Repair VOLKSWAGEN TOUAREG 2012 User Guide

WARNING
Connecting cables of external devices may obstruct visibility through the windshield or other windows.
x Route cables so as not to interfere with the driver.
WARNING
Opening a CD or DVD player's housing can lead to injuries from invisible laser radiation.
x Always have CD or DVD players repaired only by a qualified workshop.
NOTICE
Improper insertion or insertion of an improperly fitting memory card can damage the locking mechanism in the memory card slot.
x Pay attention to the proper insertion position ⇒ page 269, Media mode: Introduction.
x Excessive pressure can destroy the locking mechanism in the memory card slot.
x Only use suitable memory cards.
NOTICE
x When inserting and removing CDs and DVDs, always hold them at right angles to the front of the unit. Inserting or removing them at an angle to the DVD drive may lead to scratching.
x Inserting a second CD or DVD while a CD or DVD is inserted or is being ejected can destroy the DVD drive. Always wait until the data storage device is completely ejected.
NOTICE
Any foreign objects attached to a data medium and non-round data storage devices can dam-age the DVD drive.
x Only clean 12-cm standard CDs or DVDs should be used!
– Do not attach stickers or other items to the date storage device. Stickers may peel off and damage the drive.
– Do not insert 8-cm single CDs or non-round CDs (shaped CDs) or DVDs.
– Do not insert DVD-Plus, Dual Discs and Flip Discs, as these are thicker than standard CDs.

Lights
up Possible cause Proper response
K Depress brake pedal! Depress the brake pedal while
starting the engine.
2%!$9 Hybrid vehicles: Electric drive
is ready.
Never leave the vehicle parked in
the ready position. Remove the
remote control vehicle key out of
the ignition or for vehicle with
Keyless Access press the starter
button. When leaving the vehicle
always take the remote control
vehicle key with you.

No authorized remote control
vehicle key found (Keyless
Access).
Use an authorized remote control
vehicle key
Engine cannot be started with
starter button (Keyless Ac-
cess).
Start the engine with the remote
control vehicle key. Take the
vehicle to an authorized
Volkswagen dealer or an author-
ized Volkswagen Service Facility
and have the system checked.

When the ignition is switched on, several warning and indicator lights come on briefly for a function check. They go out after a few seconds.
WARNING
Failure to heed warning lights and instrument cluster text messages can cause the vehicle to break down in traffic and result in a collision and serious personal injury.
x Never ignore warning lights or text WARNINGS.
x Always stop the vehicle as soon as it is safe to do so.
x Whenever stalled or stopped for repair, move the vehicle a safe distance off the road, turn on the emergency flashers, stop the engine, and use other warning devices to warn ap-proaching traffic.
NOTICE
Failure to heed warning lights or text WARNINGS can result in vehicle damage.

WARNING
Failure to heed warning lights and instrument cluster text messages can cause the vehicle to break down in traffic and result in a collision and serious personal injury.
x Never ignore warning lights or text WARNINGS.
x Always stop the vehicle as soon as it is safe to do so.
x Whenever stalled or stopped for repair, move the vehicle a safe distance off the road, turn on the emergency flashers, stop the engine, and use other warning devices to warn ap-proaching traffic.
NOTICE
Failure to heed warning lights or text WARNINGS can result in vehicle damage.
Pedals

Fig. 248 Pedals in vehicles with automatic transmission: 1 Accelerator pedal, 2 brake pedal.

Brake system malfunction
If you brake and find that vehicle doesn't brake nearly as well as it used to (sudden increase in stop-ping distance), a brake circuit may have failed. The brake warning light "2!+% or H will come on and a message may appear in the instrument cluster display. If you believe the vehicle is safe to drive, immediately take it to the nearest authorized Volkswagen dealer or authorized Volkswagen Service Facility for repair. Drive slowly and very carefully, allow for the longer stopping distance, and be ready to push longer and harder on the brake pedal to slow the vehicle down.
Brake booster
The brake booster works only when the engine is running. It increases the force on the brakes above and beyond the pressure put on the brake pedal by the driver.
If the brake booster is not working, or if the vehicle has to be towed, you will have to push the brake pedal harder to make up for the lack of booster assistance and the resulting longer stopping distance
⇒ .
WARNING
New brake pads do not provide maximum braking performance.
x New brake pads do not have the best stopping power for the first 200 miles (320 km) and must be “broken in.” You can compensate for the slightly reduced braking force by putting more pressure on the brake pedal.
x Drive with extra care while the new brake pads are being broken in. This reduces the risk of collisions and serious personal injuries due to a loss of control over the vehicle.
x Never follow other vehicles too closely or put yourself into other situations that might require sudden, hard braking, especially when the brake pads have not been broken in.
WARNING
Overheated brakes will reduce the vehicle's stopping power and increase stopping distances considerably.
x When driving downhill, the brakes have to work especially hard and heat up quickly.
x Before driving downhill, especially on hills that are long or steep, always reduce speed and shift into lower gear (manual or automatic transmission). This will let the vehicle use engine braking and reduce the load on the brakes. Otherwise, the brake system could over-heat and possibly fail. Only use the brakes when you need them to slow the vehicle down more or to stop.
x A damaged front spoiler or a non-standard spoiler can reduce airflow to the brakes and make them overheat.
WARNING
Wet brakes or brakes coated with ice or road salt react slower and need longer stopping dis-tances.
x Carefully apply the brakes to test them.
x Always dry brakes and clean off ice and salt coatings with a few cautious brake applica-tions when visibility, weather, road and traffic conditions permit.

DANGER
The vehicle's high-voltage electrical system and high-voltage battery are dangerous and can cause burns, other serious personal injuries, electrocution, and death.
x Always assume that high-voltage battery and parts of the high-voltage system are fully charged and energized.
x Never touch or let jewelry or other metal objects contact high-voltage cables or the high-voltage battery and battery poles, especially if the cables, battery, and battery poles have been damaged in any way.
x Never do any work yourself on the high-voltage electrical system, the orange-colored high-voltage wiring, or on the high-voltage battery.
x Never open, service, repair, or disconnect any part of the hybrid electrical system.
x Never damage the orange-colored high-voltage cables. Never remove them and never disconnect them from the high-voltage electrical system.
x Never open or remove the orange-colored cover on the high-voltage battery.
x Always have work on the hybrid electrical system and systems that could be indirectly affected by it done by qualified, trained technicians who have the know-how, experience, documentation, and tools to do the work safely.
x All work on the high-voltage electrical system and the high-voltage battery must be done in compliance with Volkswagen standards and guidelines.
x Vehicle keys must be safely stored a safe distance from vehicle so that the ignition cannot be switched on and energize the electrical system.
x Gases vented or released from the high-voltage battery vapors are potentially poisonous and can burn.
x Physical damage to the vehicle or the high-voltage battery can result in immediate or de-layed release of poisonous gases that can also cause a fire.
x Always avoid contact with leaking fluids and gases escaping from the battery, particularly one that has been damaged.
x Always tell emergency responders that the vehicle has a high-voltage battery.
WARNING
Driver distraction causes accidents and serious personal injury. Using the instrument cluster or accessing Infotainment System menus while driving can take your attention off the road and cause accidents.
x To help reduce the risk of accidents and injuries, never change settings in the instrument cluster display or use Infotainment System functions unless the vehicle is standing still.

Maintenance of the high-voltage battery
Other than taking the vehicle in for scheduled maintenance to an authorized Volkswagen dealer or an authorized Volkswagen Service Facility that is qualified to do work on hybrid vehicles, there is nothing that the vehicle driver has to do to maintain the high-voltage battery.
The maintenance connection for the high-voltage battery is under the luggage compartment floor under an orange cover. This connection is only for scheduled maintenance, which must be performed only by specially trained service technicians. There is no need to remove the connector at any time
when the vehicle is being used ⇒ 
WARNING
The high-voltage hybrid electrical system is dangerous and can cause burns, other serious personal injuries, electrocution and death.
x Never open, service, repair, or disconnect the high-voltage hybrid battery.
x Never touch or let jewelry or other metal objects contact high-voltage cables or the high-voltage battery and battery poles, especially if the cables, battery, or battery poles have been damaged in a crash or in some other way.
x Always have work on the hybrid electrical system and on systems that could be indirectly affected by it done by qualified, trained technicians, who have the know-how, experience, documentation, and tools to do the work safely.
WARNING
Failure to heed warning lights and instrument cluster text messages can cause the vehicle to break down in traffic and result in a collision and serious personal injury.
x Never ignore warning lights or text WARNINGS.
x Always stop the vehicle as soon as it is safe to do so.
NOTICE
x Failure to heed warning lights or text WARNINGS can result in vehicle damage.
x If the 12 Volt vehicle battery is disconnected or dead or has been replaced, there is a possi-bility that the combustion engine will not automatically switch off when the vehicle is powered by the electric motor. If this situation persists for several days, take the vehicle to an author-ized Volkswagen dealer or an authorized Volkswagen Service Facility that is qualified to do work on hybrid vehicles.
x Never transport water or other liquids or fluids in open containers, such as an aquarium. If liquid is spilled in the luggage compartment, this can cause short circuits or damage the high-voltage battery.
NOTICE
Never block or cover the cooling air vents for the high-voltage hybrid battery under the rear seat. Blocking or covering these vents can damage the high-voltage battery.

WARNING
Poor visibility increases the risk of collisions and other accidents that cause serious person-al injuries.
x Always make sure all windows are clear of ice, snow and condensation for good visibility to the front, sides, and rear.
x Maximum heating output and fast defrosting will only be possible after the engine has reached operating temperature. Wait until you have good visibility before driving off.
x Always make sure you know how to properly use the heating and ventilation systems as well as the rear window defroster that you will need for good visibility.
x Never use air recirculation for long periods of time. When the air conditioner is off and recirculation mode is on, condensation can quickly form on the windows and greatly reduce visibility.
x Always switch off recirculation mode when it is not needed.
WARNING
Stale air causes driver fatigue and reduces driver alertness, which can cause accidents, colli-sions and serious personal injury.
x Never switch off the fan for a long period of time and never use air recirculation a long period of time because no fresh air will come into the passenger compartment.
NOTICE
x If you think the air conditioner is not working properly or may be damaged, switch it off to help prevent more damage. Have the air conditioner checked by an authorized Volkswagen dealer or authorized Volkswagen Service Facility.
x Air conditioner repair requires specialized knowledge and special tools. Volkswagen rec-ommends that you see an authorized Volkswagen dealer or an authorized Volkswagen Service Facility.
x Do not smoke when air recirculation is switched on. Smoke drawn into the ventilation sys-tem can leave residue on the evaporator and on the dust and pollen active carbon filter, result-ing in permanent odors whenever the air conditioner is switched on.
If the air conditioner is switched off, the fresh outside air will not be dehumidified. To help keep the windows from fogging over, Volkswagen recommends leaving the air conditioner (compressor) switched on. Press the !

DANGER
The vehicle's high-voltage electrical system and high-voltage battery are dangerous and can cause burns, other serious personal injuries, electrocution, and death.
x Always assume that high-voltage battery and parts of the high-voltage system are fully charged and energized.
x Never touch or let jewelry or other metal objects contact high-voltage cables or the high-voltage battery and battery poles, especially if the cables, battery, and battery poles have been damaged in any way.
x Never do any work yourself on the high-voltage electrical system, the orange-colored high-voltage wiring, or on the high-voltage battery.
x Never open, service, repair, or disconnect any part of the hybrid electrical system.
x Never damage the orange-colored high-voltage cables. Never remove them and never disconnect them from the high-voltage electrical system.
x Never open or remove the orange-colored cover on the high-voltage battery.
x Always have work on the hybrid electrical system and systems that could be indirectly affected by it done by qualified, trained technicians who have the know-how, experience, documentation, and tools to do the work safely.
x All work on the high-voltage electrical system and the high-voltage battery must be done in compliance with Volkswagen standards and guidelines.
x Vehicle keys must be safely stored a safe distance from vehicle so that the ignition cannot be switched on and energize the electrical system.
x Gases vented or released from the high-voltage battery vapors are potentially poisonous and can burn.
x Physical damage to the vehicle or the high-voltage battery can result in immediate or de-layed release of poisonous gases that can also cause a fire.
x Always avoid contact with leaking fluids and gases escaping from the battery, particularly one that has been damaged.
x Always tell emergency responders that the vehicle has a high-voltage battery.
WARNING
Unintended vehicle movement during maintenance work can cause serious personal injuries.
x Never work under the vehicle unless you have safely secured the vehicle from moving. If you must work under the vehicle with the wheels on the ground, always make sure that the vehicle is on level ground, that all 4 wheels are chocked to keep them from moving, and that the key is not in the ignition.
x If you must work under a vehicle raised on a floor jack, always make sure that the vehicle is safely supported on safety stands intended for that purpose that are strong enough to support the weight of the vehicle. The jack supplied with the vehicle is not strong enough for this purpose and can collapse causing serious personal injury.

WARNING
High voltage systems in the engine compartment can cause electrical shocks or even elec-trocution, severe burns, other serious injuries, and even death!
x Never short-circuit the electrical system. Be especially careful when using jumper cables. The vehicle's battery could explode!
x To reduce the risk of electrical shock and personal injury while the engine is running or being started:
– Never touch ignition cables. Never touch other components of the high-voltage elec-tronic ignition system.
– Never touch the wiring of the HID – High Intensity Discharge (Xenon) headlights.
x Read and heed the important information and warnings on cleaning the engine compart-
ment ⇒  Cleaning the engine compartment.
WARNING
Moving parts in the engine compartment can cause serious personal injury on contact.
x Never reach into the area around or touch the radiator fan. Contact with the blades can cause serious personal injury. Always remember that the radiator fan is temperature-controlled and can come on suddenly even when the engine has been switched off for a while and the key has been removed from the ignition.
x If you have to perform a check or repair when the engine is running, there are more risks from the rotating parts, such as the drive belts, alternator, radiator fan, etc., and from the high-voltage ignition system. Always use extreme care.
– Always make sure that jewelry, loose clothing and long hair do not get caught in rotat-ing engine parts. Before starting any work remove your jewelry, take off your necktie, tie back and cover your hair, and do not wear clothing that can hang down and get caught in moving engine parts.
– Always use extreme caution if the accelerator pedal has to be depressed to perform a check. The vehicle will start to move even if the parking brake is on.
x Never leave any objects in the engine compartment, for example cleaning rags and tools. Objects left behind can cause malfunctions, engine damage, and even fires.
WARNING
Operating fluids and some materials in the engine compartment can catch fire easily, causing burns and other serious personal injuries!
x Do not smoke.
x Never work next to open flames or sparks.
x Never pour or spill operating fluids or other flammable liquids on the engine. These fluids can ignite on hot engine parts and cause injuries.
x If work on the fuel system or the electrical system is necessary:
– Always disconnect the 12 Volt vehicle battery. Make sure the vehicle is unlocked when you disconnect the battery, or the alarm will go off. Never touch the electrical wiring of the ignition system.
– Never work near heaters, water heaters, or other open flames.
x Always have a functional, approved fire extinguisher nearby.

x Interior care and cleaning
x Parts, accessories, repairs and modifications
WARNING
Working on the batteries or the electrical system in your vehicle can cause serious acid burns, fires, explosions, or electrical shocks. Always read and heed the following WARNINGS and safety precautions before working on the batteries or the electrical system.
x Before working on the electrical system, always switch off the ignition and all electrical consumers and disconnect the negative cable (–) from the standard 12 Volt vehicle battery.
x When you change a light bulb, always switch off the light first.
x Always keep children away from battery acid and vehicle batteries in general.
x Always wear eye protection. Never let battery acid or lead particles come into contact with your eyes, skin, or clothing.
x Sulfuric battery acid is very corrosive. It can burn unprotected skin and cause blindness. Always wear protective gloves and eye protection. To reduce your risk of injury, never tilt the batteries, as this could spill acid through the vents and burn you.
x If you get battery acid in your eyes or on your skin, immediately rinse with cold water for several minutes and then get immediate medical attention. If you swallow any battery acid, get medical attention immediately.
x When disconnecting the batteries from the vehicle electrical system, always disconnect the negative cable (–) first and then the positive cable (+).
x Always switch off all electrical consumers before reconnecting 12 Volt vehicle batteries. Reconnect the plus cable (+) first and then the negative cable (–). Never reverse the polarity of the connections. This could cause a fire.
x A highly explosive mixture of gases is given off when the battery is being charged.
x Do not smoke and avoid fires, sparks, and open flames when working. Never create sparks or electrostatic charges when handling cables and electrical equipment. Never short circuit the battery terminals. High-energy sparks can cause serious personal injury.
x Never use or attempt to charge a damaged or frozen battery, or a battery that was frozen but has thawed. Charging a frozen or thawed battery could cause explosions and chemical burns! Replace damaged or frozen vehicle batteries immediately. A dead battery can freeze at temperatures around +32 °F (0 °C).
x If the battery has a vent line or tube, make sure that this it is properly connected to the battery.
x Always make sure that the vent line is securely attached to a vehicle battery that is located in the luggage compartment.
WARNING
California Proposition 65 Warning
x Battery posts, terminals, and related accessories contain lead and lead components, chemicals known to the State of California to cause cancer and reproductive harm. Wash your hands after handling.
NOTICE
x Do not expose the vehicle battery to direct sunlight for an extended period of time as ultra-violet rays may damage the battery housing.
x If the vehicle is left standing in the cold for a long time, protect the vehicle battery from freezing. A battery will be permanently damaged by freezing.