Volkswagen Multivan 2010, California 2010, Caravelle 2010, T5 2010 Service Training
Service Training
Self-Study Programme 453
For the T5 2010
Commercial
Vehicles
The T5 from Volkswagen Commercial Vehicles
Series production of the first Volkswagen Transporter
started in March 1950. An initial production of
10 vehicles per day quickly developed into one of the
most successful careers for an automobile, and one
which laid the foundation for a new vehicle segment.
Multivan and Caravelle also founded a new vehicle
segment in which they have continued to set new
standards right down to the present day.
Today, as in the past, the Volkswagen Commercial
Vehicles brand stands for innovative technology and
a product range that is tailored to requirements. At
the same time, e.g. TDI®, DSG® and 4MOTION®
represent unique technical solutions that are only
available in this segment in models from Volkswagen
Commercial Vehicles.
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The T5 2010 will be available in the following equipment lines:
Transporter: Panel van, window van, chassis, platform van and back-to-back cab
Caravelle: Trendline and Comfortline
California: Beach and Comfortline
Multivan: Startline, Comfortline, Highline and PanAmericana
The self-study programme shows
the design and function of new
developments!
The content is not updated.
For current inspection and setting instructions, and
workshop manuals, please refer to the service
literature that is provided.
Important
Note
2
At a glance
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
The model family of the T5 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
The body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
The tailgate emergency unlocking function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Occupant protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
The engine/gearbox combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
The gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
The four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Overview of the running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
The brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
The steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Heating and air conditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
The climate control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
The auxiliary heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
The installation locations of the control units . . . . . . . . . . . . . . . . . . . . . . . . . . 40
The networking concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
The onboard supply control unit J519 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
The lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
The lane change assist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
The reversing camera system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
The dash panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
The media device interface box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Radio, phone and navigation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
The radios and radio navigation systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
The aerial concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
The telephone preparation UHV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3
Introduction
The model family of th e T5 2010
The 2010 model year will see the launch of an extensive remodeling of what is to become the fifth model
generation of the Transporter. Yet again, this vehicle will underline the pioneering role played by Volkswagen
Commercial Vehicles in the segment of people carriers and transporters.
In the 2010 model year, the model range also includes the familiar model variants.
● Platform van
● Panel van
● Window van
● Caravelle
● Multivan
● California
Panel van
Window van
Platform van
(Example: double cab)
Overview of the most important highlights:
● new TDI® engines with common rail injection system,
7-speed dual clutch gearbox, 4MOTION with dual clutch gearbox and
Servotronic,
● Multivan now also with long wheelbase,
● new driver assistance systems, new infotainment programme and new air conditioning controls,
● new "fresh" design in the interior, e.g. new instrument clusters, new fabrics and steering wheels and
new decor for the galley in the California,
● attractive exterior, e.g. with new exterior mirrors, engine cover, headlights, front end, tail lights,
rims and a new range of colours,
● increased operating comfort.
4
The new T5 2010 consistently implements the new design language of Volkswagen.
● A clear face - high quality and timeless,
● The horizontal, clean lines make the vehicle
look wide and have great presence on the road.
● Its eyes - open, unique and self-assured.
● The night design of the new tail lights in the
Multivan with Volkswagen Commercial Vehicle's
own signature - its appearance on the road is
immediately recognisable.
Multivan
● Panel van, window van and platform van with
robust and solid, grey grained front and rear
bumpers corresponding to the type of vehicle
● Multivan, Caravelle and California with painted
front and rear bumpers - this underlines the clear,
high-quality character.
The design revisions consistently support the
character properties of the new T5 2010.
Caravelle
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California
About the model range:
● Predominantly for transporting people - window van, Caravelle, Multivan, California.
● In the other versions, the T5 2010 is chiefly used for transporting loads.
● Within the model range, there are versions with both a short and a long wheelbase and
three different roof heights.
● The maximum possible payloads of the vehicles vary depending on the different operating conditions.
● Some model variants are available with four-wheel drive (4MOTION).
5
Introduction
Technical data
Platform van
Platform van
Single cab
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Platform van
Double cab
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The pictures only show selected variants and their dimensions/dimension ranges (e.g. with short and
long wheelbase, etc.) - the chassis is not shown here. Please refer to the current sales literature for the
complete set of technical data for the model range.
6
Panel van, window van, Caravelle, Multivan, California
Panel van
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Multivan
With the launch of the T5 2010,
the Multivan will also be
available with a long wheelbase.
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The pictures only show selected variants and their dimensions/dimension ranges (e.g. short and long
wheelbase, normal roof, medium-high roof and high roof depending on the versions, etc.). Please refer
to the current sales literature for the complete set of technical data for the model range.
7
Body
The body
To a large extent, the body has been taken from the previous model.
The front end is new - it has been adapted to the current face of the Volkswagen family and is the same for the
Multivan and commercial vehicles. The engine cover and the exterior mirrors have been improved in terms of
their aerodynamics and reduced wind noise.
Acoustic glazing is also available as an option.
Innovations on the front end in detail:
– An engine cover with new lines and more angular
beading
– The engine cover extends further upwards and
covers the wiper arms in the windscreen area.
– In the lower area, the engine cover extends further
into the radiator grille area.
– The front end has a new assembly mount.
– New exterior mirrors
– New radiator grille
– Modified VW emblem design
–New headlights
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Front end
The front end is composed of the following main
components:
– Assembly mount
– Bumper mount
–Bulkhead
–Ventilator
– Radiator
–Condenser
– Intercooler (in the variants for TDI engine and TDI
engine with bi-turbocharger unit)
– Cooler for power steering
Intercooler (for TDI engine)
Bulkhead
Condenser
Assembly mount
Cooler for power steering
Ventilator
Radiator
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Bumper mount
8
Structure of the front end - exploded view
Cooler for power steering
Assembly mount
Ventilator
Intercooler
(for TDI engine)
Bulkhead
Bumper mount
The double fan concept in the previous model will
be discontinued - the T5 2010 now has a single fan
exclusively. The cooling power is adapted to the
equipment level by means of three different fan
powers (450 W, 600 W, 850 W).
Radiator
Condenser
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The attachments for all components on
the assembly mount have changed.
Please always refer to the information
in the workshop manual.
9
Body
Assembl y mo unt
In contrast to the assembly mount in the previous model, the one in the T5 2010 is no longer made from steel but
from a composite material comprising plastic with a steel insert.
The main advantage is the increased weight saving.
In order to guarantee the necessary stability and crash safety of the assembly mount, the upper cross member of
the assembly mount has been fitted with a steel insert. The plastic part is connected to the steel insert by hot
riveting. This involves the steel insert being pushed onto the extruded projections of the plastic part, and then
riveted by compression under the effect of heat.
All other parts of the assembly mount are made entirely of plastic.
Projection of the
plastic part
Upper crossmember
of the assembly mount
Projection of the plastic
part compressed by hot
riveting
Hot riveting
Steel insert of the assembly mount hot-riveted with assembly mount
Plastic part - hot-riveted
with assembly mount
Bumper mount
10
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Chassis rail
It is essential to comply with the information in the workshop manual with
regard to repair work on the front end - this applies in particular to the
service position as well
The tailgate emergency unlocking f unction
All model variants of the T5 2010 with tailgate are equipped with a tailgate emergency unlocking function.
In case of an emergency when the tailgate can no longer be opened, e.g. because:
● The tailgate or the opening mechanism has been damaged due to a crash
● The central locking has failed
● The opening system has failed on an electrically operated tailgate
then it is possible to open the tailgate from the inside.
The emergency unlocking function is installed on the tailgate above the tailgate lock behind a plastic cover.
The cover cap is identified with the "opened tailgate" symbol.
After the cover cap has been removed, the emergency unlocking function can be actuated manually by pressing
the lever for the emergency unlocking function.
Electric motor for
tailgate operation
Cover cap
Tailgate lock
Also refer to the owner's manual for
information about the emergency
unlocking function.
Lever for emergency unlocking
after removal of
the cover cap
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11
Body
Occupa nt pr otec ti o n
As a feature of the Volkswagen safety strategy, the occupant protection system in the T5 2010 has been improved in
the form of a seat belt fastening warning and a modified airbag concept for driver and front passenger protection.
Front passenger airbag
deactivation
In the commercial vehicle variants, the
Front passenger airbag deactivation is another
safety measure. The front passenger airbag can be
deactivated when the passenger door is open, using
the key-operated switch on the right-hand side end
of the dash panel.
belts at each of the outboard positions are
integrated in the body and those for the
middle seat positions are integrated in the
seat.
Module
Head / thorax airbag
Front passenger
Head airbag
Key operated switch to deactivate
front passenger side airbag E224
Module
Side airbag
Front passenger
Front airbag
Driver
Head / thorax airbag
Front passenger
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Front airbag
Front passenger
12
Module
Front airbag
Driver
Airbag control unit
with crash sensor for
front airbags
Module
Head / thorax airbag
Driver
Module
Head airbag
ISOFIX child seat restraint systems are
installed in the Multivan in the individual
seats and, in the commercial vehicles, the
outboard seats in the 1st row of the
passenger compartment.
Head airbag
Belt fastening warning
One feature in the safety concept is the seat belt
fastening warning for the driver's seat which is
installed as standard. An acoustic signal sounds if the
driver's seat belt is not fastened. In addition, a red
warning lamp lights up in the instrument cluster.
Three-point seat belt,
integrated in the seat
Crash sensor, in C-pillar at bottom
Head / thorax airbag
Driver
Three-point seat belt with
rack-type belt tensioner,
attached to body
Crash sensor, in B-pillar at bottom
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Head / thorax airbag
As a new feature, head / thorax airbags are now
fitted rather than the previously separate side and
head airbags in the passenger compartment. This
means the former two systems for each seat are now
combined into one system.
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Head / thorax airbag
Driver
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13
Engine
The engine/gearbox combinations
The engine range includes one petrol and four TDI
engines. The power plants are installed transversely.
Engine 5-speed manual
gearbox 02Z
2.0 l/85 kW
petrol engine
AXA
2.0 l/62 kW
TDI engine
CAAA
As far as the gearboxes are concerned, there are 2
manual gearboxes and one automatic.
6-speed manual
gearbox 0A5
DSG automatic
gearbox 0BT
2.0/75 kW
TDI engine
CAAB
2.0 l/103 kW
TDI engine
CAAC, CCHA
2.0 l/132 kW
TDI engine
CFCA
14
2.0 l/85 kW petrol engine
The engine has been adapted for use in the T5 2010
with the modified installation position.
Technical features
– Spray nozzles for piston cooling
– Oil pump driven by chain from the crankshaft
– Electrically heated crankcase ventilation
– Secondary air system
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Technical data
Engine identification
letter
Cubic capacity 1984 cm
Design 4-cylinder inline engine
Valves per cylinder 2
Bore 82.5 mm
Stroke 92.8 mm
Compression ratio 10.3 : 1
Max. power 85 kW at 5200 rpm
Max. torque 170 Nm at 2700 rpm
Engine management BOSCH Motronic ME 7.5
Fuel Super unleaded with ROZ 98
Exhaust
post-treatment
AXA
3
up to 4700 rpm
Pre- and post-cat lambda
probes with continuous
lambda control, exhaust gas
recirculation
Torque and power diagram
To r q u e ( N m )
Engine speed (rpm)
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Power (kW)
Emissions standard
EU5, EU4, EU3
15
Engine
2.0 l/62 kW TDI engine
The diesel engine is a further development
(2nd generation) based on the 2.0 l TDI engine in
the Tiguan or Passat, which has been adapted for the
installation conditions and the specific commercial
vehicle requirements of the T5 2010.
Technical features
– Common rail injection system
– Diesel particulate filter (EU 5)
– Exhaust gas recirculation through the cylinder
head
– Plastic intake manifold
–VTG turbocharger
Technical data
Engine identification
letter
Cubic capacity 1968 cm
Design 4-cylinder in-line engine
Valves per cylinder 4
Bore 81.0 mm
Stroke 95.5 mm
Compression ratio 16.5 : 1
Max. power 62 kW at 3500 rpm
Max. torque 220 Nm at 1250 rpm
CAAA
3
up to 2500 rpm
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Torque and power diagram
To r q u e ( N m )
Power (kW)
16
Engine management EDC 17CP 20
Fuel Diesel acc. to DIN EN 590
Exhaust turbocharger VTG turbocharger
Exhaust gas
recirculation
Emissions standard EU5 with diesel particulate filter
yes
EU4 without diesel particulate filter
EU3 without diesel particulate filter
Engine speed (rpm)
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2.0 l/75 kW TDI engine
The design of the 75 kW engine is based on the same
engine as the 62 kW engine. The difference is only the
modification to the control unit software used for the
injection system.
Technical features
– Common rail injection system
– Diesel particulate filter (EU 5)
– Exhaust gas recirculation through the cylinder
head
– Plastic intake manifold
–VTG turbocharger
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Technical data
Engine identification
letter
Cubic capacity 1968 cm
Design 4-cylinder in-line engine
Valves per cylinder 4
Bore 81.0 mm
Stroke 95.5 mm
Compression ratio 16.5 : 1
Max. power 75 kW at 3500 rpm
Max. torque 250 Nm at 1500 rpm
Engine management EDC 17CP 20
Fuel Diesel acc. to DIN EN 590
Turbocharger VTG turbocharger
Exhaust gas
recirculation
CAAB
3
up to 2500 rpm
yes
Torque and power diagram
To r q u e ( N m )
Engine speed (rpm)
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Power (kW)
Emissions standard EU5 w. diesel particulate filter
EU4 without diesel particulate filter
EU3 without diesel particulate filter
17
Engine
2.0 l/103 kW TDI engine
The design of the 2.0 l/103 kW engine is also based
on the same engine as the 62 kW engine.
The difference is only the modification to the control
unit software used for the injection system.
Tech n i c al fe a t u r es
– Common rail injection system
– Diesel particulate filter (EU 5)
– Exhaust gas recirculation through the cylinder
head
– Plastic intake manifold
–VTG turbocharger
Technical data
Engine identification
letter
Cubic capacity 1968 cm
Design 4-cylinder in-line engine
Valves per cylinder 4
Bore 81.0 mm
Stroke 95.5 mm
Compression ratio 16.5 : 1
Max. power 103 kW at 3500 rpm
Max. torque 340 Nm at 1750 rpm
CAAC - Transporter version
CCHA - Multivan, Caravelle
3
up to 2500 rpm
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Torque and power diagram
To r q u e ( N m )
Power (kW)
18
Engine management EDC 17CP 20
Fuel Diesel acc. to DIN EN 590
Turbocharger VTG turbocharger
Exhaust gas
recirculation
Emissions standard EU5 w. diesel particulate filter
yes
EU4 w/o diesel particulate filter
EU3 without diesel particulate filter
Engine speed (rpm)
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2.0 l/132 kW TDI engine with
bi-turbo unit
The design of the 2.0 l/132 kW engine is based on
the 2.0 l/103 kW engine, but it is equipped with a
bi-turbo unit to provide a power boost.
The control unit software has been adapted
accordingly.
Technical features
(in addition to the 2.0 l/103 kW engine)
– Exhaust manifold module with bi-turbo unit
– Oil filter module with integrated exhaust gas
recirculation cooler
– Cylinder block with additional cooling ducts
– Piston with cooled ring groove
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Technical data
Engine identification
letter
Cubic capacity 1968 cm
Design 4-cylinder in-line engine
Valves per cylinder 4
Bore 81.0 mm
Stroke 95.5 mm
Compression ratio 16.5 : 1
Max. power 132 kW at 4000 rpm
Max. torque 400 Nm at 1500 rpm
Engine management EDC 17 CP 20
Fuel Diesel acc. to DIN EN 590
Exhaust turbocharger Bi-turbo unit
Exhaust gas
recirculation
CFCA
3
up to 2250 rpm
yes
Torque and power diagram
To r q u e ( N m )
Engine speed (rpm)
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Power (kW)
Emissions standard EU5 w. diesel particulate filter
EU4 without diesel particulate filter
EU3 without diesel particulate filter
19
Power transmission
The gearboxes
Two manual gearboxes, the 02Z and the 0A5
gearbox, and the DSG automatic gearbox 0BT are
used in the T5 2010. They have been designed for
transverse installation in the vehicle.
5-speed manual gearbox 02Z
The 5-speed gearbox is already familiar from the
previous model, and is used with the 4-cylinder
85 kW petrol engine and the 4-cylinder TDI engines
with 62/75 kW. The gearbox can transmit torques up
to a maximum of 250 Nm.
6-speed manual gearbox 0A5
The 6-speed gearbox is also familiar from the
previous model and is used in the 4-cylinder TDI
engines with 103/132 kW. It can transmit torques
up to a maximum of 500 Nm.
The compact design is convenient for transverse
installation, and has been achieved by structuring
it as a 4-shaft gearbox. In the 4-shaft concept, the
pinion shafts are permanently engaged with the
gear on the final drive.
Depending on which gear is engaged, the powerflow
is via the input shaft onto one of the pinion shafts.
The clutch bell housing has been adapted to the
modified installation situation in order for it to be
fitted on the 4-cylinder TDI engine.
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