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• Your vehicle is not suitable for use with bio-diesel and must not be filled up or driven with biodiesel. Failure to observe this point can re-sult in damage to the fuel system and engine.
• Some diesel manufacturers blend biodiesel with diesel fuel in compliance with European Standard 590 or an equivalent standard (in Ger-many). Use of this diesel is allowed and will not damage the engine or fuel system.
• The diesel engine has been developed for use with diesel only. For this reason, petrol, heating oil or other unsuitable fuels may not be used. These fuels can cause serious damage to the fuel system and engine.
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• The service life of the diesel particulate filter can be reduced considerably if diesels with a high sulphur content are used. A Voikswagen Commercial Vehicles dealership will be able to tell you which countries have diesel with a high sulphur content.
o:::n Introduction
This chapter contains information on the following subjects:
Warning and indicator lamps Refilling Ad Blue® ... 347
348
SCR catalysts can be used to reduce emissions from diesel engines (SCR = Selective Catalytic Re-duction). The SCR catalyst uses Ad Blue® urea sol-ution to convert nitrogen oxides into nitrogen and water.
If the vehicle is equipped with this kind of emission control system for diesel vehicles, the filler neck for the Ad Blue® tank is located below the filler cap for the fuel tank.
The Ad Blue® level should be checked within the scope of the service work Service schedule.
Information on AdBiue®
The Ad Blue® consumption figures depend on the individual driving style, the system's operating tem-perature and the ambient temperature that the ve-hicle is operated in.
The vehicle is fitted with a separate tank for Ad Bl-ue®. The Ad Blue® tank holds approximately 13 li-tres. For technical reasons, the capacity may be slightly larger when refilling using refill bottles.
The Ad Blue® tank must never run empty. As of a remaining distance of approximately 2,400 km. the instrument cluster display will indicate that the
346 While drivmg
Ad Blue® must be refilled 348. If the re-maining range is 0 km, the engine cannot be star-ted anymore 347.
The Ad Blue® trademark is held by the German As-sociation of the Automobile Industry (VDA) in the USA, Germany, the European Union and other countries.
Additional information and warnings:
• Fuel 343
• Accessories, modifications, repairs and renewal of parts 394
A WARNING
If the AdBiue® level is too low, the vehicle cannot be restarted after the Ignition has been switched off. Starting with jump leads is also not possible.
• Refill AdBiue® at the latest when the re-maining distance reaches approximately 1,000 km.
• Never allow the Ad Blue® tank to run emp-ty.
A WARNING
Ad Blue® is an Irritant and corrosive fluid that can damage the skin, eyes and breathing passages upon contact.
A WARNING (Continued)
• If Ad Blue® gets Into the eyes or onto the skin, Immediately wash the area with lots of water for at least 15 minutes and consult a doctor.
• If Ad Blue® is swallowed, Immediately rinse the mouth out with lots of water for at least 15 minutes. Do not induce vomiting un-less Instructed to do so by a doctor. Seek medical assistance Immediately.
Warning and indicator lamps
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Ad Blue® can corrode surfaces such as painted vehicle parts, plastics, clothing and carpets. Remove any spiltAdBiue® as quickly as possi-ble with a damp cloth and plenty of cold water.
• If the Ad Blue® has already formed crystals, use warm water and a sponge to remove.
Lit up Possible Solution
OG The engine cannot be restarted! AdBI-Park the vehicle in a suitable. flat location and refill the minimum amount of Ad Blue® ue® level too low. 348.
OG
with The engine cannot be restarted! Fault in the Ad Blue® system. Go to a qualified workshop. Have the system checked.
,.,..,c
Ad Blue® level is low. Refill Ad Blue® before the kilometres displayed
r drop to zero 348.
with Ad Blue® system faulty or not refilled using norm-standard Ad Blue®_ Go to a qualified workshop. Have the system checked.
,.,..,c
OG Ad Blue® level is low. Refill Ad Blue® before the kilometres displayed drop to zero 348.
OG
with Ad Blue® system faulty or not refilled using Go to a qualified workshop. Have the system norm-standard Ad Blue®.
,.,..,c
Several warning and indicator lamps will light up briefly as a functional check when the ignition is switched on. They will go out after a few seconds.
A WARNING
Failure to observe illuminated warning lamps and text messages can lead to your vehicle breaking down in traffic, and can cause acci-dent and serious injury.
checked.
A WARNING (Continued)
• Never ignore any illuminated warning lamps or text messages.
• Stop the vehicle as soon as possible and when safe to do so.
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Failure to observe illuminated Indicator lamps and text messages can lead to your vehicle be-Ing damaged.
Before continuing the journey
• After refilling, switch on the ignition only.
• Leave the ignition switched on for at least 30 seconds to allow the system to detect the refill procedure.
• Do not start the engine until the 30 seconds have elapsed!
Filling at low temperatures
Ambient temperatures below -11 •c (12.F) may af-fect the filling process.
If the Ad Blue® is frozen and the warning lamp lights up, it may not be possible the complete the filling procedure. Leave the vehicle at a warmer lo-cation until the Ad Blue® is liquid again, or have a qualified workshop fill the Ad Blue®.
A WARNING
Ad Blue® should only be kept In sealed origi-nal containers In a safe place.
• Never store Ad Blue® In empty food con-tainers, bottles or any other non-original con-tainers as people finding these containers may not know that they contain Ad Blue®.
• Ad Blue® must be stored out of the reach of children.
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• Only use Ad Blue® which complies with the ISO 22241-1 standard and which Is still in its original packaging.
• Never fill AdBiue® In the diesel tank! Failure to do so can result In engine damage.
• Only refill Ad Blue® into its own tank. Never fill AdBiue® In the diesel tank! Failure to do so can result In engine damage.
• Do not transport the refill bottle in the vehi-cle habitually. The bottle may develop a leak following changes In temperature and damage and the Ad Blue® may damage the vehicle Inte-rior.
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Do not continue filling the tank once the filler nozzle stops automatically. The Ad Blue® tank may have been overfilled and AdBiue® could leak out.
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When filling with an Ad Blue® filler nozzle, you may notice an odour.
The refill bottle must be disposed of in ac-"'7!1S cordance with regulations governing the pro-tection of the environment.
r::l Suitable Ad Blue® refill bottles are available L!J from a Volkswagen dealership.
Cleaning and maintenance
In the engine compartment
Preparation for working in the engine compartment
ClJ Introduction
This chapter contains information on the following subjects:
Preparing the vehicle for working in the engine compartment . . . . . . . . . . . . . . . . . 352 Opening and closing the bonnet 352
Always park the vehicle on a level and stable sur-face before carrying out any work in the engine compartment.
The engine compartment of a motor vehicle is a hazardous area. Never carry out any work on the engine or in the engine compartment if you are not familiar with the requisite procedures and general safety requirements, or if you only have access to incorrect operating equipment, service fluids, and unsuitable tools &. The work should be carried out by a qualified workshop if you are uncertain. Serious injuries can be caused if work is carried out incorrectly.
Additional information and warnings:
• Exterior views 5
• Wipers/washer 116
• Starting and stopping the engine 257
• Brake fluid 269
• Pull-away assist systems (starUstop system) 282
• Checks when filling the tank 340
• Engine oil 353
• Engine coolant 358
• Battery page 362
• Accessories, modifications, repairs and renewal of parts 394
A wARNING
Unintentional vehicle movements during service work can cause serious injury.
• Never work underneath a vehicle if it is not secured against rolling away. If you are working underneath the vehicle while the wheels are on the ground, the vehicle must
350 I Cleanmg and maintenance
A WARNING (Continued)
be on a level, the wheels must be blocked and the vehicle key must be removed from the ignition lock.
• If you have to work underneath the vehi-cle, use suitable stands to provide extra sup-port for the vehicle. The vehicle jack is not sufficient for this task and can fail, which can lead to serious injuries.
• The start/stop system must have been de-activated.
A WARNING
The engine compartment of any motor vehi-cle is a dangerous area. Serious injuries can be sustained here.
• The utmost care and attention must be paid when carrying out any work and you must follow the general safety rules. Never take any risks.
• Never do any work on the engine or in the engine compartment unless you know exact-ly how to carry it out. If you are uncertain of what to do, the work should be carried out by a qualified workshop. Serious Injuries can re-sult from work that has not been carried out properly.
• Never open the bonnet if you see steam or coolant escaping from the engine compart-ment. Hot steam or coolant can cause seri-ous burns. Always wait until you can no lon-ger see or hear steam or coolant coming from the engine compartment.
• Always allow the engine to cool down be-fore opening the bonnet.
• Hot parts of the engine or exhaust system can burn the skin.
• The following points should be noted be-fore opening the bonnet once it has cooled down.
-Apply the handbrake fully and move the selector lever to position P or move the manual gear lever to the neutral position. .,..
A WARNING (Continued)
-Remove the vehicle key from the igni-tion lock.
-Always keep children away from the en-gine compartment and never leave the ve-hicle unattended.
• The engine cooling system Is under pres-sure when the engine Is hot. Never open the cap of the coolant expansion tank when the engine Is hot. Coolant may spray out and cause serious burns and other Injuries.
-Turn the cap slowly and very carefully anti-clockwise while exerting gentle down-ward pressure on the cap.
-Always protect the face, hands and arms from hot coolant or steam with a large, thick cloth.
• When refilling, do not spill any service flu-ids on engine components or on the exhaust system. The spilt service fluids can start a fire.
A WARNING
High voltages in the electrical system can cause electric shocks, burns, serious injuries and death!
• Never short circuit the electric system. The vehicle battery could explode.
• Please note the following guidelines to help reduce the risk of an electric shock and serious Injuries while the engine is running or being started:
-Never touch the electrical wiring of the Ignition system.
A WARNING
There are rotating components in the engine compartment that can cause serious injury.
• Never place your hand near these compo-nents or In the radiator fan. Touching the ro-tary blades can result in serious injuries. The fan Is temperature-controlled and can start automatically, even if the engine has been switched off and the vehicle key has been re-moved from the ignition lock.
• If any work has to be performed when the engine Is started or with the engine running, there is an additional, potentially fatal, safety risk from the rotating parts, such as the drive belts, alternator, radiator fan, etc., and from the high-voltage ignition system. Always be particularly careful.
A WARNING (Continued)
-Always ensure that no body parts, jew-ellery, ties, loose items of clothing or long hair can be caught up in rotating engine components. Before starting work, re-move any jewellery and ties, tie up long hair and pull clothes In tightly to avoid them getting caught In the engine com-partment.
-Always depress the accelerator careful-ly and never without due consideration. The vehicle can start to move even if the handbrake is applied.
• Always ensure that you have not left any objects, such as cleaning cloths and tools, in the engine compartment. Any forgotten items can cause malfunctions, engine damage and fires.
A WARNING
Additional insulating materials such as cov-ers in the engine compartment could disrupt the operation of the engine, cause damage and lead to severe Injuries.
• Never cover the engine with any Insulating materials.
A WARNING
Service fluids and some materials In the en-glne compartment are highly flammable and can cause fires and serious Injuries!
• Never smoke while working on the vehl-cl e.
• Never work near naked flames or sparks .
• Never spill fluids onto the engine. They could Ignite on hot engine components and hence cause injuries.
• Please note the following when carrying out any work on the fuel system or the elec-trlcal system:
-Always disconnect the vehicle battery. Ensure that the vehicle Is unlocked when the vehicle battery Is disconnected as oth-erwlse the anti-theft alarm will be activa-ted.
-Never work in the direct proximity of heating systems, water heaters or any oth-er open flames.
• Always have a fully functional and tested fire extinguisher to hand.
In the engine compartment I 351
...
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When refilling or changing service fluids, please ensure that the correct fluids are added through the correct openings. Incorrect service fluids can cause serious functional problems and engine damage.
r:(ib Service fluids leaks are harmful to the envi-f!f:J ronment. So you should regularly check the ground underneath your vehicle. If there are spots of oil or other fluids on the ground, the vehicle should be inspected by a qualified workshop. Any spilt service fluids must be disposed of properly and with respect to environmental legislation.
1"1'11 First read and observe the Introductory L-.J,::,jJ Information and safety warnings & on page 350.
Checklist
The following steps should always be carried out in the specified order before working In the engine compartment =:-&,:
..( Park the vehicle on a level and stable sur-face.
..! Depress and hold the brake pedal until the engine has stopped.
Apply the handbrake firmly ::-page 269.
Select the neutral position or move the se-lector lever toP =:-page 260 .
..( Stop the engine and remove the key from the ignition =:-page 257.
Opening and closing the bonnet
Fig. 272 The bonnet release lever is located in the driver side footwell.
1"1'11 First read and observe the introductory L-.J,::,,J Information and safety warnings & on page 350.
352 I Cleaning and maintenance
Allow the engine to cool sufficiently.
Children and other people should be kept well away from the engine compartment.
Ensure that the vehicle cannot roll away un-expectedly.
A WARNING
Ignoring any of the Items on this Important safety checklist can lead to severe Injuries.
• Always follow the Instructions In the checklist and observe the general safety pro-cedures.
Warning lamp and coolant temperature display
Fig. 276 In the instrument cluster: coolant temper-ature display with cold range @, normal range ® warning range @.
Needle posi-Lit up tion Possible cause =>Fig. 276
© Coolant temperature too Warning area high.
® Coolant level too low. Normal area
r-f"n First read and observe the introductory L,....J.:.lJ Information and safety warnings & on page 358.
In normal driving conditions, the needle will be in the middle section of the scale. The temperature may also rise when the engine is working hard, es-pecially at high ambient temperatures.
Several warning and indicator lamps will light up briefly as a functional check when the ignition is switched on. They will go out after a few seconds.
Solution
t Do not drive on! Stop the vehicle as soon as possible and when safe to do so. Stop the engine, let the engine cool down until the needle is back in the normal area. Check the coolant level =>page 361.
After the engine has cooled down, check the coolant level and refill engine coolant if the level is too low =>page 361. There is a fault if the coolant level is correct.
Fault in the coolant system. ·t Do not drive on! --Seek expert assistance.
--® Cold area --
Flashes Possible cause
Fault in the coolant system.
A WARNING
Failure to observe illuminated warning lamps and text messages can lead to your vehicle breaking down In traffic, and can cause acci-dent and serious injury.
• Always heed illuminated warning lamps and text messages.
Avoid high engine revs and heavy engine loads until the engine is warm.
Solution
Seek expert assistance.
A WARNING (Continued)
• Never ignore any illuminated warning lamps or text messages.
• Stop the vehicle as soon as possible and when safe to do so.
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Failure to observe illuminated indicator lamps and text messages can lead to your vehicle be-ing damaged.
Explanation of the warnings on the vehicle battery
Symbol Meaning
Always wear eye protection!
Electrolyte is very corrosive and caustic. Always wear protective gloves and eye protection!
No fires, sparks, naked lights or smoking!
A highly explosive mixture of gases is given off when the vehicle battery is charging!
Always keep children away from acid and the vehicle battery!
Additional information and warnings:
• Additional batteries, California 192
• Pull-away assist systems (starUstop system) 282
• Preparation for working in the engine compart-ment 350
• Accessories, modifications, repairs and renewal of parts 394
• Service schedule
A WARNING
Any work on the vehicle battery and the elec-trical system can cause serious chemical burns, fire or electric shocks. Always read the following warnings and safety informa-tion before carrying out any kind of work:
• Switch off the ignition and all electrical consumers before carrying out any work on the vehicle battery and also disconnect the negative cable from the vehicle battery.
• Children should always be kept away from electrolyte and the vehicle battery.
• Always wear eye protection.
• Electrolyte Is very aggressive. lt can burn the skin and can cause blindness. When working with the battery, ensure that your hands, arms and face in particular are protec-ted from acid spillages.
A WARNING (Continued)
• Do not smoke during the work, and never work near naked flames or sparks.
• When handling cables and electrical equipment, avoid generating sparks and elec-trostatic charge.
• Never short circuit the battery poles.
• Never use a damaged vehicle battery. it can explode. Damaged vehicle batteries must be replaced as soon as possible.
• Damaged or frozen vehicle batteries must be replaced immediately. Discharged vehicle batteries can even freeze at temperatures of around ooc (+32°F).
• In vehicles with a second battery under the driver's seta or a third battery in the lug-gage compartment, ensure that the gas dis-charge hose is connected properly to the ve-hicle battery.
• If the vehicle is left standing in cold condi-tions for a long period, protect the vehicle bat-tery from frost. If it freezes it wilt be damaged.
• Vehicles with a starUstop system are fitted with a special vehicle battery. The installation of a different vehicle battery could cause prob-lems with the vehicle electronics. When replac-ing the vehicle battery, only insert a battery with specifications that correspond exactly with those of the original battery.
W After starting the engine with a discharged L!J vehicle battery, or after the battery has been changed, system settings (time, date, personal convenience settings and programming) may have been changed or deleted. Check and correct the settings as necessary once the vehicle battery has been sufficiently charged.