VOLKSWAGEN TOURAN 2003 (02) PDF Document

For the VOLKSWAGEN TOURAN 2003, the technical data is as follows: The brake master cylinder has a diameter of 22 mm. The brake servo for left-hand drive (LHD) vehicles is 11 inches in diameter, while the brake servo for right-hand drive (RHD) vehicles is 7/8 inches in diameter.

The brake test should be performed on a single-axle roller dynamometer with contra-rotating rollers. Contra-rotating means that the dynamometer rollers are driven forwards on one side and backwards on the opposite side to prevent brake forces from being transferred to the drive train. The forward rotating wheel is measured, meaning two brake tests per axle must be performed. The maximum test speed must not exceed 6 km/h.

If no such test rig is available for the VOLKSWAGEN TOURAN 2003, you can use a standard single-axle roller dynamometer as follows:

Step 1. Drive the vehicle forwards onto the rollers.

Step 2. Switch the engine off and wait for 2 seconds.

Step 3. Carry out the front brake test.

Step 4. Start the engine and wait for approximately 5 seconds until sufficient vacuum has been built up.

Step 5. Drive the vehicle forwards until the rear wheels are positioned on the rollers.

Step 6. Switch the engine off and wait for 2 seconds.

Step 7. Carry out the rear brake test.

Step 8. Start the engine and wait for approximately 5 seconds until sufficient vacuum has been built up.

When performing repairs on the VOLKSWAGEN TOURAN 2003 anti-lock brake system, observe the following precautions:

Absolute cleanliness is required. It is not permitted to use products containing mineral oil, such as oils or greases.

Thoroughly clean all unions and adjacent areas before loosening. Do not use aggressive cleaning agents like brake cleanser, petrol, or thinners.

Place removed parts on a clean surface and cover them.

If repairs cannot be carried out immediately, cover or seal open components using sealing plugs from repair kit 1H0 698 311 A.

Only use lint-free cloths, genuine packed parts, and unpack replacement parts immediately prior to fitting.

When the system is open, do not use compressed air and do not move the vehicle.

Do not touch contact surfaces on the connector, pressure sensor, or control unit with hands or objects.

If the ABS warning lamp does not go out after switching the ignition on and completing the test sequence, possible faults include a voltage supply below 10 volts or a fault in the ABS system. If the ABS warning lamp and the brake system warning lamp both light up, the ABS is defective. In this event, note that the anti-lock brake system remains switched off and the rear wheels may lock prematurely during braking, although the conventional brake system remains operational.

If the brake pad warning lamp stays on, the brake pads are likely worn or there is a wiring fault. If the traction control system warning lamp flashes while the VOLKSWAGEN TOURAN 2003 is in motion, the system is actively regulating.

To remove the unit on the VOLKSWAGEN TOURAN 2003, follow these steps:

Step 1. Read out and note the existing control unit code.

Step 2. Disconnect the battery earth strap with the ignition switched off.

Step 3. Apply the brake pedal depressor V.A.G 1869/2.

Step 4. Connect a bleeder bottle hose to the front left and rear left brake caliper bleeder valves and open them. Depress the brake pedal at least 60 mm using the depressor, then close the valves.

Step 5. Identify and unscrew the two brake master cylinder lines from the hydraulic unit. Immediately seal the lines and threaded holes with the appropriate sealing plugs (repair kit 1H0 698 311 A).

Step 6. Identify, unscrew, and seal the brake lines leading to the calipers.

Step 7. Pull the hydraulic unit and control unit upwards out of the dampers.

To install, follow the removal steps in reverse order, use new bolts, and ensure the rubber dampers are not pressed out of the bracket. Finally, bleed the brake system and perform the necessary basic settings for the steering angle sender and pressure sensors using the diagnostic system.

New adjustment is only necessary after renewing handbrake cables and brake calipers. Follow these steps:

Step 1. Remove the centre console components to access the adjustment mechanism.

Step 2. Depress the foot brake hard at least three times.

Step 3. Firmly pull on and then release the handbrake three times. The handbrake lever must return to its released position below the first notch.

Step 4. Tighten the adjusting nut until the lever lifts off the brake caliper stop.

Step 5. The total distance to the stops on the left and right brake calipers must not exceed 1.5 mm. Check that both wheels turn freely.

For models from week 45/2005, the brake light switch is located on the brake master cylinder. To remove:

Step 1. Remove the engine cover panel and any obstructing intake hoses.

Step 2. Separate the electrical connector from the brake light switch.

Step 3. Remove the bolt from the brake master cylinder.

Step 4. Pull the brake light switch from the brake master cylinder at the bottom and remove it from the locking lug at the top.

To install, perform the steps in reverse order and tighten the Torx bolt on the brake master cylinder to 5 Nm.