A WARNING (Continued)
-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. In certain circumstances, the ethylene glycol in the engine can catch fire.
CD
• Refill only with distilled water. All other types of water can cause corrosion in the en-gine due to the chemical components con-
Vehicle battery
CQJ Introduction
This chapter conlains information on the following subjects:
Warning lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
Checking the electrolyte level of the vehicle battery ................................. 364 Charging, replacing, disconnecling and connecting the vehicle battery . . . . . . . . . . . . . 365
The vehicle battery is a component of the electrical system in the vehicle.
Never carry out any work on the electrical system if you are not familiar with the necessary procedures and the general safety requirements and only un-suitable tools are available => &. The work should be carried out by a qualified workshop if you are uncertain. Volkswagen Commercial Vehicles rec-ommends using a Volkswagen Commercial Vehi-cles dealership for this purpose. Serious injuries can be caused if work is carried out incorrectly.
3621 Cleaning and maintenance
(j)
tained therein. This can also lead to engine fail-ure. If any other type of water is refilled, the flu-id in the engine cooling system should be com-pletely replaced immediately by a qualified workshop.
• Do not fill coolant above the top of the marked area =>Fig. 277. Otherwise the excess coolant will be pressed out of the cooling sys-tem when the engine is hot and could cause damage.
• If a large amount of coolant has been lost, do not refill the coolant until the engine has cooled completely. Heavy coolant loss is an in-dication of leaks in the engine cooling system. The engine cooling system should be checked by a qualified workshop as soon as possible. Failure to do so can result in engine damage.
• Do not top up with coolant if there is no more coolant in the coolant expansion tank. Air could enter the cooling system. Do not drive on! Seek expert assistance. Failure to do so can result in engine damage.
• When refilling service fluids, please ensure that the correct container is filled. The use of incorrect service fluids can result In serious faults and engine damage.
The vehicle battery is located on the left of the en-gine compartment.
Depending on the vehicle equipment level, the ve-hicle could have two vehicle batteries. Camper vans can have up to three vehicle batteries. The second vehicle battery is located under the left front seat: the third battery in camper vans is loca-ted in the wardrobe on the rear left of the vehicle. •
Checklist (Continued)
8. VI/hen towing a trailer, unhitch the trailer from the vehicle and park it properly.
9. Remove any items of luggage from the lug-gage compartment.
10. Remove the spare wheel and vehicle tools from the vehicle.
11. Remove the hubcaps =>page 417.
Wheel bolts
Fig. 297 Loosening the wheel bolts for changing the wheels.
r-"f"'n First read and observe the Introductory l.-J,:..LJ Information and safety warnings & on page420.
Only the spanner delivered with the vehicle should be used to loosen the wheel bolts.
Only loosen the wheel bolts by approximately one turn before raising the vehicle with the vehicle jack.
If the wheel bolt is very tight, you may be able to loosen it by pushing down the end of the spanner carefully with your foot. Hold on to the car for sup-port and take care not to slip.
Loosening the wheel bolts
• Fit the box spanner over the wheel bolt as far as it will go =>Fig. 297.
• Hold the end of the box spanner and turn the wheel bolt one turn anticlockwise => &.
Loosening the anti-theft wheel bolt
The anti-theft wheel bolt must be bolted into posi-tion =>Fig. 298@ or@ on wheels with a wheel cover. Otherwise, it will not be possible to fit the wheel cover.
A WARNING
Ignoring any of the Items on this Important safety checklist can lead to accidents and se-vere Injuries.
• Always follow the Instructions In the checklist and observe the general safety pro-
Fig. 298 Tyre valve G) and locations of the anti-theft wheel bolt@ or@
• Take the adapter for anti-theft wheel bolts out of the vehicle toolkit.
• Insert the adapter into the anti-theft wheel bolt. Push it in as far as it will go.
• Insert the box spanner into the adapter as far as it will go.
• Hold the end of the box spanner and turn the wheel bolt one turn anticlockwise => &.
Important information about the wheel bolts
The design of the wheel rims and wheel bolts is matched to the factory-fitted wheels. If different rims are fitted, the correct wheel bolts with the right length and correctly shaped bolt heads must be used. This ensures that wheels are fitted securely and that the brake system works properly.
In certain circumstances, wheel bolts from a vehi-cle of the same model series may not be used.
Tightening torque for the wheel bolts
The tightening torque for wheel bolts for steel and alloy wheels is 180 Nm. The tightening torque should be checked with a torque wrench immedi-ately after changing a wheel. .,.
Practical tips 421
• Clean the area around the fastening holes of the spare wheel.
• Position the spare wheel.
• Insert the anti-theft wheel bolt using the adapter at position 298 @or® and tighten it slight-ly.
• Screw in all the other wheel bolts in a clockwise direction and use the box spanner to tighten them gently.
• Lower the vehicle with the jack.
• Use the box spanner to tighten all the wheel bolts securely in a clockwise direction &. Do not tighten the bolts in clockwise or anticlockwise se-quence. Tighten them in diagonal sequence.
• Fit the cover caps, centre covers or wheel cov-ers 417.
After changing a wheel
rl'l1 First read and observe the Introductory L-.lo:.ll Information and safety warnings & on page 420.
• If necessary, clean the vehicle tools and stow them safely in the vehicle 416.
• Stow the spare wheel or the removed wheel safely under the vehicle.
Breakdown set
CQJ Introduction
This chapter contains information on the following subjects:
Storing . . . . . . . . . . . . . . . . . . . . 426
Contents of the breakdown set . . . . . . . . . . . . 427 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
Sealing and inflating tyres . . . . • . . . . . . . 428
Test after driving for 10 minutes . . . . 429
You can use the breakdown set (tyre mobility set) to safely seal any tyre damage caused by foreign bodies or punctures (up to 4 mm (0.16 Inches) in diameter). Do not remove foreign objects (e.g. screws or nails) from the tyrel
Once the sealant has been added to the tyre, the tyre pressure must be checked again after approxi-mately 10 minutes of driving.
,A WARNING
Incorrect torque or incorrect use of wheel bolts can lead to a loss of control of the vehi-cle, cause accidents and serious Injuries.
• Always keep all wheel bolts and threads In the wheel hubs clean and free from oil and grease. The wheel bolts must be easy to turn and be tightened to the specified torque.
• The hexagonal socket In the screwdriver handle should only be used for turning wheel bolts, not use for loosening or tightening them.
• The damaged wheel should be replaced as soon as possible.
m In vehicles with a tyre monitoring system, the L!..J system may have to "re-learn" if new tyres are fitted 318.
Only use the breakdown set if the car is parked in a safe place, you are familiar with the required ac-tions and safety procedures, and you have access to the correct breakdown set. Seek expert assis-tance if this is not the case.
The tyre sealant must not be used:
• If the rim is damaged.
• If the outside temperature is below -2o•c (-4 ·F).
• If there are cuts or punctures in the tyre that are larger than 4 mm. .,.
Practical tips 425
A WARNING (Continued)
• Always follow the instructions In the checklist and observe the general safety pro-
Sealing and inflating tyres
r-"'('n First read and observe the Introductory L-J,.:.U Information and safety warnings & on page 425.
Sealing a tyre
• Unscrew the cap from the tyre valve.
• Use the valve core extractor 302 CD to screw the valve core out of the tyre valve. Place the core on a clean surface.
• Shake the tyre filler bottle 302 ® vigo-rously up and down several times.
• Screw the filler hose 302 @tightly onto the tyre filler bottle in a clockwise direction. The plastic foil on the plug is pierced automatically.
• Remove the plug from the filler hose 302@ and place the open end fully on the tyre valve.
• Hold the bottle upside down and inject the en-tire contents of the tyre filler bottle into the tyre.
• Remove the empty tyre filler bottle from the valve.
• Use the valve core extractor 302 CD to screw the valve core back onto the tyre valve.
Inflating the tyre
• Screw the tyre filler hose 302 ® of the air compressor tightly onto the tyre valve.
• Check that the bleed screw 302 (?) is closed.
• Start the engine and let it run.
• Insert the plug 302 ®into one of the ve-hicle's 12-volt sockets 163.
• Use the on/off switch 302 ®to switch on the air compressor.
• Run the compressor until the tyre pressure has reached 2.0-2.5 bar (29-36 psi I 200-250 kPa) maximum running time is 6 minutes
• Switch off the air compressor.
• If a pressure level of 2.0-2.5 bar (29-36 psi I 200 -250 kPa) cannot be achieved unscrew the tyre filler hose from the tyre valve.
428 I If and when
• Drive (or reverse) the vehicle approximately 1 0 metres so that the sealing compound is more evenly distributed in the tyre.
• Screw the tyre filler hose for the air compressor firmly back onto the tyre valve and inflate the tyre again.
• If the required pressure still cannot be reached, the tyre is too badly damaged. The tyre cannot be sealed with the breakdown set. Do not drive on. Seek expert assistance &.
• Disconnect the air compressor and unscrew the tyre filler hose from the tyre valve.
• Drive the vehicle no faster than 80 km/h (50 mph) once a tyre pressure of 2.0-2.5 bar (29-36 psi I 200-250 kPa) has been reached.
• Check the tyre pressure after driving for 10 mi-nutes 429.
A WARNING
The tyre filler hose and the air compressor can get hot during Inflation.
• Protect your hands and skin from the hot components.
• Do not place the hot tyre filler hose or the hot air compressor on any Inflammable mate-rials.
• Allow the device to cool down fully before stowing.
• If the tyre will not Inflate to at least 2.0 bar (29 psi/ 200 kPa), the tyre Is too damaged. The sealant Is unable to seal the tyre. Do not drive on. Seek expert assistance.
CD
Switch the air compressor off after a maximum of 6 minutes to avoid overheating. Let the air compressor cool down for a few minutes be-fore switching it back on.
The actions should only be carried out in the specified order:
=>Fig. 307 Dipped beam/main beam bulb Side light bulb
8.
Bulb
Swing the sealing cap upwards, and swing the wire hook over the locking lugs on the sealing cap.
H4 W5W
The actions should only be carried out In the specified order·
=>Fig. 308 Daytime running light bulb Turn signal bulb
1. Follow the instructions on the checklist =>page 433.
2. Open the bonnet &. =>page 350.
3. Remove the sealing cap@. Remove the sealing cap Q).
Turn the bulb holder® anticlockwise as Turn the bulb holder@ anticlockwise as far 4. far as it will go and pull it out to the rear as it will go and pull it out to the rear along along with the bulb. with the bulb.
5. Push the bulb slightly into the bulb holder, turn it anti-clockwise, and pull it out straight.
6. Replace the defective bulb with a new bulb of the same type (see the last line in the table "Bulbs").
7. Insert the bulb holder, and turn it clockwise until it engages.
8. Fit the sealing cap.
Bulb BA15S I PY21W
m The illustrations show the left-hand H4 halo-L.!J gen headlight from behind. The right-hand halogen headlight is a mirror image of the one shown.
The actions should only be carried out in the specified order·
311 Turn signal bulb
1. Observe and follow the instructions on the checklist ""page 433.
2. Open the bonnet.&. 350.
3. Remove the seating cap Q).
4. Release the connector@, and pull it off the bulb holder.
5. Turn the bulb holder@ anticlockwise as far as it will go and pull it out to the rear along with the bulb.
6. Push the bulb slightly into the bulb holder, turn it anti-clockwise, and pull it out straight.
7. Replace the defective bulb with a new bulb of the same type (see the last line in the table "Bulbs").
8. Insert the bulb holder into the headlight and turn it clockwise as far as it will go.
9. Fit the sealing cap.
Bulb H21W
m The illustrations show the left-hand LED W headlight from behind. The right-hand LED headlight is a mirror image of the one shown.
Fig. 312 Changing the fog light bulb.
m First read and observe the introductory information and safety warnings & on page 432.
The actions should only be carried out in the specified order:
1. Follow the instructions on the checklist 433.
2.
3.
4.
5.
6.
When changing the right bulb, set the steering wheel to the left stop, and when chang-ing the left bulb, set the steering wheel to the right stop.
Use the screwdriver from the vehicle tool kit to open the service flap 312 Q) in the wheel housing liner.
Release the connector, and pull it off the bulb holder@.
Turn the bulb holder anticlockwise and pull it out towards the rear with the bulb.
Turn the new bulb holder with the same designation and working bulb clockwise to the original position until it clicks into place (see the last line in the table "Bulbs").
__ ___:7...:.. ___ ..::.sh...:.o:...:u:....ld::.....:.c:...:lic.::.k:....i:....nt.:..:.o-"p-'-la:....c:..:e...:.. ___
Practical tips 439
The actions should only be carried out in the specified order:
8. Close the service flap CD in the wheel housing liner.
Bulb H11 <]
Fig. 313 Changing the tail light bulbs.
ro First read and observe the introductory Information and safety warnings & on page 432.
The actions should only be carried out in the specified order:
Brake light/tail Rear fog light bulb '*Fig. 313 Tail light bulb Turn signal bulb light bulb or reversing light bulb
1. Observe and follow the instructions on the checklist =>page 433.
2. Unscrew the two securing bolts G).
3. Push the tail light cluster towards the outside out of the mounting, release the connec-tor, and pull it off the bulb holder.
4. Unscrew the four securing bolts@, and pull the bulb holder@ out of the tail light cl us-ter.
Push the bulb® Push the bulb 0 Pull the bulb@ Pull the bulb ® slightly into the bulb slightly into the bulb 5. straight out of the straight out of the holder, turn it anti-holder, turn it anti-bulb holder. bulb holder. clockwise, and pull it clockwise, and pull it out straight. out straight.
6. Replace the defective bulb with a new bulb of the same type (see the last line in the table "Bulbs").
7. Insert the bulb holder into the tail light cluster and tighten the bolts.
8. Carefully insert the tail light cluster into the body so that it is flush with the vehicle body-work, and tighten the bolts.
Bulb W5W I W16W I P21/4W I H21Wor P21W <]
440 I If and whon
Changing the bulbs in the tail light cluster on vehicles with wing doors
Fig. 314 Changing the tail light bulbs.
ru First read and observe the Introductory Information and safety warnings&, on page 432.
The actions should only be carried out In the specified order:
'*Fig. 314 Tall light bulb 1 Brake light bulb I Turn signal bulb
1. Observe and follow the instructions on the checklist =:-page 433.
2. Unscrew the two securing bolts G).
3. Push the tail light cluster towards the outside out of the mounting, release the connec-tor, and pull it off the bulb holder.
4. Unscrew the four securing bolts®. and pull the bulb holder@ out of the tail light cl us-ter.
5. Pull the bulb @ straight out I Pull the bulb ® straight out I Pull the bulb ® straight out of the bulb holder. of the bulb holder. of the bulb holder.
6. Replace the defective bulb with a new bulb of the same type (see the last line in the table "Bulbs").
7. Insert the bulb holder into the tail light cluster and tighten the bolts.
8. Carefully insert the tail light cluster into the body so that it is flush with the vehicle body-work, and tighten the bolts.
Bulb wsw I W16W I W16W
The actions should only be carried out In the specified order:
'*Fig. 314 Reversing light bulb Tall light/rear fog light bulb
1. Observe and follow the instructions on the checklist =:-page 433.
2. Unscrew the two securing bolts G).
3. Push the tail light cluster towards the outside out of the mounting, release the connec-tor, and pull it off the bulb holder.
4. Unscrew the four securing bolts ®. and pull the bulb holder out of the tail light cluster.
Pull the bulb 0 straight out of the bulb Push the bulb ®slightly into the bulb hold-5. er, turn it anti-clockwise, and pull it out holder. straight.
6. Replace the defective bulb with a new bulb of the same type (see the last line in the table "Bulbs").
7. Insert the bulb holder into the tail light cluster and tighten the bolts.
Practical tips 441