Volkswagen Touran User Manual
Service.
Self-study programme 306
The Touran
Seven passengers and 121 litres of luggage
capacity or two passengers and 1913 litres of
luggage capacity is what the Touran offers as a
compact van.
Based on these figures alone, the successful
realisation of the MPV concept is for all
to see. MPV is the abbreviation for
"Multi Purpose Vehicle" or in other terms:
"A vehicle with multiple utilisation options".
The name Touran is created from the word
"Tour", i.e. to travel. To demonstrate its relation to
the Sharan, the end syllable from its big brother
was placed on the end.
Clever, innovative and dynamic is not just the
technology – that is described in detail on the
following pages – but also the production model
for the Touran: It is being produced by Auto
5000 Ltd, which is a Volkswagen AG subsidiary.
This self-study programme explains the design
and function of new developments.
The contents will not be updated.
2
For current inspection, adjustment and repair
instructions, please refer to the relevant
service literature.
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NEW Important
Note
Contents
Brief overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Occupant safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Power units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Heating and air conditioning . . . . . . . . . . . . . . . . . . . 52
Radio and navigation . . . . . . . . . . . . . . . . . . . . . . . . . 56
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
3
Brief overview
The Touran – Marketing aspects
"The flexible allrounder"
The Touran is designed so that it can be adapted
to different needs. With this in mind, one of the
most important features is the interior, which is
variable and can be restructured to suit any
situation.
On the technical side, it features engine and
gearbox combinations that are superior to the
competition and well balanced running gear
technology for safety and driving enjoyment.
All of these properties make the vehicle
appealing to particular target groups, such as
young couples with children.
Adjectives that are synonymous with this target
group are: active, self confident, well-informed
and image conscious.
The Touran is available as a 5 or 7 seater
version, which is typical for compact vans.
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4
The 5 seater
The 5 seater features a second seat row with
single seats. All seats of the second seat row can
be folded down, folded together and removed.
They are also adjustable longitudinally and can
be moved to the left or right.
The middle seat in this row can be used in its
folded down state as a table thanks to a plastic
insert in the backrest. It can also be exchanged
for a cool box.
The 7 seater
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The 7 seater has an additional third seat row with
two folding seats that can be lowered
individually. This makes the 7 seater the most
versatile Touran: It can accommodate up to
seven occupants, or it can offer a large cargo
area when all seats are removed or folded down.
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5
Brief overview
The Touran and Auto 5000 Ltd
What is Auto 5000?
Auto 5000 Ltd is a subsidiary of the Volkswagen
AG. At Auto 5000 Ltd, two aims are at the
forefront: Firstly, the construction of a new type
of vehicle, the Touran compact van, with which
Volkswagen wishes to supplement its range of
vehicles in this market segment. Secondly, it is to
prove that industrial production has a future in
Germany.
Process optimisation and cost reduction should
not simply be the task of the managers but,
above all, lie in the hands of the workers
themselves.
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Where is production carried out?
The Touran will be the first vehicle to be
produced within Auto 5000 Ltd.
The production site is the main Volkswagen
Group headquarters in Wolfsburg. On the
premises at Volkswagen, modern production
facilities were built in halls 8, 9 and 10 of the
factory.
Hall 8 Hall 9 Hall 10
For production of the Touran, the core processes:
body construction (hall 10), paintwork (hall 9)
and assembly (hall 8) are covered within Auto
5000 Ltd.
All other processes are dealt with by internal
areas of the company and external
organisations.
The Volkswagen factory in Wolfsburg
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7
Brief overview
Technical data
The diagram shows the dimensions of a 7 seater Touran with Trendline equipment.
1539
Measurements and weights
Length 4391 mm
Width 1794 mm
Height 1652 mm
Wheelbase 2678 mm
Track width, front 1539 mm
Track width, rear 1521 mm
2678
4391
1652
1794
1521
Fuel tank volume 60 ltr.
Luggage compartment
volume
Max. permissible weight 2090 kg***
Unladen weight 1423 kg***
Maximum load 667 kg***
Coefficient drag value 0.315 c
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from 121 ltr.* to 1989
ltr.**
d
*7 seater
** 5 seater with 2nd seat row removed
*** 1.6 ltr./85 kW FSI engine
8
Interior dimensions
The following diagrams show the dimensions of the interior of the Touran (7 seater).
1
3
5
4
2
6
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9
8
7
1st seat row
2nd seat row
(1) Head room, front = 1020 mm
(2) Leg room, 2nd seat row = 38 mm* - 80 mm**
(3) Head room, 2nd seat row = 989 mm
(4) Leg room, 3rd seat row = 17 mm* - 133 mm***
(5) Head room, 3rd seat row = 917 mm
* Position in accordance with DIN 700200
** with seat of second seat row moved backwards fully
*** with seat of second seat row moved forwards fully
3rd seat row
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(6) Length of interior = 1676 mm
(7) Shoulder room, front = 1422 mm
(8) Shoulder room, 2nd seat row = 1436 mm
(9) Shoulder room, 3rd seat row = 1221 mm
9
Body
The basic body structure of the Touran
Materials used
On the Touran, the trend towards high tensile
and reinforced steel is noticeable.
The use of improved steel quality offers two
advantages:
1. The rigidity of the body and thus occupant
safety are enhanced.
2. The same level of crash safety is achieved
with a reduction in weight of the vehicle,
which has a favourable influence on fuel
consumption.
Special features
The body of the Touran is bonded in many areas
using laser welding techniques. Thanks to laser
welding, long weld seams are achievable that
allow an uninterrupted joint. In this way, the
rigidity of the body is increased, compared to
spot welded joints, and also crash safety.
Key:
Blue = Occupant cell
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10
Diagonally installed side impact protection
The side impact protection carriers are attached
to the doors diagonally. They therefore bend
upwards or downwards in an accident instead of
penetrating the A, B and C pillar. This provides
easier access for crash rescue personnel as the
doors no longer become blocked in a side
impact collision.
Diagonal side impact protection
The diagonal positioning of the side impact
protection also covers a greater surface area.
This means that, in the event of a side impact
collision, the impact protection will always be hit
and is therefore able to work fully in the way
intended.
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Body
The Touran body attachments
Front body
The front body of the Touran is supplemented for
pedestrian protection by two foam elements.
A cross member with holders supports the foam
elements.
Foam
elements
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Cross member
with holders
Wings
The wings are not bolted directly to the
longitudinal member. They are bonded with the
longitudinal member via a module. This type of
construction is also installed for pedestrian
safety: The module is designed to collapse on
impact.
Diagram showing connection of wing to longitudinal member:
Golf, for example
Wings
Tou ra n
Module
12
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Plenum chamber front plate
The windscreen of the Touran is designed to
reach into the engine compartment. In order to
allow access of the components that are partly
concealed in the engine compartment behind the
bottom of the windscreen, the plenum chamber
front plate can be removed.
Door gap seal
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Door seals
Seals
The Touran has three seals to the exterior.
In addition to two door seals, a door gap seal is
installed.
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Body
Roof rails
The roof rails have been designed for optical
reasons as a continual bar.
The roof rail blocks are secured to the body by
means of hexagon nuts on the inside of the roof.
To change the roof rails, the interior trim has to
be removed.
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For further information, please refer
to the electronic service information
system ELSA.
Tailg ate
For the first time, Volkswagen has installed a
special two stage gas filled strut on the tailgate.
The tailgate opens
to the stop position first, which is at the same
level as the roof. In this position, damage to the
tailgate can be avoided in enclosed areas with
low ceilings (garages etc.). The stop position can
be overcome by simple application of hand
force. In this way,the tailgate can be opened
variably between the stop and end positions.
End position
Stop position
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The body characteristics
Touran in the wind tunnel
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With a cd value of 0.315, the Touran has a good coefficient drag factor for a compact van.
This has been partly achieved by the air flow optimised body upper part and partly by the application of
plastic underbody trim. The underbody trim provides a continual surface along which air can flow
without swirling.
The underbody trim offers an additional advantage in that there is no longer a requirement for the PVC
underbody protection. This helps to reduce weight and also the production of PVC. Since PVC has poor
recycling properties, the general recycling properties of the vehicle are improved with the removal of this
material.
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Body
The interior
Space concept
The 5 and 7 seater Touran are identical up to the C-pillar.
At a later stage in production, a front passenger seat will be installed that, when folded down, can also
be used as a table.
● The 5 and 7 seater
The second seat row consists of three single
seats. Each of the seats can be folded down,
folded forwards and removed quickly with the
aid of a pull catch. The seats can also be
adjusted individually in the longitudinal plane.
When the middle seat is removed, both outer
seats can be moved laterally inwards by 140 mm.
Attached to the outer seats of the second seat
row are Isofix mountings.
To prevent seats that have been folded forwards
from falling back, a safety device has been
installed in the second seat row.
Folded
forwards Folded down
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The middle seat of the second row doubles up as
a table as it features a plastic surface on the rear
of the backrest.
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● Properties of the 7 seater Touran
In addition to the second seat row, the 7 seater
Touran has two further seats in the third seat row.
Both of these seats can be lowered with the help
of a lever to provide a level surface in
combination with the cargo box.
The level surface is at loading height.
The head restraints are stored in the cargo box.
Unfolded
seat
Folded seat
Head restraint
Cargo box
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Further information on this subject can
be found in the multimedia training
package for the Touran.
17
Body
Stowage facilities
The interior of the Touran features up to 39 stowage facilities. The marked areas in the following
diagrams indicate where the Touran has stowage facilities.
Key:
= Compartments, stowage facilities
= Drinks holder
Compartments in front seats
The front seats generally feature one
stowage compartment each beneath the seat.
From the Trendline version, a drawer is also
installed above these
compartments. Furthermore, there is also
a folding table and pockets in the backrests.
Stowage
compartment
Drawer
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Folding
table
Pocket
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Stowage compartments in dash panel and centre console
In the dash panel and centre console there are several compartments and drinks holders.
These are as follows:
1) One stowage compartment beneath
instrumentpanel on driver side
2) One stowage compartment with cover
above instrument panel
3) One stowage compartment beneath
instrumentpanel with cover (or ash tray)
4) One stowage compartment in centre console
beneath instrument panel with open
compartment
5) Illuminated glove compartment on front
passenger side with two drinks holders in flap
(on vehicles with air conditioner, this
compartment is chilled.)
6) Stowage compartment in armrest (suitable
for CD changer)
7) Drinks holder for second seat row at rear
of centre console.
2
3
4
1
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5
7
6
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Body
Stowage compartments in roof
New and unique are three stowage
compartments in the roof console of the Touran.
They offer space, for example, for parking
permits, sunglasses or tissues. On equipment
levels with sliding/tilting sunroof, these
compartments are not included.
Door stowage compartments
In the 5 and 7 seater versions, each seat has a
1 litre bottle holder. For the front seats and both
outer seats of the second row, these stowage
facilities are incorporated in the doors.
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Stowage compartments in footwell
Directly in front of the second seat row there is a
stowage compartment in the floor on the left and
right of each footwell. The compartments can be
used to store toys or an atlas for example.
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