VOLKSWAGEN TOURAN 2003 (04) PDF Document

Batteries where the magic eye is colourless or light yellow must not be checked or charged. You should not attempt to slave/jump start the vehicle. There is a danger of explosion when checking, charging, or slave/jump starting. These batteries must be renewed.

The safety markings on your VOLKSWAGEN TOURAN 2003’s battery indicate the following precautions:

1. Fires, sparks, naked flames, and smoking are prohibited when handling batteries. Avoid sparks from electrostatic discharge and short circuits. Never lay a tool on a battery.

2. Wear eye protection before commencing work on the battery.

3. Keep children away from acid and batteries.

4. Old batteries are hazardous waste and must be disposed of at a suitable collection centre according to legislation.

5. Never dispose of old batteries in household waste.

6. There is a danger of explosion. A highly explosive gas is produced when batteries are charged.

7. Always follow instructions on the battery and in your owner’s manual.

8. Battery acid is very caustic. Wear eye protection and gloves. Do not tilt the battery, as acid can leak out of the gas vents.

To prevent damage to the battery clamps and terminals on your VOLKSWAGEN TOURAN 2003, please observe the following:

• The battery clamps should only be fitted by hand and without using force.

• Battery terminals should not be coated with grease.

• The battery clamps should be fitted so that the battery terminal is either flush with the clamp or protruding from it.

• Once the battery clamps have been tightened to the specified torque, the threaded connections should not be tightened any further.

Performing a visual check establishes the external condition of the battery on your VOLKSWAGEN TOURAN 2003. Follow these steps:

1. Ensure the battery is secured correctly. Vibrations can shorten the battery’s life and cause damage. Check that the battery is securely seated and tighten the securing bolt to the specified torque if necessary.

2. Check if the battery housing is damaged. If electrolyte is leaking, it can cause serious damage to the vehicle. Treat any components affected by leaked battery acid immediately with an acid neutraliser or a soap solution.

3. Check whether the battery terminals (battery wire connections) are damaged. Damaged terminals can prevent proper contact. When connecting battery clamps, tighten them to the specified torque to ensure the vehicle functions correctly.

Before checking, tap the magic eye lightly with a screwdriver handle to dissipate any air bubbles that might distort the colour display. The colours indicate the following:

• **Green:** The battery is charged sufficiently.

• **Black:** The battery is partly discharged (charge state < 65%) or completely discharged.

• **Colourless or light yellow:** The battery must be renewed. Do not check, charge, or jump start a battery in this state due to the danger of explosion.

Note that the magic eye only reflects the condition of one cell, so a full battery load test is recommended for an exact determination.

For batteries with a “2-colour” magic eye, the display indicates the electrolyte level, not the charge state. Before checking, tap the magic eye lightly to dissipate any air bubbles.

• **Black:** The electrolyte level is OK.

• **Colourless or light yellow:** The electrolyte level is too low. The battery must be renewed. Do not check, charge, or jump start a battery in this state due to the danger of explosion.

A battery load test is required to determine the charge state.

Based on the printout from the battery tester, take the following actions:

A current draw test helps to quickly determine the state of a discharged battery. Ensure the battery temperature is at least +10 °C.

1. Connect the battery to a suitable battery charger (e.g., VAS 5095A, VAS 5900, VAS 5903) and start the charging sequence.

2. Measure the charging current of the battery after 5 minutes using a current pick-up clamp.

Test Result:

• If the current draw (in Amperes) is **higher than 10%** of the battery’s nominal capacity (e.g., > 6.1 A for a 61 Ah battery), fully charge the battery and test it again after allowing it to rest for two hours.

• If the charge current is **below 10%** of the nominal capacity after 5 minutes, the battery must be renewed.

This test is used to assess the battery condition on stock and stored vehicles. The battery must not have been charged or discharged within the last 2 days.

1. Use a hand multimeter to check the battery’s no-load voltage.

2. Interpret the reading based on the following table:

A no-load voltage of 11.60 V indicates a 0% charge, meaning the battery is discharged and has no capacity.

The activation and deactivation of the cruise control system on your VOLKSWAGEN TOURAN 2003 is performed using a vehicle diagnostic tester.

1. Connect the vehicle diagnostic tester to your vehicle.

2. Select “Guided fault finding” mode.

3. Using the “GoTo” button, select “Functions/component” and then navigate through the following menu options in sequence:

• Drive

• Engine code

• 01 – On Board Diagnostic capable systems

• Engine management/diesel direct injection and glow plug system

• Functions

• Activating and deactivating cruise control system (CCS)

Your VOLKSWAGEN TOURAN 2003 may use several types of hose couplings for the windscreen, rear window, and headlight washer systems.

Type 1 (Simple Push-Fit):

• **To loosen:** Pull the two coupling sections apart.

• **To secure:** Push the two sections together until you hear and feel them engage.

Type 2 (Rotating Lock Ring):

• **To loosen:** Rotate the lock ring (item -1-) through 90° and pull off the hose connection.

• **To secure:** Push on the hose connection and rotate the lock ring back until it engages.

Type 3 (Pull-Up Lock Ring):

• **To loosen:** Pull up the lock ring (item -1-) by approx. 1 mm and pull off the hose connection.

• **To secure:** Attach the hose connection and press in the clip (item -1-) until it engages.

Type 4 (Headlight Washer System):

• **To loosen:** Push the lock ring (item -1-) and pull off the hose connection.

• **To secure:** Push and hold the lock ring while pushing on the hose connection. Check that the clip has engaged correctly by trying to pull it off without the clip being depressed.

To repair a smooth pipe (e.g., 5×1 mm or 6×1 mm diameter) in the washer system of your VOLKSWAGEN TOURAN 2003, you will need a suitable length of EPDM hose and cable ties.

1. Cut the damaged section out of the smooth pipe at right angles.

2. Select the appropriate EPDM hose and cable ties from the electronic parts catalogue (ETKA).

3. Cut a piece of the EPDM hose so that each end of the original smooth pipe can be pushed about 10 mm into it.

4. Secure both repair joints with cable ties.

Repairing a corrugated hose requires end pieces, correctly sized heat-shrink piping, and a hot air blower.

1. Cut the damaged section out of the corrugated pipe at right angles.

2. Select suitable end pieces (-2- and -3-) and heat-shrink piping from the electronic parts catalogue (ETKA).

3. Heat one end of the corrugated pipe (-1-) and push a connector (-2-) into it.

4. Heat the other end of the corrugated pipe (-4-) and push the other connector (-3-) into it.

5. Cut the heat-shrink hose so that it covers each end of the corrugated pipe by about 20 mm.

6. Push the heat-shrink hose over the corrugated pipe, join the connectors, and secure the repair joints by applying heat with the hot air blower.

Note: Repair points must not be subjected to pulling or bending forces. If the damaged section is longer than 20 mm, a new piece of corrugated pipe must be used.

Working on gas discharge headlights involves lethally high voltage. Always observe the following safety rules:

• **Disconnect Power:** Before working on any parts marked with yellow high voltage symbols, you must disconnect the battery earth strap.

• **Discharge Residual Voltage:** After disconnecting the battery, switch the dipped beam on and off again to eliminate any possible residual voltage.

• **Operate Safely:** Never operate the gas discharge lamp control unit without a bulb fitted. The bulb must only be operated inside the complete headlight housing.

• **Avoid Injury:** H7 and gas discharge bulbs are under pressure and can explode if changed improperly. Always wear protective goggles and gloves. Avoid touching the bulb glass with bare fingers.

• **Avoid Direct Viewing:** Do not look directly into the beam. The UV rays are about 2.5 times greater than normal halogen bulbs, and the glare can impair your vision.

• **Professional Work:** Never change bulbs if you are not familiar with the appropriate procedures, safety precautions, and tools.

Gas discharge bulbs must be disposed of as hazardous waste and should never be thrown away with conventional waste.

• They contain metallic mercury (Hg) and traces of thallium; never destroy these bulbs.

• These components must be recycled in accordance with national law.

• Dispose of them only in containers intended for this purpose at an authorised collection point.

Note: Only illuminated sockets can be removed with the puller tool T 40148. Sockets without illumination usually cannot be removed without being damaged.

Removing:

1. Remove the cigarette lighter or dummy plug from the socket if present.

2. Push the puller (T 40148) into the socket so that its locking lugs (-1-) engage in the recesses (-2-) inside the socket.

3. Pull the grip (-3-) of the tool to release the locking lugs of the retaining sleeve.

4. Pull the socket out of the retaining sleeve using the puller. Take care not to stretch the wiring.

5. Depending on access, you may need to use the thrust piece 40148/1 to help push the socket out.

6. Pull off the socket connector.

7. To release the puller from the socket, press the spindle (-1-) and turn the puller (-2-) briefly to the left.

Installing:

Installation is in the reverse order of removal. After removing the socket, carefully press the retaining springs on the socket together and check that the cigarette lighter stays in place after its heating phase.

Note: On some vehicles, the illumination is provided by a non-replaceable LED. In this case, the entire retaining sleeve must be replaced.

Removing:

1. Remove the cigarette lighter socket as previously described.

2. Press the retaining lugs on the retaining sleeve and remove the sleeve together with the bulb carrier.

3. Unclip the bulb carrier from the retaining sleeve.

4. Separate the bulb carrier into its two parts (A and B).

5. Open part B of the bulb carrier.

6. Remove the light bulb in the direction of the arrow.

Installing:

Installation is carried out in the reverse order of removal.

When performing repairs on the electrical system of your VOLKSWAGEN TOURAN 2003, please follow these guidelines:

• Always disconnect the battery earth strap before working on the electrical system.

• Before starting a repair, identify and rectify the cause of the damage (e.g., sharp edges, corrosion).

• Soldering is not permitted for repairs to vehicle wiring.

• Use the official wiring harness repair set for all wiring and connector repairs.

• Crimp connectors must not be repaired. If needed, lay a new wire parallel to the defective one.

• After crimping, connectors must be shrink-fitted using a hot air blower to prevent moisture ingress.

• Screened wires must not be repaired; if damaged, they must be replaced completely.

• For repairs in high-temperature areas like the engine compartment, only use heat-resistant wiring.

• After every repair, perform a function test. It may be necessary to interrogate and erase the fault memory.

Faulty repairs to the passenger protection system can cause malfunctions. Adhere strictly to these rules:

• Only use contacts, connectors, and wiring specifically designed for this purpose, available from the Electronic Parts Catalogue (ETKA).

• A maximum of two positions may be repaired in the wiring for the airbag and belt tensioner system.

• Crimp connectors must always be shrink-fitted to prevent corrosion.

• Mark the area of repair clearly with yellow insulating tape; do not incorporate the repaired wiring back into the vehicle’s own wiring harness loom.

• The wires to the triggering units (airbags) are entwined as standard. This twine spacing (A = 20 mm ± 5) must be maintained during repairs.

• The wires in a pair must have the same length.

• There must not be any untwisted section of wiring longer than B = 100 mm.

CAN bus wiring is an unshielded, two-wire line. When repairing, observe the following:

• Use the correct colour codes for the wires:

• When performing repairs, both bus wires must have the same length.

• When twisting the wires together, the length of each complete twist must be A = 20 mm.

• There must not be any untwisted section of wiring (e.g., near crimp connectors) longer than B = 50 mm.

• Mark the area of repair with yellow insulation tape for easy identification.

Aerial wires must not be repaired; they must be replaced with new connecting wires and adapter cables. Only the defective section needs to be replaced.

1. Pull the defective aerial wire connections off the units (e.g., radio, aerial).

2. Determine the routing of the defective wire and measure its total length.

3. To find the required length of the new central connecting wire (-2-), subtract 60 cm (for the two adapter cables) from the total measured length.

4. Obtain the required adapter cables (-1- and -3-) and the correctly sized connecting wire (-2-) as genuine parts.

5. Cut off the connectors from the old, defective aerial wire. The remainder of the wire can stay in the vehicle.

6. Connect the new adapter cables to the equipment in the vehicle.

7. Route and attach the new connection line in the immediate vicinity of the original factory routing. Do not kink or bend aerial wires with a radius tighter than 50 mm.

8. Connect the connecting wire to the adapter cables.

9. Perform a functional test.

This procedure is for when the two ends of the broken wire can be joined directly.

1. Unbind the wiring harness if necessary.

2. Cut out the damaged piece of wiring using wire strippers.

3. Strip the insulation from both wire ends by 6 – 7 mm.

4. Push a crimp connector onto both stripped wire ends and crimp it using the correct recess in the crimping pliers. The insulation must not be crimped.

5. After crimping, the connector must be shrink-fitted to prevent moisture ingress. Place the shrink element on a hot air blower.

6. Heat the crimp connector along a straight line, from the middle outwards, until it is completely sealed and adhesive escapes from the ends. Be careful not to damage other wiring.

7. If the repair position was wrapped, re-wrap it with yellow insulation tape. Attach the repaired harness with a cable tie if necessary.

Releasing contacts requires specific tools and procedures to avoid damage.

1. **Disengage Secondary Lock:** If the contact housing has a secondary locking mechanism (often a different coloured piece like a flap, slide, or toothed element), it must be opened or removed first.

2. **Use Correct Release Tool:** Select the appropriate release tool for the specific contact type (e.g., round, flat, Faston).

3. **Insert the Tool:** Insert the release tool into the designated port on the contact housing.

4. **Release the Primary Lock:** While lightly pushing the contact’s wire *into* the housing (this helps lift the locking tab), push the release tool in to disengage the primary locking tab.

5. **Remove Contact:** Simultaneously, pull the wire to remove the released contact from the back of the housing.

6. **Remove Tool:** Once the contact is out, the release tool can be removed.

Never use force to pull contacts out of housings; this will damage the contact and the housing.

Proper cleaning ensures optimal electrical contact. Do not use penetrating fluid, contact spray, or grease.

1. **Disconnect Battery:** Always disconnect the battery first.

2. **Remove Terminal:** Loosen the cap nut and remove the ring terminal from the threaded connection.

3. **Inspect and Clean:** Check the ring terminal and threaded post for corrosion and dirt.

4. **Grind:** Select a suitable adapter and sanding pad from a contact surface cleaning set (e.g., VAS 6410). Insert the adapter into the ring terminal or over the threaded post and use circular movements to grind off corrosion. Be careful not to abrade the tin coating excessively to the point where copper is exposed.

5. **Deburr:** If necessary, remove any punching burr from the ring terminal using a deburrer.

6. **Tighten:** Reattach the ring terminal and tighten the nut to the specified torque.

7. **Protect:** Apply a suitable anti-corrosion treatment to the connection.

8. **Reconnect:** Reconnect the battery. You may need to teach-in electric windows, enter the radio code, and set the clock.

1. Disconnect the battery.

2. Check the battery clamp and terminal for corrosion or dirt.

3. Use the wire brush of a battery terminal cleaner (e.g., VAG 1331) to clean the inside of the battery clamp with circular movements.

4. Use the underside of the battery terminal cleaner to clean the battery terminal post, also with circular movements.

5. Reconnect the battery and tighten the terminals to the specified torque. Optimum contact is ensured when the components are tightened to spec after cleaning.

Missing anti-corrosion treatment can result in damage to the onboard supply. Always use the hose supplied with the anti-corrosion agent tin. The sealing agent reaches the required points through capillary action.

• Hold the injector below the ring terminal and spray the pin all around.

• Hold the injector above the ring terminal and spray the pin and wiring eye all around.

Do not repair Lambda probe wires, as this can result in malfunctions. The procedure is similar for 4-pin (LSF) and 6-pin (LSU) probes.

1. Remove the defective Lambda probe from the vehicle.

2. Place the old probe and the new uniform probe next to each other so that the sensor housings are at the same height.

3. If the new probe’s wire is longer, tie back the excess length (approx. 50 – 250 mm) to match the size of the defective probe and secure it with cable ties.

4. Check that the connector housing of the new probe is compatible with the vehicle’s onboard supply side connector. On older vehicles, it may be necessary to replace the connector housing on the vehicle side with the one supplied with the new probe.

5. Install the new Lambda probe in the vehicle.