ignition VOLKSWAGEN TOUAREG 2012 Repair Manual

After switching on the ignition, the indicator light

Octane rating
Octane rating indicates a gasoline's ability to resist engine damaging “knock” caused by pre-ignition. Using the correct grade of gasoline is very important to help prevent engine damage and loss of engine performance.
The recommended gasoline octane rating for your engine is listed on a label inside of the fuel filler flap. This rating may be specified according to AKI (CLC) or RON (ROZ) standards.
If unleaded Premium grade gasoline is specified for your vehicle, then Volkswagen recommends using TOP TIER Detergent Gasoline with a minimum octane rating of 91 AKI (95 RON). For more infor-mation on TOP TIER Detergent Gasoline, please go to the official website (http://www.toptiergas.com).
The gasoline grades most commonly sold in the United States and Canada have the following octane ratings, which can usually be found on the filler pump:
x Premium grade: 91 to 96 AKI
x Regular grade: 87 to 90 AKI
Unleaded gasoline
Unleaded gasoline is available throughout the USA and Canada. Volkswagen recommends that you do not take your vehicle to places where unleaded gasoline may not be available.
Gasoline containing alcohol or MTBE
You may use unleaded gasoline blended with alcohol or MTBE (methyl tertiary butyl ether), commonly referred to as oxygenated fuels, if the blended mixture meets the following criteria:
Blends of gasoline and methanol (wood alcohol or methyl alcohol):
x Anti-Knock Index (AKI) must be 87 or higher.
x Blend must contain no more than 3% methanol.
x Blend must contain more than 2% co-solvents.
Blends of gasoline and ethanol (grain alcohol or ethyl alcohol):
x Anti-Knock Index (AKI) must be 87 or higher.
x Blend must contain no more than 15% ethanol.
Blends of gasoline and MTBE:
x Anti-Knock Index (AKI) must be 87 or higher.
x Blend must contain no more than 15% MTBE.
Seasonally adjusted gasoline
Many fuels are blended especially for winter or summer conditions. When seasons change, Volkswagen suggests that you buy fuel at busy stations where the seasonal adjustment is more likely to be made earlier.
WARNING
Starting fluids can explode and cause a run-away vehicle condition.
x Never use starting assist fluids.
NOTICE
x Never use fuel with an octane rating lower than 87 AKI/91 RON. Using lower octane fuel may cause expensive engine damage.
x Never use leaded gasoline! Leaded gasoline will severely damage your vehicle's catalytic converter.

Lights
up
Possible cause or meaning
⇒  Proper response
together
with
ing or not filled standard
AdBlue.
authorized Volkswagen dealer
or an authorized Volkswagen
Service Facility.
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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.
NOTICE
Failure to heed warning lights or text WARNINGS can result in vehicle damage.
AdBlue information

x Fold up the luggage compartment floor panel ⇒ fig. 308 (1) and hook it open or, if you have a reversible luggage compartment floor panel, take this out
x Take out the collapsible spare tire (2)- Unscrew the fastening screw (3) with washer counterclock-wise and take out the collapsible spare tire.
x Pull off the plug (4) in the spare tire well.
x Unscrew the tank filler neck cap ⇒ fig. 309 (5) counterclockwise and remove.
Refilling AdBlue
Only use Volkswagen-approved AdBlue or any Diesel Exhaust Fluid that expressly conforms to International Organization for Standardization specification ISO 22241-1. Using a DEF that does not meet the requirements of ISO 22241-1 can seriously damage your vehicle’s engine. Only use fluid in original, unopened packaging.
x Read and heed the information provided by the AdBlue refill manufacturer ⇒ .
x Note the expiration date.
x Unscrew the cap of the refill container.
x Vertically insert the neck of the refill container (6) into the tank filler neck and turn clockwise to hand-tighten.
x Press the refill container down into the tank filler neck and hold it there.
x Add at least 1.5 gallons (5.7 liters) of AdBlue which is 3 refill bottles. Adding a smaller amount is not sufficient.
x Wait until the contents of the refill container has flowed into the AdBlue tank. Do not squeeze or damage the refill container!
x Unscrew the refill container counterclockwise and lift it out carefully ⇒ .
x AdBlue stops flowing from the refill bottle when the AdBlue tank is completely full.
Closing the fuel filler neck
x Screw in the fuel filler neck cap (5) clockwise until the cap locks into place.
x Put the plug ⇒ fig. 308 (4) back in the spare wheel recess and make certain it is properly placed and secure.
x Put the collapsible spare tire (2) back in the spare wheel recess and secure it with the fastening screw (3) and washer.
x Unhook the luggage compartment floor panel (1) and fold down or, if you have a reversible lug-
gage compartment floor panel, put this back in ⇒  Luggage compartment.
Things to do before driving again
x After refilling, switch on only the ignition.
x Leave the ignition switched on for at least 30 seconds so that system can detect the refill.
x Do not start the engine for 30 seconds!
WARNING
Store AdBlue only in its closed original container and in a safe place.
x To reduce the risk of poisoning, never keep AdBlue in empty food or beverage containers that might mislead someone into drinking from them.
x Always store AdBlue outside the reach of children.

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
The engine compartment of any motor vehicle is a potentially dangerous area and can cause serious personal injury.
x Always use extreme caution when doing any work in the engine compartment. Always follow commonly accepted safety practices and use common sense. Never risk personal injury.
x Never perform any work in the engine compartment unless you know exactly how to carry out the job and have the correct technical information and the correct tools.
x If you are uncertain about what to do, have the work performed by an authorized Volkswagen dealer, an authorized Volkswagen Service Facility, or another qualified work-shop. Serious personal injury may result from improperly performed work.
x We strongly recommend that you always have HID – High Intensity Discharge (Xenon) headlights and H7 bulbs replaced by a qualified technician. Serious personal injury may re-sult from improperly performed work.
x Never open or close the engine hood if steam or coolant is escaping. Hot steam or coolant can cause serious burns. Always wait until you no longer see or hear steam or coolant escap-ing from the engine.
x Always let the engine cool down completely before carefully opening the hood.
x Hot parts of the engine and the exhaust system will burn skin on contact.
x When the engine has cooled down and you are ready to open the hood:
– Apply the electronic parking brake and shift the transmission into Park (P).
– Take the vehicle key out of the ignition.
– On vehicles with Keyless Access, make sure that the remote control vehicle key is out of range of the vehicle and that the vehicle cannot be started by depressing the starter button.
– Always keep children and others away from the engine compartment and never leave them unsupervised.
x The engine coolant system is under pressure when the engine is hot. Never unscrew the coolant expansion tank cap when the engine is hot. Hot coolant can spray out and cause severe burns and other serious injuries.
– Turn the cap slowly and very carefully in a counterclockwise direction while applying light downward pressure on the top of the cap.
– Always protect your face, hands, and arms from hot escaping coolant or steam by covering the cap with a large, thick rag.
x Never spill fluids on the engine or exhaust system when refilling. Spilling fluids onto hot parts of the engine or exhaust system can cause a fire.

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.

d Hold the brake pedal down until the engine is switched off.
d Apply the electronic parking brake to help prevent the vehicle from moving ⇒  Braking and parking.
d Shift the transmission into Park (P) ⇒  Shifting.
d Stop the engine and remove the key from the ignition switch ⇒  Starting and stopping the engine.
d Let the engine cool down sufficiently.
d Keep children and others away from the vehicle.
d Make sure the vehicle cannot move unexpectedly.
WARNING
Disregarding the safety-related checklist may result in serious injuries.
x Always review and follow the checklist. Follow accepted safety practices and use common sense.
Opening and closing the engine compartment

Fig. 314 Inside hood release lever in the footwell on the driver side.

Fig. 315 Outside hood release in the radiator grille.

Checking engine coolant level
x When the engine is cold, check the engine coolant level relative to the marking on the side of the
expansion tank ⇒ fig. 319.
x If the coolant level in the tank is below the minimum mark (“min”), add coolant. When the engine is warm, the engine coolant level may be slightly above the upper edge of the marked range.
Adding engine coolant
x Always protect face, hands and arms from hot escaping coolant or steam by covering the cap with a large, thick rag.
x Carefully unscrew the cap ⇒ .
x Add only new engine coolant according to Volkswagen specifications ( Engine coolant specifica-
tions) ⇒ .
x The engine coolant level must be inside the marks on the side of the reservoir ⇒ fig. 319. Do not
fill above the top edge of the filling range! ⇒ .
x Screw the lid tightly.
x Even in an emergency, do not use any other kind of coolant additive if engine coolant meeting Volkswagen specifications (Engine coolant specifications) is unavailable! Instead, add distilled water
only ⇒ . As soon as possible, have the correct coolant ratio restored using engine coolant that
meets Volkswagen specifications ⇒  Engine coolant specifications.
WARNING
Hot steam and hot engine coolant can cause serious burns.
x Never open the hood if you see steam or coolant escaping from the engine compartment. Always wait until you no longer see or hear steam or coolant escaping from the engine.
x Always let the engine cool down completely before carefully opening the hood. Hot com-ponents will burn skin on contact.
x When the engine has cooled down and you are ready to open the hood:
– Apply the electronic parking brake and shift the transmission into Park (P).
– Take the vehicle key out of the ignition.
– On vehicles with Keyless Access , make sure that the remote control vehicle key is out of range of the vehicle and that the vehicle cannot be started by depressing the starter
button ⇒  Starter button.
– Always keep children and others away from the engine compartment and never leave them unsupervised.
x The engine coolant system is under pressure when the engine is hot. Never unscrew the coolant expansion tank cap when the engine is hot. Hot coolant can spray out and cause severe burns and other serious injuries.
– Turn the cap slowly and very carefully in a counterclockwise direction while applying light downward pressure on the top of the cap.
– Always protect your face, hands, and arms from hot escaping coolant or steam by covering the cap with a large, thick rag.
x Never spill fluids on the engine or exhaust system when refilling. Spilling fluids onto hot parts of the engine or exhaust system can cause a fire. Under some conditions, the ethylene glycol in engine coolant can catch fire.

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.