumination regulator E20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
3.4 Removing and installing key operated switch to deactivate front passenger front airbag E224
...................................................................... 240
3.5 Removing and installing airbag disabled warning lamp, front passenger side K145 . . . . 240
3.6 Removing and installing hazard warning light switch E3 . . . . . . . . . . . . . . . . . . . . . . . . . . 241
4 Lights and switches in front doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
4.1 Front left entry light W31 and front right entry light W32 . . . . . . . . . . . . . . . . . . . . . . . . . . 243
4.2 Removing and installing window regulator switch in front passenger door E107 . . . . . . . . 245
4.3 Removing and installing switch module for mirror adjustment on driver side . . . . . . . . . . . . 246
4.4 Removing and installing driver side interior locking button for central locking system E308
........................................................................ 247
4.5 Components - front door locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
4.6 Removing and installing switch module for driver side window regulator . . . . . . . . . . . . . . 248
4.7 Removing and installing fuel tank flap release button E319 . . . . . . . . . . . . . . . . . . . . . . . . 250
5 Lights and switches in rear doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
5.1 Rear left entry light W33 and rear right entry light W34 . . . . . . . . . . . . . . . . . . . . . . . . . . 252
5.2 Components - rear door locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
5.3 Installing and removing rear left window regulator switch E52 and rear right window regulator
switch E54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
6 Lights and switches in luggage compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
6.1 Removing and installing luggage compartment light W3 . . . . . . . . . . . . . . . . . . . . . . . . . . 254
6.2 Removing and installing rear lid locking unit F256 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
7 Lights and switches in roof trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
7.1 Front interior light W1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
7.2 Rear interior light W43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
7.3 Removing and installing front passenger side illuminated vanity mirror W14 or driver side
illuminated vanity mirror W20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
8 Components on interior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
8.1 Main beam assist control unit J844 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
iv Contents
Touran 2003 ➤
8.2 Front camera for driver assist systems R242 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

9 Lights and switches in centre console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
9.1 Removing and installing buttons in centre console storage compartment . . . . . . . . . . . . . . 270
10 12 V socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
11 Cigarette lighter U1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
12 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
12.1 Removing and installing treble horn H2 and bass horn H7 . . . . . . . . . . . . . . . . . . . . . . . . 274
12.2 Checking treble horn H2 and bass horn H7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
12.3 Horn plate H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
13 Immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
13.1 Immobilizer control unit J362 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
13.2 Ignition key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
13.3 New identity on renewing all components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
13.4 Fazit system test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
14 Anti-theft alarm (ATA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
14.1 Activating and deactivating anti-theft alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
14.2 Interior monitoring deactivation switch E267 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
14.3 Anti-theft alarm system sensor G578 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
14.4 Central locking and anti-theft alarm system aerial R47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
14.5 Alarm horn H12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
14.6 Adaptions of anti-theft alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
15 Specified torques: lights, bulbs and switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
15.1 Torque settings: alarm horn H12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
15.2 Torque settings: alarm horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
1 Vehicle diagnosis, testing and information systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
2 Removing and installing fuse holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
2.1 Removing and installing fuse holder on left beneath dash panel . . . . . . . . . . . . . . . . . . . . 289
3 Removing and installing relay carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
3.1 Removing and installing relay carrier on left of dash panel . . . . . . . . . . . . . . . . . . . . . . . . 290
3.2 Removing and installing relay carrier on onboard supply control unit . . . . . . . . . . . . . . . . 290
4 Removing and installing electronics boxes (E-boxes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
4.1 Removing and installing E-box on left side of engine compartment . . . . . . . . . . . . . . . . . . 292
5 Control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
5.1 Onboard supply control unit J519 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
5.2 Data bus diagnostic interface J533 (gateway) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
5.3 Driver door control unit J386 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
5.4 Front passenger door control unit J387 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
5.5 Coding rear left door control unit J388 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
5.6 Coding rear right door control unit J389 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
5.7 Electronically controlled damping control unit J250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
5.8 Trailer detector control unit J345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
5.9 Special vehicle control unit J608 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
6 Specified torques: wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
6.1 Specified torques: E-box on left side of engine compartment . . . . . . . . . . . . . . . . . . . . . . 316
7 Wiring harness and connector repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
Volkswagen Technical Site: https://vwts.ru
Contents v
Touran 2003 ➤
vi Contents
Touran 2003 ➤
27 – Starter, current supply, CCS

1 Battery
WARNING
Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 1 !
Caution
To prevent damage to the battery or vehicle, read the informa‐

tion about the types of battery ⇒ page 1
1.1 Types of battery

All the instructions and information for this manual are found in
the workshop manual „Electrical System, General Information“. A
link to this workshop manual is not possible at present for tech‐
nical reasons. Please select the workshop manual „Electrical
System, General Information“ manually in ELSA.
1.2 Warning notices and safety regulations

1.3 Battery terminal connection

1. Battery 1
Touran 2003 ➤
2 Checking battery
2 Rep. gr.27 - Starter, current supply, CCS

Touran 2003 ➤
3 Charging battery
3. Charging battery 3
Touran 2003 ➤
4 Disconnecting and reconnecting bat‐

tery
WARNING

tions ⇒ page 1 !
Battery recharging or jump start on vehicles with start/stop sys‐

tem:
For recharging or jump start on vehicles with start/stop system,
note the following: using charging cable, first connect battery pos‐
itive terminals, then body earth. This ensures that the battery
monitor control unit -J367- (battery sensor) is not bridged. The
direct charging of the battery on the negative terminal clamp
means that the battery sensor is shunted and the battery data are
not registered by the sensor while charging. Then, the values
concerning the battery state and saved in the data bus diagnostic
interface do not correspond to the values of the charged battery.
4.1 Assembly overview

Assembly overview for vehicles with no start/stop system
⇒ page 4
Assembly overview for vehicles with start/stop system
⇒ page 6
4.1.1 Vehicles with no start/stop system

Touran 2003 ➤
1 - Earth wire battery terminal

clamp
❑ Observe notes for bat‐
tery terminal clamp bolt
⇒ page 1 .
2 - Securing nut for earth wire
battery terminal clamp
❑ M6
❑ 6 Nm
3 - Positive wire battery termi‐
nal clamp
⇒ page 1 .
4 - Securing nut for positive
wire battery terminal clamp
❑ M6
❑ 6 Nm
5 - Battery
❑ Removing and installing
⇒ page 9 .
6 - Clamping plate
7 - Clamping plate securing nut
❑ M8 x 35
❑ 20 Nm
4. Disconnecting and reconnecting battery 5

Touran 2003 ➤
4.1.2 Vehicles with start/stop system
1 - Battery earth terminal with

integrated battery monitor con‐
trol unit -J367-
⇒ page 1 .
❑ Observe information re‐
garding battery monitor‐
ing control unit -J367-
(battery sensor)
⇒ page 4
❑ M6
❑ 6 Nm
nal clamp
⇒ page 1 .
❑ M6
❑ 6 Nm
5 - Battery
⇒ page 9 .
6 - Battery tray
7 - Clamping plate
❑ M8 x 35
❑ 20 Nm
4.2 Disconnecting battery
Note
♦ By disconnecting the battery earth wire (open circuit), safety

is ensured when carrying out work on the electrical system.
♦ The battery positive wire need only be disconnected for re‐
moval of the battery.
– Switch off ignition and all electrical loads, and pull out ignition
key.

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Vehicles with battery box

– Open locking device -arrow- and remove cover.
Vehicles with battery protective jacket
– Open cover -1- of battery protective jacket.
– First unscrew the earth-wire terminal clamp -1- on the battery

negative terminal.
– Then unscrew the positive-wire terminal clamp -2- on the bat‐
tery positive terminal.
4.3 Reconnecting battery
Caution
Observe notes for battery terminal clamp bolt ⇒ page 1 .
Special tools and workshop equipment required
4. Disconnecting and reconnecting battery 7

Touran 2003 ➤
♦ Torque wrench -V.A.G 1331-
Note
After the battery has been reconnected and the ignition is switch‐
ed on, the ESP and TCS stabilisation programme warning lamp
-K155- and the warning lamp for electromechanically assisted
steering will light up permanently. The warning lamps will go out
automatically when the vehicle is driven at 15 to 20 km/h in a
straight line. This has the effect of reactivating the steering angle
sender -G85- .
– Fit positive terminal clamp -2- onto positive terminal of battery

and tighten securing bolt to prescribed torque ⇒ page 4 .
– Fit earth terminal clamp -1- onto negative terminal of battery
and tighten securing bolt to prescribed torque ⇒ page 4 .
– Work through steps listed in table after connecting.
Procedures after reconnecting battery:
Procedure Performed
Switch ignition on and off again
using ignition key
Read fault memory: ⇒ Guided
fault finding using VAS 5051A .
Check time on clock and
change as necessary
Electric window regulators:
open all electric windows fully
and close again
Check function of all electrical
consumers
Table can be printed out if necessary.
– Fit battery box cover or cover tab of battery protective jacket.

Touran 2003 ➤
5 Removing and installing battery
WARNING

tions ⇒ page 1 !
Renewing battery on vehicles with start/stop system:

Because of its higher deep-cycle resistance, only an absorbent
glass mat battery is used as a starter battery instead of the normal
lead battery in vehicles with start/stop system.
In case of repair, note correct part number designation in ETKA.
The modified components for the start/stop system have no spe‐
cial markings. They do not differ externally, or hardly, from stand‐
ard components.
5.1 Assembly overview
1 - Earth wire battery terminal

clamp
⇒ page 1 .
❑ Vehicles with a start/
stop system have bat‐
tery monitoring control
unit -J367- (battery sen‐
sor) installed in addition
⇒ page 6
❑ M6
❑ 6 Nm
nal clamp
⇒ page 1 .
❑ M6
❑ 6 Nm
5 - Battery
⇒ page 9 .
6 - Clamping plate
❑ M8 x 35
❑ 20 Nm
5. Removing and installing battery 9

Touran 2003 ➤
5.2 Vehicles with a petrol engine
5.2.1 Removing battery

– Disconnect battery ⇒ page 4 .
– Depending on equipment, pull either panel of battery box or
fleece bag upwards in direction of -arrow- off battery.
– Remove securing bolt -1- and remove battery holder -2-.

– Remove battery.
5.2.2 Installing battery


Touran 2003 ➤
Caution
A loosely fitted battery creates the following dangers:

♦ Shortened service life due to damage from vibration (dan‐
ger of explosion)
♦ The cells in the battery will be damaged if the battery is
not secured correctly.
♦ Damage to battery housing by securing bracket (possibil‐
ity of acid leaking, with high consequential costs)
♦ Poor crash safety.
Installation is carried out in the reverse order. When installing ob‐

serve the following:
– Tighten threaded connections to specified torque ⇒ page 9 .
– After installing battery, check it is firmly seated.
– Connecting battery ⇒ page 4 .
5.3 Vehicles with a diesel engine
5.3.1 Removing battery

– Pull panel of battery box out upwards in direction of arrow.
– Remove securing bolt -1- and remove battery holder -2-.
5. Removing and installing battery 11

Touran 2003 ➤
– Open handles -arrows- upwards and remove battery.
5.3.2 Installing battery

Caution
A loosely fitted battery creates the following dangers:

♦ Shortened service life due to damage from vibration (dan‐
ger of explosion)
♦ The cells in the battery will be damaged if the battery is
not secured correctly.
♦ Damage to battery housing by securing bracket (possibil‐
ity of acid leaking, with high consequential costs)
♦ Poor crash safety.

– After installing battery, check it is firmly seated.

Touran 2003 ➤
6 Starter, vehicles with manual gear‐

box
Renewing starter on vehicles with start/stop system:
Due to the higher requirements on the starter when the start/stop
system is activated, e.g. in urban traffic/driving, the deep-cycle
resistance has been increased and the starter ring gear rein‐
forced.
When renewing starter, note correct part number designation in
ETKA. The modified components for the start/stop system have
no special markings. They do not differ externally, or hardly, from
standard components.
6.1 Checking starter -B-

– Connecting vehicle diagnosis, testing and information system
-VAS 5051A- ⇒ page 288
Select „guided fault finding“ in the vehicle diagnostic, testing and
information system -VAS 5051A- .
– Using „GoTo“ button, select „Functions/component“ and then
the following menu options in succession:
♦ Body
♦ Electrical system
♦ 27 - Starter, current supply
♦ Electrical components
♦ B - Starter
6.2 Starter, vehicles with 1.2l, 77 kW injec‐

tion engine and manual gearbox
MQ200-5F
6.2.1 Assembly overview
6. Starter, vehicles with manual gearbox 13

Touran 2003 ➤
1 - Starter
⇒ page 14 .
❑ Checking ⇒ page 13
2 - Battery positive wire con‐
nection to starter
3 - Battery positive wire secur‐
ing nut to starter
❑ M8
❑ 15 Nm
4 - Starter securing bolts
❑ M12
❑ 75 Nm
5 - Protective cap
6 - Wiring retainer securing
bolts
❑ M8
❑ 23 Nm
7 - Wiring retainer
Not illustrated
♦ Air filter housing securing bolt to body – 10 Nm
6.2.2 Removing and installing starter, 1.2l,

77 kW injection engine with manual
gearbox MQ200-5F

Touran 2003 ➤
Removing:
– Remove air filter housing ⇒ Power unit; Rep. gr. 24 ; Fuel
injection system; Assembly overview - air filter .
– Push protective cap off solenoid switch downwards in direction
of -arrow-.
– Unscrew positive wire -1- and detach connector of terminal 50

-2-.
– Unscrew earth wire from upper bolt of starter -arrow-.

Touran 2003 ➤
– Remove upper securing bolt of starter -arrow-.

– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Body front; Noise insulation .
– Undo nut -1- and remove it from lower securing bolt of starter.
– Remove wire holder -2-.
– Remove lower securing bolt of starter -arrow-.

– Remove starter by taking it downwards out of the vehicle.
Installing:
Install in the reverse order of removal. When doing this, note the
following:
– Tighten threaded connections to specified torque given in as‐
sembly overview ⇒ page 13 .
6.3 Starter, vehicles with 1.4 l, 103 kW or

110 KW TSI engine and manual gear‐
box MQ200-6F

Touran 2003 ➤
1 - Starter
⇒ page 17 .
nection to starter
ing nut to starter
❑ M8
❑ 15 Nm
❑ M12
❑ 75 Nm
5 - Protective cap
bolts
❑ M8
❑ 23 Nm
7 - Wiring retainer
Not illustrated
6.3.2 Removing and installing starter, 1.4 l,

103 kW or 110 KW TSI engine with man‐
ual gearbox MQ 200-6F

Touran 2003 ➤
Removing:
– Remove air filter box ⇒ Engine mixture preparation; Rep. gr.
24 ; Repairing injection system; Removing and installing air
filter .
– Release connector -1- and disconnect.
– Push protective cap -1- off solenoid switch downwards in di‐

rection of -arrow-.
– Undo nut -1- and take positive wire -2- off thread of solenoid
switch.

Touran 2003 ➤
– Undo nut -1- from upper securing bolt of starter and remove
earth cable -2-.
– Remove upper securing bolt of starter, lies behind.
– Undo nut -1- are remove wire holder -2- from lower securing
bolt of alternator.
– Remove lower securing bolt of starter -2-.

– Remove starter -1- by taking it downwards out of the vehicle.
Installing:
following:

77 KW TDI engine and manual gearbox
MQ250-6F

Touran 2003 ➤
1 - Starter
⇒ page 21 .
nection to starter
ing nut to starter
❑ M8
❑ 15 Nm
❑ M12
❑ 75 Nm
5 - Protective cap
bolts
❑ M8
❑ 23 Nm
7 - Wiring retainer
Not illustrated

Touran 2003 ➤
6.4.2 Removing and installing starter, 1.6 l, 77 kW TDI engine with manual gear‐
box MQ250-6F
Special tools and workshop

equipment required
♦ Torque wrench -V.A.G
1331-
1332-
♦ Spring-type clip pliers -VAS
5024-
Removing:
– Pull engine cover off upwards -arrows-.

Touran 2003 ➤
– Release and disconnect connector -1-, release spring-type

clip -2- using spring type clip pliers -VAS 5024- and pull off
vacuum hose -3-.
– Undo bolt -arrow- of air filter housing.
– Release locking lug -arrow- and remove cover.
– Pull hose -arrow- off air filter housing and remove.

– Pull air filter housing upwards out of rubber mountings and
remove it from vehicle.

Touran 2003 ➤

of -arrow-.
– Unscrew positive cable -1- and release and detach connector

of terminal 50 -2-.
– Unscrew securing nut -arrow- and take earth wire off upper
securing bolt of starter.


Touran 2003 ➤
– Undo nut -1- from lower securing bolt of starter.


– Remove starter by taking it downwards out of the vehicle.
Installing:
following:
6.5 Starter, vehicles with 2.0 l, 103 kW TDI

engine and manual gearbox MQ350-6F

Touran 2003 ➤
1 - Starter
⇒ page 26 .
nection to starter
ing nut to starter
❑ M8
❑ 15 Nm
❑ M12
❑ 75 Nm
5 - Protective cap
bolts
❑ M8
❑ 23 Nm
7 - Wiring retainer
Not illustrated

Touran 2003 ➤
6.5.2 Removing and installing starter, 2.0 l, 103 kW TDI engine with manual
gearbox MQ350-6F

equipment required
1331-
1332-
5024-
Removing:

Touran 2003 ➤

vacuum hose -3-.

– Pull air filter housing upwards out of the brackets and remove.

Touran 2003 ➤

of -arrow-.

-2-.
– Unscrew upper securing bolt of starter -arrow- but leave in‐

serted in starter housing.
– Undo nut -1- from lower securing bolt of starter.


Touran 2003 ➤

– Remove starter with upper securing bolt by taking it down‐
wards out of vehicle.
Installing:
following:

Touran 2003 ➤
7 Starter, vehicles with dual clutch

gearbox (DSG)
Renewing starter on vehicles with start/stop system:
Due to the higher requirements on the starter when the start/stop
system is activated, e.g. in urban traffic/driving, the deep-cycle
resistance has been increased and the starter ring gear rein‐
forced.
When renewing starter, note correct part number designation in
ETKA. The modified components for the start/stop system have
no special markings. They do not differ externally, or hardly, from
standard components.

125 kW TSI engine and dual clutch gear‐
box (DSG) DQ200-7F
1 - Starter
⇒ page 31 .
nection to starter
ing nut to starter
❑ M8
❑ 15 Nm
❑ M12
❑ 75 Nm
5 - Protective cap

Touran 2003 ➤
Not illustrated
7.1.2 Removing and installing starter, 1.4 l, 103 kW or 125 kW TSI engine with
dual clutch gearbox (DSG) DQ200-7F

equipment required
1331-
1332-
5024-
Removing:
– Release vacuum hose -arrow- and pull off.
– First pull off engine cover upwards from its rubber mountings
-1- and then remove it forwards in direction of -arrow-.
– Remove air filter housing ⇒ Power unit; Rep. gr. 24 ; Repairing
injection system; Removing and installing air filter .
7. Starter, vehicles with dual clutch gearbox (DSG) 31

Touran 2003 ➤

rection of -arrow-.
switch.
– Remove nut -arrow- and move earth wire to side.

Touran 2003 ➤
– Unscrew lower securing bolt -2- of starter and remove starter

-1- upwards from vehicle.
Installing:
following:
7.2 Starter, vehicles with 1.4 l, 110 kW nat‐

ural gas engine and dual clutch gearbox
(DSG) DQ200-7F

Touran 2003 ➤
1 - Starter
⇒ page 34 .
nection to starter
ing nut to starter
❑ M8
❑ 15 Nm
❑ M12
❑ 75 Nm
5 - Protective cap
Not illustrated
7.2.2 Removing and installing starter, 1.4 l,

110 kW natural gas engine with dual
clutch gearbox (DSG) DQ200-7F
Removing:
– Remove air filter box ⇒ Engine mixture preparation; Rep. gr.
24 ; Repairing injection system; Removing and installing air
filter .

Touran 2003 ➤

rection of -arrow-.
switch.
– Remove nut -arrow- and move earth wire to side.

Touran 2003 ➤
– Unscrew lower securing bolt -2- of starter and remove starter

-1- upwards from vehicle.
Installing:
following:

engine and dual clutch gearbox (DSG)
DQ250-7F

Touran 2003 ➤
1 - Starter
⇒ page 38 .
nection to starter
ing nut to starter
❑ M8
❑ 15 Nm
❑ M12
❑ 75 Nm
5 - Protective cap
Not illustrated

Touran 2003 ➤
7.3.2 Removing and installing starter, 1.6 l, 77 kW TDI engine with dual clutch
gearbox (DSG) DQ200-7F

equipment required
1331-
1332-
5024-
Removing:
hose.

Touran 2003 ➤
– Pull off vacuum hose -3-.


Touran 2003 ➤

of -arrow-.

-2-.

– Remove starter by taking it upwards out of the vehicle.
Installing:
following:

DQ250-6F

Touran 2003 ➤
1 - Starter
⇒ page 42 .
nection to starter
ing nut to starter
❑ M8
❑ 15 Nm
❑ M12
❑ 75 Nm
5 - Protective cap
Not illustrated

Touran 2003 ➤

equipment required
1331-
1332-
5024-
Removing:
– Loosen spring-type clip -2- using spring-type clip pliers -VAS
5024- and pull off hose.

Touran 2003 ➤


Touran 2003 ➤

of -arrow-.

-2-.
– Unclip line -1- from bracket -2-.

Touran 2003 ➤

Installing:
following:

DQ250-6F
1 - Starter
⇒ page 46 .
nection to starter
ing nut to starter
❑ M8
❑ 15 Nm
❑ M12 = 75 Nm
❑ M10 = 40 Nm
5 - Protective cap

Touran 2003 ➤
Not illustrated

equipment required
1331-
1332-
5024-
Removing:
– Loosen spring-type clip -2- using spring-type clip pliers -VAS
5024- and pull off hose.

Touran 2003 ➤

– Pull air filter housing upwards out of the brackets and remove
from vehicle.

Touran 2003 ➤

of -arrow-.

-2-.
– Unclip line -1- from bracket -2-.

– Remove sound proofing ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation .

Touran 2003 ➤
– Remove lower securing bolt of starter -arrow- from below.

Installing:
following:

Touran 2003 ➤
8 Alternator
Note
Checking alternator ⇒ Current flow diagrams, Electrical fault find‐

ing and Fitting locations .
Renewing alternator on vehicles with start/stop system:

Until now the alternator and the voltage regulator were connected
together via their own wires to the engine and onboard supply
control unit. For vehicles with start/stop system, the information
transmission occurs via a LIN data bus to the diagnostic interface
for data bus. Via the CAN data bus, it supplies information to other
control units such as the engine control unit.
8.1 Securing B+ (battery positive) wire to al‐

ternator
Caution
If the battery positive wire is not tightened to the specified tor‐

que, there is a risk of the following:
♦ The battery will not be charged fully.
♦ Vehicle electrics or electronics fail completely (break‐
down).
♦ Danger of fires from sparks
♦ Damage to electronic components and control units due
to excessive voltage
– Tighten B+ wire -arrow- securing nut to 15 Nm.
8.2 Checking poly V-belt

– Crank engine at vibration damper on pulley using a socket.
– Check poly V-belt for:
♦ Sub-surface cracks (cracks, core ruptures, cross sectional
breaks)
♦ Layer separation (top layer, cord strands)
♦ Base break-up
♦ Fraying of cord strands
♦ Flank wear (material wear, frayed flanks, flank brittleness -
glassy flanks-, surface cracks)

Touran 2003 ➤
♦ Traces of oil and grease
Caution
If faults are found, it is essential for the poly V-belt to be re‐

newed. This will avoid possible breakdowns or operating prob‐
lems.
8.3 Checking alternator -C-

-VAS 5051A- ⇒ page 288
Select „Guided fault finding“ mode in vehicle diagnosis, test and
♦ Body
♦ 27 - Starter, current supply
♦ C - Alternator
8.4 Alternator, 1.2 l, 77 kW TSI engine
8. Alternator 51
Touran 2003 ➤
1 - Securing bolts of voltage

regulator
2 - Hexagon head flange bolts
❑ For securing protective
cap
3 - Battery positive wire
4 - Hexagon flange nut
❑ M8
❑ 15 Nm
5 - Protective cap
6 - Protective cap
7 - Protective cap
8 - Voltage regulator
voltage regulator
⇒ page 73
9 - Alternator
alternator ⇒ page 52
poly V-belt pulley on al‐
ternator ⇒ page 68
❑ Checking alternator
⇒ page 51
10 - Belt pulley
❑ 75 Nm
❑ M8
❑ 25 Nm
Not illustrated
♦ Securing bolt for guide roller: M8, 40 Nm
♦ Securing bolt for air conditioner compressor: M8, 25 Nm
8.4.2 Removing and installing alternator, 1.2 l

TSI engine

Touran 2003 ➤
Removing:
Caution
Before removing, mark the top side and direction of rotation of

the poly V-belt. When installing, ensure correct fitting position
and direction of rotation. If the belt is installed in the wrong
position or against direction of rotation, the belt will be de‐
stroyed!
– Remove poly V-belt ⇒ Power unit; Rep. gr. 13 ; Dismantling

and assembling engine; Removing and installing poly V-belt .
– Remove securing bolts -arrows- of air conditioner compressor.

– Undo third securing bolt -arrow- and remove air conditioner
compressor from bracket.
Note
♦ The hoses of the air conditioner compressor can remain con‐

nected.
♦ Suspend the air conditioner compressor -3- using a piece of
wire -1- at a suitable position under the vehicle until it is ready
to be reinstalled.
♦ Ensure that the hoses -2- are not stretched or kinked.

– Pull off protective cap -arrow-.
8. Alternator 53
Touran 2003 ➤
– Unscrew securing nut behind that and remove battery positive

cable from alternator.
– Unscrew securing bolt -arrow- of idler roller and remove idler

roller.
– Remove securing bolts -arrows- of alternator.

– Remove alternator by taking it downwards out of the vehicle.
Installing:
following:
Caution
♦ When installing used poly V-belts observe the direction of

rotation marked on removal!
♦ Before installing poly V-belt, ensure that all ancillaries (al‐
ternator, air conditioning compressor) are secure.
♦ When fitting belt, ensure that poly V-belt seats correctly in
pulleys!
– Drive threaded sleeves -A- about 4 mm in direction of

-arrow- out of alternator housing.
– Start engine and check belt running.

Touran 2003 ➤
8.5 Alternator, 1.4 l, 103 kW/125 kW TSI en‐

gine
1 - Multi-point socket head bolt

❑ M8 x 45
❑ 23 Nm
2 - Upper tensioning roller
3 - Timing case
4 - Hexagon flange bolts
❑ M8 x 45
❑ 23 Nm
5 - Hexagon flange nut
❑ M8
❑ Securing nut for B+ wire
on rear of alternator
❑ 15 Nm
6 - Cross-head screw
❑ M5 x 21
❑ 4.5 Nm
7 - Hexagon nut, flat
❑ M8
8 - Washer
❑ M5
9 - Protective cap
10 - Cross-head screws
❑ M4 x 19
❑ 2 Nm
11 - Cross-head screw
❑ M4 x 13
❑ 2 Nm
❑ Removing and installing voltage regulator ⇒ page 73
13 - Alternator
❑ Removing and installing alternator ⇒ page 56
❑ Checking alternator ⇒ page 51
❑ Securing B+ wire to alternator ⇒ page 50
❑ Removing and installing poly V-belt pulley on alternator ⇒ page 68
14 - Poly V-belt
❑ Poly V-belt routing ⇒ page 59
❑ Checking poly V-belt ⇒ page 50
❑ M8 x 90
❑ 23 Nm
8. Alternator 55
Touran 2003 ➤
16 - Centring sleeves
❑ Insert in ancillary bracket before installing air conditioner compressor
17 - Lower tensioning roller
18 - Ancillary bracket
❑ For tensioning element and air conditioner compressor
19 - Hexagon head flange bolt
❑ M10 x 65
❑ 45 Nm
Not illustrated
♦ M5 securing nut of wiring retainer on rear of alternator, 3.2 Nm
♦ M8 securing bolts of air conditioner compressor on ancillary
bracket - 23 Nm
8.5.2 Removing and installing alternator, 1.4 l

TSI engine
Caution
When batteries are disconnected and reconnected, the proce‐

dure described in the workshop manual must be strictly ob‐
served ⇒ page 4 .

♦ Locking pin -T10060-
Removing:

Touran 2003 ➤

and assembling engine; Removing and installing poly V-belt .
– Remove both securing bolts -arrows- of air conditioner com‐

pressor.

– Undo third securing bolt -arrow- and remove air conditioner
compressor from bracket for ancillaries.
Note
♦ When removing the air conditioner compressor, ensure that

both centring sleeves ⇒ Item 16 (page 56) remain in the threa‐
ded holes (one above the other) of the ancillaries bracket.
nected.
♦ Suspend the air conditioner compressor -3- using a piece of
wire -1- at a suitable position under the vehicle until it is ready
to be reinstalled.
♦ Ensure that the hoses -2- are not stretched or kinked.
8. Alternator 57
Touran 2003 ➤
– Unlock and separate connector of DF cable -1-.

– Lever off protective cap -2-.
– Undo nut -1- and detach the B+ wire under it from the con‐
necting thread of the alternator.
– Undo nuts -3- and remove cable retainer -2- from alternator.
– Relieve tension on upper tensioning roller.
– Undo the three bolts -arrows- and remove the upper tension‐
ing roller from the vehicle.
– Remove securing bolts -arrows- of alternator.

– Remove alternator by taking it downwards out of the vehicle.
Installing:
following:
Caution

♦ Before installing poly V-belt, ensure that all assemblies
(alternator, air conditioner compressor, vane pump) are
installed correctly.
pulleys!

Touran 2003 ➤
– Drive threaded sleeves -A- about 4 mm in direction of

-arrow- out of alternator housing.
– Secure wiring retainer -arrow- on back of alternator in 9 o'clock

position.
Note
Before installing the air conditioner compressor, ensure that both

centring sleeves ⇒ Item 16 (page 56) are inserted in the threaded
holes (one above the other) of the ancillaries bracket.

Caution
Observe notes for battery terminal clamp bolt ⇒ page 1 .

– Stop engine.
8.5.3 Poly V-belt routing, 1.4 l TSI engine

Vehicles with an air conditioner:
1- Poly V-belt pulley - cooling system pump
2- Poly V-belt pulley - crankshaft
3- Lower tensioning roller
4- Upper tensioning roller
5- Poly V-belt pulley - alternator
6- Poly V-belt pulley - air conditioner compressor
7- Poly V-belt
8. Alternator 59
Touran 2003 ➤
Vehicles without air conditioner:

1- Poly V-belt pulley - cooling system pump
2- Poly V-belt pulley - crankshaft
3- Lower tensioning roller
4- Upper tensioning roller
5- Poly V-belt pulley - alternator
6- Poly V-belt
7- Idler roller
8.6 Alternator, 1.6 l, 66/77 kW TDI engine
1 - Hexagon bolt with washer

and threaded element
❑ M4 x 20, M4 x 15
❑ 2 Nm
2 - Protective cap for alternator
❑ M4 x 20
❑ 2 Nm
4 - Protective cap for carbon
brushes
voltage regulator
⇒ page 73
6 - Alternator
⇒ page 51
❑ Securing B+ wire to al‐
7 - Poly V-belt
❑ Poly V-belt routing ⇒
Power unit; Rep. gr. 13 ;
Dismantling and assem‐
bling engine
❑ Checking poly V-belt
⇒ page 50
❑ M8 x 90
❑ 20 Nm

Touran 2003 ➤
Not illustrated
♦ M5 securing nut on back of alternator for wiring clamp - 3.2 Nm
bracket - 23 Nm
8.6.2 Removing and installing alternator, 1.6

l, 66/77 kW TDI engine
Caution

served ⇒ page 4 .

♦ Locking pin -T10060 A-
Removing:
8. Alternator 61
Touran 2003 ➤
Caution

stroyed!

and assembling engine .
– Remove air cowling with radiator fans V7 and V177 ⇒ Power
unit; Rep. gr. 19 ; Engine cooling .
– Remove charge air pipe (return union) „cold side“ complete

with upper and lower connecting hoses.
– To do this, open upper spring-type clip -1-. Release connector
-3- on charge air pipe and disconnect. Remove bolts -2- and
-4-.
– Remove securing bolts -arrows- of air conditioner compressor.
Note

nected.
♦ Suspend the air conditioner compressor using a piece of wire
at a suitable position until it is ready to be reinstalled.
♦ Ensure that the hoses are not stretched or kinked.

Touran 2003 ➤
– Unscrew both securing bolts -1- and securing nut -2- of fuel
filter -3- and place fuel filter to one side. The fuel hoses can
then remain connected.
– Unscrew upper securing bolt -2- of alternator.
– Open lower spring-type clip -1-.
– Tilt alternator -3- forwards.

– Undo securing nuts -4- and remove cable bracket from alter‐
nator.
8. Alternator 63
Touran 2003 ➤
– Unscrew lower securing bolt -1- of alternator.

– Remove alternator by taking it out of vehicle down to right. To
do this, shift air conditioner compressor to left (as seen in di‐
rection of travel).
Installing:
following:
Caution

pulleys!
– Drive threaded sleeve -A- about 4 mm in direction of arrow out

of alternator housing.

position.
Caution

served ⇒ page 4 .

– Stop engine.
8.7 Alternator, 2.0 l, 103/125 kW TDI engine

Touran 2003 ➤
1 - Hexagon bolt with washer

and threaded element
❑ M4 x 20, M4 x 15
❑ 2 Nm
2 - Protective cap for alternator
❑ M4 x 20
❑ 2 Nm
4 - Protective cap for carbon
brushes
voltage regulator
⇒ page 73
6 - Alternator
⇒ page 51
❑ Securing B+ wire to al‐
7 - Poly V-belt
❑ Poly V-belt routing ⇒
Power unit; Rep. gr. 13 ;
Dismantling and assem‐
bling engine
❑ Checking poly V-belt
⇒ page 50
❑ M8 x 90
❑ 20 Nm
Not illustrated
♦ M5 securing nut on back of alternator for wiring clamp - 3.2 Nm
bracket - 23 Nm
8.7.2 Removing and installing alternator, 2.0

l, 103/125 kW TDI engine
Caution

served ⇒ page 4 .
8. Alternator 65
Touran 2003 ➤
♦ Locking pin -T10060 A-
Removing:
– Move lock carrier to service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Adopting service position
Caution

stroyed!

and assembling engine .
– Unscrew both securing bolts -1- and securing nut -2- and place
fuel filter -3- to one side. The fuel hoses can then remain con‐
nected.
– Unscrew upper securing bolt -2- of alternator.
– Open lower spring-type clip -1-.

Touran 2003 ➤
– Tilt alternator -3- forwards.

– Undo securing nuts -4- and remove cable bracket from alter‐
nator.
– Unscrew lower securing bolt -1- of alternator.

– Remove alternator by taking it upwards out of the vehicle.
Installing:
following:
Caution

pulleys!
8. Alternator 67
Touran 2003 ➤
– Drive threaded sleeve -A- about 4 mm in direction of arrow out

of alternator housing.

position.
Caution

served ⇒ page 4 .

– Stop engine.
8.8 Removing and installing poly V-belt pul‐

ley on alternator
Removing and installing poly V-belt pulley with no freewheel
⇒ page 68
Removing and installing poly V-belt pulley with freewheel, make:
Bosch ⇒ page 69
Removing and installing poly V-belt pulley with freewheel, make:
Valeo ⇒ page 71
8.8.1 Removing and installing poly V-belt pul‐

ley without freewheel
♦ Socket -VAS 3310-

Touran 2003 ➤
Removing:
– Remove alternator ⇒ page 50 .
– Clamp alternator in a vice at securing points.
– Use socket -VAS 3310- to unscrew poly V-belt pulley securing
nut from alternator shaft.
Installing:
– Tighten M10 threaded connection of poly V-belt pulley without
freewheel to alternator - 65 Nm.
8.8.2 Removing and installing poly V-belt pul‐

ley with freewheel, manufacturer: Bosch
♦ Multipoint adapter -VAS 3400-
8. Alternator 69
Touran 2003 ➤
Removing:
– Remove protective cap from poly V-belt pulley with freewheel.
– Insert multi-point adapter -VAS 3400- with 17 mm ring spanner
in poly V-belt pulley with freewheel of alternator.
– Insert M10 multi-point bit -1- into alternator shaft.
– Counterhold alternator shaft and loosen poly V-belt pulley with
freewheel anti-clockwise.
– Hold poly V-belt pulley with freewheel by hand. Turn alternator
drive shaft until poly V-belt pulley with freewheel can be re‐
moved.
Installing:
following:
– First screw poly V-belt pulley with freewheel onto drive shaft
of alternator by hand as far as limit stop.
The torque wrench -V.A.G 1332- must be modified for assembly
of poly V-belt with freewheel as follows:
– Release socket drive -1- and pull off grip -2-.

– Turn torque wrench grip -2- 180° and reinsert socket drive.
– Set turning direction of torque wrench to anti-clockwise at
socket drive.

Touran 2003 ➤
– Insert a M10 multi-point bit -1- into alternator shaft.

– Counterhold using multi-point adapter -VAS 3400- and 17 mm
ring spanner.
– Tighten poly V-belt with freewheel by turning drive shaft of al‐
ternator anti-clockwise using torque wrench -V.A.G 1332- .
– Tighten M10 threaded connection of poly V-belt pulley with
freewheel to alternator to 80 Nm.
8.8.3 Removing and installing poly V-belt pulley with freewheel, manufacturer:
Valeo

equipment required
♦ Multipoint adapter -VAS
3400-
1332-
♦ TORX driver bit -V.A.G
1603/1-
8. Alternator 71
Touran 2003 ➤
Removing:
– Remove protective cap from poly V-belt pulley with freewheel.
– Insert multi-point adapter -VAS 3400- with 17 mm ring spanner
in poly V-belt pulley with freewheel of alternator.
– Insert TORX driver bit -V.A.G 1603/1- into alternator shaft.
– Counterhold alternator shaft and loosen poly V-belt pulley with
freewheel anti-clockwise.
– Hold poly V-belt pulley with freewheel by hand. Turn alternator
drive shaft until poly V-belt pulley with freewheel can be re‐
moved.
Installing:
following:
– First screw poly V-belt pulley with freewheel onto drive shaft
of alternator by hand as far as limit stop.
The torque wrench -V.A.G 1332- must be modified for assembly
of poly V-belt with freewheel as follows:
– Release socket drive -1- and pull off grip -2-.

– Turn torque wrench grip -2- 180° and reinsert socket drive.
– Set turning direction of torque wrench to anti-clockwise at
socket drive.
– Insert TORX driver bit -V.A.G 1603/1- into alternator shaft.

– Counterhold using multi-point adapter -VAS 3400- and 17 mm
ring spanner.
– Tighten poly V-belt with freewheel by turning drive shaft of al‐
ternator anti-clockwise using torque wrench -V.A.G 1332- .
– Tighten M10 threaded connection of poly V-belt pulley with
freewheel to alternator to 80 Nm.

Touran 2003 ➤
8.9 Voltage regulator for alternator

Removing and installing voltage regulator, make: Bosch
⇒ page 73
Removing and installing voltage regulator, make: Valeo
⇒ page 73
8.9.1 Removing and installing voltage regula‐

tor, manufacturer: Bosch
♦ Torque screwdriver -V.A.G 1624-
Removing:
– Unscrew securing bolt and nuts -arrows- and remove protec‐
tive cap from alternator.
– Unscrew securing bolts of voltage regulator -arrows-.

– Carefully remove voltage regulator from alternator.
Installing:
Installation is carried out in reverse order of removal.
Specified torques:
♦ M5 securing bolt cover plate to alternator - 4.5 Nm
♦ M4 securing bolt voltage regulator to alternator - 2 Nm
8.9.2 Removing and installing voltage regula‐

tor, manufacturer: Valeo
8. Alternator 73
Touran 2003 ➤
♦ Torque wrench -V.A.G 1783/-
Removing:
– Remove clamping rings -arrows- and remove protective cap
from alternator.
– Unscrew securing bolts of voltage regulator -arrows-.

– Carefully remove voltage regulator from alternator.
Installing:
following:
– Release locking lugs -arrows- and pull protective cap off volt‐
age regulator.
– Push carbon brushes into housing of voltage regulator and in‐
sert voltage regulator into alternator.

Touran 2003 ➤
– Push protective cap into guides -arrows- until it can be heard

to engage.
Specified torques:
♦ M4 securing bolt voltage regulator to alternator - 2 Nm
8. Alternator 75
Touran 2003 ➤
9 Cruise control system (CCS)


Touran 2003 ➤
10 Start/stop system
10.1 General description
Note
Additional information:
⇒ Operating manual of vehicle

⇒ Self-study programme No. 426 ; Start/stop system 2009
⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐
tions
General description:
The start/stop system is used for reducing fuel consumption by
automatically switching off the engine when the vehicle is sta‐
tionary and automatically starting it when the driver wants the
vehicle to move on. The start/stop mode is automatically activated
when, after moving off, the vehicle is driven for about four seconds
at a speed of at least 3 km/h.
Fault detection and fault display:
The start/stop system as a function is integrated in the engine
control unit -J623- software.
The engine control unit -J623- features self-diagnosis to facilitate
fault finding.
For fault finding, use the systems described in chapter „Vehicle
diagnosis, testing and information system“ in „Guided Fault Find‐
ing“ mode ⇒ page 288 .
Battery recharging or jump start on vehicles with start/stop sys‐
tem:
For recharging or slave starting vehicles with start/stop system,
note the following: first connect charger cable to battery positive
terminals and then to body earth. This ensures that the battery
sensor is not bridged. The direct charging of the battery on the
negative terminal clamp means that the battery sensor is shunted
and the battery data are not registered by the sensor while charg‐
ing. Then, the values concerning the battery state and saved in
the data bus diagnostic interface would not correspond to the val‐
ues of the charged battery.
Renewing battery on vehicles with start/stop system:
Because of its higher deep-cycle resistance, only an absorbent
glass mat battery is used as a starter battery instead of the normal
lead battery in vehicles with start/stop system.
In case of repair, note correct part number designation in ETKA.
The modified components for the start/stop system have no spe‐
cial markings. They do not differ externally, or hardly, from stand‐
ard components.
Following components are involved in the start/stop system:
♦ Battery -A- ⇒ page 1
♦ Alternator -C- ⇒ page 50
♦ Voltage regulator -C1-
♦ Starter -B- ⇒ page 13 or ⇒ page 30
10. Start/stop system 77

Touran 2003 ➤
♦ Brake light switch -F-

♦ Clutch pedal switch -F36-
♦ Start/stop operation switch -E693- ⇒ page 78
♦ Coolant temperature sender -G62-
♦ Accelerator position sender -G79-
♦ Gearbox neutral position sender -G701-
♦ Control unit for ABS with EDL -J104-
♦ Climatronic control unit -J255-
♦ Control unit with display in dash panel insert -J285-
⇒ page 83
♦ Battery monitoring control unit -J367- ⇒ page 6
♦ Power steering control unit -J500-
♦ Onboard supply control unit -J519- ⇒ page 296
♦ Voltage stabiliser -J532- ⇒ page 78
♦ Data bus diagnostic interface -J533- ⇒ page 301
♦ Engine control unit -J623-
♦ Park assist steering control unit -J791- ⇒ page 215
10.2 Start/stop operation switch -E693-

The start/stop operation switch -E693- is located in the centre
console switch panel in front of the gear lever. It serves to switch
off manually the start/stop system.
10.2.1 Removing and installing start/stop oper‐

ation switch -E693-
Removal and installation of the start/stop operation switch -E693-
are carried out in the same way for all switches in the centre
console switch panel ⇒ page 270 .
10.3 Voltage stabiliser -J532-

Voltage stabiliser -J532- can be found on left in dash panel behind
relay carrier on onboard supply control unit -J519- (LHD). It has
the task of stabilizing to 12 volts the high voltage fluctuations
generated in the onboard supply by the start/stop operation.
On RHD models, voltage stabiliser -J532- can be found on right
in dash panel behind relay carrier on onboard supply control unit
-J519- .
Assembly overview - voltage stabiliser for LHD models
⇒ page 79
Assembly overview - voltage stabiliser for RHD models
⇒ page 80
Effects in case of voltage stabiliser failure:
When the starter is operated and the voltage supply is insufficient
for devices like radio, radio navigation or telephone they will per‐
form a reset. If, in start/stop mode, the mentioned electrical con‐
sumers are identified as causing a reset for each motor start, this
indicates a defective voltage stabiliser. A direct entry concerning
a malfunction of the voltage regulator, e.g. in the fault memory of
the diagnostic interface or the onboard supply control unit, does
not occur at present. If radio, radio navigation and telephone units
fail together, first check fuse of voltage regulator.

Touran 2003 ➤
10.3.1 Assembly overview - removing and installing voltage stabiliser -J532- , LHD
models
Note
For reasons of clarity, the components in the magnified section are shown from the perspective of looking down
through the dash panel.
1 - Securing bolt
❑ Duo hex flange bolt
M6 x 20
❑ On left W-box bracket
❑ 4.5 Nm
2 - W-box bracket
3 - DC/DC bracket
4 - Voltage stabiliser -J532-
5 - Release buttons
❑ On W-box bracket
Removing:
– Switch off ignition and all electrical consumers. Remove igni‐
tion key.
– Remove rack assembly in its entirety with onboard supply
control unit -J519- , relay carrier (9 slot) and relay carrier (5
slot) ⇒ page 297 .
– Remove onboard supply control unit -J519- , data bus diag‐
nosis interface -J533- , park assist steering control unit -J791- ,
relay carrier (9 slot) and relay carrier (5 slot) from rack assem‐
bly.

Touran 2003 ➤
Note
When doing this, the connectors on the control units and relay
carriers are not separated.
– Release and separate connector -1- on voltage stabiliser -

J532- .
– Unscrew securing bolt ⇒ Item 1 (page 79) on left W-box brack‐
et.
– Press release buttons ⇒ Item 5 (page 79) on both sides of W-
box bracket. Press voltage stabiliser ⇒ Item 4 (page 79) to‐
gether with DC/DC bracket (plastic frame)
⇒ Item 3 (page 79) upwards off W-box bracket.
– Pull left W-box bracket back slightly. Shift voltage stabiliser to
left together with DC/DC bracket (plastic frame) and remove
downwards between W-box bracket and left sidewall.
– Press release buttons -arrows A- outwards and push voltage

stabiliser -2- off bracket -1- in direction of arrow.
Installing:

following:
Tighten securing bolt ⇒ Item 1 (page 79) to 4.5 Nm.
10.3.2 Assembly overview - removing and installing voltage stabiliser -J532- , RHD
models
Note
For reasons of clarity, the components in the magnified section are shown from the perspective of looking down
through the dash panel.

Touran 2003 ➤
1 - Connector
2 - Voltage stabiliser -J532-
3 - DC/DC bracket
4 - Rack assembly
Removing:
tion key.
– Remove rack assembly in its entirety with onboard supply
control unit -J519- , relay carrier (9 slot) and relay carrier (5
slot) ⇒ page 297 .
– Remove onboard supply control unit -J519- , data bus diag‐
nosis interface -J533- , park assist steering control unit -J791- ,
relay carrier (9 slot) and relay carrier (5 slot) from rack assem‐
bly.
Note
When doing this, the connectors on the control units and relay
carriers are not separated.
– Release and separate connector ⇒ Item 1 (page 81) on volt‐

age stabiliser -J532- .

Touran 2003 ➤
– Press release buttons -arrows A- on DC/DC bracket (plastic

frame) -1- and press voltage stabiliser -2- off bracket in direc‐
tion of -arrow B-.
Installing:

Touran 2003 ➤
90 – Gauges, instruments
1 Dash panel insert
Note
⇒ Self-study programme No. 306 ; The Touran

⇒ Self-study programme No. 307 ; The Touran - Electrical sys‐
tem
Integrated in the dash panel insert are the following components:
♦ Control unit with display in dash panel insert -J285-
♦ Immobilizer control unit -J362-
♦ Speedometer
♦ Rev. counter
♦ Fuel gauge
♦ Coolant temperature gauge
♦ Multifunction display
♦ Warning lamps ⇒ page 86
In vehicles with a natural gas engine (EcoFuel), the round instru‐
ment -2- indicates the gas level. The warning lamp -1- is the
reserve level indicator for the gas supply. In addition, the dash
panel insert also has a segment display -arrow- to indicate petrol
levels and a warning lamp for petrol emergency mode -3-.
To provide acoustic support to some of the visual displays, the
dash panel features a warning buzzer, which is actuated by the
control unit.
All warning lamps are fitted with light-emitting diodes (LEDs). No
provision is made for dash panel insert repair. If necessary, the
dash panel insert is renewed as a unit ⇒ page 83 .
The data bus diagnostic interface -J533- (Gateway) is an individ‐
ual control unit option and not part of the dash panel insert
⇒ page 301 , unlike on several other vehicles.
The dash panel insert is equipped with self-diagnosis, which
makes fault finding easier.
For fault finding, use vehicle diagnostic, testing and information
system -VAS 5051A- in „Guided fault finding“ mode.
1.2 Renewing dash panel insert

The procedure „Renewing dash panel insert“ covers the following
additional tasks:
1. Dash panel insert 83

Touran 2003 ➤
♦ If a new dash panel insert is installed in the vehicle, the control

unit of the dash panel insert must be adjusted to the different
equipment features and associated country settings.
♦ To adapt the integrated immobilizer to the engine control unit,
the data from the engine control unit has to be stored in the
replacement dash panel insert.
♦ Furthermore, if a new dash panel insert is installed, all ignition
keys must be adapted.
♦ Vehicle diagnosis, testing and information system -VAS
5051A-
♦ Diagnostic cable -VAS 5051/6A-

-VAS 5051A- ⇒ page 288
– Select „Guided fault finding“ mode in vehicle diagnosis, test
and information system -VAS 5051A- .
♦ Body
♦ 01 - On Board Diagnostic capable systems
♦ Dash panel insert
♦ Functions
♦ Adapting/renewing dash panel insert
84 Rep. gr.90 - Gauges, instruments

Touran 2003 ➤
1.3 Removing and installing dash panel in‐

sert
Note
Before removing the dash panel insert, the work procedure „Re‐
newing dash panel insert“ should always be carried out in order
that the data stored in the control unit can be interrogated
⇒ page 83 .
Removing:
– Switch off ignition and all electrical consumers, and remove
ignition key.
Note
There is no need to remove the steering wheel.
– Pull steering wheel fully out and lock it in lowest position.

– Remove upper part of steering column trim ⇒ General body
repairs, interior; Rep. gr. 68 ; Compartments, covers and trim;
Removing and installing steering column trim .
– Remove bolts -arrows- from dash panel insert -1-.
– Pull out dash panel insert -1- backwards in straight line from
dash panel, taking connected wiring lengths into considera‐
tion.
– Swing securing bar -1- in -direction of arrow- and pull off con‐
nector -2-.
– Remove dash panel insert from vehicle.
Installing:

Touran 2003 ➤
1.4 Description of back of dash panel insert
Note
The dash panel insert must not be dismantled. If necessary, the

dash panel insert is renewed as a unit.
1- 32-pin connector
2- Warning buzzer
Note
For the pin assignment of connectors on dash panel insert, refer

to ⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations
1.5 Warning lamp symbols in dash panel in‐

sert
Note
♦ The warning lamps on the dash panel insert depend on the

vehicle's equipment, country and engine type.
♦ Different versions of dash panel insert are installed depending
on vehicle equipment. Therefore, the arrangement of the
warning lamps may differ.

Touran 2003 ➤
1 - Equipment dependant dis‐

plays
❑ Reducing stopping dis‐
tance (RSD).
plays
❑ Symbol „glow coil“ for
vehicles with a diesel
engine (including EPC).
❑ Symbol „EPC (Electron‐
ic Power Control)“ for
vehicles with a petrol
engine.
plays
❑ Symbol „diesel particu‐
late filter blocked“ for ve‐
hicles with a diesel en‐
gine.
❑ Symbol „fuel tank flap
not closed correctly“ for
vehicles with a petrol
engine (NAR).
❑ Symbol „coolant tem‐
perature too high or
coolant temperature too
low“ for vehicles with a
natural gas engine
(EcoFuel).
4 - Oil level / oil pressure
❑ Oil pressure too low
(red).
❑ Oil level too low (yel‐
low).
❑ Switch off engine and
check oil level.
5 - Bulb failure / trailer turn signal
❑ Lights up: bulb failure or fault in dynamic bend lighting (AFS).
6 - Rear fog light
7 - Main beam switched on
8 - Left turn signal
9 - Multifunction display (equipment dependant displays)
❑ CAR outline:
♦ Door(s) open.
♦ Bonnet or rear lid open.
❑ Oil pressure too low (red).
❑ Oil level too low (yellow).
❑ Brake wear indicator (BWI).
❑ Extended servicing interval (ESI).
10 - Right turn signal
11 - Airbag display
❑ Airbag system defective.
❑ Front passenger front airbag is deactivated.
❑ Belt tensioner defective.

Touran 2003 ➤
12 - Equipment dependant displays

❑ Brake wear indicator (BWI).
13 - Anti-lock brake system (ABS)
❑ Lights up: fault in anti-lock brake system.
14 - Electronic stabilisation programme (ESP)
❑ Flashes: ESP regulating system.
❑ Lights up: ESP fault or ESP switched off.
15 - Brake system warning lamp
❑ Handbrake applied or
❑ Brake fluid low or
❑ Fault in brake system.
16 - Cruise control system (CCS) switched on
17 - Tyre pressure monitoring (TPM)
❑ Tyre inflation pressure of a wheel is too low.
18 - Fasten seat belts
19 - Shift lock
❑ Indication to depress foot brake.
❑ Rear lid open
21 - Fuel reserve
❑ Door(s) open.
23 - ECO - cold light
❑ EcoFuel (blue).
24 - Washer fluid level
❑ Lights up: windscreen washer fluid level in reservoir too low.
25 - Electric On Board Diagnosis (EOBD)
❑ Exhaust system fault.
26 - Electromechanical power-assisted steering not working (EPS)
❑ Lights up yellow: reduced electromechanical power steering.
❑ Lights up red: electromechanical power steering failure.
27 - Coolant
❑ Coolant temperature too high or
❑ Coolant level too low.
Natural gas - reserve
❑ EcoFuel
28 - Charge control
❑ Fault in alternator.
29 - ESP OFF

Touran 2003 ➤
2 Service interval display
2.1 Resetting service interval display

– Resetting service interval display ⇒ Maintenance ; Booklet
18.1
2. Service interval display 89

Touran 2003 ➤
92 – Windscreen wash/wipe system

1 Windscreen wiper system
Note

tions
⇒ Operating manual
The wiper motor control unit -J400- and the windscreen wiper
motor -V- are combined to form one unit.
To remove the wiper blades, the wiper arms should be placed in
the „service/winter position“. The „service/winter position“ is acti‐
vated within 15 seconds after ignition is switched off by operating
windscreen wiper lever in „tip wipe“ position ⇒ Operating Manual
of vehicle .
Note
The following descriptions of the windscreen wiper system refer

to a LHD vehicle. Unless the description states otherwise, the in‐
dividual modules are removed and installed using the corre‐
sponding mirror-image procedure in RHD vehicles.

The onboard supply control unit -J519- features self-diagnosis to
facilitate fault finding.
1.2 Deactivating APP function of wiper mo‐

tor
♦ Vehicle diagnosis, testing and information system -VAS
5051A-
90 Rep. gr.92 - Windscreen wash/wipe system

Touran 2003 ➤
♦ Diagnostic cable -VAS 5051/6A-
The windscreen wiper system is equipped with an APP function

(alternating park position).
With the APS function, the wiper arm is moved up slightly once it
has reached the lowest position. This occurs every second time
the wiper system is switched off.
To fit the motor crank on the wiper motor, it is necessary for the
motor to be in the lowest park position. To ensure this position is
reached, the APP function must be deactivated.
Note
♦ The APP function cannot be activated.

♦ After 100 cycles of wiper movement, the APP function is acti‐
vated automatically. This applies to wiper motors on which the
APP function has been deactivated and also to new wiper mo‐
tors.

-VAS 5051A- ⇒ page 288
♦ Body
♦ Onboard supply control unit
♦ Onboard supply control unit functions
♦ Coding control unit for wiper electronics/deactivating APP
– Read current coding and note.
– Code control unit with value noted beforehand.
Note
The reading can vary in the number of figures from the number
of spaces available for the new code. This number has absolutely
no bearing on the function of the windscreen wiper system. The
new coding simply has the effect of resetting the wiper cycle
counter to zero.
1.3 Assembly overview - windscreen wiper system
1. Windscreen wiper system 91

Touran 2003 ➤
1 - Wiper arm securing nut to

linkage
❑ 20 Nm
2 - Joint-free wipers
⇒ page 98 .
❑ Adjusting park position
⇒ page 97
3 - Wiper arms
⇒ page 93 .
4 - Wiper frame securing bolts
with linkage to body
❑ 8 Nm
5 - Wiper frame with linkage
⇒ page 95 .
6 - Wiper motor -V- with wiper
motor control unit -J400-
❑ Removing from wiper
frame and installing
⇒ page 95
❑ Coding wiper motor
control unit and deacti‐
vating APP function
⇒ page 90
7 - Rubber grommet in bulk‐
head
❑ Observe installation
notes ⇒ page 96
1.4 Removing and installing windscreen

wiper system

Touran 2003 ➤
♦ Release lever -80-200-
♦ Puller -T10369-
1.4.1 Removing windscreen wiper system

– Deactivate APP function ⇒ page 90 .
– Move wipers to park position and then switch off ignition.
Note
Before the wiper frame with linkage and wiper motor can be re‐
moved, first remove the wiper arms, the plenum chamber cover
and the air duct trim.
1.4.2 Removing wiper arms
Note
♦ Preparing windscreen wiper system for the removal of the

wiper arms ⇒ page 93 .
♦ The following illustrations show the removal of the wiper arm
on the driver side. Removal on the front passenger side is
carried out in the same way.

Touran 2003 ➤
– Lever off cap -arrow- using screwdriver.
– Remove nut -arrow-.
– Slide legs of puller -T10369/1- -2- under wiper arm -4- as

shown in the illustration.
Caution
The wiper shaft may be damaged.

Always use the thrust piece -3- to loosen the wiper arm.
– Turn thrust bolt -1- of puller clockwise until thrust piece -3-
comes into contact with wiper shaft. Turn thrust bolt -1- of
puller clockwise using a 6 mm Allen key until wiper arm -4- is
released from shaft.
– Remove puller and wiper arm.
1.4.3 Removing and installing plenum cham‐

ber cover
– Removing wiper arms ⇒ page 93
Removing and installing plenum chamber cover ⇒ General body
repairs, exterior; Rep. gr. 64 ; Flush bonded windows; Assembly
overview - plenum chamber cover .

Touran 2003 ➤
1.4.4 Removing air ducting trim

– Remove bolts -arrows- from air duct trim -1-.
– Remove air ducting trim -1- from vehicle.
1.4.5 Removing wiper frame with linkage and

wiper motor
– Disconnect connector -1-.
– Unscrew bolts -arrows- and pull wiper frame -2- forwards out
of vehicle.
1.4.6 Removing wiper motor from wiper frame

– Lever rods -arrow- off motor crank using removal lever
-80-200- .
– Remove nut -1-.

– Pull motor crank -2- off wiper motor shaft.
– Unscrew bolts -arrows- and remove wiper motor together with
control unit from wiper frame.

Touran 2003 ➤
1.4.7 Installing wiper motor in wiper frame

– Insert wiper motor with control unit in wiper frame and secure
with bolts.
– Place motor crank -1- on shaft of wiper motor. Distance -a- to
limit stop -2- should be 3 ± 1 mm.
– Secure motor crank to wiper motor shaft using hexagon nut
-3-.
– Tighten threaded connection to specified torque ⇒ page 91 .
1.4.8 Installing windscreen wiper system

– Install wiper frame in reverse order of removal.
Note
When installing, ensure the securing pin on the back of the wiper
frame is inserted in the grommet -arrow- in the bulkhead.

– Push connector onto connection of wiper motor and lock it.
– Install air duct trim in reverse order of removal.
– Installing plenum chamber cover ⇒ page 94 .
1.5 Removing and installing wiper arms

Removing:
Removing wiper arms ⇒ page 93
Installing:
Note
♦ The following illustrations show wiper arm installation on the

driver side. Installation on the front passenger's side is carried
out in the same manner.
♦ Securing nuts of wiper arms are not tightened to specified tor‐
que until after windscreen wiper park position has been ad‐
justed.
– To move wiper motor to its rest position, switch windscreen

wipers on and off with ignition on.

Touran 2003 ➤
– Fit wiper arm in approximate park position on wiper arm shaft

and tighten securing nut -arrow- by hand .
– Repeat procedure on passenger side if necessary.
– Adjusting windscreen wiper park position ⇒ page 97 .
1.6 Adjusting windscreen wiper park posi‐

tion
Note
On RHD vehicles, the wiper blades are a mirror image of those

on LHD vehicles.
– Deactivate APP function ⇒ page 90 .

– Move wipers to park position and then switch off ignition.
– Adjust windscreen wiper park position.
Driver side:
Distance -A- between wiper blade and upper edge of plenum
chamber cover should be 30 mm.
– Adjust windscreen wiper park position by moving wiper arm if
necessary.
Front passenger side:

Touran 2003 ➤
Distance -B- between wiper blade and upper edge of plenum

chamber cover should be 30 mm.
– Adjust windscreen wiper park position by moving wiper arm if
necessary.
1.7 Removing and installing joint-free wip‐

ers
Note
♦ Driver and front passenger wiper blades must not be inter‐

changed when installing.
♦ Joint-free wipers are very flexible. To lift the wiper blades off
the windscreen, touch them only in the area in which the wiper
blades are attached to the wipers.
♦ To remove the wiper blades, the wiper arms should be placed
in the „service/winter position“. The „service/winter position“ is
activated within 10 seconds after ignition is switched off by
pressing the windscreen wiper lever in position „tip wipe“.
Removing:
– Let window wiper system run to „service/winter position“.
– Lift up wiper arm.
– Press button -1- and pull wiper blade mounting -3- out of wiper
arm -2- in -direction of arrow-.
Installing:
following:
– Push wiper blade mounting -3- onto wiper arm -2- to stop.
– Ensure button -1- has locked correctly into wiper arm -2-.
– Carefully fold wiper arm back onto front windscreen.

Touran 2003 ➤
1.8 Removing and installing wiper rubber

blade of joint-free wiper
Caution
Only suitable joint-free wiper rubber blades manufactured by

Bosch are available.
The replacement wiper rubber blades from other manufactures
do not fit correctly and this may lead to poor wiper performance.
Note
Refer to chapter »Distinguishing features of joint-free wiper

blades« in Workshop manual „Electrical system, General infor‐
mation“. A link to this workshop manual is not possible at present
for technical reasons. Select workshop manual „Electrical sys‐
tem, General information“ manually in ELSA.
– Remove joint-free wiper blade ⇒ page 98 .

– Check to see on which side the wiper rubber blade cannot be
pushed into the guide.
– On the side that cannot be pushed into the guide, carefully
lever off the cap -1-.
– Using a suitable screwdriver, open the wiper rubber stop -A-

by bending up.
– Renew wiper rubber blade.
Note
Ensure that wiper rubber blade is seating correctly in wiper rubber

blade guides.

Touran 2003 ➤
– Push wiper blade stop -A- back down using a suitable screw‐
driver until wiper rubber blade can no longer be moved in the
guide.
– Fit new cap -1- and check it is seated securely.

– Reinstall joint-free wiper blade ⇒ page 98 .
– Check wiper blade is working correctly.
1.9 Rain and light sensor -G397-
1.9.1 Removing and installing rain and light

sensor -G397-
The rain and light sensor has been designed so that it can be used
again. The prerequisite for the re-use is that the coupling pad is
not damaged (check!).
Caution
On removal, store the rain and light sensor -G397- in a dust-

free location until reinstallation and ensure the silicone contact
pad is not soiled.
Note
♦ If a rain sensor is renewed and has to be replaced by a rain

sensor with another part number, the rain sensor must be co‐
ded ⇒ page 102 .
♦ The rain sensors cannot be installed optionally. Determine the
right rain sensor according to ETKA (Electronic parts cata‐
logue).
Removing:
key.
– Remove interior mirror ⇒ General body repairs, interior; Rep.
gr. 68 ; Interior mirror; Removing and installing interior mirror
with rain sensor .

Touran 2003 ➤
– Pull connector -A- off rain and light sensor -G397- -1-.
– Using a suitable plain slot screwdriver, lever rain and light

sensor -G397- -1- on recess -3- out of retaining plate -2-.
Note
On removal, take care to lever out the entire rain and light sensor
-G397- and not just the upper shell of the sensor.
Installing:
Caution
♦ Prior to installation, thoroughly clean the surface of the

windscreen inside the bracket for rain and light sensor -
G397- . Any remains of coupling pad adhering to the
windscreen must be completely removed.
♦ The surface (coupling pad) of the rain and light sensor -
G397- must not be soiled on installation. A sensor with
damaged coupling pad must be renewed.
Note
If the surface (coupling pad) of the rain and light sensor -G397-
is soiled, it may be possible to clean it by „bonding on“ and then
„pulling off“ one or more adhesive strips.
– Clean windscreen within retaining plate thoroughly; cleansing

agent ⇒ General body repairs, interior; Rep. gr. 68 ; Interior
mirror; Bonding retaining plate for interior mirror with rain sen‐
sor .
– Remove protective cap of new rain and light sensor -G397- ,
if necessary.

Touran 2003 ➤
– Insert rain and light sensor -G397- -1- into the retaining plate
on front windscreen -2- by pressing it in firmly.
Note
Even when sensor is installed correctly, small air bubbles may

first appear between windscreen and coupling pad. After approx.
10 minutes, the contact surface must be free of bubbles.
– Reconnect connector -A- and secure rain sensor by installing

cable cover.
– Install interior mirror ⇒ General body repairs, interior; Rep. gr.
68 ; Interior mirror; Removing and installing interior mirror with
rain sensor .
– If necessary, code rain and light sensor -G397- ⇒ page 102 .
1.9.2 Coding rain and light sensor -G397-

– Connecting vehicle diagnosis tester ⇒ page 288
– Select „Guided fault finding“ in vehicle diagnosis tester .
♦ Body
♦ Diagnostic capable systems
♦ Functions
♦ Coding rain and light sensor

Touran 2003 ➤
2 Windscreen washer system
Note
♦ The operation of the windscreen washer system can be

checked using the final control diagnosis of the onboard sup‐
ply control unit -J519- .
♦ Additional information:

tem
The onboard supply features self-diagnosis to facilitate fault find‐
ing.
2.1 Assembly overview - windscreen wash‐

er system
Note
One of two different types of reservoir is installed for the wind‐

screen and headlight washer system, depending on the equip‐
ment installed in the vehicle. The illustration shows the version
for vehicles with an auxiliary heater.
2. Windscreen washer system 103

Touran 2003 ➤
1 - Windscreen washer system

spray jets
⇒ page 110 .
❑ Adjusting ⇒ page 111
2 - Angled connection piece
❑ Connection to wind‐
screen spray jet
❑ Overview of hose cou‐
plings for washer fluid
lines ⇒ page 123
3 - Y-piece
❑ Distribution of washer
fluid line to windscreen
spray jets
4 - Filler pipe for washer fluid
reservoir
on vehicles without aux‐
iliary heater
⇒ page 105 .
on vehicles with auxili‐
ary heater ⇒ page 107 .
5 - Windscreen and rear win‐
dow washer pump -V59-
⇒ page 109
❑ Connection to wind‐
screen and rear window
washer pump -V59-
lines ⇒ page 123
7 - Windscreen washer fluid level sender -G33-
❑ Removing and installing ⇒ page 110 .
8 - Washer fluid reservoir
❑ Removing and installing on vehicles without auxiliary heater ⇒ page 106 .
❑ Removing and installing on vehicles with auxiliary heater ⇒ page 107 .
9 - Hose
❑ Hose repair ⇒ page 124
Not illustrated: threaded connection (M8)

♦ Between windscreen and headlight washer system reservoir
and vehicle frame (with and without auxiliary heater).
♦ 8 Nm
2.2 Removing and installing washer fluid

reservoir
The windscreen and headlight washer reservoir is designed in two
parts and is installed as two different versions depending on the
equipment level.

Touran 2003 ➤
Vehicles without seat heating:

Removing and installing filler pipe for windscreen and headlight
washer system reservoir ⇒ page 105 .
Removing and installing reservoir for windscreen and headlight
washer system ⇒ page 106 .
Vehicles with seat heating:
Removing and installing filler pipe for windscreen and headlight
washer system reservoir ⇒ page 107 .
Removing and installing reservoir for windscreen and headlight
2.2.1 Removing and installing filler pipe for

windscreen and headlight washer sys‐
tem reservoir (without seat heating)
Removing:
– Pull connecting pipe -1- off filler neck -3- on windscreen and
headlight washer system reservoir.
– Remove bolt -2-.
– Unclip hose retainer from filler neck -3- and remove filler neck
-3- from vehicle.
Installing:
following:
The protrusion on the underside of the filler neck must be inserted

in the hole -arrow- in the engine mounting.
Connecting pipe -1- and filler neck -2- should be pressed together
so that the guides -arrows- engage in each other.

Touran 2003 ➤
2.2.2 Removing and installing reservoir for

tem (without auxiliary heater)
Removing:
key.
– Remove filler neck for reservoir for windscreen and headlight
– Remove front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Front bumper
Note
The connections at the pump and hoses are colour-coded to pre‐

vent incorrect connection of the washer fluid lines to the wind‐
screen and rear window washer pump -V59- . The hose fittings
must be connected to the correct colour-coded pump connections
during installation.
– To release, turn hose lock at hose connections -3- and -5- and
pull connections off windscreen and rear window washer
pump -V59- -4-.
– If necessary, collect any escaping washer fluid in a suitable
container.
– Disconnect connector -6- for windscreen washer fluid level
sender -G33- -7-.
– Pull windscreen and rear window washer pump -V59- -4- up‐
wards out of reservoir and disconnect connector -2-.
– Pull headlight washer system pump -V11- -9- upwards out of
reservoir and disconnect connector -10-.
– Undo nuts and bolts -arrows- from reservoir and remove res‐
ervoir together with connecting pipe for filler neck from vehicle.
Installing:
Install in the reverse order of removal observing the following:
– Tighten threaded connections to specified torque
⇒ page 103 .
– On completion of installation work, bleed headlight washer
system ⇒ page 122 .

Touran 2003 ➤
2.2.3 Removing and installing filler pipe for

tem reservoir (with auxiliary heater)
Removing:
key.
– Remove hexagon bolt -1-.
– Pull filler pipe -2- off union -3- on reservoir for windscreen and
headlight washer system -arrow-.
Installing:
following:
The protrusion on the underside of the filler pipe should be inser‐
ted in the hole -arrow-.
2.2.4 Removing and installing reservoir for

tem (with auxiliary heater)
Removing:
key.
– Remove filler neck for reservoir for windscreen and headlight
Rep. gr. 63 ; Removing and installing bumper cover .
– Move lock carrier to service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Lock carrier .

Touran 2003 ➤
– Remove bolt -arrow- from windscreen washer and headlight

washer system reservoir.
– Pull hose connections -5- off windscreen and rear window

washer pump -V59- -4- and drain escaping washer fluid into a
suitable container.
Note

– Disconnect connectors from windscreen washer fluid level

sender -G33- -1- and headlight washer system pump -V11-
-2-.
– In order to separate connector -3-, pull windscreen and rear
window washer pump -V59- -4-upwards out of reservoir
-arrow-.
– Unclip pipe from clips -arrows- on reservoir.

– Pull reservoir forwards out of vehicle.

Touran 2003 ➤
Installing:
The guides on the windscreen washer and headlight washer sys‐
tem reservoir -arrows- should be inserted and engaged in the
mounting bracket in the vehicle.

and rear window washer pump -V59-
The windscreen and headlight washer reservoir is installed as two
different versions depending on the equipment level. The follow‐
ing describes removal and installation of the windscreen and rear
window washer pump -V59- on the windscreen and headlight
washer system reservoir for vehicles with auxiliary heater. Re‐
moval and installation of the windscreen and rear window washer
pump -V59- on vehicles with no auxiliary heater is carried out in
a similar way as appropriate.
Removing:
key.
– Pull hose connections -5- off windscreen and rear window
washer pump -V59- -4- and drain escaping washer fluid into a
suitable container.
Note

– Pull windscreen and rear window washer pump -V59- -4- up‐
wards -arrow- out of reservoir and disconnect connector -3-.
Installing:
following:

Touran 2003 ➤

washer fluid level sender -G33-
The windscreen washer fluid level sender -G33- is mounted on
the windscreen and the headlight washer system reservoir before
the front right wheel housing.
ing describes removal and installation of the window washer fluid
level sender -G33- on the windscreen and headlight washer sys‐
tem reservoir for vehicles with auxiliary heater. Removal and
installation of the window washer fluid level sender -G33- on ve‐
hicles without auxiliary heater is carried out in a similar way as
appropriate.
Removing:
key.
– Disconnect connector -2- for windscreen washer fluid level
sender -G33- .
– Pull windscreen washer fluid level sender -G33- -1- out of its
rubber seal.
Installing:

washer system spray jets
Removing:
– Push spray jet upwards -arrow A- and pull out of flap at the
rear -arrow B-.

Touran 2003 ➤
– Release hose clip -1- in -direction of arrow- and pull hose con‐
nection -2- off spray jet.
– Models with heater washer jets, release and disconnect con‐
nector -3-.
– Remove spray jet -4-.
Installing:
– Reconnect connector -3- to spray jet.

– Fit hose connector -2- on to spray jet and engage hose clip
-1-.
– Starting at the top, push spray jet into mounting hole until it
locks in place audibly.
– Adjusting spray jets ⇒ page 111
2.6 Adjusting windscreen washer system

spray jets
Note
In case of uneven spray field due to impurities in the spray jet:

remove spray jet and rinse it through with water, opposite to di‐
rection of spray. Purging with compressed air against the spraying
direction is then permitted. Do not use objects to clean the spray
jets!
Caution
♦ Danger of causing damage.

♦ The spray jet may be damaged.
♦ Do not use objects to clean the spray jets!
Adjusting windscreen washer system spray jets ⇒ Maintenance ;

Booklet ; Descriptions of work

Touran 2003 ➤
3 Rear window wiper system
Note
tem
Caution
To disconnect and reconnect the battery, the procedure de‐

scribed in the workshop manual should be strictly adhered to
⇒ page 4 .
3.1 Assembly overview - rear window wiper system
1 - Cover cap
2 - Securing nut
❑ 12 Nm
3 - Wiper arm
⇒ page 113 .
❑ Adjusting park position
⇒ page 114
4 - Seal
❑ In rear window
5 - Rear window wiper motor -
V12-
⇒ page 113 .
6 - M6 securing nut with wash‐
er
❑ 8 Nm
7 - Rubber ring
8 - Spacer
9 - Joint-free wiper
⇒ page 115 .

Touran 2003 ➤
3.2 Removing and installing wiper arm

Removing:
– Move wipers to park position.
– Fold cover cap -1- of rear window wiper up and unclip it.
– Loosen but do not completely remove securing nut -arrow-.
– Fold wiper arm up and release from taper by rocking arm back
and forth sideways.
– Unscrew securing nut -arrow- completely and take wiper arm
off.
Installing:
– To move wiper motor to its rest position, switch windscreen
wipers on and off with ignition on.
– Fit wiper arm in approximate park position on wiper arm shaft

and tighten securing nut -arrow- by hand .
Note
Wiper arm securing nut -arrow- is not tightened to specified torque

until wiper blade park position has been adjusted.
– Adjust rear window wiper park position ⇒ page 114 .
3.3 Removing and installing rear window

wiper motor -V12-

3. Rear window wiper system 113

Touran 2003 ➤
Removing:
– Remove lower trim on rear lid ⇒ General body repairs, interior;
Rep. gr. 70 ; Rear lid trim .
– Remove securing nuts -arrows-.
– Carefully pull rear window wiper motor -V12- inwards off rear
lid.
Installing:
– Check seal is seated correctly in opening of rear window. Mark

-1- on seal must align with mark -2- on rear window.
3.4 Adjusting rear window wiper park posi‐

tion

Distance -a- between wiper rubber and lower edge of window
must be 33 mm.
– Adjust rear window wiper park position by moving wiper arm
if necessary.
Removing wiper arm ⇒ page 113
⇒ page 112 .

Touran 2003 ➤
3.5 Renewing wiper rubber blade

– On enclosed side of wiper rubber blade, press both steel strips
and wiper rubber blade together using suitable pliers.
– Turn both steel strips and wiper rubber blade sideways out of
upper clip.
– Pull rubber blade together with strips out of remaining clips of
wiper blade.
– Fit new wiper rubber blade into lower clips of wiper blade.
– Guide both strips into the first groove of the wiper rubber blade
so that the recesses in the strips face the rubber. The strips
must engage in the rubber lugs of the groove.
– Using pliers, press both steel strips and rubber together and
insert into the upper clips so that the lugs of the clips on both
sides engage in the retaining slots -arrow- of the wiper rubber
blade.
3.6 Removing and installing joint-free wiper

Removing:
Note
Joint-free wipers are very flexible. To lift the wiper blade off the
rear window, grasp it only in the area in which the wiper blade is
attached to the wiper.
– Lift up wiper arm.

– Swivel wiper blade in -direction of arrow A-.
– Press release button -2- and pull wiper blade on wiper blade
mounting -1- in -direction of arrow B- out of wiper arm.
Installing:
3. Rear window wiper system 115

Touran 2003 ➤
4 Rear window washer system
Note
♦ The operation of the rear window washer system can be

checked using the final control diagnosis of the onboard sup‐
ply control unit -J519- .

tem
The onboard supply control unit -J519- features self-diagnosis to
4.1 Assembly overview - rear window washer system
1 - Connection piece
❑ Point of separation, pas‐
senger compartment
wiring harness
lines ⇒ page 123
❑ Point of separation, pas‐
senger compartment
wiring harness to rear lid
wiring harness
lines ⇒ page 123
❑ Connection to spray jet
for rear window washer
system
lines ⇒ page 123
4 - Spray jet for rear window
washer system
❑ Installed in high level
brake light bulb -M25-
❑ Renewing spray jet
⇒ page 117
❑ Adjusting spray jet
⇒ page 117
5 - Filler pipe for washer fluid
reservoir
on vehicles without aux‐

Touran 2003 ➤
iliary heater
⇒ page 105 .
❑ Connection to windscreen and rear window washer pump
❑ Overview of hose couplings for washer fluid lines ⇒ page 123
7 - Windscreen and rear window washer pump -V59-
❑ Removing and installing ⇒ page 109
10 - Hose
❑ Hose repair ⇒ page 124
4.2 Renewing spray jet

Spray jet is installed in additional brake light -M25- .
Removing:
– Remove additional brake light -M25- ⇒ page 183
– Release both catches -arrows- and pull spray jet -1- to rear out
of additional brake light -M25- .
Installing:
– Install in reverse order of removal.
– Adjusting spray jet ⇒ page 117
4.3 Adjusting spray jet

Adjusting rear window washer system spray jets ⇒ Maintenance ;
Booklet ; Descriptions of work
4. Rear window washer system 117

Touran 2003 ➤
5 Headlight washer system
Note
♦ The operation of the headlight washer system can be checked

using the final control diagnosis of the onboard supply control
unit -J519- .

tem
tions
Every 5th time the windscreen washer system is switched on, the
headlights are also washed. Condition is that wiper lever is pulled
at least 1.5 second towards the steering wheel and that either
dipped beam or main beam is switched on.
The „active time“ of the headlight washer system can be variably
adjusted to between 0 and 12.75 seconds ⇒ page 296 .
To guarantee sound functioning, the headlight washer system
must be vented following assembly work or when activated for the
first time ⇒ page 122 .
The onboard supply control unit -J519- is equipped with self-di‐
agnosis, which makes fault finding easier.
5.1 Assembly overview - headlight washer system

Touran 2003 ➤
1 - Spray jet assembly with left

spray jets
pop-up cylinder
⇒ page 120
❑ Adjusting spray jets
⇒ page 121
2 - Angled piece
❑ Connection to spray jet
pop-up cylinder
3 - T-piece
❑ Distribution of washer
fluid to spray jets on
headlight washer sys‐
tem
4 - Spray jet assembly with
right spray jets
pop-up cylinder
⇒ page 120
❑ Adjusting spray jets
⇒ page 121
5 - Angled piece
❑ Point of separation
6 - Hose
7 - Angled piece
❑ Connection to headlight
washer system pump -
V11-
8 - Headlight washer system
pump -V11-
⇒ page 119 .
11 - Filler pipe for washer fluid reservoir
5.2 Removing and installing headlight

washer system pump -V11-
The headlight washer system pump -V11- is mounted on the
washer fluid reservoir in the right-hand wheel housing.
5. Headlight washer system 119

Touran 2003 ➤
Note

ing describes removal and installation of the headlight washer
system pump -V11- on the windscreen and headlight washer sys‐
tem reservoir for vehicles with an auxiliary heater. Removal and
installation of the headlight washer system pump -V11- on vehi‐
cles with no auxiliary heater is carried out in a similar way as
appropriate.
Removing:
ignition key.
– Separate connector -2- and pull pump -6- upwards -arrow- out
of reservoir.
– To dismantle connecting pipe, pull securing clip off connec‐
tion.
– Pull connecting pipe off headlight washer system pump -V11- .
Installing:
5.3 Removing and installing spray jet pop-

up cylinders
Caution
Spray jet pop-up cylinders must not be extracted by hand.

Depending on type, a hand-extracted pop-up cylinder can get
stuck during return stroke.
Pushing back pop-up jet piston by hand is not permissible and
can damage pop-up cylinder.
Eject pop-up cylinder using only water pressure or air pressure.
A sticking pop-up cylinder can be brought back to full function‐
ality by ejecting it with water pressure or air pressure.

Touran 2003 ➤
Note
♦ Following illustrations show removal and installation of left

spray jet pop-up cylinder.
♦ Removal and installation of right spray jet pop-up cylinder are
Removing:
– Eject pop-up cylinder by actuating headlight washer system
and hold in ejected position.
– Unclip cover cap -1- from mounting points -arrows- on spray
jet retainer.
– Press and hold securing clip -arrow- and pull off hose con‐
nection -1- from pop-up cylinder in direction of arrow.
– Collect escaping fluid in a suitable container.
– Push together locking mechanisms -arrows- at same time and

pull out pop-up cylinder -2- from mounting in bumper cover in
direction of -arrow-.
Installing:
– Install in the reverse order of removal observing the following:
– Check cover cap is seated correctly on bumper cover.
– Check headlight washer system spray jets and adjust if nec‐
essary ⇒ page 121 .
5.4 Adjusting headlight washer system

spray jets
Adjusting spray jets for headlight washer system is described in
„Maintenance manual“ ⇒ Maintenance ; Booklet ; Description of
work
5. Headlight washer system 121

Touran 2003 ➤
5.5 Bleeding headlight washer system

To guarantee sound functioning, the headlight washer system
must be bled following assembly work or when operated for the
first time.
– Replenish washer fluid in reservoir for windscreen and head‐
light washer system.
– Start engine.
– Switch driving lights on.
– Operate headlight washer system several times (3-5 times, 3
seconds each time).
– Repeat this bleeding procedure until the pop-up cylinders and
spray jets are functioning correctly.

Touran 2003 ➤
6 Washer fluid line hose couplings

6. Washer fluid line hose couplings 123

Touran 2003 ➤
7 Hose repair

Touran 2003 ➤
94 – Lights, bulbs, switches - exterior

1 Headlight with halogen bulbs
Note
♦ Before working on headlights, always switch off the headlights

and remove the ignition key.
♦ When dealing with complaints, it is absolutely essential that
the function and operation of the lighting system are first un‐
derstood.

tions
tem
The onboard supply has a self-diagnostic function, which makes
fault finding on headlights easier.
1.2 Assembly overview - headlights with halogen bulbs
Note
After work which may effect the settings of the headlight, check settings of headlight and adjust as necessary
⇒ Maintenance ; Booklet 18.1 .
1. Headlight with halogen bulbs 125

Touran 2003 ➤
1 - Front end support part

2 - Securing bolts
❑ M6 x 22
❑ 4 Nm
3 - Headlight adapter
4 - Securing bolt
❑ AM6 x 40 - S1, (included
with headlight).
❑ 4 Nm
5 - Left main beam bulb -M30-
or right main beam bulb -M32-
and left daytime running light
bulb -L174- or right daytime
running light bulb -L175-
❑ Bulb H15 12 V, 15/55 W.
❑ Replacing ⇒ page 132 .
6 - Cover cap for main beam
bulb/daytime running light bulb
Caution
When installing cover
cap, ensure that it seats
properly. The ingress of
water will lead to perma‐
nent damage to the
headlight.
7 - Cover cap for dipped beam

bulb
Caution
nent damage to the
headlight.
8 - Bulb holder with grip element

❑ For front left turn signal bulb -M5- or front right turn signal bulb -M7- .
❑ For left dipped beam bulb -M29- or right dipped beam bulb -M31- .
10 - Left headlight dipped beam bulb -M29- or right headlight dipped beam bulb -M31-
❑ Bulb H7 12 V, 55 W.
11 - Front left turn signal bulb -M5- or front right turn signal bulb -M7-
❑ Bulb 12 V, PY 21 W.
12 - Left side light bulb -M1- or right side light bulb -M3-
❑ Bulb 12 V, W5 W.
126 Rep. gr.94 - Lights, bulbs, switches - exterior

Touran 2003 ➤
13 - Headlight
❑ Adjusting installation position of headlight ⇒ page 129 .
❑ Repairing retaining tabs ⇒ page 136 .
❑ Converting headlights to drive on the left or the right ⇒ page 138 .
❑ Adjusting ⇒ Maintenance ; Booklet ; Descriptions of work .
14 - Bumper mounting
15 - Securing bolts
❑ 4 x 16.
16 - Adjustment sleeve (hollow-core bolt)
17 - Securing bolt
❑ BM6 x 40 x 18 - S2.
❑ 4 Nm
1.3 Removing and installing headlight

Removing:
Note
♦ There is no requirement to disconnect the battery earth strap.

♦ Illustrations show removal and installation of the left headlight.
Removal and installation of the right headlight are carried out
in the same way.
♦ If a headlight is removed, it should always be adjusted follow‐
ing installation ⇒ Maintenance ; Booklet 18.1 .

ignition key.

Touran 2003 ➤
– Undo bolt -2- at rear of headlight.

– Remove the three bolts -arrows-.
– Remove headlight forwards out of body aperture.

Installing:
– First tighten bolts -arrows- to specified torque ⇒ page 125 .
– Tighten bolt -2- at rear of headlight to specified torque

⇒ page 125 .
– Check installation position so that shut lines/gaps around
headlight are even.
If the shut lines/gaps around the headlight are uneven, the instal‐
lation position must be adjusted ⇒ page 129 .
– Check functions of headlight.
Note
If a headlight is removed, it should always be adjusted following

installation.
– Check headlight setting and adjust headlight if necessary

⇒ Maintenance ; Booklet ; Descriptions of work

Touran 2003 ➤
1.4 Adjusting headlight installation position
Note
To adjust the installation position of the headlight, the front bump‐

er does not have to be removed.
When uneven gaps to body are found after installing headlight,

adjust installation position.
ignition key.
– Adjust shut lines/flushness to body by pushing in or pulling out

alignment bush -arrow-.

Touran 2003 ➤
– First tighten the three bolts -arrows- to specified torque

⇒ page 125 .

⇒ page 125 .
– Check headlight to ensure gaps are even all round and read‐
just again if necessary.
Note
If a headlight is removed or adjusted to fit more accurately to the

vehicle body, it must be aligned following such measures.
– Vehicles with automatic headlight range control, carry out ba‐

sic setting of headlight ⇒ Maintenance ; Booklet ; Descriptions
of work .
1.5 Renewing headlight bulbs
1.5.1 Renewing headlight dipped beam bulb
Note
♦ The illustrations show the renewal of the left headlight dipped

beam bulb -M29- for the left headlight. The replacement of the
headlight dipped beam bulb -M31- for the right headlight is
♦ For reasons of clarity, the headlight is shown removed in the
following illustrations.
♦ There is no requirement to remove the headlight to renew the
headlight dipped beam bulb .
Removing:
ignition key.

Touran 2003 ➤
– Pull cover -1- off.
– Turn bulb holder via grip element -1- in -direction of arrow- and
remove from headlight together with headlight dipped beam
bulb .
– Pull left side light bulb -2- in -direction of arrow- straight out of
bulb holder -1-.
Installing:
Caution
When installing cover cap, ensure that it seats properly. The

ingress of water will lead to permanent damage to the head‐
light.
Note
Do not touch bulb glass when installing a bulb. Fingers leave

traces of grease on the glass, which evaporate when the bulb is
switched on and cause the glass to cloud over.


Touran 2003 ➤
1.5.2 Renewing main beam headlight bulb or

daytime running light bulb
Note
♦ The left main beam headlight bulb -M30- or the right main
beam headlight bulb -M32- is a twin filament bulb and as‐
sumes simultaneously the function of the left daytime running
light -L174- and of the right daytime running light -L175- .
♦ The illustrations show the renewal of the headlight main
beam / daytime running light bulb on the left headlight. Re‐
newal for the right headlight is similar.
♦ There is no requirement to remove the headlight to renew the
headlight main beam / daytime running light bulb .
Removing:
ignition key.
– Turn bulb holder via grip element -1- in -direction of arrow- and
remove from headlight together with headlight dipped beam
bulb/daytime running light bulb .

Touran 2003 ➤
– Pull headlight dipped beam bulb/daytime running light bulb

-1- in -direction of arrow- straight out of bulb holder -2-.
Installing:
Caution

light.
Note


1.5.3 Renewing side light bulb
Note
♦ The diagrams show renewal of the left side light bulb -M1- for
the left headlight. The renewal of the side light bulb -M3- for
the right headlight is carried out in the same way.
♦ There is no requirement to remove the headlight to replace the
side light bulb .
Removing:
ignition key.

Touran 2003 ➤
– Unclip bulb holder with grip element -1- from headlight housing
-arrow A-.
– Pull bulb holder with grip element -1- to rear out of headlight
housing -arrow B-, taking connected wiring length into ac‐
count.
– Pull left side light bulb -1- in -direction of arrow- straight out of
bulb holder -2-.
Installing:
Caution
Make sure cover cap is correctly seated when installing. The

light.
Note


1.5.4 Renewing front turn signal bulb
Note
The illustrations show the renewal of the front left turn signal bulb
-M5- for the left headlight. The replacement of the turn signal bulb
-M7- for the right headlight is carried out in the same way.
Removing:
ignition key.

Touran 2003 ➤
– Turn bulb holder together with front turn signal bulb in

-direction of arrow- and remove from headlight.
– Push front turn signal bulb -2- into bulb holder -1-.
– Simultaneously turn front turn signal bulb -2- anti-clockwise
and pull bulb out of bulb holder.
Installing:
Note

1.6 Headlight range control motor
1.6.1 Removing headlight range control motor

The headlight range control motor cannot be removed. In the
event of damage, the headlight must be renewed.

Touran 2003 ➤
1.7 Repairing headlight retaining tabs (hal‐

ogen headlight)
If both upper headlight retaining tabs -1-, the side retaining tab
-2- or the rearmost retaining tab -3- are damaged or have broken
off, they can be repaired by installing a repair kit. There is no need
to renew the entire headlight.
1- Repairing both upper retaining tabs ⇒ page 136 .
2- Repairing side retaining tab ⇒ page 137 .
3- Repairing rearmost retaining tab ⇒ page 137 .
Note
♦ Check that there is no further damage to the headlight that

would make installation of the repair kit unnecessary.
♦ A repair kit is available for the headlight housing which can be
used for the left or right headlight ⇒ ETKA (electronic parts
catalogue) .
♦ A repair kit includes two upper, one side and one rearmost
headlight retaining tab along with the required screws.
♦ The following illustrations show the repair of the retaining tabs
on the right headlight. Repairs on the right headlight are car‐
ried out in the same way.
1.7.1 Installing repair kit for the upper retain‐

ing tab
Note
♦ The repair kit includes two identical retaining tabs along with
three securing screws for each tab (self-cutting screw
TP 4 x 16).
♦ It is not necessary to install both retaining tabs if only one is
damaged.
♦ The following description is for one retaining tab.
♦ The repair of both retaining tabs follows the same sequence.
key.

Touran 2003 ➤
– Remove headlight ⇒ page 127 .

– Remove remains of old mounting point -1- until new retaining
tab lies even.
– Fit new retaining tab -2- onto base of headlight, ensuring a
positive fit, and tighten screws -3- to 1.0 Nm.
– Install headlight ⇒ page 127 .
– Checking headlight settings and adjusting if necessary „Main‐
tenance manual“ ⇒ Maintenance ; Booklet ; Description of
work
1.7.2 Installing repair kit for the side retaining

tab
Note
The repair kit includes one retaining tab along with two securing
screws (self-cutting screw TP 4 x 16).
key.
tab has a positive fit.
– Checking headlight settings and adjusting if necessary „Main‐
work
1.7.3 Installing repair kit for the rearmost re‐

taining tab

Touran 2003 ➤
Note
The repair kit includes one retaining tab along with two securing
screws (self-cutting screw TP 4 x 16).
key.
tab has a positive fit.
– Checking headlight settings and adjusting if necessary: „Main‐
tenance manual“ ⇒ Maintenance ; Booklet ; Descriptions of
work
1.8 Converting headlights for use when driv‐

ing on the left or right
Note
♦ To avoid dazzling oncoming traffic with the asymmetrical

lights, both headlights should be converted relevant to the
country (driving on the left or right) in which the vehicle is being
driven.
♦ Each headlight conversion set comprises 2 pieces of film.
♦ Conversion of the headlights is not designed as a permanent
conversion for other countries. It is only suitable as a „tourist
solution“ for a short stay abroad.
♦ Both headlights of a vehicle must always be converted.
♦ The details „right“ and „left“ on the masking film always refer
to the direction of travel when looking forwards from inside the
vehicle.

Touran 2003 ➤
1.8.1 Converting headlights designed for driv‐

ing on the right to driving on the left
Note
♦ The headlight conversion set comprises 2 pieces of film.

♦ Please note the different part numbers for the headlight con‐
version sets from right to left-hand traffic and from left to right-
hand traffic.
♦ Before converting the lenses, clean the headlights.
– Turn light switch to „0“ position.

– Clean headlight lens.
Left headlight:
– Remove backing of film -B- only in area marked -C-.
– Align application film -B- with the outer edge to line -A- on the
headlight lens.
– Press area -C- firmly against headlight lens.
– Carefully pull off film -B- from headlight lens again.
– Masking film -C- remains on headlight lens.
Right headlight:

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headlight lens.
Caution
Risk of plastic erosion.

If using solvent-based cleaners, the plastic lens of the head‐
light could become damaged.
To remove any adhesive residue on the plastic headlight len‐
ses, use only alcohol-based cleaning agents or those with a
diluted alcohol mix (isopropanol).
Note
♦ Remove any adhesive residue using alcohol-based or diluted

alcohol-based cleaning fluids. For example a cloth soaked
with isopropyl alcohol.
♦ Inform customers how to remove adhesive that may be left
after the backing paper has been pulled off.
1.8.2 Converting headlights designed for driv‐

ing on the left to driving on the right
Note
♦ The headlight conversion set comprises 2 pieces of film.

♦ Please note the different part numbers for the headlight con‐
version sets from right to left-hand traffic and from left to right-
hand traffic.
♦ Before converting the lenses, clean the headlights.
– Turn light switch to „0“ position.

– Clean headlight lens.

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Left headlight:
headlight lens.
Right headlight:

headlight lens.
Caution
Risk of plastic erosion.

If using solvent-based cleaners, the plastic lens of the head‐
light could become damaged.
To remove any adhesive residue on the plastic headlight len‐
ses, use only alcohol-based cleaning agents or those with a
diluted alcohol mix (isopropanol).
Note
♦ Remove any adhesive residue using alcohol-based or diluted

alcohol-based cleaning fluids. For example a cloth soaked
with isopropyl alcohol.
♦ Inform customers how to remove adhesive that may be left
after the backing paper has been pulled off.
1.9 Adjusting headlights

Adjust headlight with halogen bulbs ⇒ Maintenance ; Booklet ;
Descriptions of work .

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2 Headlights with gas discharge bulbs

and cornering lights
2.1 Operation and safety notes for gas dis‐

charge bulbs
WARNING
♦ Never change bulbs if you are not familiar with the appro‐
priate procedures, safety precautions and tools.
– If repairs are to be made to the headlight with gas discharge

bulbs, observe the following:
♦ Notes on dangerous high voltage/currents ⇒ page 142
♦ Notes on pressure, temperature, radiation/arcs ⇒ page 143
♦ Assembly notes for gas discharge bulbs ⇒ page 144
♦ Disposal regulations for gas discharge bulbs ⇒ page 144
♦ Safety goggles
♦ Gloves
Note on dangerous high voltage/currents
WARNING
Control units for light systems, connectors and components

pertaining to bulb holders conduct lethally high voltage.
Operating the control unit and the starter unit is permitted only
with the bulb fitted.
WARNING
• Switch off ignition and all electrical consumers and re‐

move ignition key.
• When working on headlight system, ensure that there is
no voltage in any components, including the dissipation of
residual voltage after the headlights are switched off.
• Residual voltage can be dissipated by turning the dipped
beams on and then off again after withdrawing the ignition
key.
• When working on the headlight system, ensure that the
lights cannot be switched on.

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Notes on pressure, temperature, radiation/arcs
WARNING
♦ Within the glass bulb of a gas discharge bulb, pressure

can range from between 7 bar (cold) and 100 bar (hot).
Temperatures can reach up to 700 degrees Celsius on the
glass bulb.
♦ Should the glass bulb explode, there is a risk of injury from
burning.
♦ Always wear eye protection and gloves when removing
and installing gas discharge bulbs!
WARNING
• The bulbs may be operated in the headlight housing only

(protection against contact due to very hot bulbs, absorp‐
tion of UV radiation, avoidance of dazzling light, protection
against explosion).
• The glass bulb of the bulbs can be very hot - danger of
burns!
• Avoid looking directly into the beam, as the UV rays from
the gas discharge bulb are about 2.5 times greater than
normal halogen bulbs.
• Avoid looking at light beam (danger of blindness). The
eyesight can be impaired for a longer period.
WARNING
• Avoid contact with burst glass bulbs.

• H7 bulbs and gas discharge bulbs (xenon and bi-xenon)
are under pressure and can explode while being changed
- danger of injury.
• Always wear eye protection and gloves when removing
2. Headlights with gas discharge bulbs and cornering lights 143

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Repair notes for gas discharge bulbs
Caution
♦ Before renewing a bulb, always switch off the affected

consumer.
♦ Switch off ignition and all electrical consumers and re‐
move ignition key.
♦ Do not touch the glass bulb with bare fingers; use a clean
cloth glove. When the light bulb is switched on, the heat
would vaporise the oil of the finger prints which would then
settle on the reflector, impairing the brightness of the
headlight.
♦ A light bulb must always be renewed with a bulb of the
same sort. The designation appears on the base of the
bulb or on the glass bulb.
♦ Properly engage connector during installation and ensure
tight seating of the connection.
Disposal regulations for gas discharge bulbs
WARNING
• Gas discharge bulbs must be disposed of as hazardous

waste; never dispose of gas discharge bulbs via house‐
hold waste system.
• Gas discharge bulbs contain metallic mercury (Hg) and
traces of thallium; never destroy these bulbs.
• These components must be recycled in the correct man‐
ner according to national law.
• Only dispose of in containers intended for this purpose at
an authorised collection point.
Note
♦ Before working on headlights, always switch off the headlights

and remove the ignition key.
♦ The automatic headlight range control and cornering lights on
headlights with gas discharge bulbs is equipped with self-di‐
agnosis.
♦ When dealing with complaints, it is absolutely essential that
the function and operation of the lighting system are first un‐
derstood.

tions
tem

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The headlights with gas discharge bulbs and cornering lights
(AFS = Adaptive Front Lighting System) have a „bi-xenon“ func‐
tion.
With conventional „xenon“ headlights, the gas discharge bulbs
only generate the dipped beam. The „bi-xenon“ features makes
it possible to generate both the dipped beam and the main beam
with „one“ gas discharge bulb. To achieve this, an electrome‐
chanical adjuster ( left dip beam screen motor -V294- or right dip
beam screen motor -V295- ) uncovers the screened area of the
dipped beam on actuation of the main beam function, thus pro‐
ducing main beam light distribution.
This means that with „bi-xenon“ headlights the main beam is al‐
ways automatically adjusted together with the dipped beam.
The headlights with gas discharge bulbs and cornering lights do
not have an „additional main beam“.
The cornering light system consists of the following functions:
♦ Swivelling main and dipped beams (dynamic cornering lights):
at vehicle speeds in excess of 10 km/h and steering turned.
♦ Cornering light bulb (static cornering light): when turning into
tight bends (bend radius < 500 m) or when turning a corner at
vehicle speeds of less than 50 km/h
The automatic headlight range control, the cornering lights and
onboard supply control systems feature self-diagnosis to facilitate
fault finding for headlights with gas discharge bulbs.
Depending on equipment, the following functions can be adapted
or coded via the onboard supply control unit -J519-
⇒ page 296 .
♦ Adapting coming home time
♦ Adapting main beam for driving light assist
♦ Adapting leaving home time
♦ Coding rain and light sensor
♦ Adapting headlight washer system
♦ Coding control unit for wiper electronics/deactivating APP
♦ Coding/decoding daytime running lights
♦ Adapting delay for driving light assist
Note
The „bulb failure“ warning lamp lights-up in the dash panel when
the headlight range control or the AFS (adaptive front lighting
system) malfunctions ⇒ page 86 .

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2.3 Assembly overview - headlights with

gas discharge bulbs and cornering lights
Note
After work which may effect the settings of the headlight, check
settings of headlight and adjust as necessary ⇒ Maintenance ;
Booklet 18.1 .
1 - Front end support part

2 - Securing bolts
❑ M6 x 22
❑ Specified torque: 4 Nm
3 - Headlight adapter
4 - Securing bolt
❑ AM6 x 40 - S1, (included
with headlight).
5 - Cover cap
Caution
nent damage to the
headlight.
6 - Left gas discharge bulb -

L13- or right gas discharge
bulb -L14- („bi-xenon“) with
gas discharge light starter unit
-N195-
WARNING
Observe operating and
safety notes for gas dis‐
charge bulbs
⇒ page 142 .
❑ Type D3S, 42 V / 35 W.
7 - Screw cap
Caution
When installing screw
cap, ensure it is seated
correctly. The ingress of
nent damage to the
headlight.

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❑ For left cornering light bulb -L148- or right cornering light bulb -L149-
❑ For front left turn signal bulb -M5- or front right turn signal bulb -M7-
10 - Front left turn signal bulb -M5- or front right turn signal bulb -M7-
❑ Bulb 12 V, PY 21 W.
11 - Headlight with LED module for daytime running light and side light
❑ Converting headlights to drive on the left or the right ⇒ page 167 .
❑ Repairing retaining tabs ⇒ page 167 .
❑ Perform basic setting of headlights ⇒ Maintenance ; Booklet 18.1 .
12 - Cornering light and headlight range control unit -J745-
❑ Coding ⇒ page 163
13 - Front left vehicle level sender -G78-
❑ Securing bolt specified torque (M8): 9 Nm
14 - Rear left vehicle level sender -G76-
❑ Securing bolt specified torque (M8): 5 Nm
❑ Observe installation notes ⇒ page 166
15 - Control unit for left gas discharge bulb -J343- or control unit for right gas discharge bulb -J344-
16 - Control unit for left daytime running light and side light -J860- or control unit for right daytime running light
and side light -J861-
17 - Securing bolts
❑ 4 x 16.
18 - Bumper mounting
19 - Output module for left headlight -J667- or output module for right headlight -J668-
Note
After installing a new electronic

starter unit with AFS output module ,
code electronic starter unit with AFS
output module ⇒ page 163 then
subsequently perform basic setting
of headlights ⇒ Maintenance ; Book‐
let 18.1 .

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20 - Adjustment sleeve (hollow-core bolt)

21 - Securing bolt
❑ BM6 x 40 x 18 - S2.
22 - Left cornering light bulb -L148- or right cornering light bulb -L149-
❑ Bulb H7 12 V, 55 W.
2.4 Removing and installing headlight with

gas discharge bulb and cornering light

Removing:
Note
♦ There is no requirement to disconnect the battery earth strap.

♦ Illustrations show removal and installation of the left headlight.
Removal and installation of the right headlight are carried out
in the same way.
♦ If a headlight is removed, it should always be adjusted follow‐
ing installation ⇒ Maintenance ; Booklet 18.1 .

ignition key.

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– Remove headlight forwards out of body aperture.

Installing:
– First tighten bolts -arrows- to specified torque ⇒ page 146 .

⇒ page 146 .
– Check installation position so that shut lines/gaps around
headlight are even.
If the shut lines/gaps around the headlight are uneven, the instal‐
lation position must be adjusted ⇒ page 149 .
Note
If a headlight is removed, it should always be adjusted following

installation.

2.5 Adjusting headlight installation position
Note
The diagrams show the adjustment of the installation position for

the left headlight. The adjustment of the right headlight follows the
same principle.
When uneven gaps to body are found after installing headlight,

adjust installation position.
ignition key.

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– Adjust shut lines/flushness to body by pushing in or pulling out

alignment bush -arrow-.
– Tighten the three bolts -arrows- to specified torque

⇒ page 146 .

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⇒ page 146 .
– Check headlight to ensure gaps are even all round and read‐
just again if necessary.
– Carry out basic setting of headlights ⇒ Maintenance ; Booklet ;
Descriptions of work .
2.6 Renewing headlight bulbs
WARNING
Observe procedure and safety notes when changing gas dis‐

charge lamp bulbs ⇒ page 142 .
2.6.1 Renewing gas discharge bulb
WARNING
Observe procedure and safety notes when changing gas dis‐

charge lamp bulbs ⇒ page 142 .
Note
♦ Left gas discharge bulb -L13- and right gas discharge bulb -
L14- can be checked by the final control diagnosis for the
onboard supply control unit -J519- ⇒ page 296 .
♦ The diagrams show renewal of a gas discharge bulb for the
left headlight. Renewal for the right headlight is similar.
Removing:
– Switch off ignition and all electrical consumers, and pull out
ignition key.
– Headlights with gas discharge bulbs and cornering lights
⇒ page 148

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– Turn cover cap -1- anti-clockwise and remove it.
– Pull connector -arrow- downwards off gas discharge light start‐

er unit -N195- -1-.
WARNING
♦ Within the glass bulb of a gas discharge bulb, pressure

can range from between 7 bar (cold) and 100 bar (hot).
Temperatures can reach up to 700 degrees Celsius on the
glass bulb.
♦ Should the glass bulb explode, there is a risk of injury from
burning.
♦ Always wear eye protection and gloves when removing

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– Turn gas discharge light starter unit -N195- -1- in

-direction of arrow- and remove from reflector together with
gas discharge bulb .
Installing:
WARNING
Ensure glass bulb of gas discharge bulb is not stressed me‐

chanically. The glass bulb is extremely sensitive and is also
under a high internal pressure.
Avoid looking directly into the collimated beam as the UV ra‐
diation from the gas discharge bulb is about 2.5 times higher
than from normal halogen bulbs.
Caution
When installing screw cap, ensure it is seated correctly. The

light.
Note
♦ Do not touch bulb glass when installing a bulb. Fingers leave

traces of grease on the glass bulb, which evaporate when the
gas discharge bulb is switched on and cause the glass bulb to
cloud over.
♦ Ensure glass bulb of gas discharge bulb is not stressed me‐
chanically. The glass bulb is extremely sensitive and is also
under a high internal pressure.
♦ Avoid looking directly into the collimated beam as the UV ra‐
diation from the gas discharge bulb is about 2.5 times higher
than from normal halogen bulbs.
♦ If a headlight with automatic range control is removed, the ba‐
sic setting of the headlights is always to be checked after
installation ⇒ Maintenance ; Booklet ; Descriptions of work .

2.6.2 Renewing cornering light bulb
Note
♦ The diagrams show replacement of the cornering light bulb -

L148- on the left headlight. The replacement of the cornering
light bulb -L149- for the right headlight is carried out in the
same way.
following illustrations. There is no requirement to remove the
headlight to replace the cornering light bulb .
♦ Checking cornering light bulb ⇒ page 157 .

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Removing:
ignition key.
Note
♦ Cornering light bulb -1- is clipped into reflector.

♦ Initially, connector is not disconnected when removing cor‐
nering light bulb .
– Push connector -1- in -direction of arrow- until bulb feels loose.
– Grasp on bulb holder and pull bulb holder with cornering light
bulb out of reflector, taking connected wiring length into ac‐
count.
– Pull cornering light bulb -1- in -direction of arrow- straight out

of connector -2-.
Installing:
Caution

light.
Note
Do not touch glass of cornering light bulb when installing. Fingers

leave traces of grease on the glass, which evaporate when the
bulb is switched on and cause the glass to cloud over.

– Guide cornering light bulb into headlight housing.
– Push cornering light bulb into reflector.
– Cornering light bulb must engage audibly.

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2.6.3 Replacing LED module for daytime run‐

ning light and side light
The left LED module for daytime running light and side light -L176-
and the right LED module for daytime running light and side light
-L177- are located inside the respective headlight. The LED mod‐
ule cannot be renewed individually.
In the event of damage, the headlight must be renewed
⇒ page 148 .
2.6.4 Renewing front turn signal bulb
Note
The illustrations show the renewal of the front left turn signal bulb
-M5- for the left headlight. The replacement of the turn signal bulb
-M7- for the right headlight is carried out in the same way.
Removing:
ignition key.
– Turn bulb holder together with front turn signal bulb in
-direction of arrow- and remove from headlight.
– Push front turn signal bulb -2- into bulb holder -1-.
– Simultaneously turn front turn signal bulb -2- anti-clockwise
and pull bulb out of bulb holder.
Installing:
Note



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2.7 Headlight range control motor
2.7.1 Removing and installing left headlight

range control motor -V48- or right head‐
light range control motor -V49-
The headlight range control motors are located inside the head‐
lights. They cannot be replaced individually.
⇒ page 148 .
Note
If faulty, check wiring of headlight range control motor for wiring

defects and/or loose connections before renewing headlight.
2.7.2 Checking left headlight range control

motor -V48- or right headlight range
control motor -V49-
-VAS 5051A- ⇒ page 288
♦ Body
♦ Automatic headlight range control, cornering lights
♦ Electrical components, automatic headlight range control
♦ Checking headlight range control motor
2.8 Control motor for dynamic cornering

light
The dynamic cornering light only functions at a speed above ap‐
prox. 10 km/h when the dipped beam is switched on.
2.8.1 Removing and installing left dynamic

cornering light control motor -V318- or
right dynamic cornering light control mo‐
tor -V319-
The dynamic cornering light control motors are located inside the
headlights. They cannot be replaced individually.
⇒ page 148 .

Touran 2003 ➤
Note
If faulty, check wiring of dynamic cornering light control motor for

wiring defects and/or loose connections before renewing head‐
light.
2.8.2 Checking left dynamic cornering light

control motor -V318- or right dynamic
cornering light control motor -V319-
-VAS 5051A- ⇒ page 288
♦ Body
♦ Checking cornering light control motor
2.9 Static cornering light

The static cornering light integrated in the headlight is automati‐
cally switched on when the turn signal lever is operated and the
vehicle turns and when turning into tight bends. The static cor‐
nering light only functions at speeds lower than 40 km/h when the
dipped beam is switched on.
2.9.1 Checking left static cornering light -M51-

or right static cornering light -M52-
-VAS 5051A- ⇒ page 288
♦ Body
♦ Checking static cornering light

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2.10 Swivel module position sensor
2.10.1 Removing and installing right swivel

module position sensor -G475- or left
swivel module position sensor -G474-
The swivel module position sensor are located inside the head‐
lights. They cannot be replaced individually.
⇒ page 148 .
2.10.2 Checking right swivel module position

sensor -G475- or left swivel module po‐
sition sensor -G474-
-VAS 5051A- ⇒ page 288
♦ Body
♦ Checking swivel module position sensor
2.11 Dipped beam screen
2.11.1 Removing and installing dip beam

screen
The dipped beam screens are located inside the headlights. They
screens cannot be replaced individually or adjusted.
⇒ page 148 .
2.12 Control unit for left gas discharge bulb -

J343- or control unit for right gas dis‐
charge bulb -J344-
The left gas discharge bulb control unit -J343- and right gas dis‐
charge bulb control unit -J344- are each located on the underside
of the respective headlight housing.

Touran 2003 ➤
2.12.1 Removing and installing left gas dis‐

charge bulb control unit -J343- or right
gas discharge bulb control unit -J344-
Note
♦ The illustrations show renewal of the left gas discharge bulb

control unit -J343- on the left-hand headlight.
♦ The renewal of the right gas discharge bulb control unit -J344-
is analogue.
♦ The gas discharge bulb control unit is not capable of self-di‐
agnosis.
♦ If a new left gas discharge bulb control unit -J343- or right gas
discharge bulb control unit -J344- is installed, subsequently
code control unit for cornering light and headlight range control
-J745- ⇒ page 163 then perform basic setting of headlights
⇒ Maintenance ; Booklet 18.1 .
Removing:
ignition key.
– Unscrew the three securing bolts -arrows- of gas discharge
bulb control unit -1-.
– Carefully pull gas discharge bulb control unit -1- straight out of
headlight.
– Disconnect connector -arrow- and remove gas discharge bulb

control unit -1-.
Installing:
Caution
Ensure seal is seated correctly when installing gas discharge

bulb control unit . The ingress of water will lead to permanent
damage to the headlight.


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2.13 Output module for left headlight -J667-

or output module for right headlight -
J668-
2.13.1 Removing and installing output module

for left headlight -J667- or output module
for right headlight -J668-
Note
♦ The illustrations show renewal of the output module for left

headlight -J667- on left headlight.
♦ The renewal of the output module for right headlight -J668- on
right headlight is analogue.
Removing:
Note
When power output module for headlight is pulled off from head‐
light housing, electrical connectors are simultaneously discon‐
nected.
– Pull output module for headlight straight off headlight housing.

Installing:
Caution
When installing power output module for headlight , ensure that

the seal is seated correctly. The ingress of water will lead to
permanent damage to the headlight.
Note
The cornering light and headlight range control unit -J745- must
be recoded if a new output module for headlight is installed
⇒ page 163 . Then subsequently perform the basic setting of
headlights ⇒ Maintenance ; Booklet ; Descriptions of work .
2.13.2 Checking power output module for

headlight
The following procedure enables you to check power output mod‐
ule for left headlight -J667- or power output module for right
headlight -J668- .
– Connect vehicle diagnosis, testing and information system -
VAS 5051B- ⇒ page 288 .

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– On vehicle diagnosis, testing and information system -VAS

5051B- select „Guided fault finding“.
♦ Body
♦ Output module for left headlight -J667- or output module for
right headlight -J668-
2.14 Control unit for left daytime running light

and side light -J860- or control unit for
right daytime running light and side light
-J861-
The control unit for left daytime running light and side light -J860-
and control unit for right daytime running light and side light -J861-
are each located on the underside of the respective headlight
housing.
2.14.1 Removing and installing control unit for

left daytime running light and side light -
J860- or control unit for right daytime
running light and side light -J861-
Note
♦ The illustrations show renewal of the control unit for left day‐
time running light and side light -J860- on the left-hand head‐
light.
♦ The renewal of the control unit for right daytime running light
and side light -J861- is analogue.
Removing:

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Note
When control unit for daytime running light and side light is pulled
off headlight housing, electrical connectors are simultaneously
disconnected.
– Pull control unit for daytime running light and side light straight
off headlight housing.
Installing:
Caution
Ensure seal is seated correctly when installing control unit for

left daytime running light and side light . The ingress of water
will lead to permanent damage to the headlight.
Note
Headlight range control unit must be recoded if a new control unit

for daytime running light and side light -J745- is installed
⇒ page 163 . Then perform the basic setting of headlights ⇒ Main‐
tenance ; Booklet ; Descriptions of work .
2.14.2 Checking daytime running light and side

light control unit
A check of control unit for left daytime running light and side light
-J860- or control unit for right daytime running light and side light
-J861- can be made using following procedure.
– Connect vehicle diagnosis, testing and information system -
VAS 5051B- ⇒ page 288 .
– On vehicle diagnosis, testing and information system -VAS
5051B- select „Guided fault finding“.
♦ Body
♦ Control unit for left daytime running light and side light -J860-
or control unit for right daytime running light and side light -
J861-

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2.15 Cornering light and headlight range con‐

trol unit -J745-
2.15.1 Removing and installing cornering light

and headlight range control unit -J745-
The control unit for daytime running light and side light -J745- is
located under dash panel on centre console on driver side.
Removing:
ignition key.
– Remove storage compartment on driver side ⇒ General body
Removing and installing storage compartment on driver side .
– Release locking device -1- and pull connector -2- off cornering
light and headlight range control unit -J745- .
– Remove bolts -arrows- and take cornering light and headlight

range control unit -J745- off retainer.
Installing:
Note
After installing a new cornering light and headlight range control

unit -J745- , the control unit must be coded ⇒ page 163 .
2.15.2 Coding cornering light and headlight

range control unit -J745-
-VAS 5051A- ⇒ page 288
♦ Body
♦ Headlight range control functions

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♦ Coding AFS headlight range control unit
Note
If the cornering light and headlight range control unit -J745- has
to be coded, basic setting of the headlights must be performed
after coding ⇒ Maintenance ; Booklet 18.1 .
2.15.3 Cornering light and headlight range con‐

trol unit -J745- final control diagnosis
The following components or functions can be checked by the
final control diagnosis for the cornering light and headlight range
control unit -J745- .
♦ Left dynamic cornering light control motor -V318- or right dy‐
namic cornering light control motor -V319-
♦ Left headlight range control motor -V48- or right headlight
range control motor -V49-
♦ Checking left static cornering light -M51- or right static corner‐
ing light -M52-
♦ Cornering light warning lamp -K247-
Note
The „bulb failure“ warning lamp in the dash panel lights up when
the headlight range control or the AFS (adaptive front lighting
system) malfunctions.

-VAS 5051A- ⇒ page 288
♦ Body
♦ 55 - Final control diagnosis (selective), (Rep. Gr. 94)
2.16 Vehicle level sender

There is a vehicle level sender located on the front axle ( front left
vehicle level sender -G78- ) and on the rear axle ( rear left vehicle
level sender -G76- ).
On vehicles with electronic damper control (adaptive suspension
DCC), the vehicle level senders are wired to the control unit for
electronic damper control -J250- . Both control units ( control unit
for electronic damper control -J250- and control unit for cornering
light and headlight range control -J745- ) exchange information
with each other via the CAN bus.
In the event of malfunctions, interrogate the control unit for elec‐
tronic damper control -J250- ⇒ page 308 .

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Note
If the vehicle level senders are replaced, basic setting of the

headlights must be performed ⇒ Maintenance ; Booklet 18.1 .
2.16.1 Removing and installing front left vehicle

level sender -G78-
Removing:
ignition key.
– Pull off connector -arrow-.
– Remove nut -1-.

– Undo bolt -2- and remove front left vehicle level sender -G78-
-3-.
Installing:
⇒ page 146 .
– Carry out basic settings for headlight ⇒ Maintenance ; Booklet
18.1 .
Note
If the vehicle level senders are renewed, basic setting of the

2.16.2 Removing and installing rear left vehicle

level sender -G76-
Removing:
ignition key.

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– Pull off connector -arrow-.
– Undo the five bolts -1- and remove rear left vehicle level send‐
er -G76- -2-.
Installing:
Note
Ensure when installing rear left vehicle level sender -G76- that
lever and jointed rod are in position as illustrated. Otherwise rear
left vehicle level sender -G76- will supply incorrect data which
causes the headlight range control to malfunction.
following:
⇒ page 146 .
– Carry out basic settings for headlight ⇒ Maintenance ; Booklet
18.1 .
Note
If the vehicle level senders are renewed, basic setting of the

2.16.3 Checking vehicle level sender

The vehicle level senders transmit the longitudinal inclination an‐
gle of the vehicle by way of signals to the control unit for cornering
light and headlight range control -J745- .
The following check is to determine whether the rear left vehicle
level sensor -G76- and front left vehicle level sensor -G78- are
supplying the headlight range adjustment unit -J745- with plausi‐
ble signals.
No entry is stored in the control unit for cornering light and head‐
light range control -J745- in the following instances:
♦ Vehicle level senders installed are not of type specified in this
workshop manual.
♦ Vehicle level senders have mechanical faults.
♦ Vehicle suspension has been modified (e.g. lowered).
-VAS 5051A- ⇒ page 288

Touran 2003 ➤

♦ Body
♦ Checking vehicle level sender
2.17 Repairing headlight retaining tabs

If both upper headlight retaining tabs -1-, the side retaining tab
-2- or the rearmost retaining tab -3- are damaged or have broken
off, they can be repaired by installing a repair kit. There is no need
to renew the entire headlight.
Note
♦ Check that there is no further damage to the headlight that

would make installation of the repair kit unnecessary.
♦ A repair kit is available for the headlight housing which can be
used for the left or right headlight ⇒ ETKA (electronic parts
catalogue) .
Repair of headlight retaining tabs on headlights with gas dis‐

charge bulbs and cornering light is performed in same way as for
headlights with halogen bulbs. Repairing headlight retaining tabs
⇒ page 136 .
2.18 Converting headlights for use when driv‐

ing on the left or right
If a right-hand drive vehicle is driven in a left-hand drive country,
or vice versa, the headlights must be converted. The headlights
must be converted to avoid dazzling oncoming traffic with the
asymmetrical dipped lights.
-VAS 5051A- ⇒ page 288
– Select „Guided functions“ mode in vehicle diagnosis, test and
♦ Body
♦ 55 - Travel mode, (Rep. Gr. 94)
2.19 Adjusting headlights

Adjusting headlights ⇒ Maintenance ; Booklet ; Descriptions of
work

Touran 2003 ➤
3 Fog lights
The onboard supply control unit has a self-diagnostic function,
which makes fault finding on front fog lights easier.
3.1 Fog lights
3.1.1 Assembly overview - fog lights
1 - Front bumper cover

2 - Fog light housing
⇒ page 168 .
3 - Securing bolt
❑ Duo hex socket head
bolt, 5 x 16-Q
❑ 1.5 Nm
4 - Vent hose
5 - Left fog light bulb -L22- or
right fog light bulb -L23- and
left cornering light bulb -L148-
or right cornering light bulb -
L149-
❑ Bulb HB4 12 V, 51 W
⇒ page 169 .
6 - Cover cap
3.1.2 Removing and installing fog light
Note
The illustrations show removal and installation of the front left fog
light.

Touran 2003 ➤
Removing:
ignition key.
– Unclip cover cap -1- from engaging elements..
– Remove securing bolt -arrow-.
– Swivel fog light housing out of bumper cover, taking connected

wire lengths into account.
– Release connector -arrow- and disconnect.
– Remove fog light housing.
Installing:
– Tighten all threaded connections to specified torque given in
assembly overview ⇒ page 168 .
– Check function of headlight.
– Checking fog light settings and adjusting if necessary „Main‐
work
3.2 Removing and installing fog light bulb /

static cornering light bulb
Note
♦ Depending on activation, the bulb in the fog light housing con‐

trols the function of the fog light or the static cornering light
(depending on equipment level).
♦ The procedure for removing and installing the bulbs is the
same for both headlights and is therefore described for just
one headlight.
3. Fog lights 169

Touran 2003 ➤
Removing:
– Removing fog light ⇒ page 168
– Turn bulb holder together with fog light bulb in -1- in
-direction of arrow- and remove from fog light.
The bulb for the fog light is permanently attached to the bulb
holder and cannot be renewed separately.
Fog light bulb : HB4 12 V, 51 W
Installing:
– Check fog light settings and adjust if necessary ⇒ Mainte‐
nance ; Booklet ; Descriptions of work .
3.3 Adjusting fog lights

Adjusting fog lights ⇒ Maintenance ; Booklet ; Descriptions of
work

Touran 2003 ➤
4 Turn signal in exterior mirror
Note

tem
tions
The bulbs for the mirror turn signals (side-mounted turn signals)
are integrated into the exterior mirror housings.
4.2 Removing and installing turn signal re‐

peater bulb
The driver side turn signal lamp in exterior mirror -L131- and the
front passenger side turn signal lamp in exterior mirror -L132- are
installed in the left/right exterior mirror housing respectively.
Note
In the event of damage, the complete driver side turn signal lamp
in exterior mirror -L131- or the complete front passenger side turn
signal lamp in exterior mirror -L132- must be renewed.
Removing:
ignition key.
– Remove driver side turn signal lamp in exterior mirror -L131-
or front passenger side turn signal lamp in exterior mirror -
L132- ⇒ General body repairs, exterior; Rep. gr. 66 ; Rear
view mirror .
Installing:
– Install driver side turn signal lamp in exterior mirror -L131- or
front passenger side turn signal lamp in exterior mirror -L132-
⇒ General body repairs, exterior; Rep. gr. 66 ; Rear view
mirror .
4. Turn signal in exterior mirror 171

Touran 2003 ➤
5 Tail lights (tail light cluster)
5.1 Tail light cluster in side panel
5.1.1 General description
Note

tem
tions
which makes fault finding easier.
Note
♦ The following illustrations show the work on the tail light in the
side panel on the left side. The work on the tail light in the side
panel on the right side is carried out in the same way.
♦ The tail light (tail light cluster) in the side panel includes, be‐
sides the yellow turn signal bulb, a single-filament bulb which,
depending on activation, functions as brake and tail light.
5.1.2 Assembly overview - tail light in side panel

Touran 2003 ➤
1 - Ball head stud

2 - Connector
❑ For tail light
3 - Securing screws
❑ PT screw 4 x 12
4 - Bulb carrier
⇒ page 175 .
5 - Left brake and tail light bulb
-M21- or right brake and tail
light bulb -M22-
❑ Bulb 12 V, P 21 W
6 - Rear left turn signal bulb -
M6- or rear right turn signal
bulb -M8-
❑ Bulb 12 V, PY 21 W.
7 - Trim
8 - Securing bolt
❑ Bolt M5 x 25
❑ 3.5 Nm
9 - Tail light housing in side
panel
⇒ page 173 .
❑ Adjusting installation
position ⇒ page 176
5.1.3 Removing and installing tail light in side

panel
Removing:
Removal and reinstallation of tail lights is carried out in the same
manner on both sides and is described for one side only.
5. Tail lights (tail light cluster) 173

Touran 2003 ➤

ignition key.
– Unclip trim -1- from fasteners -arrows- on tail light.
– Pull mountings -1- off tail light in -direction of arrow- out of ball
head studs -2-.
– Release connector -arrow- and disconnect.

Installing:

Touran 2003 ➤
– Push mountings -1- of tail light in -direction of arrow- onto ball

head studs -2- until they can be felt to engage.
– Tighten securing bolt -arrow- to specified torque setting

⇒ page 172 .
– When installation is complete, check gaps of tail light to body.

Gap -A- between body and tail light should be 0.5 mm.
If the gaps around the tail light are uneven to the body, the in‐
stallation position must be adjusted ⇒ page 176 .
5.1.4 Removing and installing tail light (tail

light cluster) bulb carrier in side panel
Removing:
– Remove tail light ⇒ page 173 .

Touran 2003 ➤
– Undo bolts -arrows- and remove bulb carrier from tail light
housing.
Installing:
5.1.5 Renewing brake and tail light and turn

signal bulbs in tail light (tail light cluster)
in side panel
Note
The illustrations show removal and installation for the left side.
The removal of the right side is analogue.
Removing:
– Remove tail light bulb carrier in side panel ⇒ page 175 .
– Push brake and tail light bulb -1- slightly into bulb holder, turn
bulb anti-clockwise and pull bulb out of bulb holder.
– Push rear turn signal bulb -2- slightly into bulb holder, turn bulb
anti-clockwise and pull bulb out of bulb holder.
Installing:
5.1.6 Adjusting installation position of tail light

cluster in side panel
If the gaps around the tail light are uneven to the body, the in‐
stallation position must be adjusted.
– Switch off ignition and all electrical consumers, and pull out
ignition key.

Touran 2003 ➤
– Adjust gaps/shut lines by screwing ball head studs -arrows- in

or out.
Gap -A- between body and tail light should be 0.5 mm.
5.2 Tail lights (tail light cluster) in rear lid
Note

tem
tions
which makes fault finding easier.
Note
♦ The following illustrations show the work on the left tail light in
the rear lid of a vehicle driving on the right. The work on the
tail light in the rear lid on the right side is carried out in the
same way.
♦ Besides the tail light bulb , the reversing light bulb the tail light
in the rear lid also includes the rear fog light bulb . The rear
fog light bulb is only located in the left tail light on vehicles
driving on the right or in the right tail light on vehicles driving
on the left. The rear fog light bulb is not fitted on vehicles for
USA and Canada.
5.2.2 Assembly overview - tail light in rear lid

Touran 2003 ➤
1 - Securing nuts
❑ 3 Nm
2 - Bulb carrier
⇒ page 180 .
3 - Right tail light bulb -M2- or
left tail light bulb -M4-
❑ Bulb 12 V, P 21 W
4 - Rear left fog light bulb -L46-
or rear right fog light bulb -L47-
❑ Bulb 12 V, H 21 W.
5 - Tail light housing in rear lid
⇒ page 178 .
6 - Left reverse light bulb -M16-
or right reverse light bulb -M17-
❑ Glass-base bulb: 12 V,
W 16 W

light cluster) in rear lid

Touran 2003 ➤
Note
The following illustrations show the removal and installation of the

tail light cluster in the side panel on the left side. The work on the
tail light (tail light cluster) in the rear lid on the right side is carried
out in the same way.
Removing:
ignition key.
– Unclip service flap -1- out of trim in -direction of arrow-.
– Remove securing nuts -arrows-.

Touran 2003 ➤
– Swing tail light -1- out of body aperture in rear lid in

-direction of arrow-.
Installing:
– Swivel tail light -1- sideways into body aperture in

-direction of arrow- and then upwards, to middle, to final posi‐
tion.
– First tighten upper nuts, then tighten lower nut -arrow- to

specified torque ⇒ page 177 .
– Reconnect connector, must engage audibly.
– When installation is complete, check functions of tail light and
gaps to body.

light cluster) bulb carrier in rear lid
Removing:
ignition key.
– Unclip service flap -1- out of trim in -direction of arrow-.

Touran 2003 ➤
– Press locking device -arrows- and take bulb carrier to rear off
tail light in -direction of arrow-.
Installing:
following:
Note
When inserting bulb carrier, ensure that fastener engages audi‐

bly.
5.2.5 Renewing bulbs in tail light cluster in

rear lid
Note
The illustrations show removal and installation for the left side.
The removal of the right side is analogue.
Removing:
– Removing tail light bulb carrier in rear lid ⇒ page 180 .
– Push tail light bulb -2- slightly into bulb holder, turn bulb anti-
clockwise and pull bulb out of bulb holder.
Tail light bulb : 12 V, P 21 W
– Pull reversing light bulb -1- or rear fog light bulb -3- straight out
of bulb carrier.
Reversing light bulb : glass-base bulb 12 V, W 16 W
Rear fog light bulb : halogen bulb 12 V, H 21 W
Installing:
Install in reverse order of removal.
– Check function of tail lights.

Touran 2003 ➤
6 Number plate light
6.1 Removing and installing number plate

light -X-
Removing:
ignition key.
– Press locking lug -arrow- in -direction of arrow- using a suitable
screwdriver and pull number plate light -X- out of rear lid.
– Release connector and disconnect.
Number plate light -X- : glass-base bulb 12 V, W 5 W

Installing:
following:
– Reconnect connector, must engage audibly.
– Insert number plate light into rear lid so that connector is ori‐
ented to right side of vehicle.
– First push in -direction of arrow 1- and then in

-direction of arrow 2- until number plate light engages.
– Check function of number plate light .

Touran 2003 ➤
7 Additional brake light
Note
♦ LED failure in additional brake lights (not USA and Canada):

♦ The individual LEDs (light-emitting diodes) in the additional
brake lights are comprised in groups of four LEDs and are
supplied with current in groups.
♦ The additional brake light is designed so that it can still meet
the legal requirements of the ECE regulations (Economic
Commission for Europe) should one of the LED groups fail to
operate. If a further LED group fails, these requirements are
no longer met according to the legislator.
♦ Due to the failure of one LED group, the intact LEDs are placed
under increased strain; it must be anticipated that further LED
groups will soon fail.
♦ If more than four individual LEDs in the additional brake light
have failed, the additional brake light must be renewed (repair
measure).
The spray jet of the rear window washer system is integrated in

the additional brake light .
Renewing and adjusting spray jet of rear window washer system
⇒ page 117
♦ Wedge -T10039/1-
7.1 Removing and installing additional

brake light -M25-
Note
♦ The high-level brake light bulb -M25- uses light emitting diodes
(LEDs).
♦ The high-level brake light bulb -M25- cannot be dismantled.
♦ In the event of damage, the complete high-level brake light
bulb -M25- must be renewed.
Removing:
ignition key.
7. Additional brake light 183

Touran 2003 ➤
– Attach a strip of adhesive tape -1- to the area of rear lid above
brake light.
Caution
Make sure the seal is not damaged when removing the addi‐
tional brake light.
– Insert wedge -T10039/1- -1- at top between additional brake

light bulb -M25- -2- and rear lid.
– Release additional brake light -M25- by pushing wedge in

-direction of arrow- and remove it from rear lid taking connec‐
ted wiring lengths into consideration.
– Pull out hose lock -arrow- and pull hose connection -1- off ad‐
ditional brake light -M25- .
– Release and detach connector -2- and remove additional
brake light -M25- .
Installing:
Note
When installing additional brake light -M25- , ensure seal is seat‐

ed correctly. The seal must not form loops or be damaged.
– Connect hose connection and connectors.

– Clip brake light back into rear lid, starting at bottom.
– Check additional brake light -M25- and rear window washer
system for fault-free function.

Touran 2003 ➤
7.2 Checking additional brake light bulb -

M25-
♦ Body
♦ Electrical components, exterior light
♦ Additional brake light bulb
7. Additional brake light 185

Touran 2003 ➤
8 Steering column switch
Caution
The removal and installation of individual components of the

steering column switch must be performed in a specified se‐
quence ⇒ page 187 .
The components of the steering column combination switch,

steering column electronics control unit and steering column
switch base are installed as 2 different versions depending on
equipment level (manufacturers: Valeo or Kostal). The visible
fastening of the steering column electronics control unit to the
steering column combination switch can be used to identify which
version is installed.
♦ Manufacturer: Valeo, 3 bolts
♦ Manufacturer: 1 bolt at bottom and 2 fasteners at top
Note
♦ When a new steering column electronics control unit -J527- is

installed, it must be coded ⇒ page 191 .
The steering column electronics control unit -J527- is equipped
with self-diagnosis, which is designed to simplify fault finding.
8.2 Assembly overview - steering column

switch
Note
The components steering column electronics control unit -J527- ,

steering column combination switch -E595- and the steering col‐
umn switch base are available as different versions depending on
manufacturer (Valeo or Kostal). Illustration of assembly overview
shows Valeo version.

Touran 2003 ➤
1 - Steering column electronics

control unit -J527-
❑ Note removal and instal‐
lation sequence
⇒ page 187 .
(manufacturer: Valeo)
⇒ page 189
(manufacturer: Kostal)
⇒ page 190
❑ Securing bolt specified
torque (M8): 1.5 Nm
2 - Steering column combina‐
tion switch -E595-
lation sequence
⇒ page 187 .
⇒ page 192
⇒ page 192
3 - Steering column switch car‐
rier
lation sequence
⇒ page 187 .
4 - Shear-head bolts
❑ M8x20
❑ Shear torque: approx. 15 Nm
5 - Steering lock housing
Steering lock housing is removed and installed together with steering column switch base.
❑ Note removal and installation sequence ⇒ page 187 .
❑ Removing and installing (manufacturer: Valeo)
❑ Removing and installing (manufacturer: Kostal)
6 - Ignition/starter switch and lock cylinder
8.3 Removal and installation sequence of

components of steering column switch
Caution

served ⇒ page 4 .
8. Steering column switch 187

Touran 2003 ➤
For removal of the complete steering column switch, inc. base,

the switch is dismantled and the steering lock housing is also re‐
moved. For assembly of the steering lock housing, new shear
bolts are required.
Even if just one component of the steering column switch is re‐
moved or renewed, the sequence described as follows must be
adhered to.
Removing:
WARNING
♦ Danger of triggering of the airbag!

♦ Improper action on airbag unit may result in the triggering
of the airbag!
♦ Observe safety precautions when working on airbag ⇒
General body repairs, interior; Rep. gr. 69 ; Airbag; Safety
precautions when working on airbag .
– Remove steering wheel ⇒ General body repairs, interior; Rep.

gr. 69 ; Airbag .
– Remove steering column trim ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments, covers and trim; Removing and
installing steering column trim .
Remove components of steering column switch in the following
sequence:
♦ Steering column electronics control unit -J527- ⇒ page 188
♦ Steering column combination switch -E595- ⇒ page 191
♦ Steering column switch base
Installing:
8.4 Steering column electronics control unit

-J527-
The steering column electronics control unit -J527- comprises the
following components and cannot be dismantled:
♦ Airbag coil connector and return ring with slip ring -F138-
♦ Steering angle sender -G85-
Note
♦ If a new steering column electronics control unit -J527- is in‐

stalled, the fitted transport protection must be removed before
installation.
♦ When a new steering column electronics control unit -J527- is
installed, it must be coded ⇒ page 191 .
♦ In the event of faults in the steering column switch, the coding
of the steering column electronics control unit -J527- must be
checked ⇒ page 191 .
Removal and installation of steering column electronics control

unit -J527- are different, depending on manufacturer.

Touran 2003 ➤
♦ Removing and installing steering column electronics control

unit -J527- (manufacturer: Valeo) ⇒ page 189
♦ Removing and installing steering column electronics control
unit -J527- (manufacturer: Kostal) ⇒ page 190
8.4.1 Removing and installing steering col‐

umn electronics control unit -J527-
Removing:
Caution

WARNING

of the airbag!

Remove the following components in sequence:
gr. 69 ; Airbag .

Touran 2003 ➤
– Depending on equipment level, release and detach connec‐

tors -1-, -2-, -3- and -4-.
Note
Coil connector on steering column electronics control unit -J527-

must not be twisted from its centre position. The front wheels must
be in „straight-ahead“ position.
– Undo the three bolts -arrows- and pull steering column elec‐
tronics control unit -J527- to rear off steering column switch.
Installing:
Caution
Turn signal switch reset lever can break when control unit is
being installed.
Turn signal lever must be in 0 position when control unit is in‐
stalled so that reset lever is not extended.
– Push steering column electronics control unit -J527- onto the

steering column switch.
– Screw the three bolts of steering column electronics control
unit -J527- into steering column switch module and tighten to
1.5 Nm.
– Install all components in reverse order of removal.

umn electronics control unit -J527-
Removing:
Caution

WARNING

of the airbag!

Remove the following components in sequence:
gr. 69 ; Airbag .

Touran 2003 ➤

– Depending on equipment level, release and detach connec‐
tors -1-, -2-, -3-, -4- and -5-.
– Remove bolt -arrow B-.
Note
Coil connector for steering column electronics on steering column

electronics control unit -J527- must not be twisted from its centre
position. The front wheels must be in „straight-ahead“ position.
– Release locking devices -arrow A- and pull steering column

electronics control unit -J527- to rear off steering column
switch.
Installing:
Caution
Turn signal switch reset lever can break when control unit is
being installed.
Turn signal lever must be in 0 position when control unit is in‐
stalled so that reset lever is not extended.
– Push steering column electronics control unit -J527- straight

onto steering column switch until it securely engages.
– Screw in bolts of steering column electronics control unit -
J527- -arrow B- and tighten to 1.5 Nm.
8.4.3 Coding steering column electronics con‐

trol unit -J527-
♦ Body
♦ Steering wheel electronics
♦ Steering wheel electronics functions
♦ Coding steering wheel electronics control unit
8.5 Steering column combination switch -

E595-
Depending on equipment, the steering column combination
switch -E595- comprises the following components and cannot
be dismantled:
♦ Turn signal switch -E2-

Touran 2003 ➤
♦ Windscreen wiper switch -E-

♦ CCS switch -E45-
Removal and installation of steering column combination switch
are different, depending on manufacturer.
♦ Removing and installing steering column combination switch
-E595- (manufacturer: Valeo) ⇒ page 192
♦ Removing and installing steering column combination switch
-E595- (manufacturer: Kostal) ⇒ page 192

umn combination switch -E595- (manu‐
facturer: Valeo)
Caution

Removing:
gr. 69 ; Airbag .
– Remove steering column electronics control unit -J527-
⇒ page 189 .
– Release locking devices -arrows- and pull complete steering
column combination switch -E595- to rear straight off steering
column switch carrier.
Installing:
– Push steering column combination switch -E595- straight into
guides on steering column switch carrier until it securely en‐
gages.

umn combination switch -E595- (manu‐
facturer: Kostal)
Caution

Removing:
gr. 69 ; Airbag .

Touran 2003 ➤
– Remove steering column electronics control unit -J527-

⇒ page 190 .
– Undo bolt -arrow- and pull complete steering column combi‐
nation switch -E595- -1- to rear straight off steering column
switch carrier.
Installing:
guides on steering column switch carrier.
– Install bolt -arrow-.
8.6 Steering column switch carrier

Removal and installation of steering column switch carrier is dif‐
ferent, depending on manufacturer.
♦ Removing and installing steering column switch carrier (man‐
ufacturer: Valeo) ⇒ page 193
♦ Removing and installing steering column switch carrier (man‐
ufacturer: Kostal) ⇒ page 195

umn switch carrier (manufacturer: Va‐
leo)
Caution


♦ Angle hand drill

Touran 2003 ➤
Removing:
Note
To remove steering column switch carrier -2-, shear-head bolts

-1- of steering lock housing must be drilled out. New shear-head
bolts are required for subsequent installation ⇒ Electronics parts
catalogue (ETKA) .
Caution
♦ Ensure that all the components mounted on the base have

been removed before drilling out the shear-head bolts.
♦ The drilling operation can cause swarf to penetrate the
adjacent components resulting in damage and/or mal‐
function!
♦ Adhere to the specified sequence when removing com‐
ponents of the steering column switch ⇒ page 187 .
Caution

served ⇒ page 4 .
Removing:
– Remove all components attached to base in prescribed se‐
Removing carrier:
– Drill out shear-head bolts -1- of steering lock housing -3-.
Note
Bolts M8 -1-, core diameter 6.8 mm
– Pull steering lock housing -3- and steering column switch car‐
rier -2- to rear off steering column.
– Remove steering lock housing from steering column switch
carrier.
Installing:

Touran 2003 ➤
– Insert steering lock housing -3- into steering column switch

carrier -2-.
steering column switch carrier until it securely engages.
– Push preassembled unit consisting of steering lock housing,
steering column switch carrier and steering column combina‐
tion switch -E595- straight onto steering column as far as stop..
– Align steering column switch carrier to threaded holes.
– Secure steering lock housing -3- to steering column using new
shear-head bolts -1-.
– Tighten new shear-head bolts -1- until bolt heads shear off.

umn switch carrier (manufacturer: Kos‐
tal)
Caution


♦ Angle hand drill

Touran 2003 ➤
Removing:
Note
To remove steering column switch carrier -2-, shear-head bolts

-1- of steering lock housing must be drilled out. New shear-head
bolts are required for subsequent installation ⇒ Electronics parts
catalogue (ETKA) .
Caution
♦ Ensure that all the components mounted on the base have

been removed before drilling out the shear-head bolts.
♦ The drilling operation can cause swarf to penetrate the
adjacent components resulting in damage and/or mal‐
function!
♦ Adhere to the specified sequence when removing com‐
ponents of the steering column switch ⇒ page 187 .
Caution

served ⇒ page 4 .
Removing:
– Remove all components attached to steering column switch
carrier in prescribed sequence ⇒ page 187 .
Removing steering column switch carrier:
– Drill out shear-head bolts -1- of steering lock housing -3-.
Note
Bolts M8 -1-, core diameter 6.8 mm
– Pull steering lock housing -3- and steering column switch car‐
rier -2- to rear off steering column.
– Remove steering lock housing from steering column switch
carrier.
Installing:

Touran 2003 ➤
– Insert steering lock housing -3- into steering column switch

carrier -2-.
– Push steering column combination switch -E595- onto steer‐
ing column switch carrier and screw in bolt underneath.
– Push preassembled unit consisting of steering lock housing,
steering column switch carrier and steering column combina‐
tion switch -E595- straight onto steering column as far as stop..
– Align steering column switch carrier to threaded holes.
– Secure steering lock housing -3- to steering column using new
shear-head bolts -1-.
– Tighten new shear-head bolts -1- until bolt heads shear off.

Touran 2003 ➤
9 Ignition/starter switch and lock cylin‐

der
9.1 Removing and installing steering lock

housing
Caution

served ⇒ page 4 .
Note
The steering column switch carrier must be dismantled before the

steering lock housing can be removed.
Caution
♦ The steering lock could be destroyed.

♦ If the steering lock is actuated without lock cylinder, it will
block and must be renewed.
♦ The steering lock must not be actuated without lock cylin‐
der.
Removing:
– Removing steering column switch carrier ⇒ page 193 .
9.2 Removing and installing lock cylinder
Caution

served ⇒ page 4 .
Caution
♦ The steering lock could be destroyed.

♦ If the steering lock is actuated without lock cylinder, it will
block and must be renewed.
♦ The steering lock must not be actuated without lock cylin‐
der.
Removing:

Touran 2003 ➤
– Removing steering wheel ⇒ General body repairs, interior;

Rep. gr. 69 ; Airbag; Removing and installing steering wheel .
Note
♦ For reasons of clarity, the illustration is shown without steering

column lever, coil connector or steering wheel. There is no
need to remove the components in order to remove the lock
cylinder.
♦ The immobilizer reader coil -D2- is secured to the lock cylinder
and cannot be changed individually.
♦ For reasons of clarity, the ignition key is not shown in the fol‐
lowing illustrations.
♦ The hole may be 180° further than shown in the illustration.
This does however not affect the procedure for removing and
installing.
– Insert ignition key in lock cylinder and turn to position „Drive“.

Positions for key in lock cylinder:
1 - Position „Stop“
2 - Position „Drive“
3 - Position „Start“
Note
For reasons of clarity, the illustration is shown without turn signal

and windscreen wiper switch. There is no need to remove the
switches in order to remove the lock cylinder.
– Insert a piece of steel wire (approx. ∅ 1.2 mm) in hole

-arrow- next to ignition key.
– Using steel wire -2- release locking lever -3- of lock cylinder
-1-.
– Pull lock cylinder -1- out of steering lock housing.
9. Ignition/starter switch and lock cylinder 199

Touran 2003 ➤
– Disconnect connector to immobilizer reader coil -D2- -arrow-.

Installing:
Note
For reasons of clarity, the ignition key is not shown in the following
illustration.
– Insert ignition key in lock cylinder -1- and turn to position

„Drive“.
– Using steel wire -2- release locking lever -3- of lock cylinder
-1-.
– Attach connector to immobilizer reader coil .
– Insert lock cylinder -1- into steering lock housing.
Note
The connection for the immobilizer reader coil -D2- must be in‐
serted in the guide on the steering lock housing.
– Pull steel wire -2- out of lock cylinder -1- and check lock cyl‐
inder is seated correctly in the steering lock housing.
9.3 Removing and installing ignition/starter

switch
Caution

served ⇒ page 4 .
Removing:

Touran 2003 ➤
– Pull off connector -2- off ignition/starter switch -1-.

– Release ignition/starter switch using a small screwdriver
-arrows-.
– Pull ignition/starter switch -1- out of steering lock housing.
Installing:
– Push ignition/starter switch into steering lock housing until it
engages audibly.
– Insert ignition key in lock cylinder and turn to position „Drive“.
Note
The key must be in the „Drive“ position.
Positions for key in lock cylinder:

1 - Position „Stop“
2 - Position „Drive“
3 - Position „Start“
9.3.1 Checking ignition/starter switch

♦ Body
♦ Diagnostic capable systems
♦ Switch button
♦ Ignition/starter switch
9.4 Removing and installing ignition key

withdrawal lock solenoid -N334-
The ignition key withdrawal lock solenoid -N334- is located di‐
rectly adjacent to the ignition starter key.
9. Ignition/starter switch and lock cylinder 201

Touran 2003 ➤
Note
To remove ignition key on vehicles with dual clutch gearbox

(DSG), always move selector lever to position „P“ first, then switch
off ignition. Otherwise the ignition key withdrawal lock solenoid -
N334- will inhibit the removal of the ignition key.
Removing:
– Release catch -2- using a suitable screwdriver.
– Pull ignition key withdrawal lock solenoid -N334- -1- out of its
mounting in -direction of arrow-.
– The electrical connection will be disconnected automatically.
Installing:
Note
After reconnecting the battery, carry out final control diagnosis to

reactivate the ignition key withdrawal lock solenoid -N334- .

Touran 2003 ➤
10 Parking aid (PDC)
Note
♦ When faced with complaints, it is absolutely necessary to un‐

derstand the function and operation of the parking aid system.

tions
tem
Installed in the rear bumper of the Touran is a 4-channel parking
aid system with 4 ultrasonic sensors (parking aid senders).
The parking aid system monitors the surrounding area via the ul‐
trasonic sensors in the rear bumper. The acoustic distance warn‐
ing is provided by a warning buzzer inside the vehicle.
The rear sensors are switched off automatically when a trailer is
hitched to the vehicle and the connector is plugged into the trailer
socket.
Park assist comprises the following:
♦ Parking aid button -E266-
♦ Button illumination bulb -L76-
♦ Parking aid warning lamp -K136-
♦ Rear left parking aid sender -G203-
♦ Rear centre left parking aid sender -G204-
♦ Rear centre right parking aid sender -G205-
♦ Rear right parking aid sender -G206-
♦ Rear parking aid warning buzzer -H15-
♦ Parking aid control unit -J446-
Function:
To activate, press parking aid button -E266- with ignition switched
on or engage reverse gear. To deactivate, press parking aid but‐
ton -E266- again (warning lamp in button goes out). Once a
forward speed of about 15 km/h is exceeded, the park assist sys‐
tem switches off.
A brief audible signal is given and the warning lamp lights up when
the parking aid system is ready. If a fault is detected, a continuous
audible signal is given for 5 seconds and the parking aid warning
lamp flashes.
The intervals between the warning signals become proportionally
shorter as the distance decreases. At distances of less than 30
cm the warning signals merge into a continuous tone. Special sit‐
uation: reversing parallel to a wall = no signal.
10. Parking aid (PDC) 203

Touran 2003 ➤

The parking aid control unit -J446- controls the functions of the
parking aid system.
The park assist steering control unit -J446- is equipped with self-
diagnosis, which makes fault finding easier.
To check the parking aid system, perform final control diagnosis
10.2 Assembly overview - parking aid
1 - Parking aid button -E266-

❑ Located in centre con‐
sole in front of gear lever
⇒ page 270
2 - Rear parking aid warning
buzzer -H15-
❑ Located behind right
side panel trim
⇒ page 210 .
❑ Can be checked via final
control diagnosis
❑ Adaption ⇒ page 210
3 - Parking aid control unit -
J446-
❑ Located behind right
side panel trim in vicinity
of tail light
⇒ page 205
❑ Adapting lower volume
request ⇒ page 206
❑ Adapting parking aid ac‐
tivation sound
⇒ page 206
control diagnosis
4 - Parking aid senders in rear
bumper cover
❑ Rear left parking aid
sender -G203-
❑ Rear centre left parking
aid sender -G204-
❑ Rear centre right parking aid sender -G205-
❑ Rear right parking aid sender -G206-

Touran 2003 ➤
10.3 Rear parking aid control unit -J446-

The parking aid control unit -J446- controls the functions of the
parking aid system and can be found behind the right side panel
trim.
10.3.1 Removing and installing parking aid

control unit -J446-
The parking aid control unit -J446- is located behind the right side
panel trim, next to the tail light.
Removing:
tion key.
Vehicles with 5 seats:
– Remove right side panel trim in luggage compartment ⇒ Gen‐
eral body repairs, interior; Rep. gr. 70 ; Load and luggage
compartment trim; Removing and installing 5-seater side pan‐
el trim, Removing .
– Remove right side panel trim in luggage compartment ⇒ Gen‐
el trim, Removing .
All vehicles:
– Release connectors on control unit -2- and disconnect.
Note
Both brackets on the parking aid control unit -J446- -1- have been
engineered to break at a specified point.
– Unscrew securing bolts on both brackets -1- using AF 10

socket.
– Remove parking aid control unit -J446- from vehicle.
Installing:
Note
Both brackets on the parking aid control unit -J446- are engi‐
neered to break at a specified point and therefore have to be
renewed.

Touran 2003 ➤
– Slide bracket -1- onto parking aid control unit -J446- -3-.
– Engage parking aid control unit -J446- -3- on studs -2-.
– Fit connectors -4- to parking aid control unit -J446- .
10.3.2 Coding parking aid control unit -J446-

The parking aid control unit -J446- can be set to suit the config‐
uration in a particular vehicle by coding it accordingly.
-VAS 5051A- ⇒ page 288
♦ Body
♦ General body repairs
♦ Parking aid ll -J446-
♦ Parking aid ll functions
♦ Coding
10.3.3 Adapting parking aid control unit -J446-

With this function, the following adaptions can be set in the park‐
ing aid control unit -J446- :
♦ Volume reduction in conjunction with parking aid
♦ Activation sound when parking aid is switched on
-VAS 5051A- ⇒ page 288
♦ Body
♦ 01-Systems capable of self-diagnosis
♦ Adaption

Touran 2003 ➤
10.3.4 Pin assignment of parking aid control

unit -J446-
Refer to current flow diagram for pin assignments of parking aid
control unit -J446- ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations.
10.4 Rear parking aid senders

The following parking aid senders are located in the rear bumper
cover:
Removing and installing rear parking aid senders ⇒ page 207
10.4.1 Removing and installing rear parking aid

sender
Note
The removal of the four rear parking aid senders is carried out in
the same way and is only described for one sender in the follow‐
ing.
Removing:
ignition key.
– Remove rear bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Rear bumper
Caution
♦ The order for removing the senders must be adhered to

under all circumstances.
♦ The sender may otherwise be damaged. Fractures may
occur if too much pressure is applied to the sender, and
this may cause the sender to fail.
♦ First remove sender from holder and then disconnect
sender connector.
– Push fasteners -arrows- on sender holder -1- outwards.

– Pull out sender -2- with wiring connected backwards from
sender holder -1-.
Note
♦ When removing the sender, ensure the isolation ring (black

silicone ring) remains on the sender head and does not remain
stuck in the holder or become lost.
♦ Expanding the isolation ring must be avoided under all cir‐
cumstances.

Touran 2003 ➤
– Release and separate connector -2- and remove sender -1-.

Installing:
following:
Caution
♦ Expanding the isolation ring must be avoided under all

circumstances.
♦ Function problems may occur if a damaged isolation ring
is used.
♦ Renew damaged isolation rings.
Note
♦ Senders are available in different forms and must be assigned

to respective fitting location in bumper cover.
♦ When installing senders, note position of electrical connec‐
tions of senders.
Assignment of parking aid senders on inside of rear bumper cov‐

er:
A - Right outer
B - right centre
C - left centre
D - Left outer
Note
♦ When installing the sender, ensure that the isolation ring is

correctly mounted on the sender head and does not ride or roll
up on insertion into the sender bracket.
♦ Both locking lugs of sender holder must audibly engage when
installing the sender.
– After installing the sender, check that the sender is correctly

seated in the holder. Visible on the outer side of the bumper,
dimension -a- of the ring gap between the sender head and
bumper cover must be even all around.
10.4.2 Checking rear parking aid senders

This function can be used to check the following components via
the park assist steering control unit :

Touran 2003 ➤

-VAS 5051A- ⇒ page 288
♦ Body
♦ Electrical components of parking aid II
♦ Parking aid senders
10.4.3 Renewing parking aid senders

If a new parking aid sender is installed, the sender head must be
first painted in the colour of the bumper cover. The following pre‐
requisites must be adhered to when painting the senders to
ensure the function of the parking aid system is not adversely
affected.
10.4.4 Painting senders

– Remove isolation ring (black silicon ring) from new sender
head.
– Degrease black sender head -1- in area to be painted -2- with
isopropanol (isopropyl alcohol).
– Paint sender in area to be painted -2- in colour of bumper cov‐
er.
Note
Dimension -B- for the painted area must not exceed 3 mm (+

maximum 2 mm).
– Fit isolation ring (black silicone ring) on sender head again

once paint has dried.
Caution

circumstances.
is used.

Touran 2003 ➤
10.5 Parking aid warning buzzer
10.5.1 Removing and installing rear parking aid

warning buzzer -H15-
The rear parking aid warning buzzer -H15- is located behind the
right side panel trim.
Removing:
– Remove right side panel trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Load, luggage compartment trim .
– Release expanding rivets -arrows- and remove warning buz‐
zer for rear parking aid -H15- from holder.
Installing:
Note
Coding, basic setting and adaption are not necessary if the rear
parking aid warning buzzer -H15- is renewed.
10.5.2 Adapting rear parking aid warning buz‐

zer
With this function, the following functions of the rear parking aid
warning buzzer -H15- can be adapted:
♦ Frequency of rear parking aid warning buzzer
♦ Volume of rear parking aid warning buzzer
-VAS 5051A- ⇒ page 288
♦ Body
♦ Adaption
10.6 Parking aid button -E266-

The parking aid button -E266- is located in the centre console in
front of the gear lever.
10.6.1 Removing and installing parking aid but‐

ton -E266-
Removal and installation of the parking aid button -E266- is car‐
ried out in the same way for all other buttons in the centre console
stowage compartment.

Touran 2003 ➤
– Removing and installing parking aid button -E266-

⇒ page 270
10.6.2 Checking parking aid button -E266-

-VAS 5051A- ⇒ page 288
♦ Body
♦ Parking aid button

Touran 2003 ➤
11 Park assist steering (PAS)
Note
♦ When handling complaints, it is essential to understand the

function and operation of the park assist steering.
♦ Additional information ⇒ Owner's Manual
The park assist steering supports the driver when reversing into
a parallel parking space on the driver or passenger side. When
the park assist steering is activated and the vehicle drives by at
a speed of less than 35 km/h, the side of the road is measured by
ultrasonic sensors searching for a suitable parking space. Once
a parking space has been reliably detected, the park assist steer‐
ing requests the driver to continue passing by the parking space
until the vehicle is in a position from which rapid parking is pos‐
sible. When the reverse gear is engaged, the park assist steering
undertakes lateral guidance of the vehicle by actuating the EPS
(electronic power steering = electromechanical steering). The
system steers the vehicle into the parking space in one movement
according to a calculate nominal path. The driver maintains op‐
eration of the pedals (accelerator, clutch, brake) and longitudinal
vehicle guidance, and therefore determines the parking speed.
During the parking process, the park assist steering sensors are
used together with the parking aid senders to monitor proximity.
The following conditions lead to abortion of the parking process
with the park assist steering:
♦ The park assist steering is switched off via the park assist
steering button -E581- .
♦ Ignition is switched off
♦ Parking speed too high (>7 km/h)
♦ Steering intervention by driver during parking process
♦ Disengaging reverse gear
♦ Vehicle standstill time limit exceeded (approx. 30 s)
♦ ESP switched off or ESP intervention
♦ TCS intervention
♦ Trailer attached to vehicle coupling
♦ Front parking aid (PDC) is switched on.
♦ Sensors detect a status which endangers secure determina‐
tion of the vehicle position.
♦ System malfunction

Touran 2003 ➤
WARNING
♦ Responsibility during parking is borne by the driver.

♦ The park assist steering cannot replace the driver's atten‐
tiveness.
♦ The sensors have blind spots, in which persons and ob‐
jects can not be registered.
♦ Pay particular attention to small children and animals, as
these are not always detected by the sensors.
The park assist steering consists of:

♦ Front right parking aid sender -G252-
♦ Front centre right parking aid sender -G253-
♦ Front centre left parking aid sender -G254-
♦ Front left parking aid sender -G255-
♦ Front left sender for park assist steering on left side of vehicle
-G568-
♦ Front right sender for park assist steering on right side of ve‐
hicle -G569-
♦ Rear left park assist steering sender -G716-
♦ Rear right park assist steering sender -G717-
♦ Rear parking aid warning buzzer -H15-
♦ Front parking aid warning buzzer -H22-
♦ Park assist steering button -E581-
♦ Warning light for park assist steering -K241-
♦ Parking aid control unit -J446-
♦ Park assist steering control unit -J791-
The park assist steering features self-diagnosis to facilitate fault
finding.
To check the park assist steering as a whole, perform final control
diagnosis.
11.2 Assembly overview of park assist steering
11. Park assist steering (PAS) 213

Touran 2003 ➤
1 - Park assist steering send‐

ers in rear bumper cover
❑ Rear right park assist
steering sender -G717-
❑ Rear left park assist
steering sender -G716-
⇒ page 221
2 - Rear parking aid warning
buzzer -H15-
❑ Behind right side panel
trim.
⇒ page 210
control diagnosis
3 - Park assist steering button
-E581-
❑ In centre console stor‐
age compartment in
front of gearshift lever.
⇒ page 224 .
4 - Parking aid control unit -
J446-
❑ With integrated park as‐
sist steering control unit
-J791-
❑ In driver side footwell,
on left side of dash pan‐
el behind relay carrier
❑ Securing bolt specified torque: 5 Nm
5 - Front parking aid warning buzzer -H22-
❑ In driver side footwell, on left side of dash panel behind relay carrier
❑ Can be checked via final control diagnosis
6 - Sender for parking aid in front bumper cover
❑ Front left parking aid sender -G255-
❑ Front centre left parking aid sender -G254-
❑ Front centre right parking aid sender -G253-
❑ Front right parking aid sender -G252-
❑ Removing and installing front parking aid senders ⇒ page 217

Touran 2003 ➤
7 - Front park assist steering senders in front bumper cover

❑ Front left sender for park assist steering on left side of vehicle -G568-
❑ Front right sender for park assist steering on right side of vehicle -G569-
11.3 Parking aid control unit -J446- with park

assist steering control unit -J791-
The parking aid control unit -J446- with integrated park assist
steering control unit -J791- can be found in the driver's footwell
behind the relay carrier of the dash panel. The parking aid control
unit -J446- also simultaneously controls the park assist steering
functions on vehicles with park assist steering.
11.3.1 Removing and installing parking aid

control unit -J446-
Removing:
ignition key.
– Remove relay carrier on left of dash panel ⇒ page 290 .
– Remove relay carrier on onboard supply control unit on left of
dash panel ⇒ page 290 .
– Remove bolt from below -arrow- and remove control unit for
parallel parking assist -J791- -1- from its installation position,
noting the connected line lengths.
– Release and detach the three connectors -arrows-. Remove

park assist steering control unit -J791- -1- from vehicle.
Installing:
– On installation, insert corner of park assist steering control unit
-J791- into opening in relay carrier.
– Tighten securing bolt to specified torque ⇒ page 213 .
11.3.2 Coding parking aid control unit -J446-

-VAS 5051A- ⇒ page 288

Touran 2003 ➤

♦ Body
♦ Coding
11.3.3 Adapting parking aid control unit -J446-

With this function, the following adaptions can be set in the park‐
ing aid control unit -J446- :
♦ Volume reduction in conjunction with parking aid
♦ Activation sound when parking aid is switched on
♦ Optical display for assisted parking
-VAS 5051A- ⇒ page 288
♦ Body
♦ Adaption
11.4 Parking aid sender and park assist

steering sender
Park assist steering senders are installed in front and rear bumper
cover. Both park assist steering senders are located at outermost
lateral positions of bumper cover. During the parking process,
they are used to measure proximity together with the parking aid
senders.
11.4.1 Rear parking aid senders

The rear parking aid senders were described in
⇒ „10.4 Rear parking aid senders “, page 207 :
♦ Removing and installing ⇒ page 207
♦ Checking ⇒ page 208
♦ Replacing ⇒ page 209 .
11.4.2 Front parking aid senders

The following parking aid senders are located in the front bumper
cover:

Touran 2003 ➤

Removing and installing front parking aid senders ⇒ page 217
11.4.3 Removing and installing front left park‐

ing aid sender -G255-
Note
Removal of the four front parking aid senders is carried out in the
same way and is only described as follows for one sender.
Removing:
key.
Rep. gr. 63 ; Front bumper .
Caution

sender connector.

sender holder -1-.
Note
♦ When removing the sender, ensure the isolation ring (black

silicone ring) remains on the sender head and does not remain
stuck in the holder or become lost.
cumstances.

Touran 2003 ➤

Installing:
following:
Caution

circumstances.
♦ Function problems could occur if an incorrect or damaged
isolation ring is used.
♦ Renew damaged isolation rings and always ensure that
the correct isolation ring is fitted.
Note
As the front parking aid sender and the park assist steering send‐
ers have sender heads of different lengths, isolation rings of
different heights are also installed.
– Check whether the correct isolation ring is installed on the re‐

spective sender head.
Type of sender Isolation ring height dimen‐
sion -B-
Front parking aid senders 5.7 mm
Park assist steering senders 9.05 mm
– Renew isolation ring -1- of sender if necessary.
– Assign sender to correct installation position in bumper cover.
Note
♦ Senders are available in different forms and must be assigned

to respective fitting location in bumper cover.
♦ When installing senders, note position of electrical connec‐
tions of senders.

Touran 2003 ➤
Assignment of parking aid sender on inside of rear bumper cover:

A - Left outer
B - left centre
C - right centre
D - Right outer
Note

up on insertion into the sender holder.

11.4.4 Removing and installing front park as‐

sist steering senders
The following park assist steering senders are located in the front
bumper cover:
-G568-
hicle -G569-
Removing:
ignition key.
Rep. gr. 63 ; Front bumper .
Caution
The order for removing the senders must be adhered to under

all circumstances.
The sender may otherwise be damaged. Fractures may occur
if too much pressure is applied to the sender, and this may
cause the sender to fail.
First remove the senders from the brackets and then discon‐
nect the sender's connector.

Touran 2003 ➤

sender holder.
Note
♦ When removing the sender, make sure that the isolation ring
(black silicone ring) on the sender head does not remain in the
bracket or become lost.
♦ Stretching the isolation ring must be avoided under all circum‐
stances.
– Release and detach connector -2- and remove sender -1-.

Installing:
following:
Caution
Function problems could occur if an incorrect or damaged iso‐

lation ring is used.
Stretching the isolation ring must be avoided under all circum‐
stances.
Renew damaged isolation rings and always ensure that the
correct isolation ring is fitted.
Note
As the front parking aid sender and the park assist steering send‐
ers have sender heads of different lengths, isolation rings of
different heights are also installed.
– Check whether the correct isolation ring is installed on the

sender head.
sion -B-
Front parking aid senders 5.7 mm
– If necessary, renew isolation ring -1- of sender.
Note
When installing senders, note position of electrical connections

of senders.

Touran 2003 ➤
Assignment of senders on inside of front bumper cover:

A - Bracket for front left sender for Park Assist on left side of ve‐
hicle -G568-
B - Bracket for front right sender for Park Assist on right side of
vehicle -G569-
Note

♦ Both locking lugs of sender retainer must audibly engage
when installing the sender.

seated in the bracket. Visible on the outer side of the bumper,
11.4.5 Removing and installing rear park assist

steering sender
The following park assist steering senders are located in the rear
bumper cover:
Removing:
key.
– Remove rear bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Rear bumper .
Caution

sender connector.

Touran 2003 ➤

sender holder.
Note
♦ When removing the sender, make sure that the isolation ring
(black silicone ring) on the sender head does not remain in the
holder or become lost.
cumstances.

Installing:
following:
Caution
Function problems could occur if an incorrect or damaged iso‐

lation ring is used.
Expanding the isolation ring must be avoided under all circum‐
stances.
Renew damaged isolation rings and always ensure that the
correct isolation ring is fitted.
Note
As the parking aid senders and the park assist steering senders
have sender heads of different lengths, isolation rings of different
heights are also installed.
– Check whether the correct isolation ring is installed on the

sender head.
sion -B-
Rear parking aid senders 5.7 mm
– Renew isolation ring -1- of sender if necessary.
Note
When installing senders, note position of electrical connections

of senders.

Touran 2003 ➤
Assignment of senders on inside of rear bumper cover:

A - Holder for rear right park assist steering sender -G717-
B - Holder for rear left park assist steering sender -G716-
Note


11.4.6 Checking parking aid sender and park

assist steering sender
This function can be used to check the following components via
the park assist steering control unit -J791- :
-G568-
hicle -G569-
-VAS 5051A- ⇒ page 288
♦ Body

Touran 2003 ➤

♦ Parking aid sender, park assist steering sender
11.5 Renewing park assist steering senders

If a new park assist steering sender is installed, the sender head
must be first painted in the colour of the bumper cover. The fol‐
lowing prerequisites must be adhered to when painting the send‐
ers to ensure the function of the park assist steering system is not
adversely affected.
11.5.1 Painting senders

– Take insulation ring (black silicone ring) off sender head
– Remove grease from sender head -1- in area to be painted
-2- with isopropanol.
– Paint sender in area to be painted -2- in colour of bumper cov‐
er.
Note
Dimension -B- for the painted area must not exceed 3 mm (+

maximum 2 mm).
– Fit isolation ring (black silicone ring) on sender head again

once paint has dried.
Caution

circumstances.
is used.
11.6 Park assist steering button -E581-

The park assist steering button is located in the centre console
storage compartment in front of the gear lever. It contains the
warning light for park assist steering -K241- and cannot be dis‐
assembled any further.
11.6.1 Removing and installing park assist

steering button -E581-
Removal and installation of the park assist steering button -E581-
are carried out in the same way for all buttons in the centre
console storage compartment and are described in chapter
⇒ „9.1 Removing and installing buttons in centre console storage
compartment“, page 270 .

Touran 2003 ➤
11.6.2 Checking park assist steering button -

E581-
-VAS 5051A- ⇒ page 288
♦ Body
♦ Park assist steering button
11.7 Parking aid warning buzzer

The park assist steering control unit -J791- controls the functions
of the parking aid and park assist steering system. The acoustic
warning messages of the park assist steering system are given
via the parking aid warning buzzer ( rear parking aid warning buz‐
zer -H15- and front parking aid warning buzzer -H22- ).
Removal and installation and adaption options for the rear parking
aid warning buzzer -H15- are described in the chapter entitled
'Parking aid' ⇒ „10.5 Parking aid warning buzzer “, page 210 .
11.7.1 Removing and installing front parking

aid warning buzzer -H22-
The front parking aid warning buzzer -H22- is located under the
dash panel in the driver footwell. It is attached above the onboard
supply control unit on the rack of the relay carrier.
Removing:
ignition key.
– Remove relay carrier on left of dash panel ⇒ page 290 .
– Pull out pins of both expansion rivets -arrows- and remove
front parking aid warning buzzer -H22- -1- under consideration
of connected line lengths.

Touran 2003 ➤
– Release and disconnect connector -arrow- and remove front

parking aid warning buzzer -H22- -1- from vehicle.
Installing:
11.7.2 Adapting front parking aid warning buz‐

zer -H22-
With this function, the following functions of the front parking aid
warning buzzer -H22- can be adapted:
♦ Frequency of front parking aid loudspeaker
♦ Volume of front parking aid loudspeaker
-VAS 5051A- ⇒ page 288
♦ Body
♦ Adaption
11.8 Renewing holders for parking aid send‐

er and park assist steering sender
11.8.1 Assembly overview - holders for front

centre parking aid sender
Note
The following illustration shows the assembly overview of the

holder with right connector fitting. The assembly overview of the
holder with left connector fitting is basically a mirror image of this.

Touran 2003 ➤
1 - Outline of sender holder

❑ Outline > 1 mm to holder
❑ Line < 2° to horizontal
2 - Adhesive pad
❑ Adhesive pad is already
stuck on holder during
production
❑ Foam adhesive tape TL
52018-E, s=1
❑ Qty. 2, 30 x 20,
A=12 cm2
3 - Marking of installation posi‐
tion
❑ VRM - Front centre right
parking aid sender -
G253-
❑ VLM - Front centre left
G254-
4 - Sender holder
5 - Decoupling ring
6 - Sender
Assembly:
– Place holder in installation position of inner bumper cover and
outline installation area ⇒ Item 1 (page 227) .
Note
When marking the outline, ensure that it is 1 mm greater than the

holder. The deviation of the line to the horizontal should be less
than 2°.
– Clean area within outline and, if necessary, remove any re‐

sidual glue from old holder. Degrease area with isopropanol.
– Remove backing from adhesive tape and bond holder in in‐
stallation position of inner bumper cover.

Touran 2003 ➤
11.8.2 Assembly overview - holders for front

parking aid sender and front park assist
steering sender
Note

holder with right connector fitting. The assembly overview of the
holder with left connector fitting is basically a mirror image of this.

2 - Adhesive pad
production
52018-E, s=1
❑ Qty. 2, 30 x 20,
A=12 cm2
tion
❑ VR - Front right parking
aid sender -G252-
❑ VL - Front left parking
aid sender -G255-
❑ VLS - Front left sender
for park assist steering
on left side of vehicle -
G568-
❑ VRS - Front right sender
for park assist steering
on right side of vehicle -
G569-
4 - Sender holder
5 - Decoupling ring
6 - Sender

outline installation area ⇒ Item 1 (page 228)
Note

than 2°.

Touran 2003 ➤

11.8.3 Assembly overview - holders for rear

parking aid sender and rear park assist
steering sender
Note

holder with left connector fitting. The assembly overview of the
holder with right connector fitting is basically a mirror image of
this.

2 - Adhesive pad
production
52018-E, s=1
❑ Qty. 2, 30 x 20,
A=12 cm2
tion
❑ HL - Rear left parking
aid sender -G203-
❑ HLM - Rear centre left
G204-
❑ HMR - Rear centre right
G205-
❑ HR - Rear right parking
aid sender -G206-
❑ HLS - Rear left park as‐
sist steering sender -
G716-
❑ HRS - Rear right park
assist steering sender -
G717-
4 - Sender holder
5 - Decoupling ring
6 - Sender

outline installation area ⇒ Item 1 (page 229)

Touran 2003 ➤
Note

than 2°.

11.8.4 Painting holders

If a new park assist steering sender holder is installed, the holder
must first be painted in the required area in the colour of the
bumper cover ⇒ page 230 .
Paint area for:
♦ holder of front left sender for park assist steering on left side
of vehicle -G568-
♦ holder of front right sender for park assist steering on right side
of vehicle -G569-
♦ holder of rear left park assist steering sender -G716-
♦ holder of rear right park assist steering sender -G717-
Paint area on holder:
1 - Paint area
2 - Adhesive tape s=1
3 - Sender
4 - Bumper cover
5 - Decoupling ring
Paint:
– Degrease holder in area to be painted -1- with isopropanol.
– Paint holder in area to be painted -1- in colour of bumper cover.

– Once the paint has dried, bond holder in bumper cover.

Touran 2003 ➤
12 Reverse camera (Rear Assist)
Note
♦ When handling complaints, it is essential to understand the

function and operation of the reversing camera system.
♦ Additional information ⇒ Owner's Manual
♦ In the event of repair work or fault finding, use ⇒ vehicle di‐
agnosis, testing and information system -VAS 5051A- or ve‐
hicle diagnosis and service information system -VAS 5052- in
„Guided fault finding“ mode ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations.
♦ When the battery is reconnected, check operation of electrical
equipment (radio, clock, convenience electronics and so on)
according to the workshop manual and/or the operating man‐
ual.
The reversing camera system supports the driver during revers‐

ing by providing the driver with an image of the traffic situation
behind the vehicle via the radio or radio navigation system dis‐
play.
When the ignition is switched on and when the engine is running,
the system is activated by engaging the reverse gear, even if the
radio or radio navigation system is switched off.
Note
The reversing camera image can only be seen on the radio nav‐
igation system after a complete system start-up. Like a computer,
the radio navigation system needs, after it is switched on, a few
seconds for the system start-up.
The reversing camera system consists of the following compo‐

nents:
♦ The reversing camera -R189-
♦ The control unit with display for radio and navigation -J503-
The reversing camera system is equipped with self-diagnosis.
For fault finding, use vehicle diagnosis, testing and information
system -VAS 5051A- or vehicle diagnostic and service informa‐
tion system -VAS 5052- in „Guided fault finding“ mode.
12.2 Assembly overview - reversing camera system
12. Reverse camera (Rear Assist) 231

Touran 2003 ➤
1 - Control unit with display unit

for radio and navigation -J503-
❑ Location: at front of cen‐
tre console
⇒ Communication;
Rep. gr. 91
2 - Reversing camera -R189-
❑ Fitting location: in han‐
dle button of rear lid
⇒ page 232 .
❑ Securing nut specified
torque: 6 Nm
12.3 Removing and installing reversing cam‐

era
The reversing camera is installed in the handle button of the rear
lid. To remove reversing camera, first remove handle button from
rear lid. Reversing camera can then be removed from handle but‐
ton.
12.3.1 Removing handle button with reversing

camera from rear lid
Remove handle button ⇒ General body repairs, exterior; Rep.
gr. 55 ; Rear lid; Removing and installing handle with button for
release .

Touran 2003 ➤
96 – Lights, bulbs, switches - interior

1 Interior lights and switches
1.1 Removing and installing interior moni‐

toring deactivation switch
The functions of „interior monitoring deactivation switch“ and „de‐
activation button for vehicle inclination sender“ have been incor‐
porated in one button.
♦ Removal wedge -VAS 3409-
Caution
When removing and installing components that are in view

(switches, covers, trim and so on), mask off areas in which
tools ( removal wedge -VAS 3409- , screwdriver) are used to
lever out those components using commercially available tape.
Note
♦ The anti-theft alarm system must be deactivated before inte‐

rior monitoring switch is removed ⇒ page 281 .
♦ The interior monitoring deactivation switch is located in the B-
pillar trim on the driver side.
Removing:
key.
1. Interior lights and switches 233

Touran 2003 ➤
– Carefully prise button -1- out with removal wedge -VAS 3409-
or a suitable screwdriver.
– Release connector -arrow- and disconnect. Remove button.

Installing:
234 Rep. gr.96 - Lights, bulbs, switches - interior

Touran 2003 ➤
2 Lights and switches in engine com‐

partment
Note
The Touran has no lights in the engine compartment.
2.1 Removing and installing bonnet contact

switch -F266-
Note
♦ The bonnet contact switch -F266- is integrated in the bonnet

lock and cannot be replaced as a single item.
♦ If the bonnet contact switch -F266- is found to be defective,
the entire bonnet lock must always be replaced.
– Remove lid lock cylinder ⇒ General body repairs, exterior;

Rep. gr. 55 ; Bonnet; Removing and installing lock cylinder;
Removing .
2. Lights and switches in engine compartment 235

Touran 2003 ➤
3 Lights and switches in dash panel
3.1 Removing and installing light switch -

E1-
The following components are integrated into the light switch -
E1- :
♦ Fog light switch -E7-
♦ Rear fog light switch -E18-
♦ Bulb for illumination of light switch -L9-
Removing:
– Switch off ignition and all electrical consumers.
– Turn rotary knob part of light switch to „0“.
– Press rotary position indicator of light switch firmly inwards
-1- and turn slightly to right -2-.
– Hold rotary grip in this position and pull light switch out of dash
panel using rotary grip -3-.
– Disconnect connector -arrow-.

Installing:
– Reconnect connector on light switch.
– Hold light switch firmly in place, push in rotary grip of light

switch -1- and turn it slightly to the right -2-
– Hold rotary grip in this position and insert light switch in dash
panel -3-.
– Turn rotary grip to „0“ position, release and engage switch.

Touran 2003 ➤
3.2 Removing and installing glove compart‐

ment light -W6- and glove compartment
light switch -E26-
Caution

To prevent damage to the glove compartment light and the
glove compartment light switch, removal and installation
should be carried out as described below.
Note
The glove compartment lights -W6- and the glove compartment

light switch -E26- are permanently connected. In the event of re‐
pair, the complete unit must be renewed.
Removing:
– Carefully insert removal wedge -VAS 3409- or a suitable
screwdriver into lower area behind lens and remove light and
switch.
3. Lights and switches in dash panel 237

Touran 2003 ➤

Renewing bulb:
– Press contact plate -1- of light in direction of arrow and remove

festoon bulb -2- from bulb holder.
– Renew festoon bulb (12 V, 3 W).
Installing:
following:
– Check function of glove compartment switch. When the lid is
closed, the glove compartment light should not be on.
3.3 Removing and installing headlight range

control regulator -E102- and switch and
instrument illumination regulator -E20-
Note
The headlight range control regulator -E102- and the switch and
instrument illumination regulator -E20- form one component.
Removing:
– Remove light switch ⇒ page 236
– Unclip cover on left of dash panel.

Touran 2003 ➤
– Remove bolt -arrow-.
– Unclip trim.
– Release locking lugs -arrows- and remove headlight range

control regulator -E102- and switch and instrument illumina‐
tion regulator -E20- .
Installing:

Touran 2003 ➤
3.4 Removing and installing key operated

switch to deactivate front passenger
front airbag -E224-
WARNING
Observe safety precautions when working on airbag ⇒ Gen‐

eral body repairs, interior; Rep. gr. 69 ; Airbag; Safety pre‐
cautions when working on airbag .
Removing:
– Remove glove compartment ⇒ General body repairs, interior;
Rep. gr. 68 ; Storage compartments covers and trim; Remov‐
ing and installing glove compartment .
– Release locking lugs -arrows- and take out key-operated

switch.
Installing:
3.5 Removing and installing airbag disabled

warning lamp, front passenger side -
K145-
Removing:
– Remove trim from centre of dash panel ⇒ General body re‐
pairs, interior; Rep. gr. 68 ; Compartments, covers and trim;
Removing and installing trim in centre of dash panel; Remov‐
ing .

Touran 2003 ➤
– Disconnect connector from hazard warning light switch -E3-

-arrow-.
– Disconnect connector from passenger airbag warning lamp -
K145- .
– Release locking lugs -arrows- and remove key-operated

switch for deactivating front passenger side airbag -K145- .
Installing:
3.6 Removing and installing hazard warning

light switch -E3-
Note
The indicator lamp for hazard warning light -E3- is integrated in

the hazard warning light switch -K6- .
Removing:
– Remove trim from centre of dash panel ⇒ General body re‐
pairs, interior; Rep. gr. 68 ; Compartments, covers and trim;
Removing and installing trim in centre of dash panel; Remov‐
ing .
– Disconnect connector from passenger airbag warning lamp -
K145- .
– Disconnect connector from hazard warning light switch -E3-
-arrow-.

Touran 2003 ➤
– Release locking lugs -arrows- and take out hazard warning

light switch -E3- .
Installing:

Touran 2003 ➤
4 Lights and switches in front doors
4.1 Front left entry light -W31- and front right

entry light -W32-
4.1.1 Removing and installing rear left entry

light -W31- and rear right entry light -
W32-
Entry lights:
♦ Front left entry light -W31-
♦ Front right entry light -W32-
♦ Rear left entry light -W33-
♦ Rear right entry light -W34-
Caution

Note
Removal and installation of all entry lights are performed in the

same manner and are described only for one light.
Removing:
4. Lights and switches in front doors 243

Touran 2003 ➤
– Lever light out of door trim using removal wedge -VAS 3409-
or screwdriver.

Renewing bulb:
– Release locking lug -arrows- and remove lens from bulb car‐
rier.
– Press contact plate -1- of light in -direction of arrow- and re‐

move festoon bulb -2- from bulb holder.
Installing:
4.1.2 Checking front left entry light -W31-

The front left entry light -W31- can be checked by the final control
diagnosis for the driver side door control unit -J386- .
4.1.3 Checking front right entry light -W32-

The front right entry light -W32- can be checked using final control
diagnosis for the front passenger side door control unit -J387- .

Touran 2003 ➤
4.2 Removing and installing window regula‐

tor switch in front passenger door -
E107-
Note
The window regulator switch in front passenger door -E107- fea‐

tures an integrated button illumination bulb -L76- which cannot be
renewed individually.
Removing:
– Remove door trim ⇒ General body repairs, interior; Rep. gr.
70 ; Door trim; Removing and installing front door trim on front
passenger side ,
– Release locking lugs -arrow- and remove switch with mounting
frame out of door trim.
– Release locking lugs -arrows- and remove switch from mount‐

ing frame.
Installing:

Touran 2003 ➤
4.3 Removing and installing switch module

for mirror adjustment on driver side
The following components (depending on equipment) are inte‐
grated into the switch module for the mirror adjustment on the
driver side:
♦ Mirror adjustment switch -E43-
♦ Mirror adjustment changeover switch -E48-
♦ Exterior mirror heater button -E231-
♦ Fold-in mirror switch -E263-
♦ Mirror adjustment switch illumination bulb -L78-
Note
The switch module for driver side mirror adjustment is perma‐

nently connected to the mounting frame. In the event of repair,
the complete component must be renewed.
Removing:
70 ; Door trim; Removing and installing front door trim on driver
side ,
– Disconnect connectors -arrows-.
– Unscrew bolts -arrows- and remove cover.

– Take trim off door opener with switches out of door trim.
– Unclip switch mounting frame from trim.

Touran 2003 ➤
– Release locking lugs -arrows- and remove driver side interior

locking button -E308- from mounting frame.
Note
The switch module for driver side mirror adjustment is perma‐

nently connected to the mounting frame. In the event of repair,
the complete component must be renewed.
Installing:
4.4 Removing and installing driver side in‐

terior locking button for central locking
system -E308-
Note
The driver side interior locking button for central locking system -
E308- features an integrated button illumination bulb -L76- which
cannot be replaced individually.
Removing:
side ,
– Disconnect connectors -arrows-.
– Unscrew bolts -arrows- and remove cover.

– Take trim off door opener with switches out of door trim.
– Unclip switch mounting frame from trim.

Touran 2003 ➤
– Release locking lugs -arrows- and remove driver side interior

locking button -E308- from mounting frame.
Installing:
4.5 Components - front door locks

The following components (depending on level of equipment) are
integrated into the driver side door lock:
♦ Driver side contact switch -F2-
♦ Driver side central locking lock unit -F220-
♦ Motor for driver side central locking -V56-
♦ Driver door central locking deadlock function motor -V161-
integrated into the passenger side door lock:
♦ Front passenger side door contact switch -F3-
♦ Front passenger side central locking lock unit -F221-
♦ Front passenger door central locking motor -V57-
♦ Front passenger door central locking deadlock function motor
-V162-
Note
The above mentioned components cannot be renewed individu‐

ally.
In the event of component defects - front door locks:

– Renew respective door lock ⇒ General body repairs, exterior;
Rep. gr. 57 ; Front door, Removing and installing door lock .
4.6 Removing and installing switch module

for driver side window regulator

Touran 2003 ➤
The following components (depending on equipment) are inte‐

grated into the switch module for the driver side window regulator:
♦ Front left window regulator switch -E40-
♦ Rear left window regulator switch, in driver door -E53-
♦ Rear right window regulator switch, in driver door -E55-
♦ Front right window regulator switch, in driver door -E81-
♦ Childproof lock button -E318-
Caution

Note

ally.
Removing:
– Carefully lever mounting frame out of door trim using removal
wedge -VAS 3409- or suitable screwdriver.

Touran 2003 ➤
– Release locking lugs -arrows- and remove driver side switch

module from mounting frame.
Installing:
4.7 Removing and installing fuel tank flap

release button -E319-
Note
The fuel tank flap release button -E319- features integrated button
illumination bulb -L76- , which must not be replaced individually.
Removing:
side ,
– Release locking lugs -arrow- and remove fuel tank flap release
button -E319- along with mounting frame from door trim.

Touran 2003 ➤
– Release locking lugs -arrows- and remove fuel tank flap re‐
lease button -E319- from mounting frame.
Installing:

Touran 2003 ➤
5 Lights and switches in rear doors
5.1 Rear left entry light -W33- and rear right

entry light -W34-
5.1.1 Removing and installing rear left entry

light -W33- and rear right entry light -
W34-
Removal and installation of all entry lights are performed in the
same way and are described only for one light ⇒ page 243 .
5.1.2 Checking rear left entry light -W33- and

rear right entry light -W34-
The rear left entry light -W33- and rear right entry light -W34- can
be checked using final control diagnosis for the central control unit
for convenience system -J393- .
5.2 Components - rear door locks

integrated into the rear left door lock:
♦ Rear left door contact switch -F10-
♦ Rear left central locking lock unit -F222-
♦ Motor for rear left door central locking -V214-
♦ Rear left door central locking deadlock function motor -V163-
integrated into the rear right door lock:
♦ Rear right door contact switch -F11-
♦ Rear right central locking lock unit -F223-
♦ Motor for rear right door central locking -V215-
♦ Rear right door central locking deadlock function motor -V164-
Note

ally.
In the event of component defects - rear door locks:

– Renew respective door lock ⇒ General body repairs, exterior;
Rep. gr. 58 ; Rear door, Removing and installing door lock .
5.3 Installing and removing rear left window

regulator switch -E52- and rear right
window regulator switch -E54-
Removing:
70 ; Removing and installing rear door trim .

Touran 2003 ➤
– Release locking lugs -arrow- and remove switch with mounting

frame out of door trim.

ing frame.
Installing:
5. Lights and switches in rear doors 253

Touran 2003 ➤
6 Lights and switches in luggage com‐

partment
6.1 Removing and installing luggage com‐

partment light -W3-
Caution

Removing:
– Lever light out of luggage compartment trim using removal
wedge -VAS 3409- or suitable screwdriver.
Renewing bulb:

Installing:

Touran 2003 ➤
6.2 Removing and installing rear lid locking

unit -F256-
The rear lid locking unit -F256- is integrated into the rear lid lock
and cannot be renewed individually.
If the rear lid locking unit -F256- is found to be defective, the entire
rear lid lock must always be renewed.
– Replace rear lid lock ⇒ General body repairs, exterior; Rep.
gr. 55 ; Rear lid; Removing and installing lid lock; Removing
6. Lights and switches in luggage compartment 255

Touran 2003 ➤
7 Lights and switches in roof trim
7.1 Front interior light -W1-

The following components are integrated into the front interior
light -W1- :
♦ Driver side reading light -W19-
♦ Front passenger reading light -W13-
♦ Anti-theft alarm system sensor -G578-
♦ Depending on equipment: sunroof button -E325-
7.1.1 Removing and installing front interior

light -W1-
Note
The following illustrations show removal and installation of the

front interior light -W1- on a vehicle with sliding/tilting sunroof.
Removal and installation of front interior light -W1- on vehicles
without sliding/tilting sunroof are carried out in the same way.

Caution

Removing:
key.

Touran 2003 ➤
– Lever off trim -1- at fasteners -arrows- using removal wedge -

VAS 3409- or suitable screwdriver.
– Remove both bolts -arrows- and swivel interior light out of roof
console.
– Dependant on equipment, release connectors -arrows-, dis‐

connect and remove interior light.
Installing:
7.1.2 Renewing driver side reading light -

W13- and front passenger reading light
-W19-
Removing:
– Remove front interior light ⇒ page 256 .
– Turn bulb holder -arrows- of defective reading lamp by 90° to
the left.
– Remove bulb holder together with bulb from reading light.
7. Lights and switches in roof trim 257

Touran 2003 ➤
– Carefully pull glass-base bulb out of bulb holder.

– Glass-base bulb: 12 V, 5 W
Installing:
7.1.3 Removing and installing driver side

reading light button -E457- or front pas‐
senger side reading light button -E458-
Note
♦ The driver side reading light button -E457- and the front pas‐
senger side reading light button -E458- cannot be renewed
individually.
♦ The complete component must be renewed in the event of re‐
pair.
7.1.4 Removing and installing sunroof button

-E325-
Removing:
– Release locking lugs -arrows- and remove button from mount‐
ing frame.
Installing:
following:
– When inserting into trim, align sunroof button -E325- with lug
-1-.

Touran 2003 ➤
7.2 Rear interior light -W43-
7.2.1 Removing and installing rear interior

light -W43-
Note
Models with panorama sliding sunroof, the rear interior light -W43-
is divided and is installed in left and right headliner. Removal and
installation of left or right rear interior light -W43- is performed in
the same manner.
Removing:
key.
– Release locking lugs -arrows- with removal wedge or appro‐
priate screwdriver and remove rear interior light -W43- from
headliner, taking connected wiring length into account.
– Release and detach connector -arrow- and remove rear inte‐

rior light -W43- .
Installing:

Touran 2003 ➤
7.2.2 Renewing bulb in rear interior light -

W43-
Note
The procedure for renewal of the bulbs in rear interior light is the
same for both bulbs and is therefore described for one side only.
Removing:
– Remove rear interior light -W43- ⇒ page 259 .
– Release the four locking lugs -arrows- of light lens -1- and re‐
move lens from rear interior light by lifting it straight upwards.
– Remove bulb -1- from holder.

Rear interior light bulb: festoon bulb 12V, C5W
Installing:
7.3 Removing and installing front passenger

side illuminated vanity mirror -W14- or
driver side illuminated vanity mirror -
W20-
7.3.1 Removing and installing front passenger

side illuminated vanity mirror -W14- and
driver side illuminated vanity mirror -
W20-

Touran 2003 ➤
Note
♦ When removing and installing components that are in view

lever out those components using commercially available
tape.
♦ The procedure for removal and installation of both lights is the
same and is therefore described for just one light.
Removing:
key.
– Carefully lever light out of headliner using removal wedge -
VAS 3409- or suitable screwdriver.
– Release and detach connector -arrow- and remove light.

Installing:
7.3.2 Renewing illuminated vanity mirror bulb


Touran 2003 ➤
Note

tape.
♦ The procedure for removal and installation of both lights is the
same and is therefore described for just one light.
Removing:
key.
– Remove illuminated vanity mirror bulb ⇒ page 260 .
– Festoon bulb: 12V, C5W
Installing:

Touran 2003 ➤
8 Components on interior mirror
Note

tions
The following components are installed in the interior mirror de‐
pending on the equipment level:
♦ Rain and light sensor -G397- ⇒ page 100
♦ Main beam assist control unit -J844- with light sensor -G399-
(MBA camera) ⇒ page 263
♦ Front camera for driver assist systems -R242- (lidar camera)
⇒ page 266
Driver assist systems are:
♦ Main beam assist (MBA)
♦ Traffic sign recognition (TSR), not yet available
♦ Tiredness recognition (TR), not yet available
♦ „Lane assist (LA)“, not yet available
Automatic activation and deactivation of the main beam light, de‐
pending on the traffic situation, facilitates the main beam assist
function (MBA). The system detects vehicles travelling ahead or
travelling in the opposite direction if their exterior lights and the
street lights are on.
8.1 Main beam assist control unit -J844-

The main beam assist control unit -J844- with light sensor -G399-
can be found in the interior mirror base.
In the event of damage, the interior light must be renewed
⇒ page 264 .
The main beam assist control unit -J844- is equipped with self-
diagnosis, which is designed to alleviate fault finding.
8.1.1 Assembly overview - main beam assist control unit -J844-
8. Components on interior mirror 263

Touran 2003 ➤
1 - Adhesive plate with rain and

light sensor -G397-
rain and light sensor -
G397- ⇒ page 100
2 - Mirror base cover cap, right
3 - Automatic anti-dazzle inte‐
rior mirror -Y7-
4 - Main beam assist control
unit -J844- with light sensor -
G399-
❑ Location: in interior mir‐
ror base
⇒ page 264
5 - Mirror base cover cap, left
6 - Button for anti-dazzle inte‐
rior mirror -E386-
8.1.2 Removing and installing main beam as‐

sist control unit -J844-
Before removing „main beam assist control unit“

⇒ Item 4 (page 264) , it is essential that work procedure „Renew‐
ing control unit“ is performed to interrogate the codes stored in
the device ⇒ page 265 .

Touran 2003 ➤
Removing:
– Use wedge -VAS 3409- -arrow A- to release caps on both
sides.
– Remove caps -arrows B- from mirror base on both sides.

– Carefully slide interior mirror -2- out of retaining plate in direc‐
tion of -arrow-.
Installing:
Note
If a new main beam assist control unit -J844- is installed, it must

be coded ⇒ page 265 .
8.1.3 Renewing main beam assist control unit

-J844-
-VAS 5051A- ⇒ page 288
♦ Body
♦ Main beam assist control unit
♦ Main beam assist functions
♦ Replacing control unit
8.1.4 Coding main beam assist control unit -

J844-
-VAS 5051A- ⇒ page 288

Touran 2003 ➤
♦ Body
♦ Coding control unit
8.1.5 Adapting main beam assist control unit

-J844-
-VAS 5051A- ⇒ page 288
♦ Body
♦ Adaption
8.2 Front camera for driver assist systems -

R242-
8.2.1 Assembly overview - front camera for driver assist systems -R242-

Touran 2003 ➤
1 - Front cover (mirror base)

2 - Automatic anti-dazzle inte‐
rior mirror -Y7-
3 - Central connector
4 - Bottom cover
5 - Front camera for driver as‐
sist systems -R242-
❑ Location: in top cover of
interior mirror
⇒ page 267
❑ Calibrating ⇒ page 269
6 - Top cover
❑ Bonded to inside of
windscreen
❑ With integrated window
heater for front sensor
array -Z113-
❑ For mounting front cam‐
era for driver assist sys‐
tems -R242-
8.2.2 Removing and installing front camera

for driver assist systems -R242-
Before removing „front camera for driver assist systems“
⇒ Item 5 (page 267) , it is essential that work procedure „Renew‐
ing control unit“ is performed to interrogate the codes stored in
the device ⇒ page 268 .
Removing:
– Carefully slide interior mirror -1- out of retaining plate in direc‐
tion of -arrow-.
Note
When performing the following work up to separation of the con‐

nector bear in mind that the wiring has different lengths.

Touran 2003 ➤
– Press locking tabs -1- and -2- outwards and pull off cap -3-
from mirror.
– Separate connector -1- and place interior mirror aside.
– Release cap -1- from side locking mechanisms -arrows- and

remove.
– Press locking mechanisms -arrows A- and remove front cam‐

era for driver assist systems -2- upwards out of cover in
direction of -arrow B-.
Installing:
Note
If a new front camera for driver assist systems -R242- is installed,

it must be coded ⇒ page 269
8.2.3 Replacing front camera for driver assist

systems -R242-
-VAS 5051A- ⇒ page 288

Touran 2003 ➤

♦ Body
♦ Front camera for driver assist systems
♦ Functions of front camera for driver assist systems
8.2.4 Coding front camera for driver assist

systems -R242-
-VAS 5051A- ⇒ page 288
♦ Body
♦ Front camera for driver assist systems
♦ Functions of front camera for driver assist systems
8.2.5 Calibrating front camera for driver assist

systems -R242-
Calibration of the front camera for driver assist systems could be‐
come necessary for the following reasons:
♦ „No or incorrect basic setting / adaption“ is stored in the fault
memory.
♦ The front camera for driver assist systems -R242- has been
replaced.
♦ Windscreen has been renewed or removed.
♦ Rear axle toe has been adjusted.
♦ Modifications, which may affect vehicle height, have been per‐
formed on vehicle running gear.
♦ The vehicle level senders have been reprogrammed on vehi‐
cles with damper control.
Calibrating front camera for driver assist systems -R242- : ⇒
Running gear, axles, steering; Rep. gr. 44

Touran 2003 ➤
9 Lights and switches in centre console
9.1 Removing and installing buttons in cen‐

tre console storage compartment
Depending on equipment, the following switches are installed in
the centre console storage compartment:
♦ TCS and ESP button -E256-
♦ Park assist steering button -E581-
♦ Shock absorber damping adjustment button -E387-
♦ Winter driving program button -E598-
♦ Petrol or gas fuel selection switch -E395- (only models with a
natural gas engine, EcoFuel)
♦ Start/stop operation switch -E693-
The removal and installation procedure is the same for all
switches and is therefore described here for just one switch.
Removing:
– Remove rubber mat from compartment.

– Remove compartment from centre console.

Touran 2003 ➤

ing frame.
Installing:
9. Lights and switches in centre console 271

Touran 2003 ➤
10 12 V socket

Touran 2003 ➤
11 Cigarette lighter -U1-

11. Cigarette lighter U1 273

Touran 2003 ➤
12 Horn
12.1 Removing and installing treble horn -H2-

and bass horn -H7-
Note
♦ The treble horn -H2- and the bass horn -H7- are actuated in
parallel by the onboard supply control unit -J519- .
♦ The treble horn -H2- and the bass horn -H7- are fitted on the
left/right of the radiator respectively.
Removing and installing treble horn -H2- ⇒ page 274 .

Removing and installing bass horn -H7- without parking heater/
booster heater ⇒ page 275 .
Removing and installing bass horn -H7- with parking heater/boos‐
ter heater ⇒ page 276 .
12.1.1 Removing and installing treble horn -H2-
Note
Removing:

Touran 2003 ➤
– Undo bolt -arrow- and remove horn.

Installing:
following:
Note
♦ The installation position of the bass horn could vary somewhat

depending on the equipment level.
♦ Always position signal horns in such a way that they do not
come into contact with surrounding components.
12.1.2 Removing and installing bass horn -H7-

without parking heater/booster heater
Note
Removing:
– Undo bolt -arrow- and remove horn.

Installing:
following:
Note

12. Horn 275

Touran 2003 ➤
12.1.3 Removing and installing bass horn -H7-

with parking heater/booster heater
Note
Removing:
– Remove front right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Front wheel
housing liner .
– Loosen nut -3- and turn clip -4-. Unscrew bolt -2- and remove
bracket with signal horn -1- downwards out of vehicle, bearing
wiring length in mind.
– Disconnect connector.
Installing:
following:
Note

12.2 Checking treble horn -H2- and bass

horn -H7-
The horns ( treble horn -H2- and bass horn -H7- ) can be checked
in final control diagnosis by the onboard supply control unit -
J519- .
12.3 Horn plate -H-

The horn is operated via the spring mounted cover in the centre
of the steering wheel. Depending on equipment, the horn plate is
either a component part of the steering wheel or integrated into
the airbag unit on the driver side and cannot be replaced as an
individual item. If horn plate is defective, renew driver side airbag
unit or steering wheel.
Removing steering wheel ⇒ General body repairs, interior; Rep.
gr. 69 ; Airbag; Removing and installing driver side airbag unit .
Removing driver side airbag unit ⇒ General body repairs, interior;
Rep. gr. 69 ; Airbag; Removing and installing steering wheel .
12.3.1 Checking horn plate -H-

-VAS 5051A- ⇒ page 288

Touran 2003 ➤

♦ Body
♦ Steering wheel electronics
♦ Horn plate -H-
12. Horn 277

Touran 2003 ➤
13 Immobilizer
Note

tem
The Touran is equipped with a fourth-generation immobilizer with
online link and download. The main component of the fourth gen‐
eration immobilizer is a central database, in which all of the theft-
relevant data from the participating control units is stored.
Adapting the control units associated with the immobilizer is not
possible without an online link to this database.
FAZIT system test ⇒ page 280
♦ A PIN request for the immobilizer components via fax or tem‐
porary access authorisation to the components is not availa‐
ble.
♦ All components associated with the immobilizer must be adap‐
ted online.
♦ All – including re-ordered – vehicle keys are pre-coded to a
specific vehicle in the factory and can only be adapted to this
vehicle.
♦ The relevant chassis number must be specified when re-or‐
dering vehicle keys.
♦ It is no longer possible to adapt components of other brands
for use in Volkswagen vehicles.
Immobilizer components:
♦ Immobilizer control unit -J362- ⇒ page 279
♦ Engine control unit -J623- ⇒ Rep. gr. 23 ; Engine control unit
♦ Ignition key ⇒ page 279
New identity on renewing all components of immobilizer system
⇒ page 280
Immobilizer control unit -J362- functions:
♦ Communication between all components associated with the
immobilizer.
♦ Encryption of data between associated control units.
The immobilizer is equipped with self-diagnosis, which makes
fault finding easier.
To localise faults, refer to chapter entitled „Vehicle diagnosis,
testing and information system“ and use „Guided fault finding“
function.

Touran 2003 ➤
13.1 Immobilizer control unit -J362-
13.1.1 Removing and installing immobilizer

control unit -J362-
The immobilizer control unit -J362- is integrated in the dash panel
insert. In the event of control unit failure, the complete dash panel
insert must be renewed ⇒ page 85 .
13.1.2 Adapting immobilizer control unit -J362-

-VAS 5051A- ⇒ page 288
♦ Body
♦ Immobilizer IV download
♦ Immobilizer functions
♦ Adaption when changing immobilizer
13.2 Ignition key
13.2.1 Loss of the ignition key

All – including re-ordered – vehicle keys are pre-coded to a spe‐
cific vehicle in the factory and can only be adapted to this vehicle.
The relevant chassis number must be specified when re-ordering
vehicle keys. The new keys must subsequently be adapted to the
immobilizer control unit -J362- .
Note
After exchanging lock set or control units „New identity on renew‐

ing all components“ function must be called up ⇒ page 280 .
Adapting ignition key ⇒ page 279
13.2.2 Adapting ignition keys
Note
If new or additional ignition keys are required they must be adap‐

ted to the immobilizer control unit.
Adapting ignition key to immobilizer control unit -J362- :

-VAS 5051A- ⇒ page 288
13. Immobilizer 279

Touran 2003 ➤

♦ Body
♦ Adapting ignition keys
13.3 New identity on renewing all compo‐

nents
This program performs all the processes required for a recon‐
struction/reinitialisation of all immobilizer components.
-VAS 5051A- ⇒ page 288
♦ Body
♦ New identity
13.4 Fazit system test

The following processes are performed with this test program:
♦ System test for online connection
♦ Check of user authorization
♦ Test for correct line connection to Volkswagen database
Prerequisite: tester must have an online connection (network
connection)
-VAS 5051A- ⇒ page 288
♦ Body
♦ FAZIT system test

Touran 2003 ➤
14 Anti-theft alarm (ATA)
Note
tem
The functions of the anti-theft alarm are integrated into the on‐
board supply control unit -J519- .
After renewal of the onboard supply control unit -J519- , the anti-
theft alarm must be adapted ⇒ page 296 .
The anti-theft alarm has a self-diagnosis function, which makes
fault finding easier.
system -VAS 5051A- in „Guided fault finding“ mode
⇒ page 288 .
14.1 Activating and deactivating anti-theft

alarm
Activating anti-theft alarm:
The anti-theft alarm is switched on automatically when the vehicle
is locked. The anti-theft alarm is then immediately primed.
Note
To stop the anti-theft alarm system triggering an alarm unneces‐

sarily, close all windows and doors before locking vehicle.
Deactivating anti-theft alarm:

♦ The anti-theft alarm is deactivated on unlocking the vehicle
with the remote control unlocking button or
♦ when the ignition is switched on.
Unlock the vehicle mechanically (emergency open)
– Open driver door.
The anti-theft alarm system remains active, although no alarm is
triggered.
– Switch ignition on within 15 seconds.
Note
If you do not switch on the ignition, the alarm will trigger after 15
seconds.
When the ignition is switched on, the electronic immobilizer de‐

tects a valid vehicle key and deactivates the anti-theft alarm.
14. Anti-theft alarm (ATA) 281

Touran 2003 ➤
14.2 Interior monitoring deactivation switch -

E267-
Interior monitoring deactivation switch -E267- includes deactiva‐
tion button for vehicle inclination sender -E360- . They comprise
one component and are installed in the B-pillar on the driver side.
14.2.1 Removing and installing interior moni‐

toring deactivation switch -E267-
– Removing and installing interior monitoring deactivation
switch -E267- ⇒ page 233
14.3 Anti-theft alarm system sensor -G578-
Note
♦ The anti-theft alarm sensor -G578- includes the vehicle incli‐

nation sender -G384- and the interior monitoring sensor -
G273- (three sensors).
♦ The anti-theft alarm sensor -G578- cannot be dismantled and
must be replaced as one component.
14.3.1 Removing and installing anti-theft alarm

sensor -G578-
♦ Removal wedge -3409-
Note

tape.
♦ The following illustrations show removal and installation of the
anti-theft alarm sensor -G578- on a vehicle with sliding/tilting
sunroof. Removal and installation of anti-theft alarm sensor -
G578- on vehicles without sliding/tilting sunroof are carried out
in the same way.
Removing:
key.

Touran 2003 ➤
– Release the three locking lugs -arrows- and remove anti-theft

alarm sensor -G578- -1- from interior light, taking connected
wiring length into consideration.
– Unclip wiring from retainers -1-.

– Release fasteners -arrows- and pull both interior monitor sen‐
sors -2- out of interior light.
– Remove anti-theft alarm sensor -G578- from vehicle.
Installing:
following:
Note
♦ To prevent malfunction of the anti-theft alarm sensor, both

sensors and the interior monitor receiver must be installed in
their correct location in the interior light.
♦ The sensors which are wired to the control unit as a pair, are
the senders and these must be engaged into the outer mount‐
ings of the interior light.
♦ The single sensor is the receiver, and it must be installed into
the middle mounting of the interior light.
14.4 Central locking and anti-theft alarm sys‐

tem aerial -R47-
Note

tions
The central locking and anti-theft alarm system aerial -R47- is
routed from the convenience system central control unit -J393- to
the A-pillar (driver side) in the main wiring harness.
Note
♦ The aerial cannot be repaired as this would adversely affect

the reception quality.
♦ In the event of damage, it is necessary to replace the central
locking and anti-theft alarm system aerial -R47- .

Touran 2003 ➤
14.5 Alarm horn -H12-

The alarm horn -H12- is located on the left below the plenum
chamber cover.
Note
On right-hand drive vehicles, the alarm horn -H12- is in the mirror-

image position on the right-hand side.
14.5.1 Removing and installing alarm horn -

H12-
Note
If the alarm horn -H12- is removed, the anti-theft alarm system

must be deactivated ⇒ page 281 .
Removing:
– Remove wiper frame with linkage and wiper motor on driver
side ⇒ page 92 .
– Release connector -2- and detach it from alarm horn -H12- .
– Remove nuts -1-.
Installing:
– Tighten all nuts and bolts to specified torque ⇒ page 287 .
14.5.2 Checking alarm horn -H12-

The alarm horn -H12- can be checked using final control diagno‐
sis for convenience system central control unit -J393- .

Touran 2003 ➤
14.6 Adaptions of anti-theft alarm
14.6.1 Adapting sensitivity of interior monitor‐

ing
♦ Body
♦ Functions
♦ Adapting sensitivity of interior monitoring
14.6.2 Adapting sensitivity of inclination sensor

– Connect vehicle diagnosis tester ⇒ page 288
♦ Body
♦ Functions
♦ Adapting sensitivity of inclination sensor
14.6.3 Adapting alarm delay on opening driver

door
♦ Body
♦ Functions
♦ Adapting alarm delay on opening driver door
14.6.4 Adapting country setting for intelligent

alarm horn

Touran 2003 ➤

♦ Body
♦ Functions
♦ Adapting country setting for intelligent alarm horn

Touran 2003 ➤
15 Specified torques: lights, bulbs and

switches - interior
15.1 Torque settings: alarm horn -H12-

Threaded connections Specified torques
Securing nuts 9 Nm
15.2 Torque settings: alarm horns

Treble tone horn -H2-
Securing nuts of bracket to longitudinal M6 20 Nm
member
Bass tone horn -H7-

Securing nuts of bracket to longitudinal M6 20 Nm
member
15. Specified torques: lights, bulbs and switches - interior 287

Touran 2003 ➤
97 – Wiring
1 Vehicle diagnosis, testing and infor‐
mation systems
288 Rep. gr.97 - Wiring

Touran 2003 ➤
2 Removing and installing fuse holder
2.1 Removing and installing fuse holder on

left beneath dash panel
Caution

served ⇒ page 4 .
Removing:
– Undo bolts -arrows- and pull fuse holder -1- downwards off
retainer.
Installing:
2. Removing and installing fuse holder 289

Touran 2003 ➤
3 Removing and installing relay carrier
3.1 Removing and installing relay carrier on

left of dash panel
Caution

served ⇒ page 4 .
Removing:
– Release fasteners -arrows A- and pull relay carrier -1- down‐
wards slightly out of retainer.
– Tilt out relay carrier -1- under lug -arrow B-.
– Release connectors on rear of relay carrier -1-.
– Remove relay carrier -1- from vehicle.
Installing:
3.2 Removing and installing relay carrier on

onboard supply control unit
The relay carrier on the onboard supply control unit is located
under the dash panel in the driver footwell.
The relay carrier on the onboard supply control unit is clipped un‐
der the onboard supply control unit and can be removed as an
individual unit. Removing and installing relay carrier on onboard
supply control unit: ⇒ page 290 .
3.2.1 Removing and installing relay carrier on

onboard supply control unit
Removing:
key.
– Remove trim in driver footwell ⇒ General body repairs, inte‐
rior; Rep. gr. 68 ; Compartments, covers and trim; Removing
and installing left trim on driver side .
– Remove fuse holder ⇒ page 289 .

Touran 2003 ➤
– Release both locking lugs -arrow- and pull relay carrier -2-
counter to direction of travel, to rear, out of onboard supply
control unit -1-.
– Taking connected wiring length into consideration swing relay
carrier downwards and unclip relay.
Installing:
Install in reverse order of removal.
3. Removing and installing relay carrier 291

Touran 2003 ➤
4 Removing and installing electronics

boxes (E-boxes)
4.1 Removing and installing E-box on left

side of engine compartment
Caution

served.
Removing:
– Push safety clip -1- in -direction of arrow- and remove cover
from E-box -2- upwards.
All vehicles:
Note
Mark position of wiring connections in respect of connections on

E-box.
Caution
♦ Electrical components that are protected by the multiple

fuse may fail, e.g. the electromechanical power steering!
♦ The multiple fuse will be damaged when the hexagon nuts
of wire connections are loosened!
♦ The multiple fuse must be renewed after any loosening of
the connections!

Touran 2003 ➤
– Remove hexagon nuts -1-.

– Open cable guide covers of E-box -2- in -direction of arrows-.
– Remove wires from connecting bolts.
– Unclip wiring from wiring guides.
– Undo central bolt -arrow- of E-box -1-.
Note
When the central bolt -arrow- is removed, the E-box -1- is pushed
upwards off the E-box holder.
– Pull E-box -1- upwards off bracket of E-box.
Note
For removal of the flat contact housing -1-, the air filter housing
(on vehicles with diesel engine only), the battery and the battery
console must be removed.
– If necessary, remove air filter housing.

– Remove battery ⇒ page 9 .
4. Removing and installing electronics boxes (E-boxes) 293

Touran 2003 ➤
– Undo and remove bolts -arrows- of battery console -1-..

– Remove battery console -1- from vehicle.
– Press tabs apart on retainer of E-box -arrows B- and slide flat

contact housing -1- sideways -arrow A- out of retainer of E-
box.
Note
The installation of an additional relay carrier depends entirely on

the vehicle equipment.
– Pull retainer of E-box -1- upwards off studs (as far as cables
of additional relay carrier allow).
– Unclip additional relay carrier -1- sideways out of retainer of

E-box -2-.
– Remove E-box -2-retainer from vehicle.
Installing:
Caution
♦ Electrical components that are protected by the multiple

fuse may fail, e.g. the electromechanical power steering!
♦ The multiple fuse will be damaged when the hexagon nuts
of wire connections are loosened!
♦ Renew the multiple fuse after loosening any connection!

Touran 2003 ➤
– Reconnect wiring -1- to E-box, to positions marked before re‐

moval ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
⇒ page 316 .
– Slide cover -2- on E-box and push safety clip -1- in

-direction of arrow- until cover -2- engages.
Note
Then check whether the cover -2- of the E-box is engaged cor‐
rectly.
4. Removing and installing electronics boxes (E-boxes) 295

Touran 2003 ➤
5 Control units
5.1 Onboard supply control unit -J519-
Note
♦ If the onboard supply control unit -J519- is to be renewed, the

procedure „coding onboard supply control unit“ ⇒ page 298
must always be carried out for reading the codes stored in the
control unit.
♦ After renewing the onboard supply control unit -J519- and de‐
pending on equipment, the other functions of the onboard
supply control unit, such as „immobiliser“, „anti-theft alarm“,
„tyre pressure monitor“ and the central locking system keys
must also be adapted.
♦ When doing this, start with adaption of the immobiliser
⇒ page 278 . Then adapt the remaining onboard supply control
unit -J519- functions (depending on equipment) in any order
⇒ page 298 .

tions
The onboard supply control unit -J519- controls the following
functions in the vehicle:
♦ Electrical load management
♦ Exterior light control
♦ Turn signal control
♦ Wipe/wash, windscreen and rear window
♦ Headlight washer system
♦ Rain and light sensor
♦ Heated windscreen and rear window
♦ Interior light control
♦ Terminal control
♦ Dimmers, instrument lighting
♦ Footwell light
♦ Fuel pump presupply
♦ Alternator stand-by
♦ Horn
♦ Hazard warning light
♦ Release control
♦ Control of the central locking system

Touran 2003 ➤
♦ Actuation of the front and rear door control units

♦ Activation of the rear lid unlocking function
♦ Activation of the fuel filler flap unlocking function
♦ Activation of the anti-theft alarm (ATA)
♦ Activation of the immobilizer
The following functions for onboard supply control unit -J519- can
be adapted ⇒ page 298 :
♦ Adapting acoustic feedback when unlocking
♦ Adapting acoustic feedback when locking
♦ Adapting turn signal cycles for lane change flash
♦ Adapting automatic unlocking on removing ignition key
♦ Adapting automatic locking at 15 km/h
♦ Adapting confirmation of convenience closing
♦ Adapting coming home time
♦ Adapting leaving home time
♦ Adapting ATA delay on opening driver door
♦ Adapting unlocking of individual doors
♦ Adapting sensitivity of interior monitoring
♦ Adapting sensitivity of inclination sensor
♦ Deactivating factory mode
♦ Adapting footwell lighting dimmer value
♦ Adapting convenience operation via remote control
♦ Adapting country setting for intelligent alarm horn
♦ Adapting visual feedback when locking
♦ Adapting remote control key
♦ Onboard supply control unit final control diagnosis
⇒ page 299
Note
It depends on the fitted equipment options as to whether the

above mentioned adaptions can be carried out.

The onboard supply control unit -J519- is equipped with self-di‐
agnosis, which makes fault finding easier.
For fault finding, use the systems described in chapter „Vehicle
diagnosis, testing and information system“ in „Guided Fault Find‐
ing“ mode ⇒ page 288 .
5.1.2 Removing and installing onboard supply

control unit -J519-
The onboard supply control unit -J519- is located beneath the re‐
lay carrier, in the driver's side footwell.
The „relay carrier on onboard supply control unit“ is clipped in
place beneath onboard supply control unit -J519- and can be re‐
moved as an individual unit.
5. Control units 297

Touran 2003 ➤
Note
♦ If the onboard supply control unit -J519- is to be renewed, the

procedure „coding onboard supply control unit“ ⇒ page 298
must always be carried out for reading the codes stored in the
control unit.
♦ The following illustrations show removal on a LHD vehicle.
Removal and installation of onboard supply control unit on an
RHD vehicle are performed using the corresponding mirror-
image procedure.
Removing:
key.
– Remove relay carrier on onboard supply control unit
⇒ page 290
– Release and detach the three connectors.
– Press both catches -arrows- and swivel onboard supply con‐
trol unit downwards slightly.
– Pull onboard supply control unit downwards and pull from
holder contrary to direction of travel.
Installing:
– First, insert rear side of onboard supply control unit -J519- into
holder and then push upwards until it audibly engages in hold‐
er.
5.1.3 Coding onboard supply control unit -

J519-
♦ Body
♦ Functions
♦ Coding onboard supply control unit online
5.1.4 Adapting onboard supply control unit -

J519-
♦ Body

Touran 2003 ➤

♦ Functions - onboard supply control unit
– Select one of the listed methods of adaption.
5.1.5 Onboard supply control unit -J519- final

control diagnosis
Note
It depends on the fitted equipment options as to whether the sub‐

sequently mentioned adaptions can be carried out.
The following components and/or functions can be checked by

the final control diagnosis for the onboard control unit:
♦ Left sidelight bulb -M1- , Right sidelight bulb -M3- , Left tail light
bulb -M4- and Right tail light bulb -M2-
♦ Left headlight dipped beam bulb -M29- and right headlight
dipped beam bulb -M31-
♦ Left daytime running light bulb -L174- and right daytime run‐
ning light bulb -L175-
♦ Left headlight main beam bulb -M30- and right headlight main
beam bulb -M32-
♦ Left gas discharge bulb -L13- and right gas discharge bulb -
L14-
♦ Left dip beam screen motor -V294- and right dip beam screen
motor -V295-
♦ Left cornering light bulb -L148- and right cornering light bulb -
L149- (cornering light)
♦ Left dynamic cornering light control motor -V318- and right
dynamic cornering light control motor -V319-
♦ Left headlight range control motor -V48- and right headlight
range control motor -V49-
♦ Left fog light bulb -L22- and right fog light bulb -L23-
♦ Right reverse light bulb -M17- or left reverse light bulb -M16-
♦ Left brake light bulb -M9- or right brake light bulb -M10- and
high-level brake light bulb -M25-
♦ Rear left fog light bulb -L46- or rear right fog light bulb -L47-
♦ Front left turn signal bulb -M5- and rear left turn signal bulb -
M6-
♦ Front right turn signal bulb -M7- and rear right turn signal bulb
-M8-
♦ Number plate light -X-
♦ Dimmed interior light
♦ Instrument lighting of all keys and switches and the dash panel
insert
♦ Terminal 30 voltage supply relay -J317-
♦ LED heated rear window / heated rear window
♦ LED heated exterior mirrors / heated exterior mirrors

Touran 2003 ➤
♦ Release of sliding/tilting sunroof

♦ Release of seat heating
♦ Fuel pump relay -J17-
♦ Headlight washer system relay -J39- and headlight washer
system pump -V11-
♦ Windscreen wipers
♦ Washer pump -V5-
♦ Dual tone horn relay -J4- , treble horn -H2- and bass horn -H7-
♦ Heated windscreen -Z2-
♦ Luggage compartment lock
-VAS 5051A- ⇒ page 288
♦ Body
♦ Onboard supply control unit functions
♦ Final control diagnosis
– Choice one of the components or functions listed.

Touran 2003 ➤
5.2 Data bus diagnostic interface -J533-

(gateway)

The data bus diagnostic interface -J533- (Gateway) -arrow- is lo‐
cated below the dash panel above the relay carrier.
Note

tem
The data bus diagnostic interface -J533- (Gateway) is a separate
unit on the Touran. It has two functions in the vehicle:
♦ It enables data exchange between CAN data bus systems
„drivetrain CAN data bus“, „convenience CAN data bus“ and
„infotainment CAN data bus“.
♦ It converts diagnostic data from CAN data bus systems to
COM wire and vice versa. In this way, data can also be used
by the vehicle diagnosis, testing and information system -VAS
5051A- .
Note
If the data bus diagnosis interface -J533- is to be replaced, it is

essential that the procedure for replacing the „data bus diagnosis
interface -J533“ is carried out so that the codes stored in the unit
can be read ⇒ page 302 .

The data bus diagnostic interface -J533- is equipped with self-
diagnosis, which is designed to simplify fault finding.
system -VAS 5051A- in „Guided fault finding“ mode
⇒ page 288 .
The following functions for data bus diagnostic interface -J533-
can be adapted:
♦ Replacing control unit ⇒ page 302
♦ Coding control unit ⇒ page 302
♦ Identification ⇒ page 303
♦ Reading measured values ⇒ page 303
♦ Checking bus activity ⇒ page 303
♦ Adapting list of control units that should be installed
⇒ page 304
♦ Transportation mode ⇒ page 304

Touran 2003 ➤
5.2.2 Renewing data bus diagnostic interface

-J533-
This test procedure must be performed before the data bus diag‐
nostic interface is renewed.
-VAS 5051A- ⇒ page 288
♦ Body
♦ Data bus diagnostic interface
♦ Data bus diagnosis interface functions
5.2.3 Removing and installing data bus diag‐

nostic interface -J533-
Note
Before removing „data bus diagnostic interface“ -2-, it is essential

that the following work procedure „Renewing data bus diagnostic
interface“ is carried out, so that access can be gained to the codes
stored within ⇒ page 302 .
Removing:
key.
– Removing storage compartment on driver side.
⇒ General body repairs, interior; Rep. gr. 68 ; Compartments,
covers and trim; Removing and installing storage compartment
on driver side .
– Release connector -1- and pull it off data bus diagnostic inter‐
face -J533- -2-.
– Push securing pins -arrows A- together and pull upwards out
of holes in retainer.
– Pull data bus diagnostic interface -J533- -2- upwards off re‐
tainer.
Installing:
Install in the reverse order of removal. When doing this, ensure
that pin -arrow B- is seated correctly in the hole of the retainer
The pin -arrow B- should be located, as shown in the diagram, in
front of the relay carrier.
5.2.4 Coding data bus diagnostic interface -

J533-
This test can be used to code the data bus diagnostic interface.

Touran 2003 ➤

♦ Body
♦ Data bus diagnostic interface functions
5.2.5 Identification
With this test it is possible to check whether the individual buses
(powertrain, convenience and infotainment) have switched to
sleep mode.
♦ Body
♦ Identification
5.2.6 Reading measured values

♦ Body
♦ Reading measured values
5.2.7 Checking bus activity

♦ Body

Touran 2003 ➤

♦ Checking bus activity
5.2.8 Adapting list of control units that should

be installed
♦ Body
♦ Adapting list of control units that should be installed
5.2.9 Transportation mode

♦ Body
♦ Transportation mode
5.3 Driver door control unit -J386-
Note
♦ The driver door control unit -J386- and the driver side window
regulator motor -V147- are contained in one unit and cannot
be replaced individually.
♦ If the driver door control unit -J386- or the driver side window
regulator motor -V147- are replaced, then the work procedure
„Coding driver door control unit“ must be subsequently per‐
formed ⇒ page 305 .

tem
tions

Touran 2003 ➤
5.3.1 Removing and installing driver door con‐

trol unit -J386-
Removing and installing driver door control unit -J386- ⇒ General
body repairs, exterior; Rep. gr. 64 ; Front door window; Removing
and installing window regulator motor .
Note
If the driver door control unit -J386- or the driver side window reg‐
ulator motor -V147- are replaced, then the work procedure „Cod‐
ing driver door control unit“ must be subsequently performed
⇒ page 305 .
5.3.2 Coding driver door control unit -J386-

♦ Body
♦ Door electronics, driver's side
♦ Driver door electronics functions
♦ Coding (Rep. Gr. 57)
5.4 Front passenger door control unit -J387-
Note
♦ The front passenger door control unit -J387- and the front
passenger side window regulator motor -V148- are contained
in one unit and cannot be replaced individually.
♦ If the front passenger door control unit -J387- or the front pas‐
senger side window regulator motor -V148- are replaced, then
the work procedure „Coding front passenger door control unit“
must be subsequently performed ⇒ page 306 .

tem
tions
5.4.1 Removing and installing front passenger

door control unit -J387-
Removing and installing front passenger door control unit -J387-
⇒ General body repairs, exterior; Rep. gr. 64 ; Front door window;
Removing and installing window regulator motor .

Touran 2003 ➤
Note
If the front passenger door control unit -J387- or the front pas‐
senger side window regulator motor -V148- are replaced, then the
work procedure „Coding front passenger door control unit“ must
be subsequently performed ⇒ page 306 .
5.4.2 Coding front passenger door control unit

-J387-
♦ Body
♦ Door electronics, front passenger's side
♦ Front passenger door electronics functions
♦ Coding (Rep. Gr 57)
5.5 Coding rear left door control unit -J388-
Note
♦ The rear left door control unit -J388- and the rear left window
regulator motor -V26- are contained in one unit and cannot be
replaced individually.
♦ If the rear left door control unit -J388- or the rear left window
„Coding rear left door control unit“ must be subsequently per‐

tem
tions
5.5.1 Removing and installing rear left door

control unit -J388-
Removing and installing rear left door control unit -J388- ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 64 ; Rear door window;

Touran 2003 ➤
Note
If the rear left door control unit -J388- or the rear left window reg‐
ulator motor -V26- are replaced, then the work procedure „Coding
rear left door control unit“ must be subsequently performed
⇒ page 307 .
5.5.2 Coding rear left door control unit -J388-

♦ Body
♦ Rear left door electronics
♦ Rear left door electronics functions
5.6 Coding rear right door control unit -J389-
Note
♦ The rear right door control unit -J389- and the rear right win‐
dow regulator motor -V27- are contained in one unit and
cannot be replaced individually.
♦ If the rear right door control unit -J389- or the rear right window
„Coding rear right door control unit“ must be subsequently
performed ⇒ page 308 .

tem
tions
5.6.1 Removing and installing rear right door

control unit -J389-
Removing and installing rear right door control unit -J389- ⇒
General body repairs, exterior; Rep. gr. 64 ; Rear door window;
Note
If the rear right door control unit -J389- or the rear right window
„Coding rear right door control unit“ must be subsequently per‐

Touran 2003 ➤
5.6.2 Coding rear right door control unit -J389-

♦ Body
♦ Rear right door electronics
♦ Rear right door electronics functions
5.7 Electronically controlled damping con‐

trol unit -J250-
The electronically controlled damping control unit -J250- is an el‐
ement of the adaptive chassis control DCC. It can be found on
the rear right behind the side panel trim.
Note

tem
tions
The driver is able to adapt the suspension (adaptive chassis con‐
trol DCC) according to his/her driving style or the road conditions
using the damper setting button -E387- .
On vehicles with automatic headlight range control and AFS sys‐
tems (Adaptive Frontlighting System), the control unit for elec‐
tronically controlled damping -J250- and the control unit for
cornering light and headlight range control -J745- exchange in‐
formation over the CAN bus ⇒ page 163 .
The control unit for electronically controlled damping -J250- is
equipped with self-diagnosis, which makes fault finding easier.
5.7.1 Assembly overview - electronically controlled damping control unit -J250-

Touran 2003 ➤
1 - Shock absorber damping

adjustment button -E387-
❑ In centre console stor‐
age compartment in
front of gear lever
⇒ page 270
2 - Front right vehicle level
sender -G289-
❑ Location: on right of
front axle
⇒ page 310
3 - Connector
❑ On electronically con‐
trolled damping control
unit -J250-
4 - Electronically controlled
damping control unit -J250-
⇒ page 309
❑ Basic setting
⇒ page 310
5 - Bracket
❑ For electronically con‐
trolled damping control
unit -J250-
6 - Rear left vehicle level send‐
er -G76-
❑ Location: on left of rear
axle
⇒ page 310
7 - Front left vehicle level sender -G78-
❑ Location: on left of front axle
Not shown
♦ Front left body acceleration sender -G341- , location: on front
left suspension strut turret
♦ Front right body acceleration sender -G342- , location: on front
right suspension strut turret
♦ Rear body acceleration sender -G343- , location: on rear left
shock absorber mounting
Removing and installing body acceleration sender ⇒ Running
gear, axles, steering; Rep. gr. 43
5.7.2 Removing and installing electronically

controlled damping control unit -J250-
Removing:
key.

Touran 2003 ➤
– Remove right side panel trim ⇒ General body repairs, interior;

Rep. gr. 70 ; Load, luggage compartment trim .
– Press release buttons -arrows A- and push off electronically
controlled damping control unit -2- from bracket in direction of
-arrow B-.
Installing:
Note
After installing a new electronically controlled damping control

unit -J250- , the control unit must be coded ⇒ page 310 .
5.7.3 Coding electronically controlled damp‐

ing control unit -J250-
-VAS 5051A- ⇒ page 288
♦ Body
♦ Electronically controlled damping
♦ Functions
5.7.4 Removing and installing front left vehicle

level sender -G78- and front right vehi‐
cle level sender -G289-
Removal and installation of front left vehicle level sender -G78- is
described in ⇒ page 165 .
Removal and installation of front right vehicle level sender -G289-
is performed in the same manner and does not require extra
instructions.
5.7.5 Removing and installing rear left vehicle

level sender -G76- :
Removal and installation of rear left vehicle level sender -G76- is
described in ⇒ page 165 .
5.7.6 Basic setting of adaptive chassis control

DCC
-VAS 5051A- ⇒ page 288

Touran 2003 ➤

♦ Body
♦ Electronically controlled damping
♦ Functions
♦ Basic setting
5.8 Trailer detector control unit -J345-

The trailer detector control unit -J345- -arrow- is located behind
the left panel trim.
Note

tem
tions
Note
For checking control unit, use socket tester -V.A.G 1537/A- or -

VAS 5800-
⇒ „5.8.3 Trailer detector control unit J345 final control diagnosis“,
page 312 .
The trailer detector control unit -J345- detects from a power draw
of minimum 5 W1) the „trailer operation“ and transmits this infor‐
mation to various control units via the CAN data bus.
The trailer detector control unit -J345- is supplied with information
(light control) from the onboard supply control unit -J519- via the
CAN data bys.
1) „Trailer operation“ can only be detected if at least turn signal indicators or side
marker lights are switched on.

The trailer detector control unit -J345- features self-diagnosis to
5.8.1 Removing and installing trailer detector

control unit -J345-
Removing:
key.

Touran 2003 ➤

– Remove left side panel trim in luggage compartment ⇒ Gen‐
el trim, Removing .
el trim, Removing .
All vehicles:
– Release connector -2- and detach it from trailer detector con‐
trol unit -J345- .
– Undo bolts -1- and remove trailer detection control unit -J345-
from bracket.
Installing:
following:
Note
Following installation, a new trailer detector control unit -J345-

must be encoded ⇒ page 312 .
5.8.2 Coding trailer detector control unit -

J345-
-VAS 5051A- .
♦ Body
♦ Trailer detector
♦ Functions
5.8.3 Trailer detector control unit -J345- final

control diagnosis
Note
♦ The trailer detector control unit -J345- only detects „Trailer op‐
eration“ as of a power decrease of at least 5 W1).
♦ For checking, use socket tester -V.A.G 1537/A- or trailer sock‐
et tester -VAS 5800- .

Touran 2003 ➤
♦ Trailer socket tester -VAS 5800-
♦ Socket tester -V.A.G 1537/A- 2)
2) The socket tester -V.A.G 1537/A- will become too warm after some minutes of
use and will switch itself off. The socket tester -V.A.G 1537/A- will function again
without problem after it has cooled down.
– Connect socket tester -V.A.G 1537/A- .

-VAS 5051A- .
♦ Body
♦ Trailer detector
♦ Functions
♦ Trailer detector control unit - final control diagnosis

Touran 2003 ➤
5.9 Special vehicle control unit -J608-

The special-purpose vehicle control unit -J608- -arrow- is located
behind the rear left side trim.
Note

tem
The special vehicle control unit -J608- is used by the following
special-purpose vehicles, their special equipment and functions:
♦ Taxis
♦ Driving schools
♦ Disabled
♦ Driving schools for the disabled
♦ Special signal vehicles
♦ Special protection vehicles
The special vehicle control unit -J608- is equipped with self-diag‐
nosis, which is designed to simplify fault finding.
5.9.1 Removing and installing special vehicle

control unit -J608-
Removing:
key.
el trim, Removing .
el trim, Removing .
All vehicles:

Touran 2003 ➤
– Release connector -2- and detach it from special vehicle con‐

trol unit -J608- .
– Undo bolts -1- and remove special vehicle control unit -J608-
from bracket.
Installing:
Note
If a new special-purpose control unit -J608- is installed, it must be

coded ⇒ page 315 .
5.9.2 Coding special vehicle control unit -

J608-
-VAS 5051A- ⇒ page 288
♦ Body
♦ Multifunction control unit
♦ Multifunction control unit functions

Touran 2003 ➤
6 Specified torques: wiring

6.1 Specified torques: E-box on left side of
engine compartment
Securing nuts -1- M5 (8 mm 4.5 Nm
spanner)
Securing nuts -1- M6 (10 mm 6 Nm
spanner)
Electronics box central 9 Nm
bolt

Touran 2003 ➤
7 Wiring harness and connector re‐

pairs
7. Wiring harness and connector repairs 317

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Service

Service Department. Technical Information

27 - Starter, current supply, CCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Renewing dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

94 - Lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

1.9 Adjusting headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

10.5 Parking aid warning buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

96 - Lights, bulbs, switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

8.2 Front camera for driver assist systems R242 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

Volkswagen Technical Site: https://vwts.ru

27 – Starter, current supply, CCS

Danger of injury! Observe warning notices and safety regula‐

To prevent damage to the battery or vehicle, read the informa‐

1.1 Types of battery

1.2 Warning notices and safety regulations

1.3 Battery terminal connection

2 Rep. gr.27 - Starter, current supply, CCS

4 Disconnecting and reconnecting bat‐

Danger of injury! Observe warning notices and safety regula‐

Battery recharging or jump start on vehicles with start/stop sys‐

4.1 Assembly overview

4.1.1 Vehicles with no start/stop system

4 Rep. gr.27 - Starter, current supply, CCS

1 - Earth wire battery terminal

4. Disconnecting and reconnecting battery 5

4.1.2 Vehicles with start/stop system

1 - Battery earth terminal with

4.2 Disconnecting battery

♦ By disconnecting the battery earth wire (open circuit), safety

6 Rep. gr.27 - Starter, current supply, CCS

Vehicles with battery box

– Open cover -1- of battery protective jacket.

– First unscrew the earth-wire terminal clamp -1- on the battery

4.3 Reconnecting battery

Observe notes for battery terminal clamp bolt ⇒ page 1 .

Special tools and workshop equipment required

4. Disconnecting and reconnecting battery 7

♦ Torque wrench -V.A.G 1331-

– Fit positive terminal clamp -2- onto positive terminal of battery

8 Rep. gr.27 - Starter, current supply, CCS

5 Removing and installing battery

Danger of injury! Observe warning notices and safety regula‐

Renewing battery on vehicles with start/stop system:

5.1 Assembly overview

1 - Earth wire battery terminal

5. Removing and installing battery 9

5.2 Vehicles with a petrol engine

5.2.1 Removing battery

– Remove securing bolt -1- and remove battery holder -2-.

5.2.2 Installing battery

10 Rep. gr.27 - Starter, current supply, CCS

A loosely fitted battery creates the following dangers:

Installation is carried out in the reverse order. When installing ob‐

5.3 Vehicles with a diesel engine

5.3.1 Removing battery

– Remove securing bolt -1- and remove battery holder -2-.

5. Removing and installing battery 11