Service

Workshop Manual
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Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
50 - Body - front
55 - Bonnet, rear lid AG. Volkswagen AG d
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57 - Front doors, door components, central locking by V ol not
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2015 Volkswagen AG, Wolfsburg K0058971020

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

Contents

50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Lock carrier - service position ►07.2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Lock carrier - service position 08.2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Pressure hose with push-on coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Front wing ► 07.2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 Front wing 08.2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4 Wing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5 Removing and installing wing securing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3 Noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2 Assembly overview - noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4 Underbody cladding . . . . . . . . . . . . . . . . . . . . . . . .G.. .Vo. l.ks.w.a.ge. n. . . . . . . . . . . . . . . . . . . . . . 25

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4.2 Assembly overview - underbody cover d b. . . . . . . . . . . . . . . . . . . . . . . . . . . u.ar.a. . . . . . . . . . .
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4.3 Assembly overview - front underbody utho panel . . . . . . . . . . . . . . . . . . . . . . . . . . . e.or. . . . . . . . 27
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5 Protectors for natural gas tanksss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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6 Plenum chamber bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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6.2 Assembly overview - plenum chamber bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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7 Bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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7.2 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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7.3 Assembly overview - plenum chamber bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

55 - Bonnet, rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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1 Bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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1.2 Assembly overview - bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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1.3 Removing and installing bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . f inform

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1.4 Removing gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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1.5 Releasing gas from gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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1.6 Removing and installing bonnet hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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1.7 Insulation ► 07.2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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1.8 Insulation 08.2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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1.9 Assembly overview - bonnet lock and release components . . . . . . . . . . . . . . . . . . . . . . . . 40
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1.10 Bonnet lock ► 07.2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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1.11 Bonnet lock 08.2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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1.12 Removing and installing safety catch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Prote AG.
43
1.13 Detaching the Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.14 Adjusting bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.15 Removing and installing release lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2 Rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.2 Assembly overview - rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.3 Removing and installing rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.4 Removing gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.5 Releasing gas from gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.6 Removing and installing rear lid hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Contents i
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.7 Removing and installing striker pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

2.8 Adjusting rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.9 Assembly overview - rear lid locking and release components . . . . . . . . . . . . . . . . . . . . . . 55
2.10 Removing and installing handle trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.11 Removing and installing rear lid lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.12 Stop buffer 09.2010 > . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.13 Registration plate carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.14 Rear lid seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.15 Removing and installing rear lid seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3 Tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.2 Assembly overview - tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

57 - Front doors, door components, central

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1.3 Removing and installing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

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1.4 Adjusting door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

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1.5 Assembly overview - assembly carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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1.6 Removing and installing assembly carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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1.7 Assembly overview - door handle and door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

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1.8 Removing and installing lock cylinder housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

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1.9 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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1.10 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.11 Bearing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.12 Reinforcement in the front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

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1.13 Door inner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
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1.14 Removing and installing door inner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

1.15 Removing and installing door outer seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . nf 87
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1.16 Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
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2 Central locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
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2.1 Overview of fitting locations - central locking components . . . . . . . . . . . . . . . . . . . . . . . . . . 92

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2.2 Removing and installing battery for folding key with remote control . . . . . . . . . . . . . . . . . . 94
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58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

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1 Rear door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
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1.2 Assembly overview - door hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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1.3 Removing and installing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
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1.4 Adjusting door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

1.5 Assembly overview - assembly carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.6 Removing and installing assembly carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.7 Assembly overview - door handle and door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.8 Removing and installing lock cylinder housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.9 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.10 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.11 Bearing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.12 Reinforcement in the rear door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.13 Door inner seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.14 Removing and installing door inner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.15 Removing and installing door outer seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
1.16 Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

60 - Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1 Sunroof with glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

ii Contents
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

1.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1.3 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1.4 Removing sliding/tilting sunroof glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.5 Installing sliding/tilting sunroof glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.6 Adjusting height of sliding/tilting sunroof glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.7 Checking parallel running of glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.8 Adjusting parallel running of glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.9 Renewing panel seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.10 Removing wind deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.11 Removing sliding headliner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.12 Removing sliding/tilting sunroof drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1.13 Adjusting drive for sliding/tilting sunroof (zero position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1.14 Removing pre-selector control for sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1.15 Removing and installing carrier unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.16 Operating without current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.17 Cleaning water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2 Panorama sliding/tilting sunroof (Arvin Meritor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

satelettronica
2.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2.3 Basic setting, panoramic sliding sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2.4 Assembly overview - panoramic sliding roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2.5 Removing and installing front glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2.6 Removing and installing rear glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
2.7 Adjusting height of front and rear glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2.8 Renewing seals for rear glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2.9 Removing and installing the exterior seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
2.10 Removing and installing interior seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
2.11 Removing and installing wind deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2.12 Removing and installing preselectoragfor n Aglass
G. Volkpanel
swagenand AG dosunroof sun blind . . . . . . . . . . . . 152
w e e
2.13 Removing and installing sliding V osunroof motor . . . . . . . . s. n.o.t g. . . . . . . . . . . . . . . . . . . . . . .
lks
153
by ua
d r
2.14 Removing and installingorsunroof ise sun blind motor . . . . . . . . . . . .an.te.e. . . . . . . . . . . . . . . . . . 156
h
2.15 Assembly overview s-asunroofut
sun blind . . . . . . . . . . . . . . . . . . . . . . o.r a. c. . . . . . . . . . . . . . . . 159
s
2.16 Removing and installing sunroof sun blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
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2.17 Removing and installing sunroof sun blind cross strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
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2.18 Assembly overview - assembly frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

erm

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2.19 Removing and installing sunroof sun blind cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

ility
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wit

2.20 Removing and installing assembly frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

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2.21 Removing and installing rear part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

hole

spec

2.22 Removing and installing front motor plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

es, in part or in w

t to the co

2.23 Removing and installing tilting mechanism and front glass panel cable . . . . . . . . . . . . . . 184
2.24 Operating without current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
2.25 Cleaning water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
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63 - Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
l purpos

1 Front bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

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ercia

1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

1.2 Repairing front bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
m

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om

io

1.3 Installing brackets for parking aid system - vehicles 8.2010 ► . . . . . . . . . . . . . . . . . . . . . . 192
n
c

in t
or

1.4 Front bumper cover ► 10.2006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

his
ate

1.5 Front bumper cover 11.2006 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

do
priv

cum

1.6 Front bumper cover 08.2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

for

en
ng

t.
yi
2 Rear bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Co
Cop py
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
t. rig
gh ht
yri by
2.2 Repairing rear bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
cop Vo
by lksw
cted agen
2.3 Installing brackets for parking aid system - vehicles 8.2010 ► . . . . . . . . . . . . . . . . . . . . . .Prote
213
AG.

Contents iii
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015
n AG. Volkswagen AG
2.4 Rear bumper kscover
wage ▶ 07.2010 . . .d.oe.s.n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Vol ot g
2.5 Rear bumper
edb
y cover 08.2010 ► . . . . . . . . .ua.ra.n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
ris te
3 Towing
aut
ho bracket . . . . . . . . . . . . . . . . . . . . . . . . e.o.r a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
3.1 sTools
s
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

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3.2 Assembly overview - towing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

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64 - Glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
erm

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ility
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1 Flush bonded windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

wit
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h re
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
hole

spec
1.2 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
es, in part or in w

1.3 Repairing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

t to the co
1.4 Assembly overview - windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
1.5 Assembly overview - plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

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1.6 Removing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
1.7 Installing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
l purpos

1.8 Assembly overview - rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

1.9 Removing undamaged rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

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ercia

1.10 Removing broken rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

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om

1.11 Installing rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

io

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n
c

1.12 Assembly overview - rear side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

in t
or

his
te

1.13 Removing undamaged rear side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

a

do
priv

c
1.14 Removing broken rear side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
um
for

en
g

1.15 Installing rear side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

n

t.
yi Co
op
1.16 Preparing old undamaged window for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
C py
t. rig
gh ht
1.17 yri
Preparing new window without precoating for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
p by
co Vo
lksw
1.18 Preparing new window with precoating for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
by
cted agen
Prote AG.
1.19 Preparing body flange for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
1.20 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
1.21 Minimum curing period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
1.22 Touching up paint damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
1.23 Cleaning off excess adhesive sealing material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
2 Front door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
2.2 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
2.3 Removing and installing door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
2.4 Removing and installing window regulator motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
2.5 Removing and installing window channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
3 Rear door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
3.2 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
3.3 Removing and installing door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
3.4 Removing and installing window regulator motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
3.5 Removing and installing window slot outer seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
3.6 Assembly overview - window channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
3.7 Removing and installing window channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
4 Windows having threaded connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
4.2 Removing and installing front side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

1 Wheel housing liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
1.2 Front wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
1.3 Rear wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
2 Exterior mirrors - vehicles ► 7.2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

iv Contents
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

2.2 Assembly overview - exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
2.3 Removing and installing mirror glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
2.4 Removing and installing mirror housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
2.5 Removing and installing turn signal repeater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
2.6 Removing and installing assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
2.7 Removing and installing exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
3 Exterior mirrors - vehicles 8.2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
3.2 Assembly overview - exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
3.3 Removing and installing mirror glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
3.4 Removing and installing adjustment unit with motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
3.5 Removing and installing frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
3.6 Removing and installing mirror housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
3.7 Removing and installing side turn signal and entry light in exterior mirror . . . . . . . . . . . . . . 290
3.8 Removing and installing exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
4 Radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
4.2 Radiator grille ► 10.06 . . . . . . . . . . . . . . . . . . . . .ge. n. A.G. ..V.ol.ks.w.a.g.en. A. G. d. . . . . . . . . . . . . . . . . 294

satelettronica
wa oe
4.3 Radiator grille 11.06 ► . . . . . . . . . . . . . . . y.V.ol.ks. . . . . . . . . . . . . . . . . . . .s n. o.t g. u. . . . . . . . . . . 297
b a
4.4 Removing and installing radiator grille 08.2010 ris
ed ▶ . . . . . . . . . . . . . . . . . . . . . . r.an. te. . . . . . . . 299
o e
4.5 Removing and installing company emblem au
th 11.06 ► . . . . . . . . . . . . . . . . . . . . . . . .or.a . . . . . 302
s c
4.6 Removing and installing companys emblem 08.2010 ▶ . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304

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5 Mouldings and trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

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5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
erm

ab
ility
5.2 Assembly overview - water deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
ot p

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5.3 Renewing protective side strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
, is n

h re
5.4 Removing and installing stone-chip protection trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
hole

spec
5.5 Decorative trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
es, in part or in w

t to the co
5.6 Wheel arch trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
6 Removing and installing roof railing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316

rrectness of i
6.2 Assembly overview - roof railing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
l purpos

6.3 Removing and installing roof railing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

6.4 Assembly overview - roof railing retaining bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

nform
ercia

6.5 Removing and installing roof railing retaining bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

m

at
7 Special body kit, Cross Touran . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
om

ion
c

7.1 Safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

in t
or

his
e

7.2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

at

do
riv

7.3 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

p

cum
for

7.4 Assembly overview - bolt-on components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

en
ng

t.
yi Co
7.5 Side member extension and wheel arch trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Cop py
ht. rig
7.6 Retaining strip for side member extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
rig ht
py by
o Vo
7.7 Front and rear wheel arch trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
by c lksw
cted agen
Prote
7.8 Bumper trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
AG.

7.9 Preparing add-on parts for bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

7.10 Preparing body kit component for bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
7.11 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
7.12 Minimum curing period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
7.13 Touching up paint damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
7.14 Cleaning off excess adhesive sealing material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
8 Lettering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
8.2 Fitting notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
8.3 Company emblem on rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

Contents v
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

8.4 Rear lettering - dimensions > 07.2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347

8.5 Rear lettering - dimensions 08.2010 > . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
8.6 Dimensions for lettering on side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
9 Scuff protection film . . . . . . . . . . . . . . . . . . . . . . . . . . .. V. o.lk.s.w.ag. . . . . . . . . . . . . . . . . . . . . . 351
n AG en A
9.1 Renewing scuff protection film . . . . . . . . . . o. lk.s.w.ag. e. . . . . . . . . . . . .G.d.oe. s.n.o . . . . . . . . . . . . . 351
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vi Contents
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

50 – Body - front
1 Lock carrier
(VRL007797; Edition 02.2015)

1.1 Tools

Special tools and workshop

equipment required
♦ Guide pins - T 10093-
♦ Torque wrench - V.A.G
1331-
♦ Torque wrench - V.A.G
1332-

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1. Lock carrier 1
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.2 Lock carrier - service position ►07.2010

1.2.1 Assembly overview - lock carrier

1 - Lock carrier with add-on

parts
❑ Moving to service posi‐
tion ⇒ page 3
❑ Moving from service po‐
sition ⇒ page 4
❑ Removing and installing
lock carrier with add-on
parts ⇒ page 4
2 - Bolt
❑ Qty. 2.
❑ Specified torque: 8 Nm
3 - Bolt

satelettronica
❑ Qty. 2
❑ Specified torque: 8 Nm
4 - Bolt
❑ Qty. 8
❑ Specified torque: 60 Nm
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2 Rep. gr.50 - Body - front

 n AG. Volkswagen AG do
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General body repairs, exterior - Edition ac
02.2015

ce
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un

pt
1.2.2 Moving to service position

an
d
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op py

satelettronica
t. C rig
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by
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– Remove front bumper ► 10.06 ⇒ page 197 .

– Remove front bumper ► 11.06 ⇒ page 203 .
– Unbolt horn on left-hand side of longitudinal member.
– Remove bolts -4- on longitudinal members.
– Screw in special tool guide pin - T 10093- on left and right-
hand sides.
– Remove bolts -2- and -3- on left and right.
• If vehicle has charge air cooler, disconnect pressure hoses.

1. Lock carrier 3
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Release plug-in connector -1-, and pull pressure hoses -2- in

-direction of arrow- out of coupling.

– Lock carrier can be pulled about 10 cm in -direction of arrow-

forwards on special tool -1- guide pin - T 10093- . agen
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es, in part or in w

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1.2.3 Moving from service position
Install in reverse order of removal.

rrectness of i
– Align lock carrier on longitudinal members and between wings
l purpos

⇒ Body Repairs; Rep. gr. 00; Karosseriespaltmaße; Karos‐

serie vorn

nform
mercia

Note

at
om

ion
c

in t
r

♦ Make sure that the charge air cooler pressure hoses are prop‐
o

his
te

erly engaged again.

a

do
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or

♦ Hoses and lines must not be pinched.

f

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1.2.4 Removing and installing lock carrier with
t. rig
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add-on parts
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Note

♦ Because the lock carrier is a safety-relevant component, it

must not be repaired.
♦ If damaged, the lock carrier must be renewed.

4 Rep. gr.50 - Body - front

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

satelettronica
AG. Volkswagen AG d
agen oes
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Removing
un

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– Move lock carrier -1- to service position ⇒ page 3 .

erm

ab
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– Unhook Bowden cable in coupling ⇒ page 43 .

wit
is n

h re

– Disconnect any electrical connectors.

ole,

spec
urposes, in part or in wh

– Drain coolant and disconnect coolant lines ⇒ Engine, me‐

chanics; Rep. gr. 19 ; Cooling system; Draining and filling
t to the co

coolant .
– Disconnect wiring for condenser ⇒ Heating and air condition‐
rrectne

ing system; Rep. gr. 87 ; Air conditioning system; Removing

and installing condenser .
ss

– With the aid of a second mechanic, screw guide pins - T

o
cial p

f i

10093- out of left and right longitudinal member and lift out the
nform

lock carrier.
mer

atio
om

n
c

WARNING
i
or

n thi
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sd
iva

Do not start the engine if the air conditioning system and/or the
pr

cum
r
fo

coolant system lines are disconnected.

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1. Lock carrier 5
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

Note

♦ Do not hang condenser and hydraulic oil cooler from lines.

♦ Do not kink lines for condenser and hydraulic systems.

Installing
Install in reverse order of removal. AG. Volkswagen AG d
agen oes
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• During assembly, make sure that all connectors
ise
d b and hose ara
nte
connections are properly installed. tho r eo
au ra
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– Align lock carrier on longitudinal members
s and between wings

ce
le

⇒ Body Repairs; Rep. gr. 00; Karosseriespaltmaße; Kapos‐

un

pt
an
serie vorn
d
itte

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rm

ab
1.3 Lock carrier - service position 08.2010 ►
pe

ility
ot

wit
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hole

spec
1.3.1 Assembly overview - lock carrier
es, in part or in w

t to the co

satelettronica
Note

rrectness of i
Minor differences may be encountered on add-on parts, depending on vehicle model.
l purpos

nform
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tion in
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6 Rep. gr.50 - Body - front

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1 - Lock carrier with add-on

parts
❑ Moving to service posi‐
tion ⇒ page 8
❑ Moving from service po‐
sition ⇒ page 9
❑ Removing and installing
lock carrier with add-on
parts ⇒ page 10
2 - Cover AG. Volkswagen AG d
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3 - Assembly part ed b ara
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4 - Air duct aut ra
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5 - Bolt

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❑ Qty. 2.
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❑ Specified torque: 2 Nm

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6 - Bolt
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❑ Qty. 2
hole

spec
❑ Specified torque: 12 Nm
es, in part or in w

satelettronica
t to the co
❑ For bonnet lock
⇒ page 40

rrectness of i
7 - Bolt
❑ Qty. 3 on each side.
l purpos

❑ Specified torque: 8 Nm

nform
ercia

8 - Front-end bracket
m

❑ Left and right.

at
om

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c

9 - Air baffle
in t
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ate

10 - Air guide
do
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❑ Left and right.

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11 - Support for lock carrier . Cop py
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❑ rig ht
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12 - Bolt cted agen
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❑ Qty. 2 on each side.
❑ Specified torque: 8 Nm
13 - Bolt
❑ Qty. 4 on each side.
❑ Specified torque: 60 Nm
14 - Cross member
15 - Hexagon nut
❑ Specified torque: 8 Nm
16 - Pedestrian protection
17 - Bolt
❑ Qty. 2.
❑ Specified torque: 8 Nm

1. Lock carrier 7
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.3.2 Moving to service position

n AG. Volkswagen AG do
lkswage es n
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Cop py
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– Remove front bumper cover ⇒ page 207 .

– Unhook Bowden cable at coupling ⇒ page 43 .
– In vehicles with charge air cooler, disconnect pressure hoses
⇒ page 11 .
– Loosen rear lower bolt for securing for left and right headlights
-5- ⇒ Vehicle electrics; Electrical system; Rep. gr. 94 ; Lights,
bulbs, switches - exterior; Headlights; Removing and installing
headlight .
– Remove bolts -4- on longitudinal members.
– Screw in 2 guide pins - T 10093- on each side (left and right).
– Unscrew bolts -3- on left and right from upper part of front-end
bracket -2-.
– The lock carrier -1- can be pulled forwards on the special tool
guide pin - T 10093- about 10 cm in -direction of arrow-.

8 Rep. gr.50 - Body - front

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.3.3 Moving from service position

AG. Volkswagen AG d
agen oes
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byV gu
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du

satelettronica
an
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erm

ab
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es, in part or in w

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nf
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Install in reverse order of removal. . Cop py
rig
ht ht
rig
– Align lock carrier with add-on parts to longitudinal members py by
co Vo
and between wings ⇒ Body Repairs; Rep. gr. 00 ; Technical
by lksw
cted agen
data; Body gaps/shut lines; Body - front .
Prote AG.

– Specified torque for bolts -4-: 60 Nm.

– Specified torque for bolts -3-: 8 Nm.
– Tighten rear lower bolt for securing for left and right headlights
-5- ⇒ Vehicle electrics; Electrical system; Rep. gr. 94 ; Lights,
bulbs, switches - exterior; Headlights; Removing and installing
headlight .

Note

♦ Ensure that the charge air cooler pressure hoses are properly engaged again.
♦ Hoses and lines must not be pinched.

1. Lock carrier 9
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.3.4 Removing and installing lock carrier with add-on

swa
parts
gen AG. Volkswagen AG d
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Note utho eo
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♦ Because the lock carrier is a safety-relevant component, it must not be repaired.

nl

pt
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an
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♦ If damaged, the lock carrier must be renewed.

y li
erm

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es, in part or in w

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Removing
– Move lock carrier -1- to service position ⇒ page 3 .
– Unhook Bowden cable in coupling ⇒ page 43 .
– Detach any electrical connectors.
– Drain coolant and disconnect coolant line ⇒ Engine, mechan‐
ics; Rep. gr. 19 ; Cooling system; Draining and filling coolant .
– Disconnect wiring for condenser ⇒ Heating and air condition‐
ing system; Rep. gr. 87 ; Air conditioning system; Removing
and installing condenser .

10 Rep. gr.50 - Body - front

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– With the aid of a second mechanic, screw guide pins - T

10093- out of left and right longitudinal member -2- and lift out
the lock carrier.

WARNING

Do not start the engine if the air conditioning system and/or the
coolant system lines are disconnected.

Note

♦ Do not hang condenser and hydraulic oil cooler from lines.

♦ Do not kink lines for condenser and hydraulic systems.

Installing
Install in reverse order of removal.
• During assembly, ensure that all connectors and hose con‐
nections are properly installed.

satelettronica
– Align lock carrier on longitudinal members and between wings
⇒ Body Repairs; Rep. gr. 00; Karosseriespaltmaße; Kapos‐
serie vorn wage
n AG. Volkswagen AG do
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1.4 Pressure hose with push-on coupling ris
ed by ara
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Pressure hose can also be fastened on with a hose clip.
erm

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ility
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1.4.1 Releasing push-on coupling

h re
ole,

spec
– Disengage retaining clip -1- in direction of -arrow a-.
urposes, in part or in wh

– Pull pressure hose -2- in direction of -arrow b- out of coupling t to the co

-3-. rrectness o
cial p

f inform
mer

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c

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1.4.2 Engaging push-on coupling

r
fo

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ng

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op
• Ensure that the retaining clip -2- is in the upper position. C py
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Prote AG.

1. Lock carrier 11
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Insert pressure hose -3- in direction of -arrow- into coupling

-1-.
– Press retaining clip -2- all the way downwards.

Note

♦ If the retaining clip cannot be pushed down fully, the pressure

hose is not inserted sufficiently in the coupling.
♦ Press pressure hose again and and lock the retaining clip.

• Check push-on coupling by pulling on it.

satelettronica
AG. Volkswagen AG d
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mer

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Prote AG.

12 Rep. gr.50 - Body - front

 n AG. Volkswagen AG do Touran 2003 ➤
wage es n
Vo General body repairs, exterior
lks ot g - Edition 02.2015
by ua
ed ran
oris tee
th or
2 Wing au ac
ss

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nl

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2.1 Tools

ab
ility
ot p

wit
Special tools and workshop equipment required

, is n

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hole
♦ Torque wrench - V.A.G 1783-

spec
es, in part or in w

t to the co
rrectness of i
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ate

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p

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♦ Hot air blower - V.A.G 1416-

um
for

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2.2 Front wing ► 07.2010

2.2.1 Assembly overview - front wing

Note

Only the left side is shown. The right side is similar.

2. Wing 13
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015 en AG. Volkswagen AG
ag does
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1 - Wing ed
b ara
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ris
❑ Removing ⇒ page 14 au
tho eo
ra
ss c
2 - zinc intermediate piece

ce
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pt
❑ zinc intermediate piece -

an
d
itte

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AKL 381 035 50-

erm

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ility
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3 - Bolt

wit
❑ Qty. 2, A-pillar. is n

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ole,

spec
❑ 1 bolt on sill for vehicles
urposes, in part or in wh

> 10.06, 2 bolts for vehi‐

t to the co
cles 11.06 >
❑ Qty. 2, wing strut

rrectne
❑ Qty. 4, wing connection
piece

s
❑ 6 Nm

s o
cial p

f i
4 - Wing bracket

nform
mer

❑ Removing and installing

atio
⇒ page 21
om

n
c

i
or

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5 - Filler piece

thi
e

satelettronica
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sd
va

6 - Wing securing bracket

i

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pr

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❑ Removing and installing

en
ng

t.
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⇒ page 22
Co
Cop py
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gh
7 - Bolt
ht
pyri by
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❑ Qty. 2. Prote
cted AG.
agen

❑ 6 Nm
8 - Bolt
❑ Qty. 2
❑ 6 Nm
9 - Seal
❑ Sealed with adhesive
sealant - D 511 500 A2-

2.2.2 Removing

Note

The removal and installation sequence is only described for the

left wing. Removal and installation of the right wing is similar.

14 Rep. gr.50 - Body - front

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

satelettronica
n AG. Volkswagen AG do
lkswage es n
o ot g
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ility
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wit
is n

h re
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spec
urposes, in part or in wh

t to the co

– Remove front bumper ► 10.06 ⇒ page 197 .

– Remove front bumper ► 11.06 ⇒ page 203 .
rrectne

– Remove wheel housing liner ⇒ page 272 .

s

– Removing front side window ⇒ page 270 .

s o
cial p

f i

– Unbolt guide ► 10.06 ⇒ Item 10 (page 200) .

nform
mer

– Unbolt guide 11.06 ► ⇒ Item 3 (page 206) .

atio
om

– Remove bolts -2- and -6-

c

i
or

n thi
te

– Remove bolts -3- in wing -1-

sd
iva

o
pr

cum
r

– Heat adhesive sealant -2- between A-pillar and wing with a hot
fo

en
ng

air blower - V.A.G 1416- in wheel housing area.

t.
yi Co
Cop py
. rig
– Adhesive sealant -2- is loosened and wing -1- can be carefully
t
gh ht
yri by
removed. cop Vo
by lksw
cted agen
Prote AG.

Note

Only heat adhesive sealant gently and briefly. Adhesive sealant must not change in colour or blister.

2. Wing 15
 AG. Volkswagen AG d
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d b ara
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Touran 2003 ➤ autho eo
ra
General body repairs, exterior - Edition 02.2015 ss c

ce
le
un

pt
an
d
2.2.3 Installing

itte

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erm

ab
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wit
is n
Note

h re
ole,

spec
urposes, in part or in wh
♦ Lock carrier must be installed free of tension

t to the co
♦ It may be necessary to loosen the securing bracket -5- before
bolting on the wing.

rrectne
♦ Adhesive sealant - D 511 500 A2- must be restored according
to specifications in the ⇒ Paintwork shop manual .

ss
♦ To prevent problems during subsequent removal of the wing,

o
cial p

f
adhesive sealant - D 511 500 A2- must be applied in its original

inform
thickness and covered with protective backing - AKL 448 030
mer

05- .

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t.

satelettronica
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Apply adhesive sealant - D 511 500 A2- in the area of the A-

column and cover the adhesive sealant - D 511 500 A2- with
the protective film - AKL 448 030 05- .
– Screw in bolts -2- and -6-, but do not tighten.
– Loosen bolts -7- fastening bracket -5-.

16 Rep. gr.50 - Body - front

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Tighten bolts -2- and -6-.

– Adapt retaining bracket -5- to the wing -1- and tighten bolts
-7-.
– Tighten bolts in the prescribed sequence ⇒ page 17 .
Further installation is performed in the reverse order of removal.
– Make sure that joints are parallel and specified dimensions for
gaps/shut lines are maintained. ⇒ Body Repairs; Rep. gr. 00 ;
Body gaps/shut lines; Body, front

2.2.4 Front wing - bolting sequence

Note

♦ Only the left side is shown. The right side is similar.

♦ The specified bolting sequence must strictly be maintained.

AG. Volkswagen AG d
agen oes
olksw not
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b

satelettronica
d ara
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tho eo
au ra
ss c

ce
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nl

pt
du

an
itte

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erm

ab
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wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
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atio
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or c

thi
te

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rp

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en
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t.
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Cop py
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gh ht
pyri by
Vo
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by
cted agen
Prote AG.

– The sequence in which the bolts -1- to -14- are tightened can
be seen in the illustration.

2. Wing 17
 Touran 2003 ➤
General body repairs, exterior - Edition
AG. Vo02.2015
lkswagen A n G do
wage es n
Volks ot g
2.3 Front wing 08.2010 ► ris
ed
by ua
ran
tee
tho
or
au ac
ss
Note

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un

pt
an
d
itte

y li
The removal and installation sequence is only described for the
rm

ab
left wing. Removal and installation of the right wing is similar.
pe

ility
ot

wit
, is n

h re
2.3.1 Assembly overview - front wing
hole

spec
es, in part or in w

t to the co
Note

rrectness of i
Only the left side is shown. The right side is similar.
l purpos

1 - Wing

nform
ercia

❑ Removing ⇒ page 19
m

a
com

t
❑ Installing ⇒ page 20 .

ion in
r
te o

2 - Seal

thi

satelettronica
s
iva

do
❑ Sealed with adhesive
r
rp

cum
sealant - D 511 500 A2-
fo

en
ng

t.
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3 - Bolt . Cop py
rig
ht
❑ Qty. 3, A-pillar. rig ht
py by
co Vo
❑ Qty. 1, side member
by lksw
cted agen
Prote AG.
❑ Qty. 2, wing strut
❑ Specified torque: 6 Nm
4 - zinc intermediate piece
❑ zinc intermediate piece -
AKL 381 035 50-
5 - Wing bracket
❑ Removing and installing
⇒ page 21
6 - Bolt
❑ 2 bolts for wing fasten‐
ing bracket
❑ Specified torque: 6 Nm
7 - Bolt
❑ Qty. 2, wing connection
piece
❑ Specified torque: 6 Nm
8 - Wing securing bracket
❑ Removing and installing
⇒ page 22
9 - Bolt
❑ 2 bolts, wing fastening
bracket
❑ Specified torque: 6 Nm
10 - Filler piece
❑ Between wing and longitudinal member

18 Rep. gr.50 - Body - front

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.3.2 Removing

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
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satelettronica
s a c
s

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
r

– Remove front bumper cover ⇒ page 209 .

p

cum
r
fo

en
ng

– Remove front wheel housing liner ⇒ page 272 .

t.
yi Co
Cop py
t. rig
– Remove front side window ⇒ page 270 . opyri
gh by
Vo
ht
c
– Remove guide ⇒ page 212 .
by lksw
cted agen
Prote AG.
– Pull out foam part -7- between wing -1- and longitudinal mem‐
ber.
– Unscrew bolts -3, 5,- and -6- from wing -1-.
– Heat adhesive sealant -2- between A-pillar and wing with a hot
air blower - V.A.G 1416- in wheel housing area.

Note

Only heat adhesive sealant gently and briefly. Adhesive sealant must not change in colour or blister.

– Adhesive sealant -2- is loosened and wing -1- can be carefully

removed.

2. Wing 19
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

Note

The zinc intermediate piece -4- will be destroyed during removal.

2.3.3 Installing

Note

♦ Lock carrier must be installed free of tension

♦ It may be necessary to loosen the securing bracket -7- before bolting on the wing.
♦ Adhesive sealant - D 511 500 A2- must be restored according to specifications in the ⇒ Paintwork shop
manual .
♦ To prevent problems during subsequent removal of the wing, adhesive sealant - D 511 500 A2- must be
applied in its original thickness and covered with protective backing - AKL 448 030 05- .
n AG. Volkswagen AG do
♦ Replace zinc intermediate piece -4-. lkswage es n
o ot g
byV ua
d ran
ir se tee

satelettronica
tho
u or
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ss

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un

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an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Replacing zinc intermediate piece - AKL 381 035 50- -4-.

20 Rep. gr.50 - Body - front

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Apply adhesive sealant - D 511 500 A2- -2- in area of A-pillar,

and cover adhesive sealant - D 511 500 A2- with protective
film - AKL 448 030 05- .
– Screw in bolts -3, 6- and -8-, but do not tighten.
– Loosen bolts -5- of fastening bracket -7-.
– Tighten bolts -3, 6- and -8-.
– Adapt retaining bracket -7- to the wing -1- and tighten bolts
-5-.
Further installation is performed in the reverse
gen AG. Volksworder
agen Aof
G dremoval.
wa oes
olks no
– Make sure that joints are d bparallel and specified dimensions for
yV t gu
ar
gaps/shut lines are maintained
orise
⇒ Body Repairs; Rep. gr. 00 ;antee
Body panel gaps/shut
au
th
lines; Body - front . or
a
ss c
2.4 Wing bracket

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
2.4.1 Removing and installing wing bracket ▶
ot p

wit
is n

07.2010

h re
ole,

satelettronica
spec
urposes, in part or in wh

t to the co
Note

The removal and installation sequence is described for the left

rrectne
wing bracket. The removal and installation of the right wing brack‐
et is similar.

ss o
cial p

f
Removing
inform
mer

– Remove wing ⇒ page 14 .

atio
om

– Undo bolts -2- and remove wing bracket -1-.

c

i
or

n thi
te

Installing
sd
iva

o
pr

cum
r

Installation of the wing bracket -1- is carried out in reverse order

fo

en
ng

of removal.
t.
yi Co
Cop py
t.
– Specified torque for bolts -2-: 6 Nm.
rig
gh ht
pyri by
Vo
co
– Wing and wing strut must be aligned with bonnet and bumper.
by lksw
cted agen
Prote
⇒ Body Repairs; Rep. gr. 00 ; Body gaps/shut lines; Body,
AG.

front

2.4.2 Removing and installing wing bracket

08.2010 ▶

Note

The removal and installation sequence is described for the left

wing bracket. The removal and installation of the right wing brack‐
et is similar.

Removing
– Remove wing ⇒ page 14 .

2. Wing 21
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Undo bolts -2- and remove wing bracket -1-.

Installing
Installation of the wing bracket -1- is carried out in reverse order
of removal.
– Specified torque for bolts -2-: 6 Nm.
– Wing and wing strut must be aligned with bonnet and bumper.
⇒ Body Repairs; Rep. gr. 00 ; Body gaps/shut lines; Body,
front

AG. Volkswagen AG d
agen oes
olksw not
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2.5 Removing and installing wing securing orised b ara
nte
eo
bracket
h
aut ra
ss c

ce
le
un

pt
an
d
itte
Note

y li
erm

ab
ility
ot p

The removal and installation sequence is only for the left wing

wit
is n

bracket. The removal and installation of the right wing bracket is

satelettronica
h re
ole,

similar.

spec
urposes, in part or in wh

t to the co
Removing
– Remove wing ⇒ page 14 .

rrectne
– Undo bolts -2- and remove wing fastening bracket -1-.
Installing

ss o
cial p

f
Install in reverse order of removal.

inform
mer

– Fastening bracket and wing must be adjusted in relation to the

atio
door ⇒ Body Repairs; Rep. gr. 00 ; Body panel gaps/shut lines;
om

n
Body - front .
c

i
or

n thi
te

sd
– Specified torque for bolts -2-: 6 Nm.
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

22 Rep. gr.50 - Body - front

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

3 Noise insulation

3.1 Tools
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-

satelettronica
3.2 Assembly overview - noise insulation
AG. Volkswagen AG d
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Note d byV gu
ara
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th
♦ The removal and
s au installation procedures may have to be modified r a slightly
c depending on engine fitted.
s
ce
le

♦ The bolt -2- is microencapsulated and must be renewed each time it is removed.
un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

3. Noise insulation 23
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1 - Noise insulation
❑ Arrow points forwards
❑ Removing:
– Remove bolts -2- and
-3-

2 - Bolt
❑ The bolt is microencap‐
sulated and must be re‐
newed after each time it
has been loosened
❑ Qty. 3.
❑ 6 Nm
3 - Bolt
❑ Qty. 6.
❑ 2 Nm

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
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ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

24 Rep. gr.50 - Body - front

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

4 Underbody cladding

4.1 Tools
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

satelettronica
t to the co
4.2 Assembly overview - underbody cover

rrectness of i
Note
l purpos

Only the left side is shown. The right side is similar.

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

4. Underbody cladding 25
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1 - Underbody cladding agen

AG. Volkswagen AG d
oes
lksw not
❑ Arrow points forwards by Vo gu
ara
d
❑ Removing: rise nte
ho e t or
au ac
– Remove bolts
ss -2-.

ce
le
un

pt
2 - Hexagon nut

an
d
itte

y li
❑ Qty. 8
erm

ab
ility
ot p

❑ 1.5 Nm

wit
is n

h re
3 - Cover
ole,

spec
❑ Removing:
urposes, in part or in wh

t to the co
– Remove bolts -4-.

4 - Bolt

rrectne
❑ Qty. 2
❑ 2 Nm

ss o
cial p

f inform
mer

atio
m

satelettronica
o

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

26 Rep. gr.50 - Body - front

 AG. Volkswagen AG d
agen oes
olksw not
y V gu
rise
d b ara
nte Touran 2003 ➤
autho
General
eo
ra body repairs, exterior - Edition 02.2015
ss c

ce
4.3le Assembly overview - front underbody panel
un

pt
an
d
itte

y li
rm

ab
pe

ility
1 - Left cover
ot

wit
, is n

❑ Removing:

h re
hole

spec
– Remove bolts -4-.
es, in part or in w

t to the co
2 - Hexagon nut
❑ Qty. 2

rrectness of i
❑ 2 Nm
l purpos

3 - Left plug
❑ Removing:

nform
ercia

– Pull plug out of mount‐

m

ing.

a
com

tion in
4 - Right plug
r
te o

thi
s
iva

❑ Removing:

do
r
rp

cum
fo

– Pull plug out of mount‐

en
ng

t.
ing.
yi

satelettronica
Co
Cop py
t. rig
gh
5 - Bolt
ht
pyri by
Vo
co lksw
by
❑ Qty. 2. Prote
cted AG.
agen

❑ 2 Nm
6 - Right cover
❑ Removing:
– Remove bolts -4-.

4. Underbody cladding 27
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

5 Protectors for natural gas tanks

Note

Instructions and work specifications for the natural gas system can be found in ⇒ Engine; 4-cylinder injection
engine (1.4 l engine, natural gas); Rep. gr. 20 ; Fuel supply system, gas, operation .

1 - Rear protector
Removing

– Unscrew bolts
-2, 3 and 4-.

– Remove protective cov‐

er.

2 - Bolt
❑ Qty. 4.

satelettronica
❑ 2 Nm
3 - Bolt
❑ Qty. 2.
❑ 6 Nm
4 - Hexagon nut
❑ Qty 1 for front protector
❑ Qty. 2 for rear protector
on 7-seater
❑ Qty. 1 for rear protector
on 5-seater
❑ 6 Nm
n AG. Volkswagen AG do
5 - Clamping nut olkswage es n
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❑ Qty. 4. ir se
d b ua
ran
o tee
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ac
ss
6 - Flange nut
ce
e
nl

pt
du

❑ Qty. 3.
an
itte

y li

❑ 4 Nm
erm

ab
ility
ot p

7 - Front protector
wit
, is n

h re

Removing
hole

spec
es, in part or in w

– Remove exhaust pipe

t to the co

⇒ page 29

– Remove nuts -4, 5 and 6-.

rrectness of i

– Remove protective cover ⇒ Item 7 (page 28) .

l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by

28
cted agen
Prote AG.
Rep. gr.50 - Body - front
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

Removing and installing exhaust pipe

– Detach hanger -1- and release clip -2-.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
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un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

satelettronica
m

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

5. Protectors for natural gas tanks 29

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

6 Plenum chamber bulkhead

AG. Volkswagen AG d
6.1 Tools olksw
agen oes
not
y V gu
b ara
Special tools and workshop equipment required rise
d
nte
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u
♦ Torque wrench - V.A.G 1783- ss a ra
c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne

satelettronica
ss
6.2 Assembly overview - plenum chamber bulkhead

o
cial p

f inform
mer

1 - Seal

atio
om

n
c

2 - Plenum chamber bulkhead

i
or

n thi
e

middle
t

sd
iva

o
pr

c
3 - Bolt

um
r
fo

en
ng

❑ Qty. 5.
t.
yi Co
op py
❑ 9 Nm
t. C rig
gh ht
pyri by
Vo
o
4 - Right plenum chamber
c by lksw
cted agen
bulkhead Prote AG.

5 - Left plenum chamber bulk‐

head
6 - Bolt
❑ Qty. 4.
❑ 9 Nm

30 Rep. gr.50 - Body - front

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

7 Bulkhead

7.1 Tools

Special tools and workshop

equipment required
♦ Torque wrench 5…50 Nm -
V.A.G 1331-
♦ Cartridge heater -
V.A.G 1939-
♦ Cartridge gun -
V.A.G 1628-

satelettronica
AG. Volkswagen AG d
agen oes
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wit
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spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

7.2 Materials
atio
om

n
c

i
or

♦ 1K glass adhesive 1)
thi
te

sd
iva

o
r

♦ Activator
p

cum
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fo

en
ng

t.
yi
♦ Glass and paint primer
Co
Cop py
ht. rig
rig ht
by
♦ Cleaning solution copy Vo
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Prote AG.
♦ Primer applicator

1) Warm according to manufacturer's instructions, using cartridge heater - V.A.G

1939- .
2) Observe minimum curing period

7. Bulkhead 31
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

7.3 Assembly overview - plenum chamber bulkhead

Note

The plenum chamber bulkhead -1- is bolted and also bonded in place with PUR adhesive sealant -3-.

1 - Bulkhead
❑ Removing:
– After unbolting bolts -2-,
cut through adhesive
bead -3- using suitable
means.

2 - Body flange
3 - PUR adhesive sealant
❑ DH 009 100 03.
G. Volkswagen AG d
❑ Bead cross section: lkswagen A oes
not
width = 8 mm; height V =
o

satelettronica
by gu
ara
10 mm rised
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ut
❑ Minimums acuring period ra
c
⇒ page s251 .
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4 - Bolt
an
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itte

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❑ Qty. 10.
erm

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ility
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❑ Specified torque: 25 Nm
wit
is n

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ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
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pr

cum
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fo

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t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

32 Rep. gr.50 - Body - front

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

55 – Bonnet, rear lid AG. Volkswagen AG d

agen oes
olksw not
1 Bonnet y V gu
d b ara
rise nte
tho eo
au ra
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ce
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1.1 Tools

un

pt
an
d
itte

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Special tools and workshop equipment required

rm

ab
pe

ility
♦ Torque wrench - V.A.G 1331-

ot

wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

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ercia

satelettronica
m

a
com

tion in
r

♦ Removal lever - 80-200-

te o

thi
s
iva

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rp

cum
fo

en
ng

t.
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Cop py
t. rig
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pyri by
Vo
co lksw
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cted agen
Prote AG.

1.2 Assembly overview - bonnet

Note

The bonnets 08.2010 ► only differ in respect of their appearance and add-on parts.

1. Bonnet 33
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1 - Bonnet
❑ Removing and installing
⇒ page 34
❑ Adjusting ⇒ page 43 agen
AG. Volkswagen AG d
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2 - Hinge ed by gu
ara
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❑ Removing and installing ut
ho eo
ra
⇒ page 36 ss a c

ce
e
❑ Adjusting ⇒ page 43

nl

pt
du

an
itte
3 - Gas strut

y li
erm

ab
❑ Removing ⇒ page 36

ility
ot p

wit
❑ Releasing gas
, is n

h re
⇒ page 36
hole

spec
4 - Insulation
es, in part or in w

t to the co
❑ Removing and installing
► 07.2010 ⇒ page 37
❑ Removing and installing

rrectness of i
from 08.2010 ►
l purpos

⇒ page 39

satelettronica
5 - Adjustment buffer

nform
ercia

❑ Qty. 2.
m

at
❑ From 08.2010 ► 2 on
om

io
each side

n
c

in t
or

his
e

❑ Adjusting ⇒ page 43
at

do
priv

c
6 - Right seal

um
for

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❑ Clipped into bonnet.

n

t.
yi Co
Cop py
t.
7 - Left seal
rig
gh ht
pyri by
Vo
❑ Clipped into bonnet.
o
by c lksw
cted agen
Prote AG.

1.3 Removing and installing bonnet

Note

The bonnets 08.2010 ► only differ in respect of their appearance.

34 Rep. gr.55 - Bonnet, rear lid

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.3.1 Removing

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
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un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co

satelettronica
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove connectors of all installed electrical components and

hoses of the washing system.
– Loosen hexagon nuts -3- on left and right (do not remove
completely).
Further dismantling requires the help of a second mechanic.
– Remove gas strut -4- from bonnet.-1- ⇒ page 36 .
– Now, unscrew hexagon nuts -3-, and lift bonnet -1- out of hing‐
es -2-.

1.3.2 Installing
Install in reverse order of removal.
– Specified torque: hexagon nuts -3- (22 Nm).
– Adjusting bonnet -1- ⇒ page 43 .

1. Bonnet 35
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.4 Removing gas strut

– Open and support bonnet.
– Insert a small screwdriver beneath spring clip -3-.
– Raise spring clip -3- until it can be moved over ball socket in
direction of -arrow-.
– Pull gas strut -1- off ball-head pins -2- and bearing bracket with
ball-head pins -4-.
After removing gas strut -1-, slide spring clip -3- back immediately.

WARNING

Proceed with care if gas strut is reused. Spring clip must not
be levered completely out of ball socket, as it will otherwise be
damaged. Gas strut will spring out of mounting, causing dam‐
age or injury to operator.

satelettronica
Note

The ball-head pin -4- is a part of the mounting bracket.

Component Specified torque

Ball-head pin 22 Nm
Bolts for mounting bracket 10 Nm
AG. Volkswagen AG d
agen
1.5 Releasing gas from gas strut y Volksw
oes
not
gu
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e
– Clamp gas strut in vice in area x = 50 mm. thoris nte
eo
au ra
ss c ce
WARNING
e
nl

pt
du

an
itte

y li

Clamp gas strut only within area -x-; otherwise danger of ac‐
erm

ab

cident!
ility
ot p

wit
, is n

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hole

spec

– Saw through cylinder of gas strut within first third of cylinder's

es, in part or in w

overall length using piston rod end of cylinder as reference

t to the co

point.
rrectness of i

Note
l purpos

♦ Wear protective goggles when sawing.

nform
ercia

♦ Cover area of separating cut with a cleaning cloth.

m

♦ Dispose of oil and cloth via existing disposal channels.

at
om

ion
c

in t
or

his
te

1.6 Removing and installing bonnet hinge

a

do
priv

cum
for

en
ng

t.
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op
Note C py
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gh ht
pyri by
Vo
o
The removal and installation sequence is only described for the
c by lksw
cted agen
left hinge. The removal and installation of the right hinge is similar.
Prote AG.

36 Rep. gr.55 - Bonnet, rear lid

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.6.1 Removing
– Remove bonnet ⇒ page 34 . agen
AG. Volkswagen AG d
oes
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– Unscrew bolts -2-, and remove d b bonnet hinge -1-.
y ara
rise nte
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pt
an
d
itte

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erm

ab
ility
ot p

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is n

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ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform

satelettronica
mer

atio
1.6.2 Installing
om

n
c

i
or

n
Install in the reverse order of removal.

thi
te

sd
iva

o
r

– Specified torque for bolts -2-: 22 Nm.

p

cum
r
fo

en
ng

– Adjusting bonnet ⇒ page 43 .

t.
yi Co
Cop py
t. rig
1.7 Insulation ► 07.2010
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1.7.1 Removing and installing

1. Bonnet 37
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

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ole,

spec
urposes, in part or in wh

t to the co

satelettronica
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Removing
– Lever retaining clips -1- (qty. 5) out of insulation -2- using re‐
moval lever - 80-200- .
– Pull insulation -2- out of bonnet opening.
Installing
– Push all catches into the oblong holes.
– Fit retaining clips on so that they click into place.

Note

When installing insulation -2-, make sure that retaining clips -1- are fitted with short side facing upwards.

38 Rep. gr.55 - Bonnet, rear lid

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.8 Insulation 08.2010 ►

1.8.1 Removing and installing

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

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ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
m

Removing
o

n
c

i
or

n thi
e

– Lever retaining clips -3- (qty. 10) out of insulation -2- using
t

sd
va

removal lever - 80-200- .

i

o
pr

cum
r
fo

en

– Pull insulation -2- out of bonnet opening.

ng

t.
yi Co
op py
– Pull insulation -1- out of longitudinal holes. t. C rig
gh ht
pyri by
Installing
co Vo
by lksw
cted agen
Prote AG.
– Push all catches into the oblong holes.
– Fit retaining clips on so that they click into place.

Note

When installing insulation -2-, make sure that retaining clips -1- are fitted with short side facing upwards.

1. Bonnet 39
 Touran 2003 ➤
AG. Volkswagen AG d
General body repairs, exterior - Edition 02.2015 ksw
agen oes
not
ol
byV gu
ara
d
1.9 Assembly overview - bonnet lock and release components ise nte
or eo
h
aut ra
ss c

ce
e
nl
1 - Safety catch

pt
du

an
itte

y li
❑ Removing:

erm

ab
ility
ot p
– Unscrew bolts -2- and

wit
remove arrester.

, is n

h re
hole
❑ Safety catch 08.2010 ►

spec
⇒ page 43
es, in part or in w

t to the co
2 - Bolt
❑ Qty. 3.

rrectness of i
❑ 10 Nm
l purpos

3 - Bowden cable
❑ Separating

nform
ercia

⇒ page 43 .
m

at
4 - Release lever
om

ion
c

❑ Removing and installing

in t
or

his
e

⇒ page 45
at

satelettronica
do
priv

c
5 - Mounting bracket

um
for

en
ng

t.
yi
6 - Bolt
Co
Cop py
.
❑ Qty. 2.
ht rig
rig ht
py by
Vo
❑ 1.5 Nm
co lksw
by
cted agen
Prote AG.
7 - Bonnet lock
❑ Removing and installing
⇒ page 40
❑ Adjusting ⇒ page 45
8 - Bowden cable coupling
❑ Separating
⇒ page 43 .

1.10 Bonnet lock ► 07.2010

1.10.1 Removing and installing

Removing
– Remove radiator grille ⇒ page 296 .

40 Rep. gr.55 - Bonnet, rear lid

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Disconnect Bowden cable ⇒ page 43 .

– Detach connector -4- for bonnet contact switch - F 266- .
The connector is secured over the right headlight.
– Unscrew bolts -3- on lock carrier -2-, and remove bonnet lock
-1-.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
d
– To unclip Bowden cable -2-, press tab -3- and oBowden
ris
e cable nte

satelettronica
eo
together -arrows-. aut
h
ra
ss c
– Fastener is released and Bowden cable -2- can be removed

ce
le
un

pt
from bonnet lock -1-.

an
d
itte

y li
rm

Installing

ab
pe

ility
ot

Install in reverse order of removal.

wit
, is n

h re
hole

Component Specified torque

spec
es, in part or in w

Screws 12 Nm

t to the co
– Adjust bonnet lock ⇒ page 45 .

rrectness of i
• Before closing bonnet, check function of release lever and
Bowden cable.
l purpos

1.11 Bonnet lock 08.2010 ►

nform
mercia

a
com

1.11.1 Removing and installing tion in

r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1. Bonnet 41
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne

Removing
ss

– Disconnect Bowden cable ⇒ page 43 .

o
cial p

f inform

– Remove bolts -3- of lock carrier on the inside.

mer

atio
m

– Remove bonnet lock -1- upwards out of lock carrier.

o

n
c

i
or

– Detach connector -2- for bonnet contact switch - F 266- .

thi
te

sd
iva

– Unclip Bowden cable -4- from bonnet lock -1-.

pr

cum
r
fo

en
ng

Installing
t.
yi Co
Cop py
Install in reverse order of removal.
t. rig
gh ht
pyri by
Vo
o
Adjusting by c lksw
cted agen
Prote AG.
– Loosen bolts -2- so that the bonnet shut gap can be slightly
corrected or adjusted ⇒ Body Repairs; Rep. gr. 00; Techni‐
sche Daten; Karosseriespaltmaße; Karosserie vorn
Component Specified torque
Screws 12 Nm

42 Rep. gr.55 - Bonnet, rear lid

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.12 Removing and installing safety catch

Removing
– Unscrew bolts -3- and then remove safety catch -2- from the
bonnet -1-.
Installing
Install in reverse order of removal.
Bolts -2-, torque setting 10 Nm
Adjusting wage
n AG. Volkswagen AG do
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lks ot g
Vo
– The safety catch ed -2- can be adjusted from left to right rin
b y ua its
an
oblong holes thoby
r loosening the bolts -3-.
is tee
or
au ac
ss

ce
e
nl

pt
du

an
itte

y li
1.13 Detaching the Bowden cable
erm

ab
ility
ot p

– Open bonnet.

wit
, is n

h re
– Unclip Bowden coupling -1- over headlight on driver side of
hole

spec

satelettronica
lock carrier -2-.
es, in part or in w

t to the co
– Open Bowden coupling -1- at the top and remove Bowden ca‐
ble -3- from Bowden coupling in -direction of arrow-.

rrectness of i
Note
l purpos

When installing, ensure that the Bowden cable sleeve is inserted

nf
ercia

correctly and the coupling engages.

orm
m

atio
m

• Before closing bonnet, check function of release lever and

o

n in
or c

Bowden cable.
thi
te

sd
iva

o
r
rp

cu

1.14 Adjusting bonnet

o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh
Note
ht
pyri by
Vo
co lksw
by
cted agen
Prote
Only the adjustment for the left bonnet hinge is described. Adjustment of the right hinge is analogous.
AG.

1. Bonnet 43
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform

satelettronica
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– For initial adjustment of bonnet, -1-, the vehicle must be stand‐

ing on the ground and the latch hook be removed.
– Remove safety catch -8- ⇒ Item 1 (page 40) .
– Remove gas strut -6- from bonnet -1- ⇒ page 36 .
– Loosen hexagon nuts -4- (do not remove) in order to centre
the bonnet -1- between the wings
– The height of the rear part of the bonnet -1- can be adjusted
by loosening the bolts -4- (do not remove).
– The stop -5- dampens the bonnet hinge (stop is adjustable).
– The front part of the bonnet -1- can be adjusted to the wing
height by using the adjustment buffers -7-.
– Make sure that gaps/shut lines are uniform. ⇒ Body Repairs;
Rep. gr. 00 ; Body gaps/shut lines; Body, front
– Following assembly or adjustment work, carry out corrosion
protection measures on hinge -4- and hexagonal nuts -3-.
– After the bonnet -1- has been adjusted, the safety catch can
be fitted again.

44 Rep. gr.55 - Bonnet, rear lid

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.14.1 Adjusting bonnet lock

– If gaps change when the bonnet is closed, correct the adjust‐
ment via bonnet lock.
– Remove radiator grille ⇒ page 296 .
– If bolts -1- are now loosened, bonnet gap dimensions can be
corrected or adjusted ⇒ Body Repairs; Rep. gr. 00 ; Body
panel gaps/shut lines; Body - front .
– Specified torque for bolts -1-: 12 Nm.

1.15 Removing and installing release lever

AG. Volkswagen A n G do
wage es n
Volks ot g
by ua
ed ran
1.15.1 Removing thoris tee
or
s au ac
– Pull release lever
s
-1- to release bonnet.

satelettronica
ce
le
un

pt
– Insert a small screwdriver in the gap between the release lever

an
d
itte

y li
-1- and clip -2-.
rm

ab
pe

ility
– Lever clip -2- out of release lever -1- and remove release lever.
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum

1.15.2 Installing
fo

en
ng

t.
yi Co
op
– Push clip -2- completely into release lever -1-.
C py
ht. rig
rig ht
py by
– Then, press release lever -1- onto mounting in mounting
co Vo
by lksw
cted
bracket, and engage it.
agen
Prote AG.

• Before closing bonnet, check function of release lever and

Bowden cable.

1. Bonnet 45
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2 Rear lid

2.1 Tools
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

satelettronica
2.2 Assembly overview - rear lid

Note

The rear lids 08.2010 ► only differ in respect of their appearance

and add-on parts.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
46
by c lksw
cted
Rep. gr.55 - Bonnet, rear lid
agen
Prote AG.
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1 - Rear lid
❑ Removing and installing
⇒ page 47
❑ Adjusting ⇒ page 53
2 - Rear lid lock
❑ Removing and installing
⇒ page 58
3 - Damper
❑ Adjusting ⇒ page 54
4 - Gas strut
❑ Removing ⇒ page 50
❑ Releasing gas
⇒ page 50
5 - Hinge
❑ Removing and installing
⇒ page 50
6 - Striker pin

satelettronica
❑ Removing and installing
⇒ page 53
❑ Adjusting ⇒ page 54
7 - Cap

n AG. Volkswagen AG do
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ir se tee
tho
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a ac
ss

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un

pt
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itte

2.3 Removing and installing rear lid

y li
rm

ab
pe

ility
ot

wit
, is n

h re
Note
hole

spec
es, in part or in w

The rear lids 08.2010 ► only differ in respect of their appearance.

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Rear lid 47
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.3.1 Removing

AG. Volkswagen AG d
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– Open rear lid -1-.
agen
Prote AG.

– Because a two-step gas-filled strut is installed in the Touran,

the rear lid must be pushed fully open by hand.
– Remove rear lid trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Trims, insulation; Rear lid trim .
– Detach connectors of all installed electrical components and
pull washing system hose off.
– Thread cables and hose through the openings.
Remove cable bushing: ⇒ page 49
– Loosen bolts -3- of left and right hinges -4- (do not unbolt com‐
pletely).
Further dismantling requires the help of a second mechanic.
– Remove gas struts -2- on left and right-hand sides of rear lid
-1- ⇒ page 50 .
– Now, unscrew bolts -3- completely, and then remove rear lid
-1-.

48 Rep. gr.55 - Bonnet, rear lid

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.3.2 Removing cable bushing

satelettronica
AG. Volkswagen AG d
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There is a release clip -3- in the rubber grommet -2-.

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– Press release lever -3- downwards forcefully -arrow-.

hole

spec
es, in part or in w

– You will then be able to remove cable bushing from the rear
t to the co

roof -1- and pull the cable -4- out of the roof at the rear.

2.3.3 Installing
rrectness of i

Install in reverse order of removal.

l purpos

– Specified torque for bolts -3-: 10 Nm.

nf
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– Adjusting the rear lid ⇒ page 53 .

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2. Rear lid 49
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.4 Removing gas strut

– Open rear lid to second level and support it.
– Insert a small screwdriver beneath spring clip -2-.
– Raise spring clip -2- until it can be moved over ball socket in
direction of -arrow-.
– Pull gas strut -1- off ball-head pins -3- and -4-.
After removing gas strut -1-, slide spring clip -3- back immediately.

WARNING

Proceed with care if gas strut is reused. Spring clip must not
be levered completely out of ball socket, as it will otherwise be
damaged. Gas strut will spring out of mounting, causing dam‐
age or injury to operator.

– Specified torque for ball-head pins -3- and -4-: 21 Nm.

– Releasing gas from gas strut ⇒ page 50 .

satelettronica
AG. Volkswagen AG d
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2.5 Releasing gas from gas strut ol not
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– Clamp gas strut in vice in area x = 50 mm. auth eo
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WARNING

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Clamp gas-filled strut only within area -x-.

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– Saw through cylinder of gas strut within first third of cylinder's

spec
urposes, in part or in wh

overall length using piston rod end of cylinder as reference

t to the co
point.

rrectne
Note

♦ Wear protective goggles when sawing.

ss o
cial p

♦ Cover area of saw cut with a cloth.

inform
mer

♦ Dispose of oil and cloth via existing disposal channels.

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2.6 Removing and installing rear lid hinges

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Removal and installation is described for the right-hand rear lid cop Vo
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hinge. Left rear lid hinge removal and installation are analogous.
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Prote AG.

2.6.1 Removing

50 Rep. gr.55 - Bonnet, rear lid

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

AG. Volkswagen AG d
agen oes
olksw not
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or

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– Remove rear lid -1- ⇒ page 47 .
– Remove roof end strip ⇒ General body repairs, interior; Rep.
gr. 70 ; Trims, insulation; Removing and installing roof end
strip .
– Unscrew hexagon nut -3-, and remove rear lid hinge -2- from
roof member.

2.6.2 Installing

Note

Retighten hexagon nut to 24 Nm once installation is complete.

2. Rear lid 51
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

satelettronica
AG. Volkswagen AG d
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– Fit rear lid hinge -2-, and tighten hexagon nut -3- to 24 Nm.
erm

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Further installation is performed in the reverse order of removal.

wit
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– Retighten hexagon nut -3- to 24 Nm once installation is com‐

hole

spec

plete.
es, in part or in w

t to the co

– Adjusting rear lid ⇒ page 53 .

rrectness of i
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52 Rep. gr.55 - Bonnet, rear lid

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.7 Removing and installing striker pin

2.7.1 Removing
– Remove lock carrier cover ⇒ General body repairs, interior;
Rep. gr. 70 ; Luggage and load area compartment trim; Re‐
moving and installing lock carrier cover .
– Unscrew bolts -1-, and remove striker pin in
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2.7.2 Installing
hole

spec
es, in part or in w

Install in reverse order of removal.

satelettronica
t to the co
– Specified torque for bolts -1-: 23 Nm.
– Adjusting rear lid ⇒ page 53 .

rrectness of i
2.8 Adjusting rear lid
l purpos

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Note
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io
♦ The rear lid is adjusted correctly if the gaps/shut lines are even

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all around, the door is not too deep or does not stand proud
o

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and all contours align when the rear lid is closed.

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♦ The vehicle must be standing on its wheels when the adjust‐

f

en
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ment is performed.
n

t.
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Cop py
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Gaps/shut lines ⇒ Body Repairs; Rep. gr. 00 ; Body gaps; Body py by
co Vo
- rear .
by lksw
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Prote AG.
– The rear lid can be adjusted only by means of the striker pin
on lock cross member. The rear lid lock is bolted directly to the
rear lid. It does not have elongated holes, so it cannot be ad‐
justed.
– Adjusting buffers cannot be used to adjust rear lid as they are
in some other vehicles. They have the function of stabilising
and damping the rear lid. The adjusting buffer is referred to as
damper below.
– Rear lid adjustment is described step by step below. This in‐
cludes adjustment of the striker pin and the dampers.

2. Rear lid 53
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.8.1 Adjusting the striker pin

– Remove lock carrier cover ⇒ General body repairs, interior;
Rep. gr. 70 ; Luggage and load area compartment trim; Re‐
moving and installing lock carrier cover . olkswagen AG
en AG. V ag does
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– Loosen striker pin. y Vol gu
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– Move striker pin to upper
tho position -arrow-, and tighten bolts eo
-1-. s au ra
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– Close rear lid and make sure adjustment has been carried out
un

pt
an
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correctly.
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– Loosen bolts -1- to slide striker pin in over-sized holes.
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– Specified torque for bolts -1-: 23 Nm.

h re
hole

spec
2.8.2 Adjusting dampers
es, in part or in w

t to the co
Note

rrectness of i
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Only the adjustment for the right damper is described. Adjustment

satelettronica
of the left damper is analogous.

nform
ercia

– Loosen clamping bolt -2- until it is visible in rubber buffer.

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a
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tio
– Pull detent slide -1- out of damper.

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Prote AG.

– Adjust detent slide to dimension -a = 12.5 mm-.

– Close rear lid, applying light force in the centre, and press
pushbutton.

54 Rep. gr.55 - Bonnet, rear lid

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Open rear lid again.

– Screw in clamping screw -1- to dimension -a = 25 mm-.
– Check the gap.

2.9 Assembly overview - rear lid locking and release components

1 - Handle trim with pushbutton

for releasing in the rear lid han‐
dle - E234-
❑ Removing ⇒ page 56
2 - Hexagon nut

satelettronica
❑ Qty. 5.
❑ 8 Nm
3 - Number plate lights
❑ Qty. 2.
❑ Registration plate lights
are a component part of
the handle trim
4 - Connector for release but‐
ton
5 - Opening for emergency re‐ agen
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❑ The emergency release orise nte
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can be accessed auth
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through the opening in s s c
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the rear lid trim, once the

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hazard warning triangle

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has been removed.

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6 - Rear lid lock

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❑ Removing and installing

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hole

⇒ page 58
spec
es, in part or in w

7 - Rear lid lock connection

t to the co
rrectness of i
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2. Rear lid 55
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.9.1 Removing handle trim > 08.2010

satelettronica
AG. Volkswagen AG d
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urposes, in part or in wh

t to the co

– Remove rear lid trim ⇒ General body repairs, interior; Rep.

gr. 70 ; Trims, insulation; Rear lid trim .
rrectne

– Detach connector -4- from handle trim -1-.

– Undo and remove hexagon nuts -2-.
ss o

– Then remove handle trim -1-.

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2.9.2 Installing
mer

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Install in reverse order of removal.

c

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– Specified torque: Hexagon nuts -2- 8 Nm.

sd
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pr

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• Before closing rear lid, check function of rear lid release com‐
fo

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ponents.
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56 Rep. gr.55 - Bonnet, rear lid

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.10 Removing and installing handle trim

2.10.1 Removing

AG. Volkswagen AG d
agen oes

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– Undo and remove hexagon nuts -4-.

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t.
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– Remove protective cap -3-.
Co
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– Detach existing electrical connectors -1 and 2-.
ht
pyri by
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– Press in locking hooks -arrows- and remove handle trim from
cted agen
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rear lid.

2.10.2 Installing
Install in reverse order of removal.
– Specified torque: Hexagon nuts -4- 6 Nm.
• Before closing rear lid, check function of lid release compo‐
nents.

2. Rear lid 57
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.11 Removing and installing rear lid lock

Note

The emergency release -1- can be accessed through the opening

-5- in the rear lid trim, once the hazard warning triangle has been
removed.

2.11.1 Removing
– Remove rear lid trim ⇒ General body repairs, interior; Rep.
gr. 70; ; Trims, insulation; Rear lid trim .
– Disconnect connector -4- from rear lid lock -2-.
– Unscrew bolts -3-, and then remove rear lid lock -1- from rear
lid.

satelettronica
AG. Volkswagen AG d
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2.11.2 Installing ris nte
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Install in reverse order of removal. s

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nl

pt
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– Specified torque for bolts -3-: 23 Nm.

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itte

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• Before closing rear lid, check function of rear lid release com‐ ab
ility
ot p

ponents. wit
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2.12 Stop buffer 09.2010 >
hole

spec
es, in part or in w

t to the co
rrectness of i
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py by
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Prote AG.

58 Rep. gr.55 - Bonnet, rear lid

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1 - Rear lid
2 - Stop buffer
❑ Not adjustable
3 - Cover agen
AG. Volkswagen AG d
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4 - Stop byV gu
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es, in part or in w

t to the co
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satelettronica
nform
mercia

at
om

ion
c

in t
or

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ate

do
priv

cum
for

en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2. Rear lid 59
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.13 Registration plate carrier

Note

♦ This is not so much a registration carrier as a protective film.

♦ This protective film protects the rear lid against damage due to a registration plate being fitted.

1 - Protective film
❑ Self-adhesive.
2 - Rivet nuts
❑ Qty. 2.

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Note
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♦ In some markets, a registration plate carrier is required by law.

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tion in

♦ The registration plate must then be attached to the registration plate carrier.
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te o

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Prote AG.

60 Rep. gr.55 - Bonnet, rear lid

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1 - Registration plate carrier

2 - Bolt
❑ For securing the regis‐ n AG. Volkswagen AG do
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3 - Rivet nut

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❑ Qty. 2.

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Prote AG.

2.14 Rear lid seal

During production, a sealant is applied to the rear lid seals, the
seal is then placed on the door flange and rolled on.

Note

♦ When seals are removed, the sealant will spread to the inside
of the seal and the flanks will be bent out slightly. If the seal is
then refitted, sealing and firm seating are no longer guaran‐
teed.
♦ Therefore each seal which is removed completely must be re‐
newed with a so-called “tap-on” seal.
♦ If a seal has been partially removed, squeeze sides of seal
together before refitting.

2. Rear lid 61
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.15 Removing and installing rear lid seal

2.15.1 Removing
– Pull rear lid seal -1- off body flange.

satelettronica
2.15.2 Installing agen
AG. Volkswagen AG d
oes
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– Align the vulcanised point -arrow- d b on the rear lid seal -1- with
y V gu
ara
the middle of the rear lid light.
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nl

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ility
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spec
es, in part or in w

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Prote AG.

62 Rep. gr.55 - Bonnet, rear lid

 n AG. Volkswagen AG do
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b ua
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d General body ran repairs,
tee exterior - Edition 02.2015
tho
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3 Tank flap unit

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3.1 Tools

wit
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Special tools and workshop equipment required

spec
urposes, in part or in wh

♦ Socket - T 10010-

t to the co
rrectness o
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3.2 Assembly overview - tank flap unit

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
1 - Tank flap unit
c by lksw
cted agen
Prote AG.
❑ Removing ⇒ page 65
2 - Water drain hose
3 - Bolt
❑ 1.5 Nm
4 - Assembly part
5 - Release rod
6 - Securing bolt for actuator
❑ Qty. 2.
❑ 1.5 Nm
7 - Fuel tank filler flap actuator
( F 219 )
❑ Removing ⇒ page 66
8 - Seal

3. Tank flap unit 63

 Touran 2003 ➤ AG. Volkswagen AG d
General body repairs, exterior - Edition 02.2015 agen oes
olksw not
byV gu
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is nte
3.2.1 Assembly overview - tank flap unit for natural gas vehicle or eo
h
aut ra
ss c

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un

pt
Note

an
d
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ab
ility
♦ Removal and installation of tank flap unit for gas vehicles are carried out as for petrol and diesel vehicles,

ot p
as appropriate.

wit
is n

h re
ole,
♦ Instructions and work specifications for the natural gas system can be found in ⇒ Engine; 4-cylinder injection

spec
urposes, in part or in wh
engine (1.4 l engine, natural gas); Rep. gr. 20 ; Fuel supply system, gas, operation .

t to the co
1 - Tank flap unit

rrectne
❑ Removing ⇒ page 65

s
2 - Filler cap

s o
cial p

f i
3 - Cap for natural-gas filler

nform
neck
mer

atio
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4 - Natural-gas filler neck

o

n
c

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5 - Bolt
te

sd
va

satelettronica
i

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❑ 1.5 Nm
pr

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fo

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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

64 Rep. gr.55 - Bonnet, rear lid

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

3.2.2 Removing tank flap unit

Note

♦ The tank flap unit for natural gas vehicle is only slightly different from the one for petrol or diesel vehicles.
♦ Follow same instructions as appropriate.

satelettronica
AG. Volkswagen AG d
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ility
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hole

spec
es, in part or in w

t to the co
rrectness of i
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nf
ercia

orm
m

atio
om

n in
or c

– Open tank flap.

thi
te

sd
iva

– Screw off tank cover. In the case of natural gas vehicles, also
o
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rp

cu

remove the cap of the natural-gas filler neck.

o

m
f

en
ng

t.
yi Co
– Remove bolt -3-. t. Cop py
rig
gh ht
– Pull rubber element off fuel filler neck. On natural gas vehicles, pyri by
Vo
co
pull rubber element off filling connection as well.
by lksw
cted agen
Prote AG.
– Pull tank flap unit -1- together with water drain hose -2- to‐
wards rear out of side panel.
– Unclip assembly piece -4- from side panel, and pull it off re‐
lease rod -5-.

3. Tank flap unit 65

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

3.2.3 Installing tank flap unit

Install in the reverse order of removal.
– Following installation, a functional check is to be carried out.

3.2.4 Removing actuator

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
r

satelettronica
ho eo
aut ra
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nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

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mercia

at
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ion
c

in t
or

his
ate

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priv

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for

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Cop py
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pyri by
Vo
– Remove luggage compartment side panel trim ⇒ General
o
by c lksw
cted agen
body repairs, interior; Rep. gr. 70 ; Trim/insulation; Load and Prote AG.
luggage compartment trims .
– Separate connector at actuator -7-.
– Unscrew actuator -7- with special tool socket wrench - T
10010- .
– Pull actuator -7- out of seal -8- together with release rod -5-.

Note

If fuel tank filler flap does not open, it can be opened by hand using the release rod -5-. The side trim must be
removed to do this.

66 Rep. gr.55 - Bonnet, rear lid

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

3.2.5 Installing actuator

Install in the reverse order of removal.
n AG. Volkswagen A
– Following installation, awfunctional
olks
age check is Gtodobe
es ncarried out.
o V t gu
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Only on vehicles rias
se of 07.2012 > on which a new actuator
d ranis in‐
tee
stalled utho
or
a ac
ss

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nl

pt
du

an
itte

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ab
ility
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wit
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h re
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spec
es, in part or in w

t to the co
rrectness of i
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satelettronica
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or c

thi
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f

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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Note

When making the elongated holes, make sure that surrounding components are not damaged.

– At the end of elongated hole -2- another vertical elongated

hole is made.
Dimension -a- is 6 mm.
– The original paintwork structure must be reestablished.

3. Tank flap unit 67

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

57 – Front doors, door components, central locking

1 Front door

1.1 Tools

AG. Volkswagen AG d
agen oes
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un

pt
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d

satelettronica
itte

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pe

ility
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spec
es, in part or in w

t to the co
rrectness of i
l purpos

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a
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tion in
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te o

thi
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Cop py
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Vo
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Prote AG.

1.1.1 Required special tools, workshop equip‐

ment, test and measuring devices and
auxiliary items
♦ Socket - T 10072-
♦ Assembly tool - T 10118-
♦ Door alignment tool - 3320-
♦ Universal joint for 3320 - 3320/1-
♦ Bit for 3320 - 3320/2-
♦ Bit for 3320 - 3320/3-

68 Rep. gr.57 - Front doors, door components, central locking

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

♦ Roller - 3356-
♦ Torque wrench 5…50 Nm - V.A.G 1331-

1.2 Assembly overview - door hinges

Note

♦ The right side is shown. The left side is similar.

♦ The hinge bolts must always be renewed if loosened.
♦ The dash panel must be removed to remove and adjust the upper door hinges.

1 - Door
❑ Removing and installing
⇒ page 70
❑ Adjusting ⇒ page 72
2 - Multi-point socket head bolt
❑ M8×28

satelettronica
❑ 20 Nm + 1/4 turn further
(90°).
❑ Always renew bolts after
loosening.
3 - Door hinge
❑ Hinge is split.
4 - Multi-point socket head bolt n AG. Volkswagen AG do
wage es n
❑ M8×28 yV
olks ot g
b ua
❑ Removeoronly ise this bolt
d ran
tee
from hinge
auth to remove or
ac
door.ss
ce
le

❑ 20 Nm + 1/4 turn further

un

pt
an
d
itte

(90°).
y li
rm

ab

❑ Always renew bolts after

pe

ility
ot

loosening.
wit
, is n

h re

5 - Door hinge with arrester

hole

spec

❑ Hinge is split.
es, in part or in w

t to the co

6 - Multi-point socket head bolt

❑ M8×28
rrectness of i

❑ Installed from inside ve‐

hicle.
l purpos

❑ Remove lower A-pillar

trim ⇒ General body re‐
nform
ercia

pairs, interior; Rep. gr.

70 ; Trims, insulation;
m

a
com

ti

Pillars and side trims .

on in
r
te o

❑ 20 Nm + 1/4 turn further (90°).

thi
s
iva

do

❑ Always renew bolts after loosening.

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rp

cum
fo

en
g

7 - Multi-point socket head bolt

n

t.
yi Co
op py
❑ M8×28 t. C rig
gh ht
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❑ 20 Nm + 1/4 turn further (90°). cop Vo
by lksw
cted agen
Prote
❑ Always renew bolts after loosening.
AG.

1. Front door 69
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

8 - Nut
❑ 14 Nm
❑ Remove this nut from hinge pin to remove door.
9 - Door hinge
AG. Volkswagen AG d
❑ Hinge is split. agen oes
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10 - Multi-point socket head bolt rise
d
nte
ho eo
❑ M8×22 s aut ra
c
s
❑ Installed from inside vehicle.

ce
e
nl

pt
du
❑ To loosen or tighten bolt, remove dash panel and then reinstall ⇒ General body repairs, interior; Rep.

an
itte

y li
gr. 70 ; Trim, insulation; Dash panel; Removing and installing dash panel .
erm

ab
ility
❑ 20 Nm + 1/4 turn further (90°).
ot p

wit
, is n

❑ Always renew bolts after loosening.

h re
hole

spec
11 - Multi-point socket head bolt
es, in part or in w

t to the co
❑ M8×28
❑ 20 Nm + 1/4 turn further (90°).

rrectness of i
❑ Always renew bolts after loosening.

satelettronica
l purpos

12 - Multi-point socket head bolt

❑ M8×28

nf
ercia

❑ 20 Nm + 1/4 turn further (90°).

orm
m

atio
❑ Always renew bolts after loosening.
om

n in
or c

13 - Door hinge

thi
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sd
a

❑ With threaded hinge pin for securing nut.

iv

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❑ Hinge is split.
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Cop py
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1.3 Removing and installing door
cop Vo
by lksw
cted agen
Prote AG.

Note

The removal and installation sequence is only for the right door.
The removal and installation of the left door is similar.

70 Rep. gr.57 - Front doors, door components, central locking

 AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
c
Touran 2003 ➤
s
s General body repairs, exterior - Edition 02.2015

ce
e
nl

pt
du

an
itte
1.3.1 Removing

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
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or c

thi
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sd
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Cop py
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satelettronica
gh ht
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Vo
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Prote AG.

– Release bellows -2- by pressing catch -arrow a- and pull off A-

pillar.
– Swing locking lever -3- downwards -arrow b- and separate
electrical connector -4- from coupling station.
– Remove nut -1- from hinge pin.
– Remove lower bolt -5- from hinge using door alignment tool -
3320- and bit - 3320/3- .
– Lift door upwards -direction of arrow- out of hinges.

1.3.2 Installing
Install in reverse order of removal.
– Specified torque: hexagon nuts -1- 14 Nm.
– Specified torque: bolt -5- 20 Nm + 1/4 turn further (90°).

• Always renew this bolt -5-.

– Observe front door gap/shut lines ⇒ Body Repairs; Rep. gr.
00; Karosseriespaltmaße; Karosserie vorn .

1. Front door 71
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.4 Adjusting door

satelettronica
AG. Volkswagen AG d
agen oes
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ara
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spec
es, in part or in w

t to the co
rrectness of i
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nform
mercia

Note
a
com

tion in
r
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♦ To enable adjustment of the front door, vehicle must be standing on its wheels.
thi
s
iva

do

♦ The front door is adjusted correctly if the gaps/shut lines are even all around, the door is not too deep or
r
rp

cum
fo

does not stand proud and all contours align when the is door closed.
en
ng

t.
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op
♦ To check or adjust the gaps/shut lines ⇒ Body Repairs; Rep. gr. 00 ; Body gaps/shut lines; Body - front .
C py
ht. rig
rig ht
by
♦ After installing or adjusting, carry out corrosion protection measures to hinge and bolts.
copy Vo
by lksw
cted agen
Prote AG.
To ensure a correct door adjustment, the door hinge must be
loosened on the pillar. Other measures such as raising the door
have no effect. Subsequent pressure from above will cause the
door to sack again.
Use door adjustment wrench 3320 with bit insert 3320/2 (Emden
production only) or bit insert 3320/3.
If it is necessary to loosen the upper door hinge on the A-pillar
from inside, insert 3410 can be used. To do this, the dash panel
must be removed: ⇒ General body repairs, interior; Rep. gr. 70 ;

72 Rep. gr.57 - Front doors, door components, central locking

 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ho
ir se tee Touran 2003 ➤
t or
au General ac body repairs, exterior - Edition 02.2015
ss

ce
e
nl
Trims, insulation; Dash panel; Removing and installing dash pan‐

pt
du

an
itte
el

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ab
Adjusting striker pin: ⇒ page 73 .

ility
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wit
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1.4.1 Adjusting the striker pin

h re
hole

spec
es, in part or in w

t to the co
Note

♦ Only the adjustment for the right front door is described. The

rrectness of i
adjustment of the left front door is similar.
l purpos

♦ The front door must lock fully when closing without any addi‐
tional force being required and must not have any play.

nform
ercia

♦ The front door must not be pushed up or down as a result of

m

the striker pin adjustment.

at
om

ion
c

in t
or

The following can be adjusted at the striker pin:

his
ate

do
riv

• When the front door does not align with the rear door.
p

cum
for

en
ng

– Loosen striker pin -1- by loosening bolts -2- in B-pillar.

t.
yi Co
op

satelettronica
C py
.
– Adjust the front door with the striker pin -1- so that the front
t rig
gh ht
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door is flush with the rear door when shut (to prevent wind
cop Vo
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noise). cted agen
Prote AG.

– Tighten bolts -2- of striker pin -1-.

Specified torque for bolts -2-: 20 Nm

1.5 Assembly overview - assembly carrier

Note

The right side is shown. The left side is similar.

1. Front door 73
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1 - Window regulator motor

❑ Removing ⇒ page 258
2 - Mounting bracket
❑ Removing ⇒ page 258
3 - Wiring harness agen
AG. Volkswagen AG d
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4 - Bolt d by ara
rise nte
❑ Qty. 2. utho eo
ra
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❑ 20 Nm ss

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nl

pt
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5 - Caps for assembly opening

an
itte

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❑ Qty. 2.
erm

ab
ility
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6 - Loudspeaker

wit
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h re
7 - Cable retainer
hole

spec
es, in part or in w

8 - Bolt

t to the co
❑ Qty. 10.
❑ 8 Nm

rrectness of i

satelettronica
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co lksw
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cted agen
Prote AG.

1.6 Removing and installing assembly car‐

rier

Note

The removal and installation sequence is only for the right as‐
sembly carrier. The removal and installation of the left assembly
carrier is similar.

Window regulator, door lock and loudspeaker are secured to the

assembly carrier.
The door lock can be removed only together with the assembly
carrier.
Assembly carrier can only be removed when door window is un‐
bolted at window regulator clamping bolts. To do this, lower door
window to the height of the assembly holes in assembly carrier
and loosen clamping bolts.
If door window cannot be lowered with electric window regulators,
first determine the precise cause of the fault.

74 Rep. gr.57 - Front doors, door components, central locking

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

To do this, read the fault memory of the convenience system us‐

ing vehicle diagnostic, testing and information system - VAS 5051
A- or -VAS 5052- ⇒ Vehicle diagnostic tester.
If an electrical fault exists, rectify it first.
If an electric fault occurs on window regulator motor, it can be
unscrewed from assembly carrier and door window can be slid by
hand in the necessary repair position.

1.6.1 Removing

satelettronica
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
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pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
– Remove front door trim ⇒ General body repairs, interior; Rep. . Cop py
gr. 70 ; Trim, insulation; Door trims .
t rig
gh ht
pyri by
Vo
co
– Remove door handle ⇒ page 81 .
by lksw
cted agen
Prote AG.
– Lever out caps -3-.
– Lower door window until securing bolts -1- for door window are
accessible.
– Loosen bolts -1- (specified torque: 8 Nm) and press clamping
brackets -2- apart.
– Push door window 1 upwards and secure door window in po‐
sition (e.g. with adhesive tape).

1. Front door 75
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

– Release protective sleeve fasteners -arrow a- and pull off pro‐

h re

tective sleeve.
ole,

spec
urposes, in part or in wh

– Open catch -1- for A-pillar connector by swinging it downwards

t to the co

-arrow b- and disconnect connector.

– Detach connector for exterior mirror -arrow c- from window
regulator motor.
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

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pr

cum
r
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

76 Rep. gr.57 - Front doors, door components, central locking

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

satelettronica
inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove bolts -2- for door lock.

– Guide lines/wiring in door and release line/wiring retainer -4-.
– Remove bolts -1-, -3- and -arrows-.
– With assembly carrier touching door, push assembly carrier
upwards and pull lower section away from door. Lower part of
window regulator must also be guided out of door.
– Pull the assembly carrier down diagonally to the hinge pillar
out of the door. The upper part of the window regulator must
be guided out of the door first and after that the door lock.

1. Front door 77
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.6.2 Installing

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
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ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

o
– Position assembly carrier in door.
rm
m

atio
m

– Lock wiring retainer -4- in mounting hole in door.

o

n in
or c

thi
te

sd
iva

Note
o
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f

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ng

t.
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If wiring retainer is not engaged in mounting hole in door, wiring harness may be damaged, resulting in the
Co
op py
failure of all electrical components in the door.
. C rig
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copy Vo
by lksw
– Position bolts. First tighten bolt -1- and then tighten bolt -3-. cted agen
Prote AG.

– Tighten remaining bolts -arrows- in any desirable order.

– Secure door window ⇒ page 257 .
– Then perform remaining installation in reverse order of remov‐
al.

78 Rep. gr.57 - Front doors, door components, central locking

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.7 Assembly overview - door handle and door lock

Note

Only the left side is shown. The right side is similar.

1 - Door lock
❑ The door lock can be re‐
moved only together
with the assembly carri‐
er.
❑ Removing and installing
⇒ page 83
2 - Cable
AG. Volkswagen AG d
❑ To release lock
lksw from ex‐
agen oes
not
terior door
db
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3 - Bolt utho or
a ac

satelettronica
❑ ss20 Nm ce
e
nl

❑ Qty. 2
pt
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an
itte

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4 - Bearing bracket
erm

ab
ility
ot p

❑ Installation instructions
wit

⇒ page 84 .
, is n

h re
hole

❑ Removing lock cylinder

spec

housing ⇒ page 80
es, in part or in w

t to the co

❑ Remove door handle

⇒ page 81 .
❑ Remove door assembly
rrectness of i

carrier ⇒ page 74 .
l purpos

❑ Remove bolt
⇒ Item 13 (page 80) ,
slide bearing plate
nf
ercia

slightly to rear and re‐

rm
m

move from door.

atio
om

n in
c

5 - Bolt
or

thi
e

❑ For lock cylinder.

t

sd
iva

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cu

6 - Retaining screw
o

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f

en
ng

t.
yi
❑ 6 Nm
Co
Cop py
t.
❑ This bolt is installed to
rig
gh ht
yri by
provide additional se‐ op Vo
by c lksw
curity for the bearing plate. cted agen
Prote AG.

7 - Base
8 - Lock cylinder housing
❑ Removing and installing ⇒ page 80
9 - Cover
❑ For lock cylinder housing.
❑ Secured to lock cylinder housing with three locking lugs.
10 - Key
❑ Changing battery ⇒ page 94 .
❑ Adapting new or additional key to remote control ⇒ page 95 .
11 - Door handle with base
❑ Removing and installing ⇒ page 81

1. Front door 79
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

12 - Base
❑ Part of door handle.
13 - Torx bolt
❑ 4.5 Nm
❑ Socket - T 10072-
❑ Loosen this screw to remove bearing plate from door.
14 - Spreader rivet
❑ Qty. 2
15 - Retaining bracket
❑ Pushed onto door lock and riveted.
AG. Volkswagen AG d
❑ Not supplied with door lock. agen oes
olksw not
V gu
d by ara
16 - Cable orise nte
h eo
❑ To release lock from door interior ut
handle.
a ra
ss c

ce
e

17 - Cover
nl

pt
du

an
❑ Not supplied with door lock.
itte

y li
erm

ab
❑ Secured to door lock with three locking lugs.

ility
ot p

satelettronica
wit
, is n

h re
hole

spec
1.8 Removing and installing lock cylinder
es, in part or in w

t to the co
housing

rrectness of i
Note
l purpos

The removal and installation sequence is only for the right lock
cylinder. The removal and installation of the left lock cylinder is

nform
ercia

similar.
m

at
om

io
1.8.1 Removing
n
c

in t
or

his
te

– Lever caps off bolts -1-.

a

do
priv

cum
or

– Pull door handle -2- in -direction of arrow- and unscrew screw

f

en
ng

-1- using socket wrench - T 10072- until lock cylinder housing

t.
yi Co
op
-3- can be pulled out (pressure must be exerted on socket
C py
t. rig
gh
wrench).
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Note

In some vehicles of model year 2004, unscrewing the bolt too far
may result in the locking bar separating from the bearing plate
and falling into the door.

– Secure locking bar on bearing plate ⇒ page 84 .

– Pull lock cylinder housing -3- out of door handle bearing brack‐
et at right angles.

80 Rep. gr.57 - Front doors, door components, central locking

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.8.2 Installing
– Fit lock cylinder housing -3- into door handle bearing bracket
at right angles -arrow-. agen
AG. Volkswagen AG d
o w es n
olks o
Door handle -2- must rest onlyedlightly
by
V
against outer panel of door. t guara
ris nte
– Now tighten bolt -1- inaubearing
tho bracket using socket wrench - eo
ra
T 10072- . ss c

ce
e
nl

The door handle -2- engages in the lock cylinder housing -3- with

pt
du

an
itte

a clearly audible click.

y li
erm

ab
ility
ot p

wit
, is n

Note

h re
hole

spec
During installation, lock cylinder housing must be pressed against
es, in part or in w

outer door panel. The door handle just rests lightly against the

t to the co
outer panel of door.

rrectness of i
Further installation is performed in the reverse order of removal.
l purpos

• Then always check function while door is still open, as an in‐

correctly fitted and adjusted Bowden cable cannot open the

satelettronica
door.

nform
mercia

at
1.9 Removing and installing door handle
om

ion
c

in t
or

his
ate

do
riv

Note
p

cum
for

en
ng

t.
The removal and installation sequence is only for the right door
yi Co
op py
handle. The removal and installation of the left door handle is t. C rig
gh ht
similar. yri
p by
co Vo
by lksw
cted agen
Prote AG.
1.9.1 Removing
– Removing lock cylinder housing ⇒ page 80 .
– Release clip -2- from door handle -1-.
– Swivel door handle -1- out of door -arrow-.

1.9.2 Installing

1. Front door 81
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

satelettronica
spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
– Guide assembly tool - T 10118- into door through opening in pyri by
Vo
o
by c
door inner panel.
lksw
cted agen
Prote AG.
– Use a hand torch to illuminate inside of door for improved vis‐
ibility.
– Hook assembly tool - T 10118- in spring -arrow A-.
– Hook spring onto door lock by pulling assembly tool - T 10118-
-arrow B-.
The release lever is now secured.

Note

Hooking the spring into the operating lever secures the lock. This prevents incorrect attachment of the Bowden
cable to the door handle later.

82 Rep. gr.57 - Front doors, door components, central locking

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Swivel door handle -1- into door.

– Pull clip -2- in the panel opening and engage clip in door han‐
dle -1- -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
Note ed by
V gu
ara
ris nte
ho eo
ut
♦ Press door handle -1- against outer panel
s aof door when as‐ ra
c
sembling. s

ce
e
nl

pt
du
♦ Clip -2- must engage in door handle -1- with a clearly audible

an
itte

y li
click.

erm

ab
ility
ot p

wit
Install lock cylinder housing ⇒ page 81 .
, is n

h re
hole

• Then always check function while door is still open, as an in‐

spec
correctly fitted and adjusted Bowden cable cannot open the
es, in part or in w

t to the co
door.

1.10 Removing and installing door lock

rrectness of i
l purpos

satelettronica
Note

nf
ercia

o
The removal and installation sequence is only for the right door

rm
m

atio
lock. The removal and installation of the left door lock is similar.
om

n in
or c

thi
e

1.10.1 Removing
t

sd
iva

o
r
rp

cu
o

– Remove door assembly carrier ⇒ page 74 .

m
f

en
ng

t.
yi Co
– Turn assembly carrier around and pull connections -4- off door Cop py
t. rig
lock -5-. gh ht
pyri by
Vo
o
by c lksw
– Drive clip -2- out using a punch. Prote
cted AG.
agen

– Lever door lock -5- with retaining bracket -1- out of assembly
carrier using a screwdriver.

Note

The retaining bracket is not supplied with the door lock -5-. The
door lock is pushed -3-onto retaining bracket -1- and secured with
a pop rivet -6-.

– Unclip Bowden cable -1- from door lock.

– Turn cable nipple through 90° -arrow- and remove cable from
eye.

1.10.2 Installing
Install in reverse order of removal.

1. Front door 83
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

• Then always check function while door is still open, as an in‐

correctly fitted and adjusted Bowden cable cannot open the
door.

1.11 Bearing bracket

Note

On some model year 2004 vehicles, the locking bar of the bearing
plate is not permanently attached.

When the lock cylinder or door handle is removed, the relay lever
-3- may separate from the locking bar -2-.
– Pull relay lever -3- onto bearing plate -1-.
– Push locking bar -2- in direction of relay lever -3-.
– Tips of relay lever -3- must be located -arrows- in notches of
locking bar -2-.
When installing individual parts, ensure that this position does not
change.

satelettronica
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
1.12 Reinforcement in the front door ss
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

84 Rep. gr.57 - Front doors, door components, central locking

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

satelettronica
h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
op
If a new door has been fitted, a reinforcement -2- must be adhered C py
t. rig
from the inside in the area of the door handle. gh ht
pyri by
Vo
o
by c lksw
– Clean the surfaces on the reinforcement and on the door with Prote
cted AG.
agen
silicone remover, LSE 020 100 A3.
– Apply adhesive D 190 MKD A3 to the reinforcement surfaces.
– Attach the reinforcement directly underneath the ribbing -4-
and 16 mm -3- in front of the small opening for the door handle
-5-.
– Secure the reinforcement against slipping with commercially
available adhesive tape.

1.13 Door inner seal

During production, a sealant is applied to the door inner seals,
which are then placed on the door flange and rolled on.

1. Front door 85
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

Note

♦ When seals are removed, the sealant will spread to the inside
of the seal and the flanks will be bent out slightly. If the seal is
then refitted, a tight seal is not guaranteed.
♦ Therefore each seal which is removed completely should be
replaced by a so-called “tap-on” seal.
♦ If a seal has been partially removed, squeeze sides of seal
together before refitting.

1.14 Removing and installing door inner seal

Note

The removal and installation sequence is only for the left door
inner seal. The removal and installation of the right door inner seal
is similar.

satelettronica
1.14.1 Removing
– To remove door inner seal, remove pillar trims as required ⇒
General body repairs, interior; Rep. gr. 70 ; Trim, insulation;
Pillar trim
– Remove sill moulding ⇒ General body repairs, interior; Rep.
gen AG
. Volkswagen AG
does
gr. 68 ; Interior equipment; Sill moulding . Volkswa not
y gu
db ara
– Pull door inner seal -1- off body flange.orise nte
eo
th
au ra
c
ss ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

86 Rep. gr.57 - Front doors, door components, central locking

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.14.2 Installing
– Align door inner seal so that the vulcanised point -arrow b- is
located at the height of the lower hinge.
– Start installing door inner seal at top radius -arrow a- of door
aperture.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit

satelettronica
, is n

h re
hole

1.15 Removing and installing door outer seal

spec
es, in part or in w

t to the co
Note

rrectness of i
♦ Removal and installation are described only for the right door
outer seal. Removal and installation of the left door outer seal
l purpos

are similar.

nform
ercia

♦ Remove protective backing immediately before installation.

Working temperature of all parts approx. 20° C.
m

at
om

io
♦ Use only adhesive remover D 002 000 10. n
c

in t
or

his
e

♦ The door outer seal must be bonded in place immediately after

at

do
riv

cleaning.
p

cum
for

en
ng

t.
yi
1.15.1 Removing
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Front door 87
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Pull outer door seal -1- off door -2-.

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

88 Rep. gr.57 - Front doors, door components, central locking

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015
AG. Volkswagen AG d
agen
1.15.2 Installing
oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

satelettronica
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove existing adhesive residues using adhesive residue

remover - VAS 6349- .
– Immediately before bonding door outer seal, clean bonding
surface thoroughly with adhesive remover D 002 000 10.
– The vulcanised point -arrow- of door outer seal -1- must be
located in the middle section of the side member.
– Pull off protective foil -3- and install seal on door. Do not pull
door outer seal excessively to avoid stretching seal.

1. Front door 89
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le

satelettronica
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r

– Press complete bonding surface of seal -3- on door -1- all

te o

thi

around using roller - 3356- .

s
iva

do
r
rp

cum

– To do this, push the seal aside -arrow a- so that the roller -

fo

en
ng

3356- runs directly over the contact surface of the seal.

t.
yi Co
Cop py
. rig
The roller can apply the necessary force -arrow b- to the bonding
ht ht
rig by
py
surface -2- only when procedure described above is followed. co Vo
by lksw
cted agen
Prote
– If the seal has stretched, cut seal to required length and press
AG.

on butt joint well.

– If seal -3- comes loose in small areas again, press seal on well
again using roller - 3356- .

Note

The door must not be closed for a period of 2 hours to ensure the door outer seal does not move or loosen
again.

90 Rep. gr.57 - Front doors, door components, central locking

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.16 Insulation

1 - Insulation
❑ Self-adhesive.
❑ Installing:
– Cut to size if necessary
Volkswagen AG
– Warm using hot air agen
AG. does
ksw
blower - V.A.G 1416- yV
ol not
gu
and push on to outer db ara
rise nte
door panel with force. utho eo
ra
a c
ss
2 - Sticker

ce
le
un

pt
an
❑
d
itte

y li
erm

ab
❑ If necessary, manufac‐

ility
ot p

ture using commercially

wit
available textile adhe‐
is n

h re
sive tape.
ole,

spec
urposes, in part or in wh

3 - Sticker

t to the co

satelettronica
❑ 250 mm x 20 mm
❑ If necessary, manufac‐
ture using commercially

rrectne
available textile adhe‐
sive tape.

ss o
4 - Sticker
cial p

f inform
❑ 40 mm x 20 mm
mer

atio
❑ If necessary, manufac‐
om

ture using commercially

n
c

i
or

n
available textile adhe‐
thi
te

sd
a

sive tape.
iv

o
pr

cum
r
fo

5 - Sticker
en
ng

t.
yi Co
❑ 40 mm x 20 mm t. Cop py
rig
❑ If necessary, manufac‐
gh ht
pyri by
ture using commercially
co Vo
by lksw
cted
available textile adhe‐
agen
Prote AG.
sive tape.

1. Front door 91
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2 Central locking

2.1 Overview of fitting locations - central locking components

1 - Coupling station
❑ Location: right A-pillar
❑ To separate connector,
release boot at pillar
⇒ page 70 .
2 - Front right door control unit
-J387-
❑ Integrated in window
regulator motor.
❑ Removing ⇒ page 258
3 - Front right door lock -F221-
❑ Door lock is secured to
assembly carrier.

satelettronica
❑ Electric central locking
is integrated into door
lock.
❑ Removing ⇒ page 83
4 - Coupling station
❑ Fitting location: right B-
pillar.
❑ To separate connector,
release boot at pillar
⇒ page 98 .
5 - Rear right door control unit
-J 389-
AG. Volkswagen AG d
❑ Integrated in window lksw
agen oes
not
regulator motor. d by
Vo gu
ara
e nte
❑ Removing ⇒ page 266 horis
eo
aut ra
6 - Door lock, rear right -F 223- ss c
ce
le
un

❑ Door lock is secured to

pt
an
d

assembly carrier.
itte

y li
erm

ab

❑ Electric central locking

ility
ot p

is integrated into door

wit
is n

lock.
h re
ole,

❑ Removing ⇒ page 110

spec
urposes, in part or in wh

7 - Tank filler flap release -V 155-

t to the co

❑ Location: behind luggage compartment trim on right

❑ Removing ⇒ page 65
rrectne

8 - Coupling station, right side of rear lid

s

❑ Location: under moulded headliner.

s o
cial p

❑ Removing and installing ⇒ General body repairs, interior; Rep. gr. 70 ; Trims, insulation; Roof trims .
inform
mer

9 - Coupling station, left side of rear lid

atio
m

❑ Location: near rear roof cross member, covered by roof trim

o

n
c

i
or

n thi

❑ Removing and installing ⇒ General body repairs, interior; Rep. gr. 70 ; Trims, insulation; Roof trims .
te

sd
iva

o
r

10 - Handle trim with release button -E 234-

p

cum
r
fo

en
ng

❑ Removing ⇒ page 56
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
92
by c lksw
cted
Rep. gr.57 - Front doors, door components, central locking
agen
Prote AG.
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

11 - Rear lid lock -F256-

❑ Location: bolted to rear lid
❑ Removing and installing
wage ⇒ page 58
n AG. Volkswagen AG do
es ks not
Vol g
12 - Door lock, rear ed left -F 222-
by ua
ran
ris tee
❑ Door lock uth is secured to assembly carrier.
o
or
a ac
❑ Electric central locking is integrated into door lock.
ss

ce
e
nl

❑ Removing ⇒ page 110

pt
du

an
itte

y li
13 - Rear left door control unit -J 388-
erm

ab
ility
ot p

❑ Integrated in window regulator motor.

wit
, is n

❑ Removing ⇒ page 266

h re
hole

spec
14 - Coupling station
es, in part or in w

t to the co
❑ Fitting location: left B-pillar
❑ To separate connector, release boot at pillar ⇒ page 98 .

rrectness of i
15 - Door lock, front left -F220-
❑ Door lock is secured to assembly carrier.
l purpos

❑ Electric central locking is integrated into door lock.

satelettronica
❑ Removing ⇒ page 83

nform
mercia

16 - Central switch for window lifters -E189-

at
om

io
❑ Location: installed in door panel

n
c

in t
or

his
e

❑ Removing and installing central switches for window regulators ⇒ Vehicle electrics; Rep. gr. 96 ; Elec‐
at

do
riv

trical system; Interior lights, lamps, switches; Lights and switches in doors .
p

cum
for

17 - Driver door control unit -J386-

en
ng

t.
yi Co
op
❑ Integrated in window regulator motor. C py
ht. rig
rig ht
❑ Removing ⇒ page 258 py by
co Vo
by lksw
cted agen
18 - Coupling station Prote AG.

❑ Fitting location: left A-pillar

❑ To separate connector, release boot at pillar ⇒ page 70 .
19 - Convenience system central control unit -J393-
❑ Location: under dash panel on front passenger side
❑ Removing ⇒ General body repairs, interior; Rep. gr. 70 ; Trims, insulation; Dash panel
20 - Anti-theft alarm horn
❑ Location: under plenum chamber cover
❑ Removing ⇒ page 239
21 - Bonnet contact switch -F 266-
❑ Anti-theft warning system (ATW) contact cannot be renewed individually.
❑ Location: on bonnet lock
❑ Removing and installing bonnet lock ⇒ page 40

2. Central locking 93
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.2 Removing and installing battery for folding key with remote control

1 - Key with variable code

transponder
2 - Transmitter unit - upper part
❑ Version also with 3 but‐
tons
3 - LED
❑ When remote control is
operated, this LED must
flash briefly.
❑ If LED does not flash
during remote control
operation, the battery is
dead and must be re‐
newed.
4 - Battery
❑ Removing battery
⇒ page 94

satelettronica
❑ Installing battery
⇒ page 95
5 - Transmitter unit - lower part
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
2.2.1 Removing rrectness of i
l purpos

– Insert a screwdriver in slot between transmitter unit -1- and key

nf

-2-.
ercia

orm
m

– Twist screwdriver in -direction of arrow- to separate transmitter

atio
m

unit from key.

o

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

94 Rep. gr.57 - Front doors, door components, central locking

 AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
rised
Touran
nte 2003 ➤
o eo
aut
h
General body repairs, exterior - Edition r a 02.2015
ss c

ce
e
– Press transmitter unit -1- apart using profile section of key

nl

pt
du

an
-2-.

itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Unclip battery -1- from retainers -2- with a screwdriver in di‐

nform
ercia

rection of -arrow-.
m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co

satelettronica
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2.2.2 Installing

Note

♦ Before installing battery, always press any key once.

♦ Thus transmitter unit is reset and can recognize a new battery
only now.

Note polarity and correct position when installing battery.

– Lay battery -1- with positive terminal downwards in sender unit
-2- (positive terminal is marked on housing).
– Engage battery in transmitter unit by pressing down lightly.
– Fit cover to transmitter unit (do not damage seal).
– Then clip transmitter unit to key.
Adapting ignition keys
Keys are adapted using ⇒ Vehicle diagnostic tester.
– Select “Guided functions” in the vehicle diagnostics tester.
– Press GoTo button and select “Function/component selec‐
tion”.

2. Central locking 95
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

58 – Rear doors, door components

1 Rear door

1.1 Tools

AG. Volkswagen AG d
agen oes
olksw not
V

satelettronica
by gu
d ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
1.1.1 Required special tools, workshop equip‐
cted agen
Prote AG.

ment, test and measuring devices and

auxiliary items
♦ Socket - T 10072-
♦ Assembly tool - T 10118-
♦ Door alignment tool - 3320-
♦ Universal joint for 3320 - 3320/1-
♦ Bit for 3320 - 3320/2-
♦ Bit for 3320 - 3320/3-

96 Rep. gr.58 - Rear doors, door components

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

♦ Roller - 3356-
♦ Torque wrench 5…50 Nm - V.A.G 1331-

1.2 Assembly overview - door hinges

Note

♦ The right side is shown. The left side is similar.

♦ The hinge bolts must always be renewed if loosened.

1 - Door
❑ Removing and installing
⇒ page 98
2 - Multi-point socket head bolt
❑ M8×28
❑ 20 Nm + 1/4 turn further
(90°).

satelettronica
❑ Always renew bolts after
loosening.
3 - Multi-point socket head bolt
❑ M8×28
❑ Remove only this bolt
from hinge to remove
door.
❑ 20 Nm + 1/4 turn further
(90°).
❑ Always renew bolts after
loosening. wage
n AG. Volkswagen AG do
e ks s no
Vol t gu
4 - Door hinge with
d b arrester
y ara
rise nte
❑ Hingeuthis
o split. eo
ra
sa c
5 - Multi-point
s
socket head bolt
ce
e
nl

pt
du

❑ M8×28
an
itte

y li

❑ Installed from inside ve‐

erm

ab

hicle.
ility
ot p

wit

❑ Remove lower B-pillar

, is n

h re

trim ⇒ General body re‐

hole

spec

pairs, interior; Rep. gr.

es, in part or in w

70 ; Trims, insulation;
t to the co

Pillars and side trims .

❑ 20 Nm + 1/4 turn further
rrectness of i

(90°).
❑ Always renew bolts after
l purpos

loosening.
6 - Multi-point socket head bolt
nf
ercia

orm

❑ M8×28
m

atio
m

❑ 20 Nm + 1/4 turn further (90°).

o

n in
or c

thi
e

❑ Always renew bolts after loosening.

t

sd
iva

o
r
rp

cu

7 - Door hinge
o

m
f

en
ng

❑ Hinge is split.
t.
yi Co
Cop py
t.
8 - Multi-point socket head bolt
rig
gh ht
pyri by
Vo
❑ M8×22
co lksw
by
cted agen
Prote AG.

1. Rear door 97
 Touran 2003 ➤
General body repairs,AG
exterior
. Volkswa-ge
Edition
n
02.2015
agen AG do
lksw es n
❑ Installed from by inside vehicle.
Vo ot g
ua
ed ran
❑ Remove horB-pillar trim to loosen or fasten bolt ⇒ General
is tee body repairs, interior; Rep. gr. 70 ; Trims,
insulation;
aut
Pillar trims and side trims . or
ac
ss
❑ 20 Nm + 1/ turn further (90°).

ce
le

4
un

pt
an
d

❑ Always renew bolts after loosening.

itte

y li
rm

ab
9 - Door hinge
pe

ility
ot

wit
❑ Hinge is split.
, is n

h re
hole

10 - Stud

spec
es, in part or in w

❑ Part of hinge ⇒ Item 14 (page 98) .

t to the co
❑ For securing nut ⇒ Item 11 (page 98) .
11 - Nut

rrectness of i
❑ 14 Nm
l purpos

12 - Multi-point socket head bolt

❑ M8×28

nform
ercia

❑ 20 Nm + 1/4 turn further (90°).

m

a
com

tio
❑ Always renew bolts after loosening.

n in
r
te o

satelettronica
thi
13 - Multi-point socket head bolt
s
iva

do
r

❑ M8×28
rp

cum
fo

en
g

❑ 20 Nm + 1/4 turn further (90°).

n

t.
yi Co
Cop py
❑ Always renew bolts after loosening.
t. rig
gh ht
pyri by
Vo
o
14 - Door hinge
c by lksw
cted agen
Prote AG.
❑ With threaded hinge pin for securing nut.
❑ Hinge is split.

1.3 Removing and installing door

Note

The removal and installation sequence is only for the right door.
The removal and installation of the left door is similar.

98 Rep. gr.58 - Rear doors, door components

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.3.1 Removing

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un

pt
an
d
itte

y li

– Release boot -3- by pressing fastener -arrow a- and pull boot

rm

ab
pe

ility

off B-pillar.
ot

wit
, is n

– Swing release lever -4- downwards -arrow b- and disconnect

h re
hole

electrical connector -5- from coupling station.

spec
es, in part or in w

– Screw hexagon nut -6- on hinge pin downwards.

t to the co

– Remove lower bolt -2- from hinge using door alignment tool -
3320- and bit - 3320/3- .
rrectness of i

– Lift door -1- upwards out of hinges.

l purpos

1.3.2 Installing
nform
ercia

Install in reverse order of removal.

m

– Specified torque: hexagon nuts -6- 14 Nm.

com

tion in
r

– Specified torque: bolt -2- 20 Nm + 1/4 turn further (90°).

te o

thi
s
iva

do
r

• Always renew this bolt -2-.

rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen

99
Prote AG.
1. Rear door
 n AG. Volkswagen AG do
lkswage es n
Touran 2003 ➤ byV
o ot g
ua
ed ran
General body repairs, exterior - Edition 02.2015 horis tee
ut or
a ac
ss
– Note rear door shut line dimensions ⇒ Body Repairs; Rep. gr.

ce
le
00 ; Technical data; Body panel gaps/shut lines; Body - front

un

pt
an
d
and rear .

itte

y li
rm

ab
1.4 Adjusting door

pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
g

satelettronica
n

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Note

♦ To enable adjustment of the rear door, vehicle must be standing on its wheels.
♦ The rear door is adjusted correctly if the gaps/shut lines are even all around, the door is not too deep or
does not stand proud and all contours align when the is door closed.
♦ To check or adjust the gaps/shut lines ⇒ Body Repairs; Rep. gr. 00 ; Body panel gaps/shut lines; Body -
rear .
♦ After installing or adjusting, carry out corrosion protection measures to hinge and bolts.

To ensure a correct door adjustment, the door hinge must be

loosened on the pillar. Other measures such as raising the door
have no effect. Subsequent pressure from above will cause the
door to sack again.
Use door alignment tool 3320 with bit insert 3320/2.

100 Rep. gr.58 - Rear doors, door components

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

If it is necessary to loosen the door hinge on the B-pillar from

inside, insert 3410 can be used. To do this, B-pillar lower trim must
be removed ⇒ General body repairs, interior; Rep. gr. 70 ; Trims,
insulation; Pillar trims and side panel trims .
Adjusting striker pin: ⇒ page 101 .
AG. Volkswagen AG d
1.4.1 Adjusting Vthe
olks striker pin
wage
n oes
not
y gu
db ara
rise nte
tho eo
Note au ra
c
ss

ce
le
un

pt
♦ Only the adjustment for the right front door is described. The

an
d
itte

adjustment of the left front door is similar.

y li
erm

ab
ility
♦ The rear door must lock fully when closing without any addi‐
ot p

tional force being required and must not have any play.

wit
is n

h re
ole,

♦ The rear door must not be pushed up or down as a result of

spec
urposes, in part or in wh

the striker pin adjustment.

t to the co
The following can be adjusted at the striker pin:

rrectne
• When the rear door does not align with the rear side panel.

satelettronica
– Loosen U-shaped striker -1- by loosening bolts -2- on C-pillar.

ss o
– Adjust the rear door with the striker pin -1- so that the rear door
cial p

f in
is flush with the rear side panel when shut (wind noise).

form
mer

– Tighten bolts -2- of striker pin -1-.

atio
om

n
c

Specified torque for bolts -2-: 20 Nm i

or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1.5 Assembly overview - assembly carrier

Note

The right side is shown. The left side is similar.

1. Rear door 101

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1 - Bolt
❑ Qty. 11
❑ 8 Nm
2 - Window regulator motor
❑ Removing ⇒ page 266
3 - Wiring harness
4 - Bolt
❑ Qty. 2
❑ 20 Nm
5 - Loudspeaker
6 - Sealing plug
7 - Cable retainer

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit

1.6 Removing and installing assembly car‐

, is n

h re
hole

rier
spec
es, in part or in w

t to the co

Note
rrectness of i

The removal and installation sequence is only for the right as‐
sembly carrier. The removal and installation of the left assembly
l purpos

carrier is similar.
nf
ercia

Window regulator, door lock and loudspeaker are secured to the

rm
m

assembly carrier.
atio
om

n in
c

The door lock can be removed only together with the assembly
or

thi

carrier.
te

sd
iva

o
r
rp

cu

Assembly carrier can only be removed when door window is un‐

o

m
f

bolted at window regulator clamping bolts. To do this, lower door

en
ng

t.
yi
window to the height of the assembly holes in assembly carrier
Co
Cop py
and loosen clamping bolts.
t. rig
gh ht
pyri by
Vo
o
If door window cannot be lowered with electric window regulators,
c by lksw
cted agen
first determine the precise cause of the fault.
Prote AG.

102 Rep. gr.58 - Rear doors, door components

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

To do this, read the fault memory of the convenience system us‐

ing vehicle diagnostic, testing and information system - VAS 5051
A- or -VAS 5052- ⇒ Vehicle diagnostic tester.
If an electrical fault exists, rectify it first.
If an electric fault occurs on window regulator motor, it can be
unscrewed from assembly carrier and door window can be slid by
hand in the necessary repair position.
AG. Volkswagen AG d
1.6.1 Removing olksw
agen oes
not
V gu
by ara
– Removing door trim ⇒ General body repairs,
rised
interior; Rep. gr. nte
70 ; Trims, insulation; Door trims . autho eo
ra
ss c
– Remove door handle ⇒ page 108 .

ce
le
un

pt
an
d

– Lever out cover caps -4-.

itte

y li
erm

ab
– Lower door window until spreader pin -2- and spreader plug

ility
ot p

-3- in cut-out of window regulator is accessible.

wit
is n

h re
– Screw a 5 mm bolt (approx. 70 mm long) into the spreader pin
ole,

spec
-3- and pull out from spreader plug -2-.
urposes, in part or in wh

t to the co
– Screw an 8 mm bolt (approx. 80 mm long) into spreader plug

satelettronica
-2-.

rrectne
Note

ss o
Do not exert too great a pressure on the plug because otherwise
cial p

f in
the plug will fall into the door.

form
mer

atio
m

– Pull spreader plug -2- out of window regulator guide -1- and
o

n
c

i
therefore out of door window.
or

n thi
te

sd
va

– Push door window -5- upwards -direction of arrow- and secure

i

o
pr

cum
door window in position (e.g. with adhesive tape).
r
fo

en
ng

t.
yi Co
op
– Release protective sleeve locking devices at B-pillar
C py
t. rig
gh
-arrow a- and pull off protective sleeve.
ht
pyri by
Vo
o
by c lksw
cted
– Open catch for B-pillar connector by swinging it downwards
agen
Prote AG.
-arrow b- and disconnect connector.

1. Rear door 103

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

– Remove bolts -2- for door lock.

t to the co
– Guide lines/wiring in door and release line/wiring retainer -4-.
– Remove bolts -1-, -3- and -arrows-.

rrectne
– With assembly carrier touching door, push assembly carrier
upwards and pull lower section away from door. Lower part of ss o
window regulator must also be guided out of door.
cial p

f inform

– Pull the assembly carrier down diagonally to the hinge pillar

mer

atio

out of the door. The upper part of the window regulator must
om

be guided out of the door first and after that the door lock.
n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

104 Rep. gr.58 - Rear doors, door components

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.6.2 Installing
/

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i

– Position assembly carrier in door.

l purpos

– Lock wiring retainer -4- in mounting hole in door.

nf
ercia

orm

Note
m

atio
om

n in
c

If wiring retainer is not engaged in mounting hole in door, wiring harness may be damaged, resulting in the
or

thi
e

failure of all electrical components in the door.

t

sd
iva

o
r
rp

cu
o

m
f

– Position bolts. First tighten bolt -1- and then tighten bolt -3-.
en
ng

t.
yi Co
op py
– Tighten remaining bolts -arrows- in any desirable order. . C rig
ht ht
rig by
py
– Secure door window ⇒ page 265 .
co Vo
by lksw
cted agen
Prote AG.
– Then perform remaining installation in reverse order of remov‐
al.

1. Rear door 105

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.7 Assembly overview - door handle and door lock

Note

The right side is shown. The left side is similar.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
1 - Door lock hor eo
aut ra
❑ The door lock can be sre‐
s c
moved only together

ce
le
un

pt
with the assembly carri‐

an
d
itte

y li
er.
rm

ab
pe

ility
❑ Removing and installing
ot

⇒ page 110

wit
, is n

h re
hole

2 - Retaining bracket

spec
es, in part or in w

❑ Pushed onto door lock

t to the co
and riveted.
❑ Not supplied with door
lock.

rrectness of i

satelettronica
3 - Spreader rivet
l purpos

❑ Joins retaining bracket

to assembly carrier.

nform
ercia

4 - Cable
m

a
com

t
❑ To release lock from

ion in
door interior handle.
r
te o

thi
s
iva

5 - Cover do
r
rp

cum

❑ Not supplied with door

fo

en
ng

lock.
t.
yi Co
op py
❑ Secured to door lock
t. C rig
gh ht
yri
with three locking lugs. p by
o Vo
by c lksw
cted agen
6 - Bearing bracket Prote AG.

❑ Installation notes
⇒ page 111
7 - Bolt
8 - Base
❑ Part of door handle.
9 - Door handle with base
❑ Removing and installing
⇒ page 108
10 - Cover
❑ For lock cylinder housing with no opening for lock cylinder.
❑ Secured to lock cylinder housing with three locking lugs.
11 - Lock cylinder housing
❑ Removing and installing ⇒ page 107
❑ Without cylinder lock.
12 - Base
13 - Torx bolt
❑ Socket - T 10072-
❑ Loosening this screw releases the lock cylinder housing ⇒ Item 11 (page 106) , which can then be pulled
out of bearing bracket.

106 Rep. gr.58 - Rear doors, door components

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

14 - Bolt
❑ 18 Nm
15 - Cable
❑ To release lock from exterior door handle.

1.8 Removing and installing lock cylinder

housing

Note

The removal and installation sequence is only for the right lock
cylinder. The removal and installation of the left lock cylinder is
similar.

1.8.1 Removing
– Lever caps off bolts -1-.

satelettronica
– Pull door handle -2- in -direction of arrow- and unscrew screw
-1- using socket wrench - T 10072- until lock cylinder housing
-3- can be pulled out (pressure must be exerted on socket
wrench).

Note

In some vehicles of model year 2004, unscrewing

AG. Volkswthe
agebolt
n AG dtoo far
may result in the locking bar separating
lksw from the bearing plate
agen oes
not
and falling into the door.
o
byV gu
ar
d e an
ris tee
tho or
– Secure locking barsson bearing plate ⇒ page 111 . au ac
ce
le

– Pull lock cylinder housing -3- out of door handle bearing brack‐
un

pt
an

et at right angles.
d
itte

y li
rm

ab
pe

ility

1.8.2 Installing
ot

wit
, is n

h re

– Fit lock cylinder housing -2- into door handle bearing bracket
hole

spec

at right angles.
es, in part or in w

t to the co

Door handle -1- must rest only lightly against outer panel of door.
– Now tighten bolt -3- in bearing bracket using socket wrench -
rrectness of i

T 10072- .
l purpos

The door handle engages in the lock cylinder housing with an

audible click.
nform
ercia

Note
m

a
com

tion in
r

During installation, lock cylinder housing must be pressed against

te o

thi

outer door panel. The door handle just rests lightly against the
s
iva

do

outer panel of door.

r
rp

cum
fo

en
ng

t.
yi Co
– Then perform remaining installation in reverse order of remov‐ Cop py
al. ht. rig
rig ht
py by
co Vo
• Then always check function while door is still open, as an in‐
by lksw
cted agen
Prote
correctly fitted and adjusted Bowden cable cannot open the
AG.

door.

1. Rear door 107

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.9 Removing and installing door handle

n AG. Volkswagen AG do
lkswage es n
o ot g
Note d byV ua
ran
ir se tee
tho
or
The removal and installation
ss
au
sequence is only for the right door ac
handle. The removal and installation of the left door handle is

ce
le

similar.
un

pt
an
d
itte

y li
rm

ab
1.9.1 Removing
pe

ility
ot

wit
, is n

– Removing lock cylinder housing ⇒ page 107 .

h re
hole

spec
– Release clip -2- from door handle -1-.
es, in part or in w

t to the co
– Swivel door handle -1- out of door -arrow-.

rrectness of i
l purpos

nform
ercia

satelettronica
m

a
com

tion in
r
te o

thi
1.9.2 Installing

s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

108 Rep. gr.58 - Rear doors, door components

 AG. Volkswagen AG d
agen oes
olksw not
V
d by Touran
gu
ara 2003 ➤
ise nte
thor General body repairs, exterior - Edition 02.2015
eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

satelettronica
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Guide assembly tool - T 10118- into door through opening in

door inner panel.
– Use a hand torch to illuminate inside of door for improved vis‐
ibility.
– Hook assembly tool - T 10118- in spring -arrow A-.
– Hook spring onto door lock by pulling assembly tool - T 10118-
-arrow B-.
The release lever is now secured.

1. Rear door 109

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Swivel door handle -1- into door.

– Pull clip -2- in the panel opening and engage clip in door han‐
dle -1- -arrow-.

n AG. Volkswagen AG do
wage es n
Note yV
olks ot g
ua
d b ran
ir se tee
♦ Press door handle -2- against
utho
outer panel of door when as‐ or
sembling.
a ac
ss

ce
le
un

♦ Clip -2- must engage in door handle -1- with a clearly audible

pt
an
d

click.
itte

y li
rm

ab
pe

ility
Install lock cylinder housing ⇒ page 107 .
ot

wit
, is n

h re
• Then always check function while door is still open, as an in‐
hole

spec
correctly fitted and adjusted Bowden cable cannot open the
es, in part or in w

door.

t to the co
1.10 Removing and installing door lock

rrectness of i
l purpos

satelettronica
Note

nform
ercia

The removal and installation sequence is only for the right door
lock. The removal and installation of the left door lock is similar.
m

a
com

tion in
r

1.10.1 Removing
te o

thi
s
iva

do
r
rp

c
– Remove door assembly carrier ⇒ page 102 .
um
fo

en
ng

t.
– Turn assembly carrier around and pull connections -4- off door
yi Co
op
lock -5-.
C py
t. rig
gh ht
yri by
– Drive clip -2- out using a punch.
cop Vo
by lksw
cted agen
Prote AG.
– Lever door lock -5- with retaining bracket -1- out of assembly
carrier using a screwdriver.

Note

The retaining bracket is not supplied with the door lock -5-. The
door lock is pushed -3-onto retaining bracket -1- and secured with
a pop rivet -6-.

– Unclip Bowden cable -1- from door lock.

– Turn cable nipple through 90° -arrow- and remove cable from
eye.

1.10.2 Installing
Install in reverse order of removal.

110 Rep. gr.58 - Rear doors, door components

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

• Then always check function while door is still open, as an in‐

correctly fitted and adjusted Bowden cable cannot open the
door.

1.11 Bearing bracket

Note

On some model year 2004 vehicles, the locking bar of the bearing
plate is not permanently attached.

When the lock cylinder or door handle is removed, the relay lever
-3- may separate from the locking bar -2-.
– Pull relay lever -3- onto bearing plate -1-.
– Push locking bar -2- in direction of relay lever -3-.
– Tips of relay lever -3- must be located -arrows- in notches of
locking bar -2-.
When installing individual parts, ensure that this position does not
change.

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
yV
1.12 Reinforcement in the rear door b gu
d ara
ise nte
or eo
h
aut ra
ss c
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1. Rear door 111

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
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wit
is n

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satelettronica
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
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or

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te

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iva

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pr

cum
r
fo

en
ng

t.
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Cop py
t. rig
If a new door -1- has been fitted, a reinforcement -2- must be stuck gh ht
yri by
from the inside in the area of the door handle. cop Vo
by lksw
cted agen
Prote AG.
– Clean the surfaces on the reinforcement and on the door with
silicone remover, LSE 020 100 A3.
– Apply adhesive D 190 MKD A3 to the reinforcement surfaces.
– Attach the reinforcement directly underneath the ribbing -4-
and 16 mm -3- in front of the small opening for the door handle
-5-.
– Secure the reinforcement against slipping with commercially
available adhesive tape.

1.13 Door inner seals

During production, a sealant is applied to the door inner seals,
which are then placed on the door flange and rolled on.

112 Rep. gr.58 - Rear doors, door components

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

Note

♦ When seals are removed, the sealant will spread to the inside
gen AG
. Volkswagen AG
of the seal and the flanks will be bent out slightly.
Vol
kIf
swthe
a
seal is d oes
not
then refitted, a tight seal is not guaranteed.ed by gu
ara
is nte
or
♦ Therefore each seal which is removedautcompletely
h should be eo
ra
replaced by a so-called “tap-on” seal.
ss c

ce
e
nl

pt
♦ If a seal has been partially removed, squeeze sides of seal

du

an
itte
together before refitting.

y li
erm

ab
ility
ot p

1.14 Removing and installing door inner seal

wit
, is n

h re
hole

spec
es, in part or in w

Note

t to the co
The removal and installation sequence is only for the left door
inner seal. The removal and installation of the right door inner seal

rrectness of i
is similar.
l purpos

satelettronica
1.14.1 Removing

nf
ercia

or
– To remove door inner seal, remove pillar trims as required ⇒

m
m

atio
General body repairs, interior; Rep. gr. 70 ; Trim, insulation;
om

n in
Pillar trim
or c

thi
e

– Remove sill panel moulding ⇒ General body repairs, interior;

t

sd
iva

o
Rep. gr. 68 ; Interior equipment; Sill moulding .
r
rp

cu
o

m
f

en
ng

– Pull door inner seal -1- off body flange.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Rear door 113

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.14.2 Installing
– Align door inner seal so that the vulcanised point -arrow b- is
located at the height of the lower hinge.
– Start installing door inner seal at top radius -arrow a- of door
aperture.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

satelettronica
1.15 Removing and installing door outer seal

rrectness of i
l purpos

Note
nform
ercia

♦ Removal and installation are described only for the right door
outer seal. Removal and installation of the left door outer seal
m

a
com

ti

are similar.
on in
r
te o

thi

♦ Remove protective backing immediately before installation.

s
iva

Working temperature of all parts approx. 20° C.

do
r
rp

cum
fo

♦ Use only adhesive remover D 002 000 10.

en
ng

t.
yi Co
op
♦ The door outer seal must be bonded in place immediately after
C py
t. rig
gh
cleaning.
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1.15.1 Removing
– Pull door outer seal off door -1-.

114 Rep. gr.58 - Rear doors, door components

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.15.2 Installing
– Remove existing adhesive residues using adhesive residue
remover - VAS 6349- .
– Immediately before bonding door outer seal, clean bonding
surface thoroughly with adhesive remover D 002 000 10.
• Bonding surfaces must be free of dust and grease and there
should be no adhesive residues.
– The vulcanised point -arrow- of door outer seal -1- must be
located in the middle section of the side member.
– Pull off protective foil and install seal on door. Do not pull door
outer seal excessively to avoid stretching seal.

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Rear door 115

 AG. Volkswagen AG d
agen oes
Touran 2003 ➤ Vol
ksw not
gu
by
General body repairs, exterior
ris
ed - Edition 02.2015 ara
nte
tho eo
au ra
– Press complete bonding surface
ss of seal -3- on door -1- all c
around using roller - 3356- .

ce
e
nl

pt
du

an
itte
– To do this, push the seal aside -arrow a- so that the roller -

y li
erm

ab
3356- runs directly over the contact surface of the seal.

ility
ot p
The roller can apply the necessary force -arrow b- to the bonding

wit
, is n

h re
surface -2- only when procedure described above is followed.
hole

spec
– If the seal has stretched, cut seal to required length and press
es, in part or in w

on butt joint well.

t to the co
– If seal -3- comes loose in small areas again, press seal on well
again using roller - 3356- .

rrectness of i
l purpos

Note

nform
ercia

The door must not be closed for a period of 2 hours to ensure the door outer seal does not move or loosen
again.
m

at
om

ion
c

in t
or

1.16 Insulation

his
ate

do
priv

cum
or

satelettronica
f

en
g

1 - Insulation
n

t.
yi Co
op
❑ Self-adhesive.
C py
t. rig
gh ht
yri
❑ Installing:
p by
co Vo
by lksw
cted agen
– Cut to size if necessary
Prote AG.

– Warm using hot air

blower - V.A.G 1416-
and push on to outer
door panel with force.

2 - Sticker
❑ 40 mm x 20 mm
❑ If necessary, manufac‐
ture using commercially
available textile adhe‐
sive tape.
3 - Sticker
❑ 40 mm x 20 mm
❑ If necessary, manufac‐
ture using commercially
available textile adhe‐
sive tape.

116 Rep. gr.58 - Rear doors, door components

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

60 – Sunroof
1 Sunroof with glass panel

1.1 Tools
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

satelettronica
wit
, is n

h re
hole

spec
♦ Cleaning and pull-in cable - VAS 6620-
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

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or c

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ng

1.2 Function
t.
yi Co
Cop py
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All actions of the sliding/tilting sunroof with glass panel can be
gh ht
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performed with the ignition switched on.
cop Vo
by lksw
cted agen
Prote AG.
After the ignition is switched off, actions can be performed until
either the driver or front passenger door is opened.

1. Sunroof with glass panel 117

 Touran 2003 ➤ . Volkswagen AG
General body repairs, gen AG - Edition
waexterior 02.2015
does
olks no
V t gu
by ara
ed n
The opening of thethoglass
ris
panel in sliding or tilting positions cantee o
be preselected using
au the rotary knob. ra
c
ss

ce
le
Pre-selector switch
un

pt
an
d
itte

The sunroof is equipped with a force limitation (anti-trap) mech‐

y li
erm

ab
anism for the sliding function. If the sunroof encounters an ob‐

ility
ot p

struction while closing, it will open automatically.

wit
is n

h re
In addition, there is an emergency closure function. If problems
ole,

spec
occur during closure, the sunroof can be forced to shut by press‐
urposes, in part or in wh

ing the pre-selector switch when it is in the “close sunroof” posi‐

t to the co
tion.
The anti-trap mechanism works with raised clamping forces in the

rrectne
emergency closure function.
The sunroof drive is protected against overheating by a time lim‐

s
itation. The protective mechanism activates when the sunroof is

s o
cial p

operated continuously for approx. 2 minutes. It is functional again

f in
after a cooling-off phase.

form
mer

atio
In the event of power failure, the sunroof can be moved using a
om

crank directly on the drive. The crank is located on the inside of

n
c

i
or

n
the interior light trim.

thi
te

sd
a

satelettronica
iv

o
pr

cum
r

1.3 Assembly overview

fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
1 - Glass panel for sliding/tilting yri
p by
o Vo
sunroof (single pane safety
c by lksw
cted agen
glass)
Prote AG.

❑ Removing sliding/tilting
sunroof glass panel
⇒ page 119 .
❑ Installing sliding/tilting
sunroof glass panel
⇒ page 120 .
❑ Adjusting sliding/tilting
sunroof glass panel
⇒ page 121
2 - Panel seal
❑ Renewing panel seal
⇒ page 122 .
3 - Sliding headliner
❑ Removing and installing
sliding headliner
⇒ page 123 .
4 - Slide
❑ For sliding headliner.
5 - Boot
❑ To cover guide plate.
6 - Water channel
❑ Is removed together
with guide plate.
7 - End piece
❑ Use Butyl adhesive
sealing cord AKL 450
005 05 to seal.

118 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

8 - Bolt
9 - Carrier unit
❑ Removing carrier unit ⇒ page 125 .
❑ U-frame with guide channels: grease guide channels as required with special grease G 000 450 02 only.
Otherwise correct operation cannot be guaranteed.
10 - Electric drive
❑ Removing ⇒ page 124
❑ Adjusting drive ("0" position) ⇒ page 124 .
11 - Bolt
❑ For drive.
12 - Cover
❑ For drive.
13 - Crank for emergency operation
❑ Clipped into cover for electric drive.
❑ No longer exists from 11.2004
14 - Spring

satelettronica
❑ Pushes up wind deflector.
15 - Wind deflector
n AG. Volkswagen AG do
❑ Removing ⇒ page wage
olks 123
es n
o V t gu
by ara
16 - Torx bolt rised nte
ho eo
❑ 4.5 Nm sa
ut ra
c
s
17 - Guide plate
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e
nl

pt
du

an

❑ Is removed together with water channel.

itte

y li
erm

ab

18 - Rear guide
ility
ot p

wit

❑ Is removed together with water channel and guide plate.

, is n

h re
hole

19 - Connecting element
spec
es, in part or in w

❑ Connects water channel with guide plate.

t to the co

20 - Countersunk-head bolts (microencapsulated)

❑ If removed, always use new countersunk-head bolts.
rrectness of i

❑ 3.5 Nm
l purpos

nf
ercia

1.4 Removing sliding/tilting sunroof glass

orm
m

panel
atio
om

n in
or c

– Push sliding headliner to rear.

thi
te

sd
iva

– Raise sliding/tilting sunroof glass panel.

o
r
rp

cu
o

m
f

en
ng

– Unclip bellows at lower trim strip. yi

t.
Co
op py
– Loosen both front fastenings and push bellows to rear
. C rig
ht ht
rig
-arrow- out of guide. py by
co Vo
by lksw
cted agen
Prote AG.

1. Sunroof with glass panel 119

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Remove securing screws -1- (Torx key T25, 4.5 Nm) from
bracket guide -3-.
– Remove sliding/tilting sunroof panel -2- upwards.

1.5 Installing sliding/tilting sunroof glass

panel
Panel must be installed in the zero position (panel closed).
n AG. Volkswagen AG do
wage
1.5.1 Zero position: byV
olks es n
ot g
ua
d ran
ir se
Guide pins -1- must align withthmarkings
o -arrow- on left and right tee
or
guide plates.

satelettronica
au ac
ss

ce
e

If this is not the case, adjust parallel running ⇒ page 122

nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i

– Install sliding/tilting sunroof panel from above and fit securing

l purpos

screws -arrows- (guide plates/panel).

– Tighten securing screws -arrows- lightly and only tighten the
nf
ercia

securing screws to 4.5 Nm once the panel height adjustment

orm

has been completed.

m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

120 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.6 Adjusting height of sliding/tilting sunroof

glass panel
– Push sliding headliner to rear.
– Raise sliding/tilting sunroof glass panel.
– Unclip bellows at lower trim strip.
– Loosen both front fastenings and push bellows to rear
-arrow- out of guide.
– Position glass panel in "0" position.
– To prevent wind noises, carry out front and rear height adjust‐
ments in accordance with figures.

Front panel adjustment:

a = 0…1 mm lower than roof level
Arrow = direction of travel AG. Volkswagen AG d
agen oes
olksw not
V

satelettronica
by gu
d ara
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

Rear panel adjustment:

spec
es, in part or in w

b = 0…1 mm higher than roof level

t to the co
Arrow = direction of travel

rrectness of i
– Tighten screws for glass panel to 4.5 Nm.
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
riv

1.7 Checking parallel running of glass panel

p

cum
for

en
ng

t.
– Push sliding headliner to rear.
yi Co
Cop py
t. rig
– Raise sliding/tilting sunroof glass panel.
gh ht
pyri by
Vo
co lksw
by
– Unclip bellows at lower trim strip. Prote
cted AG.
agen

– Loosen both front fastenings and push bellows to rear

-arrow- out of guide.

1. Sunroof with glass panel 121

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Position glass panel in "0" position.

Guide pins -1- must align with markings -arrow- on left and right
guide plates.
If this is not the case, adjust parallel running ⇒ page 122 .

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
1.8 Adjusting parallel running of glass panel
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

Note

h re
hole

spec
The parallel running adjustment can only be undertaken when the
es, in part or in w

drive and solar panel are removed (zero position).

t to the co

satelettronica
– Removing sunroof drive ⇒ page 124 .

rrectness of i
– Slide guide plates by hand only.
l purpos

Guide pins -1- must align with markings -arrow- on left and right
guide plates.

nform
ercia

– Install drive and glass panel again.

m

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
ht
1.9 Renewing panel seal
rig by
copy Vo
by lksw
cted agen
Prote
– Removing glass panel for sunroof ⇒ page 119 .
AG.

– Pull seal -1- off glass panel.

– Press new seal centrally in glass panel -2-.

Note

To ease fitting of seal, coat panel edge with a soapy solution.

122 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015
AG. Volkswagen AG d
1.10 Removing wind deflector
Vol
ksw
agen oes
not
y gu
db ara
– Open sliding/tilting sunroof fully.orise nte
h eo
ut ra
– Push wind deflector -2- on both
ss
a sides towards middle of vehi‐ c
cle -arrow- out of support -3-.

ce
e
nl

pt
du

an
– Remove wind deflector with vertical stop -1- under roof to‐

itte

y li
wards rear.
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
1.11 Removing sliding headliner
l purpos

– Push sliding headliner to rear.

nf
ercia

– Raise sliding/tilting sunroof glass panel.

orm
m

– Unclip bellows at lower trim strip.

atio
m

satelettronica
o

n in
c

– Loosen both front fastenings and push bellows to rear

or

thi
e

-arrow- out of guide.

t

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Remove securing screws -1- (Torx key T25, 4.5 Nm) from
bracket guide -3-.
– Remove sliding/tilting sunroof panel -2- upwards.

– Push sliding headliner forwards.

– Remove bolts -1- on left and right. Push slide to rear and re‐
move sliding headliner upwards.

1. Sunroof with glass panel 123

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.12 Removing sliding/tilting sunroof drive

Note

Remove or install drive for sunroof only when sunroof is closed

(zero position ⇒ page 124 ).

– Remove lights and operating unit. ⇒ Electrical system; Rep.

gr. 96 ; Lights, bulbs, switches - interior .
– Remove screws -arrows- and pull off drive -1- for sliding/tilting
sunroof.
– Disconnect connector -2- on drive -1-.
• The screws for the drive are microencapsulated and must al‐
ways be renewed (3.5 Nm).

AG. Volkswagen AG d
agen oes
lksw not

satelettronica
Vo gu
by
1.13 Adjusting drive for sliding/tilting sunroof d ara
rise nte
ho eo
(zero position) ut ra
s a c
s
ce
e
nl

Drive removed but still connected electrically. pt

du

an
itte

y li
– Switch ignition on.
erm

ab
ility
ot p

– Select “close sunroof” using preselection control rotary knob.

wit
, is n

h re

– Drive automatically runs to zero position and switches off.

hole

spec

– Switch off ignition.

es, in part or in w

t to the co

The viewing hole is protected by a cover -1-.

– Lever out cap -1-.
rrectness of i

The coloured marking -2- in viewing hole and protruding lug -3-
l purpos

must align.
– Install drive in this position ("0" position) with sunroof closed.
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

1.14 Removing pre-selector control for slid‐

t.
yi Co
Cop py
ing/tilting sunroof
t. rig
gh ht
pyri by
Vo
co lksw
by
– Remove lights and operating unit. ⇒ Electrical system; Rep. cted agen
Prote AG.
gr. 96 ; Lights, bulbs, switches - interior .
– Release the three locking devices -arrows- on back of light
unit.
– Push out the rotary knob from the front side by hand.

124 Rep. gr.60 - Sunroof

 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se
tho tee
or Touran 2003 ➤
u
ss
a
General body repairs, exterior ac
- Edition 02.2015

ce
e
nl

pt
du
1.15 Removing and installing carrier unit

an
itte

y li
erm

ab
ility
ot p

wit
, is n
1.15.1 Removing

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
op py

satelettronica
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove moulded headliner ⇒ General body repairs, interior;

Rep. gr. 70 ; Trim, insulation; Roof trims .
– Pull water drain hoses -arrows- off carrier unit -1-.
– Disconnect connector on drive -3-.
– Remove screws -2- and remove carrier unit from vehicle with
the help of a second mechanic.

1. Sunroof with glass panel 125

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.15.2 Installing

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re

satelettronica
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Fit carrier unit -1- into roof aperture with the help of a second
mechanic.
– Align carrier unit in roof frame using cylindrical pins (shafts of
inverted drill bits), 12 mm at front right -4- and 10 mm at rear
left -2-.
Carrier unit must not contact roof frame.
– Check routing of wiring and connectors of electrical consum‐
ers in roof and restore if necessary.
– Tighten screws for carrier unit -1-, starting at sunroof drive
-5- and moving towards rear, alternating between left and right
sides. Specified torque for bolt -2-: 8 Nm.
– Install water drain hoses -arrows-.
– Reconnect connector to drive -5-.
– Install moulded headliner ⇒ General body repairs, interior;
Rep. gr. 70 ; Trim, insulation; Roof trims .

126 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.16 Operating without current

– Lever cover out of locking devices -direction of arrow-.

AG. Volkswagen AG d
agen oes
olksw not
V gu
– Insert hexagon key in bolt of drive and spush d b upwards
y ara
i e nte
-arrow-. thor eo
au ra
– The bolt will be pressed a few millimetres
ss
inwards -a-. The c

ce
e

sliding/tilting sunroof panel can only be moved in this position.

nl

pt
du

an
itte

y li
erm

ab

satelettronica
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
1.17 Cleaning water drain hoses
l purpos

1.17.1 Front water drain hoses

nf
ercia

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1. Sunroof with glass panel 127

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

satelettronica
AG. Volkswagen AG d
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The front water drain hoses run through the A-pillars and end at

spec
the engine bulkhead. Cleaning is done from the sunroof panel
es, in part or in w

aperture.

Note t to the co
rrectness of i
l purpos

The cleaning and pull-in cable - VAS 6620- , an auxiliary tool, is recommended for cleaning.
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128 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.17.2 Rear water drain hoses

AG. Volkswagen AG d
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nl

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es, in part or in w

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cted agen
Prote AG.

The rear water drain hoses run through the D-pillars and end in
the rear wheel housings. Cleaning is done from the wheel hous‐
ing. The wheel housing liner must be removed.

Note

The cleaning and pull-in cable - VAS 6620- , an auxiliary tool, is recommended for cleaning.

1. Sunroof with glass panel 129

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2 Panorama sliding/tilting sunroof (Ar‐

n AG. Volkswagen AG do
vin Meritor) yV
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2.1 Tools
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Special tools and workshop equipment required

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ab
♦ Roller for door insulation foil - 3356-

ility
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spec
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♦ Torque wrench - V.A.G 1783-

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♦ Adhesive strip remover - VAS 6349-

2.2 Function
All actions of the panoramic sliding roof can be performed with
ignition switched on.
After the ignition is switched off, actions can be performed until
either the driver or front passenger door is opened.

130 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

Opening of front glass panel can be preselected using rotary knob

-1-.
Opening glass panel to the so called comfort position -4-, pre‐
vents to a large extent wind noise while driving, which can occur
when roof is fully open.
Glass panel can be tilted and closed using pull and push function
on rotary knob.
Sunroof sun blind opening button -2- and sunroof sun blind clos‐
ing button -3- are integrated into rotary knob.
The panoramic sliding roof is equipped with a force limitation (an‐
ti-trap) mechanism. If the glass panel encounters an obstruction
while closing from tilting or sliding position, it will open automati‐
cally.
In addition, there is an emergency closure function. If problems
occur during closure, panoramic sliding roof can be forced to
close by pulling rear end of rotary knob. Rotary knob must there‐
fore be in “Sliding sunroof closed”
genposition.
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The roll-back function isd bdisabled when the emergency closure
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The sliding roofssmotor
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whose activation depends on various parameters. The sliding

ce
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sunroof motor is functional again after a cooling-off phase.
du

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In the event of power failure, front glass panel and sunroof sun

ab
ility
blind can be moved manually ⇒ page 188 .
ot p

wit
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2.3 Basic setting, panoramic sliding sunroof h re

hole

spec
es, in part or in w

t to the co

Note
rrectness of i

After renewal of the glass panel, a motor, the tilting mechanism

or the sunroof sun blind, basic setting must be carried out for the
l purpos

respective drive.
nf
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Adaptation is carried out using the vehicle diagnostic tester -

rm
m

VAS 5051 A- .
atio
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n in
c

– Select “Guided functions” in vehicle diagnostics tester -

or

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VAS 5051 A- .
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Prote AG.

2. Panorama sliding/tilting sunroof (Arvin Meritor) 131

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1 - Exterior seal
❑ Renewing ⇒ page 145
2 - Rear glass panel
❑ Removing and installing
⇒ page 137
❑ Adjusting ⇒ page 139
3 - Bolts
❑ For rear glass panel.
❑ Qty. 6.
❑ 5 Nm
4 - Bolts
❑ For front glass panel
❑ Qty. 6.
❑ 5 Nm
5 - Trim
❑ Conceals the screws of agen
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6 - Assembly frame rise nte
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❑ Assembly overview ss a c
⇒ page 169 .

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❑ Removing and installing
d
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⇒ page 174
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7 - Sunroof sun blind
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❑ Removing and installing
hole

⇒ page 160

spec
es, in part or in w

8 - Bolt

t to the co
❑ For securing cover of
sunroof sun blind

rrectness of i
❑ Qty. 2.
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❑ 3 Nm
9 - Bolt

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❑ For securing cover of sunroof sun blind

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❑ Qty. 2.
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10 - Cover for sunroof sun blind

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cted AG.
agen

12 - Sunroof sun blind motor

❑ Removing and installing ⇒ page 156
❑ Initialising ⇒ page 131 .
13 - Bolt
❑ For securing sliding roof motor
❑ Qty. 3.
❑ 5 Nm
14 - Sliding sunroof motor
❑ Removing and installing ⇒ page 153
❑ Initialising ⇒ page 131 .

132 Rep. gr.60 - Sunroof

 AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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horis
eo Touran 2003 ➤
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ss a General
ra
c body repairs, exterior - Edition 02.2015

ce
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un

pt
15 - Tilting mechanism

an
d
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❑ Removing and installing ⇒ page 184
erm

ab
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16 - Wind deflector

wit
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❑ Removing and installing ⇒ page 149
ole,

spec
urposes, in part or in wh

17 - Bolt

t to the co
❑ For securing wind deflector
❑ Qty. 5.

rrectne
❑ 2 Nm
18 - Front glass panel

ss
❑ Removing and installing ⇒ page 133

o
cial p

f in
❑ Adjusting ⇒ page 139

form
mer

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2.5 Removing and installing front glass pan‐

thi
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2.5.1 Removing
t. C rig
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2. Panorama sliding/tilting sunroof (Arvin Meritor) 133

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Open glass panel -1- until trim -2- is accessible.

– Release locking lugs -4- by pressing -arrow B- on rear -3-.
– Pull trim -1- off downwards at rear end -arrow A-.
– Push trim forwards -arrow C- and remove.

AG. Volkswagen AG d
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satelettronica
nl

pt
du

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es, in part or in w

t to the co
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at
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ion
c

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or

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do
priv

cum
for

en
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t.
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rig ht
py by
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cted agen
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– Unscrew bolts -2- from glass panel -1- on left and right.
AG.

Note

To unscrew bolts, use a magnetic tool so that bolts do not fall into mechanism of panoramic sliding roof.

– Lift out glass panel -1- upwards.

Caution

To avoid damaging wind deflector, do not move tilting mecha‐

nism when glass panel is removed.

134 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.5.2 Installing

Note

♦ New bolts must always be used when installing glass panel.

♦ To screw in bolts, use a magnetic tool so that bolts do not fall into panoramic sliding roof guide.

AG. Volkswagen AG d
agen oes
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satelettronica
aut ra
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nl

pt
du

an
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ab
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t to the co
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l purpos

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c

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or

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cum
for

en
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t.
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Cop py
ht. rig
rig ht
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co Vo
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cted agen
Prote AG.

– Insert glass panel -1- from above and screw in screws -2- but
do not tighten them firmly.
– Adjusting front glass panel ⇒ page 139 .
– Tighten bolts -2-, specified torque: 5 Nm.

2. Panorama sliding/tilting sunroof (Arvin Meritor) 135

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

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spec
es, in part or in w

t to the co
rrectness of i
l purpos

satelettronica
nform
mercia

at
om

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c

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or

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ate

do
priv

cum
for

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t.
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t. rig
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pyri by
Vo
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by c lksw
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Prote AG.

– Fit trim -2- into glass panel at front -1- -5-.

– Push trim -2- towards the rear -arrow A-.
– Push trim onto glass panel -arrow B- and clip locking lugs -4-
in on the rear.
– On completion of all work, operate the sliding roof motor to
establish reference points ⇒ page 131 .

136 Rep. gr.60 - Sunroof

 AG. Volkswagen AG d
not Touran 2003 ➤
agen oes
olksw
by General body repairs, exterior -guEdition 02.2015
V
d ara
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th or
2.6 Removing and installing rear glass pan‐ ss
au ac

el

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2.6.1 Removing

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Note

es, in part or in w

t to the co
To unscrew bolts, use a magnetic tool so that bolts do not fall into panoramic sliding roof guide.

rrectness of i
l purpos

nform
mercia

a
com

tion in
r
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thi
s
iva

do
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satelettronica
um
fo

en
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t.
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Cop py
t. rig
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Vo
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by c lksw
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– Operate front glass panel until it is in tilted-open position.

– Undo front screws -2- of rear glass panel -1-.
– Make a note of the number of spacers and take out under the
screw-attachment surface.
– Pull inner seal -3- inwards slightly at the points -arrows- and
undo screws -2-.
– Lift out rear glass panel -1- upwards.

2. Panorama sliding/tilting sunroof (Arvin Meritor) 137

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.6.2 Installing
AG. Volkswagen AG d
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Note ise
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♦ Always use new
ss a
screws when installing or removing glass panel. c

ce
le

♦ To screw in bolts, use a magnetic tool so that bolts do not fall into panoramic sliding roof guide.
un

pt
an
d
itte

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erm

ab
ility
ot p

wit
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ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform

satelettronica
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Install in reverse order of removal.

– Insert glass panel -1- from above.
– Position spacers and tighten screw -2- from above, specified
torque: 5 Nm.
– Pull inner seal -3- inwards slightly at the points -arrows- and
screw in screws -2- but do not tighten completely.
– Adjust rear glass panel ⇒ page 139 .
– After adjusting rear glass panel, tighten screws, 5 Nm.
– On completion of all work, operate sliding roof motor to estab‐
lish reference points ⇒ page 131 .

138 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.7 Adjusting height of front and rear glass

panel

2.7.1 Checking height adjustment

Note

♦ Front glass panel must only be adjusted at front edge -3- and rear glass panel at rear edge -1-.
♦ To achieve the best possible optical appearance, ensure that adjustments on left and right are as far as is
possible uniform (symmetric).
♦ Arrow -d- points in direction of normal travel.

AG. Volkswagen AG d
agen

satelettronica
oes
olksw not
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ara
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ris nte
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aut ra
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e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
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n in
or c

thi
te

sd
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en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Checking height adjustment

– Check adjustment of front glass panel -3- and rear glass panel
-1- with a depth gauge.
If measured values differ from specifications, respective glass
panel must be adjusted.

2. Panorama sliding/tilting sunroof (Arvin Meritor) 139

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.7.2 Adjusting front glass panel

Note

The glass panel height adjustment is performed after the glass

panel has been closed from slide open position.

– Remove trims ⇒ page 133 .

– Only undo the two front screws -2- on the left and right,
– Close glass panel.

satelettronica
– Adjust glass panel -1- according to illustration.
♦ Dimension -a- : 1.5 ± 1 mm
♦ Dimension -b- : 1 ± 1 mm
– Insert and tighten screws on left and right, 5 Nm.
– Installing trim ⇒ page 135 .

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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ris nte
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aut ra
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2.7.3 Adjusting rear glass panel

un

pt
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d
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– Pull inner seal -3- inwards slightly at indicated points

erm

ab
ility

-arrows- and undo screws -2-.

ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

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pr

cum
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fo

en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

140 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Adjust rear glass panel -2- according to illustration.

♦ Dimension -c- : 1 ± 1 mm
– Insert and tighten screws on left and right, 5 Nm.

2.8 Renewing seals for rear glass panel

2.8.1 Removing exterior seal

satelettronica
AG. Volkswagen AG d
agen oes
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un

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es, in part or in w

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com

tion in
r
te o

thi
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iva

do
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cum
fo

en
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t.
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op
– Remove rear glass panel ⇒ page 137 . C py
t. rig
gh ht
yri by
– Pull seal -2- off rear glass panel -1- all round. op Vo
by c lksw
cted agen
Prote AG.

2. Panorama sliding/tilting sunroof (Arvin Meritor) 141

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Remove existing adhesive residues with. Vadhesive

olkswagen Astrip re‐
mover - VAS 6349- . wagen AG G do
e
ks sn ol ot g
yV ua
2.8.2 Installing exterior seal ris
edb ran
tee
tho or
au ac
ss

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Note
nl

pt
du

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erm

To guarantee a good bonding of seal, do not bond at a temperature below 20°.

ab
ility
ot p

wit
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

satelettronica
at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Bonding surface on glass panel must be free of dust and

grease.
– Clean complete bonding area with cleaning solution - D 009
401 04- .
– Pull protective film -3- off adhesive tape of new seal -2- and
press seal on at corners and ends.
– If the seal is excessively long, any excess length is evenly
compressed.
– Press seal on evenly all round using roller - 3356- .
– Install rear glass panel ⇒ page 137 .

142 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.8.3 Removing interior seal

AG. Volkswagen AG d
agen oes
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nl

pt
du

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ab
ility
ot p

wit
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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

satelettronica
nf
ercia

orm
m

atio
om

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or c

thi
te

sd
iva

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f

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Open front glass panel completely via the convenience posi‐

tion.
– Pull seal -2- off rear glass panel -1-.
– Remove existing adhesive residues with adhesive strip re‐
mover - VAS 6349- .

2. Panorama sliding/tilting sunroof (Arvin Meritor) 143

 n AG. Volkswagen AG do
lkswage es n
o ot g
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d ran
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Touran
au 2003 ➤
th or
ac
General body repairs, exterior - Edition 02.2015
ss

ce
le
un

pt
an
d
2.8.4 Installing interior seal
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
. rig

satelettronica
t
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Bonding surface on glass panel must be free of dust and

grease.
– Clean complete bonding area with cleaning solution - D 009
401 04- .
– Pull protective film -4- off adhesive tape of new seal -2- and
press seal on at ends.
– If the seal is excessively long, any excess length is evenly
compressed.
– Press seal on evenly all round using roller - 3356- .

144 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015
AG. Volkswagen AG d
agen oes
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2.9 Removing and installing the exterior ol not
y V gu
d b ara
ise
seal r nte
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au ra
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e
nl

pt
du
2.9.1 Removing exterior seal

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
c

satelettronica
or

thi
te

sd
iva

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rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove front glass panel ⇒ page 133 .

– Remove rear glass panel ⇒ page 137 .
– Pull exterior seal -1- off all round.
– Cut off all round profile of outer seal -1- in -arrow- area, flush
with edge of roof -2-.
– Remaining part -5- stays between roof -4- and assembly frame
-4-.
– Remove any adhesive residue with adhesive strip remover -
VAS 6349- .

2. Panorama sliding/tilting sunroof (Arvin Meritor) 145

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.9.2 Installing exterior seal

Note

♦ New seal is supplied in excess length. The new seal must be cut to length appropriately. It is recommended
to leave new seal 1-2 mm longer than it should be and to compress any excess length.
♦ To guarantee a good bonding of seal, do not bond at a temperature below 20°.
♦ After bonding outer seal, wait at least 30 min before fitting glass panel to assure seal does not unstick.

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– Entire bonding surface on roof cut-out must be free of dust and

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– Clean complete bonding area with cleaning solution - D 009 pyri by
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401 04- .
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– Centre new exterior seal -1- with joint -arrow- to centre of rear
roof cut-out.
– Pull protective film from adhesive tape -3- of new exterior seal
-1- and press seal onto roof -3-.
– The seal must not pull into the radii, otherwise the seal will
stretch and compress.

146 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Press exterior seal on firmly and evenly 2x around circumfer‐

ence using roller - 3356- .
– Install rear glass panel ⇒ page 137 .
– Install front glass panel ⇒ page 133 .

2.10 Removing and installing interior seal

2.10.1 Removing interior seal

AG. Volkswagen AG d

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es, in part or in w

t to the co
rrectness of i
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nform
mercia

a
com

tion in
r
te o

thi
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cum
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t.
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Cop py
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pyri by
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– Remove front glass panel ⇒ page 133 . Prote AG.

– Remove rear glass panel ⇒ page 137 .

– Pull interior seal -2- off assembly frame -1-.
– Remove any adhesive residue with adhesive strip remover -
VAS 6349- .

2. Panorama sliding/tilting sunroof (Arvin Meritor) 147

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.10.2 Installing interior seal

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ot

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es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
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tion in
r
te o

thi
s
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cum
fo

en
ng

t.
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Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote
– Bonding surface must be free of dust and grease.
AG.

– Clean complete bonding area with cleaning solution - D 009

401 04- .

Note

To guarantee a good bonding of seal, do not bond at a temperature below 20°.

– Align interior seal -2- with butt positioned on rear centre of roof
cut-out, onto bonding surface of assembly frame -1-.
– Pull protective film off adhesive tape of new interior seal and
press on.
– The seal must not pull into the radii, otherwise the seal will
stretch and compress.
– Press interior seal on firmly and evenly 2x around circumfer‐
ence using roller - 3356- .
– Install rear glass panel ⇒ page 137 .

148 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Install front glass panel ⇒ page 133 .

2.11 Removing and installing wind deflector

2.11.1 Removing

satelettronica
AG. Volkswagen AG d
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es, in part or in w

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– Open front glass panel.

rrectness of i

– Using a screwdriver, remove mounting bracket of wind deflec‐

l purpos

tor -1- from assembly frame.

– Undo bolts -2- securing wind deflector -1-
nf
ercia

– Take out wind deflector -1- upwards.

rm
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Prote AG.

2. Panorama sliding/tilting sunroof (Arvin Meritor) 149

 AG. Volkswagen A
Touran 2003 ➤ agen G do
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General body repairs,
ed by exterior - Edition 02.2015 ua
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2.11.2 Installing au ra
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un

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itte

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spec
urposes, in part or in wh

t to the co
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cial p

f inform
mer

atio
om

n
c

i
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te

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r
fo

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t.
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Cop py
t. rig
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pyri by
Vo
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Prote AG.

Install in reverse order of removal.

– Removing and installing wind deflector bracket ⇒ page 151
Specified torque
Wind deflector bolts 2 Nm

Note

Wind deflector mounting bracket must engage audibly.

150 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.11.3 Removing and installing wind deflector bracket

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AG. Volkswagen AG d
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urposes, in part or in wh

Removing
t to the co

– Remove wind deflector -1- ⇒ page 149 .

– Lever apart mounting bracket -2- and plugs -3-.
rrectne

Installing
ss

– Connect mounting bracket -2- and plugs -3- together.

o
cial p

f in

– Install wind deflector -1- ⇒ page 149 .

form
mer

atio
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Prote AG.

2. Panorama sliding/tilting sunroof (Arvin Meritor) 151

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.12 Removing and installing preselector for glass panel and sunroof sun blind

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Removing
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– Removing lights and front operating unit ⇒ Electrical system;

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for

Rep. gr. 96 ; Lights and switches in roof trim .

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t.
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op py
– Disconnect connector -2-. t. C rig
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– Release locking hooks -arrows- and remove switch -1-.
co Vo
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Prote AG.
Installing
– Push in switch -1- until locking hooks -arrows- engage audibly.
– Connect connector -2-.

152 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.13 Removing and installing sliding sunroof

motor

2.13.1 Removing

AG. Volkswagen AG d
agen oes
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au ra
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nl

pt
du

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es, in part or in w

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c

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or

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ate

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priv

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en
ng

t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Removing lights and front operating unit ⇒ Electrical system;

Rep. gr. 96 ; Lights and switches in roof trim .
– Unclip frame -4- from moulded headliner.
– Remove bolts -2-.
– Remove sliding roof motor -1-.
– Disconnect connector -5-.

2. Panorama sliding/tilting sunroof (Arvin Meritor) 153

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.13.2 Installing

AG. Volkswagen AG d
agen oes

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cial p

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mer

atio
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With front glass panel removed:

o

n
c

i
or

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– Push tilting mechanism -1- fully forwards -arrow a- on both

te

sd
a

sides until it is completely lowered.

iv

o
pr

cum
r
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– Push tilting mechanism only at indicated point -arrow- of slider

en
ng

t.
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-1- not at guide plate -2-.
Co
Cop py
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pyri by
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Prote AG.

154 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
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nl

pt
du

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Further installation is performed in the reverse order of removal. ab

ility
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Specified torque for sliding sunroof motor bolts -2-: 3.5 Nm h re

hole

spec
– On completion of all work, operate sliding roof motor to estab‐
es, in part or in w

lish reference points ⇒ page 131 .

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

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or

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ate

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cum
for

en
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t.
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Prote AG.

2. Panorama sliding/tilting sunroof (Arvin Meritor) 155

 . Volkswagen AG
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General body repairs, exterior - Edition
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2.14 Removing and installing sunroof sun
a c
ss

ce
le
blind motor

un

pt
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itte

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ab
ility
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2.14.1 Removing

wit
is n

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spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

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te

sd
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pr

cum
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en
ng

t.
yi Co
Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

– Move sunroof sun blind as far back as possible.

– Remove moulded headliner ⇒ General body repairs, interior;
Rep. gr. 70 ; Roof trim .
– Disconnect connector -4-.
– Remove bolts -3-.
– Remove sunroof sun blind motor -1-.

156 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.14.2 Installing

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
tho eo
au ra
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nl

pt
du

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ility
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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Before installing motor, adjust sunroof sun blind by ensuring

parallel distance -a- between sunroof sun blind cross strut
-1- and sunroof sun blind housing -2-.
nf
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Prote AG.

2. Panorama sliding/tilting sunroof (Arvin Meritor) 157

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

n AG. Volkswagen AG do
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ot

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, is n

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spec
es, in part or in w

t to the co
rrectness of i
l purpos

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mercia

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Further installation is performed in the reverse order of removal. t. Cop py
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– Connect connector -4-. pyri by
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– Tighten screws -3-, specified torque: 3.5 Nm. Prote AG.

– On completion of all work, operate sunroof sun blind motor to

establish reference points ⇒ page 131 .

158 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.15 Assembly overview - sunroof sun blind

1 - Cross strut
Volkswagen AG
2 - Slide agen
AG. does
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❑ Left and
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3 - Cableau
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❑ sLeft and right.

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4 - Sunroof sun blind

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5 - Guide bracket

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❑ Left and right.

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6 - Bolt
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spec
❑ Qty. 2 on each side.
es, in part or in w

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❑ 2 Nm
7 - Bolt

rrectness of i
❑ Qty. 2.
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❑ 2 Nm

satelettronica
8 - Cover

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Prote AG.

2. Panorama sliding/tilting sunroof (Arvin Meritor) 159

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.16 Removing and installing sunroof sun

blind
AG. Volkswagen AG d
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2.16.1 Removing
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Note

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nl

pt
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In the event of power failure, the sunroof sun blind can be moved by turning the sunroof sun blind motor with

y li
erm

ab
a commercially available hexagon key to removal position (fully open). ⇒ page 188

ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

satelettronica
nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
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Prote AG.

– Open sunroof sun blind completely using button -arrow a-.

– Remove moulded headliner ⇒ General body repairs, interior;
Rep. gr. 70 ; Roof trim .
– Mark the position of the cross strut -4- on the left and right on
frame.
– Remove rear glass panel ⇒ page 137 .
– Mechanically move sunroof sun blind with cross strut -4- in
under cover -arrow b- to stop.

160 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

Note

During this, press cross strut down slightly so that it does not hit assembly frame.
n AG. Volkswagen AG
age does
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– Remove assembly frame ised b ⇒ page 174 . ara
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– Set assembly frameaut with inner side upwards on an appropriate ra
c
s
surface. s

ce
e
nl

pt
du

– Remove sunroof sun blind motor ⇒ page 156 .

an
itte

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ab
– Remove bolts -2 and 3- of cover -1-.

ility
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wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

satelettronica
nform
mercia

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om

ion
c

in t
or

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ate

do
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cum
for

en
ng

t.
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Cop py
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Prote AG.

– Release locking hooks on guide bracket -5- -arrows b-.

– Remove cover from guides -3 and 4- and remove -arrow a-.

2. Panorama sliding/tilting sunroof (Arvin Meritor) 161

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
ss c

ce
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un

pt
an
d
itte

satelettronica
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rm

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ility
ot

wit
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es, in part or in w

t to the co
rrectness of i
l purpos

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tion in
r
te o

thi
s
iva

– Pull sunroof sun blind -1- out of assembly frame -3- a little and
do
r
rp

pull it downwards a little in -direction of arrow-.

um
fo

en
ng

t.
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– Release catch of inner -2- and outer -4- sunroof sun blind
Co
op py
guide.
t. C rig
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pyri by
Vo
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– Remove inner sunroof sun blind guide -2-.
c by lksw
cted agen
Prote AG.

162 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

AG. Volkswagen AG d
agen oes
olksw not
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ara
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ris nte
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aut ra
ss c

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un

pt
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ility
ot

wit
, is n

satelettronica
h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
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cum
fo

en
ng

t.
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Cop py
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rig ht
Note
py by
co Vo
by lksw
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Prote AG.
When doing so, make sure that the sunroof sun blind fabric is not damaged.

– Pull cross strut -2- with slide -3- out of roller guide.
– The steel strip of the sunroof sun blind -5- becomes detached
from the slide -3-.
– Detach cable -4- from slide -3-.
– Separate sunroof sun blind fabric -1- with steel strip -5- from
guides.
The cables -4- and the sunroof sun blind guides remain in the
assembly frame.
Sunroof sun blind cross strut can be renewed when sunroof sun
blind is removed ⇒ page 168 .

2. Panorama sliding/tilting sunroof (Arvin Meritor) 163

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.16.2 Installing

satelettronica
AG. Volkswagen AG d
agen oes
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nl

pt
du

an

The following steps require 2 mechanics.

itte

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– Pull cables -4- evenly out of guides about 5 cm.

ility
ot p

wit
, is n

– Push outer part of sunroof sun blind guide onto cable -4-.
h re
hole

– Hook slides -3- into cables -4-.

spec
es, in part or in w

t to the co

– Attach steel strip of sunroof sun blind -5- to slide -3-.

– Push sunroof sun blind guide onto the carefully assembled
slide with cables and steel strip.
rrectness of i

– Push back cables into guides to stop.

l purpos

nf
ercia

Note
orm
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atio

Do not grease sunroof sun blind slide or sunroof sun blind cables.
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164
co Vo
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cted
Rep. gr.60 - Sunroof
agen
Prote AG.
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

AG. Volkswagen AG d
agen oes
lksw not

satelettronica
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Note
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When doing so, make sure that the sunroof sun blind fabric is not damaged.
r
te o

thi
s
iva

do

– Assemble inner -2- and outer -4- sunroof sun blind guide.
r
rp

cum
fo

en
g

– Push sunroof sun blind guides -2 and 4- into assembly frame

n

t.
yi Co
op
-3-. C py
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pyri by
Vo
co lksw
by
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Prote AG.

2. Panorama sliding/tilting sunroof (Arvin Meritor) 165

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

satelettronica
n AG. Volkswagen AG do
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nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

– Attach sunroof sun blind cover -1- to sunroof sun blind guides
-2-.
rrectness of i
l purpos

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ercia

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f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

166 Rep. gr.60 - Sunroof

 AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
horis nte
eo Touran 2003 ➤
aut General body repairs,r aexterior - Edition 02.2015
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
op

satelettronica
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Align cross strut -4- according to the markings made.

Tighten screws -2 and 3-, specified torque: 2 Nm.

Note

♦ After installation, check that sunroof sun blind moves easily and evenly.
♦ To do this, turn drive of sunroof sun blind motor manually, using a standard hexagon spanner.
♦ Watch out for folding and twisting of the sunroof sun blind fabric.

– Install moulded headliner ⇒ General body repairs, interior;

Rep. gr. 70 ; Roof trim .
– On completion of all work, carry out normalisation run for sun‐
roof sun blind motor ⇒ page 131 .

2. Panorama sliding/tilting sunroof (Arvin Meritor) 167

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.17 Removing and installing sunroof sun blind cross strut

satelettronica
AG. Volkswagen AG d
agen oes
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ab

Note
ility
ot p

wit
is n

Make sure that the sunroof sun blind fabric -2- is not damaged.
h re
ole,

spec
urposes, in part or in wh

Removing
t to the co

– Remove sunroof sun blind ⇒ page 160

– Pull slide -3- on left and right out of cross strut -2- -arrow a-.
rrectne

– Carefully pull sunroof sun blind cross strut -2- in direction of

-arrow b- out of beading -1- of sun blind fabric.
ss o
cial p

Installing
inform
mer

– Carefully push sunroof sun blind cross strut -1- onto beading
atio
m

-1- of sunroof sun blind fabric.

o

n
c

i
or

– Push slide -3- on left and right into cross strut -2-.
thi
te

sd
iva

– Install sunroof sun blind ⇒ page 164 .

pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by

168
co Vo
by lksw
cted
Rep. gr.60 - Sunroof
agen
Prote AG.
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.18 Assembly overview - assembly frame

1 - Inner seal
❑ Renewing ⇒ page 147
2 - Bolt
❑ For the cover
❑ 2 Nm
3 - Cover
❑ Part of inner seal
❑ Cannot be renewed in‐
dividually
4 - Sunroof sun blind rail
❑ Part of guide rail
❑ Cannot be renewed in‐
dividually
5 - Rear part
❑ Removing and installing

satelettronica
⇒ page 177
6 - Rear motor plate
❑ Removing and installing
⇒ page 170
7 - Guide rail with front part
❑ Cannot be renewed in‐
dividually
❑ Part of the front part

AG. Volkswagen AG d
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nl

pt
du

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2. Panorama sliding/tilting sunroof (Arvin Meritor) 169

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.19 Removing and installing sunroof sun

blind cable

2.19.1 Removing

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Remove moulded headliner ⇒ General body repairs, interior;

Rep. gr. 70 ; Roof trim .
nf
ercia

– Remove sunroof sun blind motor ⇒ page 156 .

rm
m

atio
m

– Remove sunroof sun blind ⇒ page 160 .

o

n in
or c

thi

– Remove bolts -arrows- of cable covers -1- and -2-.

te

sd
iva

o
r

– Remove cable covers -1- and -2-.

rp

cu
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m
f

en
ng

t.
Motor plate -3- remains on rear part -4-.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

170 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

satelettronica
orm
m

atio
om

n in
or c

thi
te

sd
iva

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r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Using an appropriate screwdriver -6-, lever motor plate -4- out

of rear part -5-.

2. Panorama sliding/tilting sunroof (Arvin Meritor) 171

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
m

satelettronica
o

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Lift guide pipe -1- out of cable support bracket -6-.

– Pull cable -5- out of blind rail -4-.
– Pull cable -5- out of guide pipe -1-.

172 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.19.2 Installing

AG. Volkswagen AG d
agen oes
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y V gu
d b ara
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au ra
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ce
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un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

satelettronica
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Install in reverse order of removal.

Tighten screw -arrows-, specified torque: 2 Nm.

Note

Do not grease motor plate and sunroof sun blind cables.

– Install sunroof sun blind ⇒ page 164 .

– Install sunroof sun blind motor ⇒ page 157 .
– Install moulded headliner ⇒ General body repairs, interior;
Rep. gr. 70 ; Roof trim .
– On completion of all work, carry out a normalisation run for all
panoramic sliding roof drives ⇒ page 131 .

2. Panorama sliding/tilting sunroof (Arvin Meritor) 173

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.20 Removing and installing assembly

frame

2.20.1 Removing

Note
AG. Volkswagen AG d
agen oes
A second mechanic is required for removing and installing assembly
yV
olksframe.
w not
gu
b ara
ed nte
oris eo
th
au ra
c
ss

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

satelettronica
t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Remove moulded headliner ⇒ General body repairs, interior;

Rep. gr. 70 ; Roof trim .
– Pull water drain hoses off the connection pieces -arrows c- of
the assembly frame -1-.
– Disconnect connector to wiring harness on sliding roof motor
-3-.
– Loosen bolts -2-, do not unscrew.

174 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

Further dismantling requires the help of another mechanic.

– Unscrew bolts -2- and take assembly frame out of vehicle.

2.20.2 Installing

satelettronica
AG. Volkswagen AG d
agen oes
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nl

pt
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itte

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erm

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ility
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, is n

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hole

spec
es, in part or in w

t to the co

– Lift assembly frame -1- into vehicle with the help of at least a
second mechanic.
rrectness of i

– When bolting assembly frame, use 2 cylindrical pins (reversed

10 mm drill bits) to align frame with centring holes -a- (oblong
l purpos

hole) and -b- and with roof.

– Screw in bolts -2- but do not fully tighten.
nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Panorama sliding/tilting sunroof (Arvin Meritor) 175

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

satelettronica
h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
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op py
The alignment -arrows- of the assembly frame must be watched t. C rig
gh ht
when the screws are being tightened. yri
p by
o Vo
by c lksw
cted
– Bolts must be tightened in specified sequence -1 to 18-.
agen
Prote AG.

– Specified torque for bolts: 8 Nm.

Further installation is performed in the reverse order of removal.
– Install moulded headliner ⇒ General body repairs, interior;
Rep. gr. 70 ; Roof trim .

176 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.21 Removing
swa
gen Aand
G. Volkinstalling
swagen AG
doesrear part
olk not
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edb ara
ris nte
tho eo
2.21.1
ss
au Removing ra
c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio

satelettronica
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Remove front glass panel ⇒ page 133 .

– Remove rear glass panel ⇒ page 137 .
– Remove sunroof sun blind ⇒ page 160 .
– Remove assembly frame from vehicle ⇒ page 174 .
– Pull interior seal -2- off assembly frame -1-.
– Remove any adhesive residue with adhesive strip remover -
VAS 6349- .

2. Panorama sliding/tilting sunroof (Arvin Meritor) 177

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

satelettronica
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Release wiring harness from rear section.

– Mark position -arrow- of rear part -1- in relation to guide rails
-4- for purposes of later installation.
– Remove bolts -2-.
– Separate bonded connection -5- between guide rail -4- and
rear part -1-, using a knife.
– Pull entire rear part -1- together with discharge tubes -3- out
of guide rails -4-.

178 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.21.2 Installing

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

satelettronica
t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove any adhesive residue with adhesive strip remover -

VAS 6349- .
– Clean bonding surfaces -5- on rear part and guide rails with
cleaning solution -D 009 401 04- .
– Insert a 3.5 mm butyl sealing cord - AKD 497 010 04 R10-
-5- into bonding channel on rear section -1- as shown.
– Push entire rear part -1- with discharge tubes -2- in direction
of -arrow- onto guide rails -3-.
– Tighten bolts -2-, specified torque: 2 Nm.

Note

Before installation, check assembly frame for leaks.

2. Panorama sliding/tilting sunroof (Arvin Meritor) 179

 AG. Volkswagen AG d
agen oes
olksw not
yV gu
Touran 2003 ➤ ed b ara
nte
ris
General body repairs,ut
hexterior - Edition 02.2015
o eo
ra
s a c
s

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi

satelettronica
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Seal water drain fitting -3-.

– Fill marked area -4- between rear section -2- and guide rail
-5- with water.
– Wait for at least 5 minutes and then check for leaks.
– Seal any leaks with butyl sealing cord - AKD 497 010 04 R10- .
– Install sunroof sun blind ⇒ page 160 .
– Install sunroof sun blind motor ⇒ page 156 .
– Install new interior seal ⇒ page 147 .
– Install assembly frame ⇒ page 175 .
– On completion of all work, carry out a normalisation run for all
panoramic sliding roof drives ⇒ page 131 .

180 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.22 Removing and installing front motor

plate

2.22.1 Removing

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee

satelettronica
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
yri
– Remove assembly frame ⇒ page 174 . p by
co Vo
by lksw
cted agen
– Remove sliding roof motor ⇒ page 153 . Prote AG.

– Unscrew bolts -arrows-.

– Remove cables -1 and 2-.
Front motor plate -3- remains on front part. -4-.

2. Panorama sliding/tilting sunroof (Arvin Meritor) 181

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

– Pull ends of cables -1- out of motor plate -2-. t to the co

rrectne
– Using appropriate screwdriver -4-, lever motor plate -2- out of
front part -3-.
ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

182 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.22.2 Installing

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

satelettronica
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Note

♦ Insert motor plate -2- into front part -3- as shown.

♦ Do not grease motor plate and cables -1-.

Further installation is performed in the reverse order of removal.

Specified torques
Bolt for cable cover: 2 Nm
– Install sliding roof motor ⇒ page 153 .
– Install assembly frame ⇒ page 175 .
– On completion of all work, carry out normalisation run for sun‐
roof sun blind motor ⇒ page 131 .

2. Panorama sliding/tilting sunroof (Arvin Meritor) 183

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.23 Removing and installing tilting mecha‐

nism and front glass panel cable

2.23.1 Removing

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac

satelettronica
ss

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
– Remove front glass panel ⇒ page 133 . cted agen
Prote AG.

– Remove rear glass panel ⇒ page 137 .

– Remove assembly frame from vehicle ⇒ page 174 .
– Remove sliding roof motor ⇒ page 153 .
– Remove rear section from assembly frame ⇒ page 177 .
After removal of rear part, tilting mechanism can be slid out back‐
wards.
– Push glass panel tilting mechanism only by indicated position
-arrow b- on slider -2-, not by guide plate -1-.

184 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

Note

Tilting mechanism tilts when moving.

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec

Caution
es, in part or in w

t to the co

Note position of cables before removal.

rrectness of i

Do not pull or push tilting mechanism guide plate.

l purpos

– Detach cable -4- from sliders -1- -arrow B-.

nf
ercia

– Pull slider -1- out of guide rail -3- -arrow A-.

rm
m

atio
m

– Pull cable -4- out of guide rails -3-.

o

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen

185
Prote AG.
2. Panorama sliding/tilting sunroof (Arvin Meritor)
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.23.2 Installing

Note

♦ Clean guide rails only if heavily soiled ⇒ Maintenance ; Booklet 18 ; Descriptions of work; Sunroof: Checking
function, cleaning guide rails and greasing with special grease .
♦ Do not grease cables. wagen AG. Volkswagen AG doe
ks s no
Vol t gu
d by ara
e nte
ris
tho eo
au ra
c
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

satelettronica
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Push tilting mechanism -1- partially into guide rail -3- -arrow-.
– Ensure that slides -2- face towards rear when being pushed
into guide rail -1-.
– Push cable -4- into guide rail -3- -arrow B-.
– Attach cable -4- to sliders -1- -arrow A-.

186 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
Note
ce
e
nl

pt
du

an
itte

y li

Do not pull or push tilting mechanism guide plate.

erm

ab
ility
ot p

– Push glass panel tilting mechanism only by indicated position

wit
, is n

h re

-arrow b- on slider -2-, not by guide plate -1-.

hole

spec

– Push tilting mechanism fully forwards -arrow a- on both sides

es, in part or in w

t to the co

until it is completely lowered.

rrectness of i

Note
l purpos

Tilting mechanism is lowered when it is moved.

nform
ercia

– Attach rear section to assembly frame ⇒ page 177 .

m

at

– Install assembly frame in vehicle ⇒ page 174 .

om

ion
c

in t
r

– Install rear glass panel ⇒ page 137 .

o

his
ate

do
riv

– Install front glass panel ⇒ page 133 .

p

cum
for

– Install sliding roof motor ⇒ page 153 .

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo

187
by lksw
cted agen
Prote 2. Panorama sliding/tilting sunroof (Arvin Meritor)
AG.
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– On completion of all work, carry out a normalisation run for all

panoramic sliding roof drives ⇒ page 131 .

2.24 Operating without current

2.24.1 Glass panel

Note

♦ In the event of power failure, front glass panel near to sliding sunroof motor can be moved by hand using a
commercially available hexagon key.
♦ Front glass panel must only be moved manually until its front edge is flush with front edge of rear glass
panel. If glass panel is moved further backwards, mechanism cables may hook off.

satelettronica
n AG. Volkswagen AG do
lkswage es n
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d ran
ir se tee
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u or
a ac
ss ce
le
un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Removing lights and front operating unit ⇒ Electrical system;

Rep. gr. 96 ; Lights and switches in roof trim .
– Using a standard hexagon key, undo the bolt -3-.
When turning by hand, greater force is necessary since motor is
not uncoupled from drive.

188 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.24.2 Sunroof sun blind

Note

In the event of power failure, sunroof sun blind can be moved by hand on sunroof sun blind motor using a
commercially available hexagon key.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

satelettronica
y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove moulded headliner ⇒ General body repairs, interior;

Rep. gr. 70 ; Roof trim .
– Using a standard hexagon key, undo the bolt -2-.
When turning by hand, greater force is necessary since motor is
not uncoupled from drive.

2.25 Cleaning water drain hoses

2.25.1 Tools
Special tools and workshop equipment required

2. Panorama sliding/tilting sunroof (Arvin Meritor) 189

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015
n AG. Volkswagen AG do
swage es n
♦ Cleaning and pull-in cableb-y VVAS
olk
6620- ot g
ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne
2.25.2 Front water drain hoses

ss o
cial p

f inform
mer

atio
om

n
c

i
or

satelettronica
thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

The front water drain hoses -1- run through the A-pillars and end
at the bulkhead cross member.
– Cleaning is done from panorama sliding roof cut-out.

190 Rep. gr.60 - Sunroof

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.25.3 Rear water drain hoses

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un

pt
an
d

The rear water drain hoses -1- are routed through the C-pillars
itte

y li

and end in the rear wheel housings.

rm

ab
pe

ility
ot

– Cleaning is done from the wheel housing. The wheel housing

wit
, is n

liner must be removed.

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
191
by c lksw
cted
2. Panorama sliding/tilting sunroof (Arvin Meritor)
agen
Prote AG.
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

63 – Bumpers
1 Front bumper

1.1 Tools
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

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tho
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ss

ce
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satelettronica
nl

pt
du

an
itte

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erm

ab
ility
ot p

♦ Torque wrench - V.A.G 1332-

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

1.2 Repairing front bumper cover

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

Note
t.
yi Co
Cop py
t. rig
If bumper cover is damaged, determine whether plastic can be
gh ht
pyri by
repaired before renewing bumper.
co Vo
by lksw
cted agen
Prote AG.

⇒ General Information; Body Repairs, General Body Repairs ;

Work procedures; Plastic repair procedure

1.3 Installing brackets for parking aid sys‐

tem - vehicles 8.2010 ►

Note

♦ Bumper covers for vehicles ► 8.2010 are supplied with holes

and brackets.
♦ The holes and brackets cannot be retrofitted.

192 Rep. gr.63 - Bumpers

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.3.1 Tools
Special tools and workshop equipment required
♦ Installation tool for PDC bracket - VAS 6614-

♦ Cartridge gun - VAS 5155-

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lkswage es n
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ir se

satelettronica
o tee
th or
au ac
ss
ce
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un

pt
an
d
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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co

1.3.2 Materials
rrectne

Note
ss o

The part numbers of the materials can be found in the “electronic

cial p

f i

parts catalogue”.
nform
mer

atio
m

♦ Cleaning solution 3) 1
o

n
c

i
or

n thi
te

sd
a

3) Observe manufacturer's instructions enclosed in the packaging.

iv

o
pr

cum
r
fo

4) Observe minimum curing period ⇒ page 196 .

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ng

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op
1.3.3 Installing brackets
C py
t. rig
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pyri by
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co lksw
by
cted agen
Prote
Note
AG.

The brackets are installed after the bumper cover has been pain‐
ted.

1. Front bumper 193

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i

satelettronica
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

The 4 markings for brackets -1- can be found on the inside of the
bumper cover.
– If there are no markings, the centre point -2- must be deter‐
mined.
– The holes must be drilled from the inside to the outside with
the drill in the tool kit -3-.

194 Rep. gr.63 - Bumpers

 AG. Volkswagen AG d
agen oes
olksw not
d by
V gu
ara Touran 2003 ➤
e nte
horis General body repairs, exterior
eo - Edition 02.2015
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

satelettronica
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Set hole punch in position with bolt head -1-, washer -2- and
thrust bearing -3- from inside bumper cover -5-.
– Screw on punch -4-, not quite as far as bumper cover.
– Press punch -4- against bumper cover.
– Tighten hole punch -1-.

Note

The punch -4- must not turn on the paint of the bumper cover.

– Pull the punch -4- through the material of the bumper cover
-5- -arrows- by turning the bolt head -1-.
– Remove hole punch and make the next holes.
– Thoroughly clean bumper cover and bracket with cleaning sol‐
ution.

1. Front bumper 195

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
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ce
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un

pt
an
d
itte

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rm

– Thoroughly clean bonding surfaces on bumper cover -4-.

ab
pe

ility
ot

– Push bracket -2- onto centring pin -1-.

wit
, is n

h re

– Pull protective foil off double-sided adhesive tape -3- on brack‐

hole

spec

et.
es, in part or in w

t to the co

– Insert centring pin -1- into hole until the bracket is touching the
bumper cover -4-.
rrectness of i

– Press bracket forcefully against bonding surface -3-.

l purpos

– Removing centring pin and repeat the procedure for all brack‐
ets.
nform
ercia

– Further work can carried out on bumper cover only after min‐
imum curing period ⇒ page 196 .
m

a
com

tio

1.3.4 Minimum curing period

n in
r
te o

thi
s
iva

Do not carry out any further work on the bumper cover or brackets
do
r

until the minimum curing period of 2 hours has expired.

rp

cum
fo

en
ng

t.
The minimum curing period must be observed so that the adhe‐
yi Co
op
sive tape can develop its full adhesive strength.
C py
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In this time, the bumper cover must remain where it is and should cop Vo
by lksw
not be moved.
cted agen
Prote AG.

196 Rep. gr.63 - Bumpers

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.4 Front bumper cover ► 10.2006

1.4.1 Assembly overview

1 - Front bumper cover

AG. Volkswagen AG d
❑ Material PP/EPDM. agen oes
olksw not
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❑ Removing ised and installing
b ara
nte
⇒ page
ut
h 197
or eo
ra
sa c
2 - Bolt s

ce
e
nl

pt
❑ Qty. 4.
du

an
itte

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❑ 1.5 Nm
erm

ab
ility
ot p

3 - Bolt

wit
, is n

❑ Qty. 2.

h re
hole

spec
❑ 6 Nm
es, in part or in w

t to the co
4 - Bolt
❑ Qty. 2.

satelettronica
❑ 6 Nm

rrectness of i
5 - Spreader rivet
l purpos

❑ Qty. 2.
nf
ercia

6 - Guide bracket orm

m

❑ Left and right.

atio
om

n in
c

7 - Bolt
or

thi
te

❑ Qty. 6 on each side.

sd
iva

o
r
rp

cu

❑ 2 Nm
o

m
f

en
ng

❑ Left and right.

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1.4.2 Removing and installing

Note

The removal and installation procedures may have to be modified

slightly depending on variations in equipment.

1. Front bumper 197

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015 agen
AG. Volkswagen AG d
oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
e

satelettronica
at

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Removing
– Remove radiator grille ⇒ page 296 .
– Remove wheel housing liners ⇒ page 272 .
– Undo and remove bolts -3- and -4-.
– From below, remove bolts -2- and -7-.
– Using a screwdriver, lever out spreader rivets -5- on left and
right.
– Disconnect connectors from all existing electrical components
and separate hoses.
– With the help of a second mechanic, pull bumper cover out of
guide brackets -6-.
Installing
Install in reverse order of removal.
– Ensure gaps are parallel and specified dimensions are main‐
tained. ⇒ Body Repairs; Rep. gr. 00 ; Body gaps/shut lines;
Body, front

198 Rep. gr.63 - Bumpers

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.4.3 Front bumper cover add-on parts

. Volkswagen AG
gen AG does
1 - Front bumper cover olks
wa not
yV gu
❑ Material PP/EPDM. ris
ed
b ara
nte
ho eo
❑ Removing and installingau
t ra
⇒ page 197 ss c

ce
e
nl

pt
2 - Bumper strip du

an
itte

y li
❑ Material PP/EPDM.
erm

ab
ility
ot p

❑ Engages in cover

wit
, is n

❑ Bumper strip can be lev‐

h re
hole

ered out of fastenings

spec
carefully from outside
es, in part or in w

using a plastic wedge

t to the co
and removed
3 - Spoiler

rrectness of i
❑ Material PC/ABS
l purpos

❑ Engages in cover.
❑ Can be removed only

satelettronica
nform
ercia

with bumper removed.

m

at
4 - Left air intake grille
om

ion
c

❑ Pull forward out of fas‐

in t
or

his
e

tenings
at

do
riv

-direction of arrow-.
p

cum
for

5 - Right air intake grille

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ng

t.
yi Co
op
❑ Pull forward out of fas‐ C py
ht. rig
tenings rig ht
py by
-direction of arrow-.
co Vo
by lksw
cted agen
Prote AG.
6 - Towing eye cap
❑ Engages in cover

1. Front bumper 199

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.4.4 Front bumper cover substructure parts

1 - Left guide
❑ Bolted to bumper carrier
2 - Bolt
❑ Qty. 3 for each bracket
❑ 2 Nm
3 - Left bracket
4 - Hexagon nut
❑ Qty. 2.
❑ 8 Nm
5 - Cross member
6 - Bolt AG. Volkswagen AG d
agen
❑ Qty. 6. olksw
oes
not
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ara
❑ 8 Nm rised
nte
ho eo
ut
7 - Right bracket

satelettronica
a ra
ss c

ce
le

8 - Right guide
un

pt
an
d
itte

❑ Bolted to bumper carrier

y li
erm

ab
9 - Expanding nut

ility
ot p

wit
is n

❑ Qty. 3.

h re
ole,

10 - Guide bracket

spec
urposes, in part or in wh

❑ Removing:
❑ On side of wing. t to the co
❑ Remove with bolts -11-.
rrectne

❑ Left and right.

s

11 - Bolt
s o
cial p

❑ Qty. 4.
inform

❑ 1.5 Nm
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

200 Rep. gr.63 - Bumpers

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.4.5 Assembly overview - bumper carrier

AG. Volkswagen AG d
agen
1 - Bumper carrier Volksw
oes
not
gu
d by ara
2 - Bolt orise nte
eo
h
ut
❑ Qty. 8. ss a ra
c
❑ 60 Nm

ce
e
nl

pt
du

an
3 - Bolt itte

y li
erm

ab
❑ Qty. 4.

ility
ot p

wit
❑ 8 Nm
, is n

h re
hole

4 - Middle foam element

spec
es, in part or in w

❑ Self-adhesive.

t to the co
5 - Left foam element
❑ Self-adhesive.

rrectness of i
6 - Right foam element
l purpos

❑ Self-adhesive.

satelettronica
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1. Front bumper 201

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.5 Front bumper cover 11.2006 ►

1.5.1 Assembly overview

Note

Minor visual differences will be encountered during removal and installation depending on version of special
models.

1 - Front bumper cover

❑ Material PP/EPDM.
❑ Removing ⇒ page 203
❑ Installing ⇒ page 204 .
2 - Bolt
❑ Qty. 3.
❑ 1.5 Nm

satelettronica
3 - Bolt
❑ Qty. 2. agen
AG. Volkswagen AG d
oes
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❑ 6 Nm by
Vol not
gu
ara
ed
is nte
4 - Bolt hor eo
aut ra
❑ Qty. 5 on each side. ss c

ce
e

❑ 6 Nm
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

202 Rep. gr.63 - Bumpers

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.5.2 Removing

Note

♦ The removal and installation procedures may have to be modified slightly depending on variations in equip‐
ment.
♦ For some repairs, it is unnecessary to remove the bumper cover completely. It is enough to loosen the bolts
and locking hooks on the side needed and pull the bumper off the guide.

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
op
– Remove radiator grille ⇒ page 298 . C py
t. rig
gh ht
yri
– Remove bolts -3, 4 and 7-.
p by
o Vo
by c lksw
cted agen
– Pull bumper cover sideways -arrows a- out of fasteners in
Prote AG.

guides -6-.
Further dismantling requires a second mechanic.
– Press locking hooks -2- downwards -arrows b- and pull bump‐
er cover -1- forwards off lock carrier -5-.
– Disconnect connectors from all existing electrical components
and separate hoses.

1. Front bumper 203

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

Instructions and work specifications for the Park Assist system

can be found in ⇒ Electrical system; Rep. gr. 94 ; Park Assist
system (PA) .
– Disconnect washer fluid hose connectors (if fitted) ⇒ Electrical
system; Rep. gr. 92 ; Headlight washer system .

1.5.3 Installing

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio

– With the help of a second mechanic, guide -arrows a- bumper

om

n in

cover -1- onto lock carrier -5- until all locking hooks -2- are
or c

completely engaged in bumper.

thi
te

sd
iva

– Press bumper cover sideways -arrows b- onto guides -6- until

r
rp

cu
o

locking hooks can be heard to engage.

f

en
ng

t.
yi Co
op
– Ensure gaps are parallel and specified dimensions are main‐ C py
ht. rig
tained. ⇒ Body Repairs; Rep. gr. 00 ; Body gaps/shut lines; rig ht
py by
Body, front
co Vo
by lksw
cted agen
Prote AG.
Further installation is performed in the reverse order of removal.
Specified torque of bolts ⇒ page 202
Instructions and work specifications for the Park Assist system
can be found in ⇒ Electrical system; Rep. gr. 94 ; Park Assist
system (PA) .

204 Rep. gr.63 - Bumpers

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.5.4 Front bumper cover add-on parts

AG. Volkswagen AG d
agen oes
olksw not
V gu
Note ed by ara
nte
ris
ho eo
ut ra
Minor visual differences will be
ss a encountered during removal and installation depending
c on version of special
models.

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
1 - Front bumper cover
ot p

wit
, is n

❑ Material PP/EPDM.

h re
hole

❑ Removing ⇒ page 203

spec
es, in part or in w

❑ Installing ⇒ page 204 .

t to the co
2 - Front bumper cover trim
❑ Only for “Cross Touran”

rrectness of i
❑ Removing ⇒ page 339
l purpos

❑ Installing ⇒ page 340 .

3 - Clip

nform
ercia

satelettronica
❑ Only for trim on “Cross
m

at
Touran”
om

ion
c

in t
4 - Left chrome strip
or

his
ate

❑ Attached to bumper

do
priv

c
strip

um
for

en
g

❑ Can only be removed

n

t.
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op
when bumper cover has C py
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removed
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5 - Left bumper strip Prote
cted AG.
agen

❑ Material PP/EPDM.
❑ Engages in cover
❑ Bumper strip can be lev‐
ered out of fastenings
carefully from outside
using a plastic wedge
and removed
6 - Left air intake grille
❑ Pull forwards out of de‐
tent.
7 - Spoiler
❑ Material PC/ABS
❑ Engages in cover.
❑ Can be removed only with bumper removed.
8 - Centre air intake grille
❑ Pull forwards out of detent.
9 - Right air intake grille
❑ Pull forwards out of detent.
10 - Right bumper strip
❑ Material PP/EPDM.
❑ Engages in cover
❑ Bumper strip can be levered out of fastenings carefully from outside using a plastic wedge and removed
11 - Right chrome strip
❑ Attached to bumper strip

1. Front bumper 205

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015
❑ Can only be removed when bumper cover has removed

1.5.5 Front bumper cover substructure parts

1 - Lock carrier
2 - Expanding nut
❑ Qty. 4 on each side.
3 - Guide bracket
❑ Removing:
❑ On side of wing.
❑ Remove with bolts -11-.
❑ Left and right.
4 - Bolt
❑ Qty. 3 for each bracket agen
AG. Volkswagen AG d
oes
olksw not
❑ 2 Nm d by V gu
ara
rise nte
5 - Foam element o

satelettronica
th eo
au ra
c
❑ Self-adhesive. ss

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nl

pt
du

6 - Bumper carrier

an
itte

y li
erm

ab
7 - Bolt

ility
ot p

❑ Qty. 2.

wit
, is n

h re
❑ 3.5 Nm
hole

8 - Bolt spec
es, in part or in w

t to the co
❑ Qty. 2.
❑ 8 Nm
rrectness of i

9 - Bolt
l purpos

❑ Qty. 2.
❑ 8 Nm
nform
ercia

10 - Bolt
m

at

❑ Qty. 2.
om

ion
c

❑ 3.5 Nm
in t
or

his
ate

11 - Cross member
do
priv

cum

❑ Pedestrian protection
for

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

206 Rep. gr.63 - Bumpers

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.5.6 Assembly overview - bumper carrier

1 - Bumper carrier
2 - Bolt
❑ Qty. 8.
❑ 60 Nm
3 - Bolt
❑ Qty. 4.
❑ 8 Nm
4 - Middle foam element
❑ Self-adhesive.
5 - Left foam element
❑ Self-adhesive.
6 - Right foam element
❑ Self-adhesive.

satelettronica
n AG. Volkswagen AG do
lkswage es n
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ir se tee
tho
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ss
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un

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itte

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ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co

1.6 Front bumper cover 08.2010 ►

rrectness

Note
o
cial p

f inform

♦ The removal and installation procedures may have to be modi‐

mer

fied slightly depending on variations in equipment.

atio
om

n
c

♦ For some repairs, it is unnecessary to remove the bumper

i
or

n thi
e

completely. It is enough to loosen the bolts and locking hooks

t

sd
va

on the side needed and pull the bumper off the guide.
i

o
pr

cum
r
fo

♦ Minor visual differences will be encountered during removal

en
ng

t.
yi Co
and installation depending on version of special models.
t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Front bumper 207

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.6.1 Assembly overview

1 - Front bumper cover

❑ Material PP/EPDM.
❑ Removing ⇒ page 209
❑ Installing ⇒ page 210 .
2 - Bolt
❑ Qty. 2.
❑ Specified torque: 2 Nm.
❑ Bolted to lock carrier.
3 - Bolt
❑ Left and right.
❑ Facing upwards, bolted
to wing
⇒ Item 8 (page 212)
❑ Specified torque: 2 Nm.
AG. Volkswagen AG d
agen oes
4 - Bolt lksw not

satelettronica
Vo gu
by ara
d
❑ Qty. 3 on each side. orise nte
th eo
❑ Specified torque: 2 Nm. s au ra
c
s
❑ Bolted to wheel housing

ce
le
un

pt
liner.

an
d
itte

y li
erm

5 - Bolt

ab
ility
ot p

❑ Qty. 3 on each side.

wit
is n

h re
❑ Specified torque: 2 Nm.
ole,

spec
❑ Bolted to lower part of
urposes, in part or in wh

wheel housing liner from

t to the co
underside
6 - Bolt

rrectne
❑ Qty. 3.
❑ Specified torque: 2 Nm. ss o
❑ Bolted to lock carrier.
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

208 Rep. gr.63 - Bumpers

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.6.2 Removing

n AG. Volkswagen AG do
lkswage es n
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u or
a ac
ss

ce
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nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re

satelettronica
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove bolts -2-.
– Remove bolts -3- (pointing upwards) on left and right of wheel
housing.
– Unscrew bolts -4- from wheel housing.
– Remove bolts -5- and -6- from below.
Further dismantling requires the help of a second mechanic.
– Pull front bumper cover -1- out of fasteners of guides on left
and right of wing -arrows a-.
– With the aid of a second mechanic, pull off front bumper cover
-1- parallel -arrows b- from vehicle.
– Remove connectors of all installed electrical components.
Notes and work sequence for Park Assist (if fitted) are located in
⇒ Electrical system; Rep. gr. 94 ; Lights, bulbs, switches - exte‐
rior; Park Assist
– Disconnect washer fluid hose connectors (if there are any) ⇒
Electrical system; Rep. gr. 92 ; Headlight washer system

1. Front bumper 209

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.6.3 Installing

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

satelettronica
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Notes on washer fluid hose connectors can be found in ⇒

Electrical system; Rep. gr. 92 ; Headlight washer system
– With the help of a second mechanic, place front bumper cover
-1- parallel -arrows a- onto lock carrier.
– Push front bumper cover -1- onto guides until both engage
-arrows b- with one another.

Note

When positioning front bumper cover, ensure it is parallel to wing.

– Ensure parallel alignment and correct shut lines of front bump‐

er cover -1- ⇒ Body Repairs; Rep. gr. 00;
Karosseriespaltmaße; Karosserie vorn
– Fit bolts -2, 3, 4, 5- and -6- in place and tighten them to the
respective specified torque ⇒ page 208

210 Rep. gr.63 - Bumpers

 n AG. Volkswagen AG do
wage es n
yV
olks ot g Touran 2003 ➤
b ua
ir se
d General body repairs, exterior ran - Edition 02.2015
tee
ho
aut or
ac
1.6.4 Front bumper cover add-on parts ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
Note

ility
ot p

wit
, is n
Minor visual differences will be encountered during removal and installation depending on version of special

h re
models.
hole

spec
es, in part or in w

t to the co
1 - Front bumper cover
❑ With radiator grille

rrectness of i
❑ Material PP/EPDM.
l purpos

❑ Removing ⇒ page 209

❑ Installing ⇒ page 210 .

nf
ercia

o
❑ Removing radiator grille

rm
m

atio
⇒ page 299
om

n in
c

2 - Left cover
or

thi
te

sd
a

❑ For headlight washing

iv

o
r
rp

cu
system
o

satelettronica
f

en
ng

❑ Instructions and work

t.
yi Co
op
specifications for the C py
t. rig
headlight washer sys‐
gh ht
yri by
tem ⇒ Electrical sys‐
cop Vo
by lksw
cted
tem; Rep. gr. 92 ; Head‐
agen
Prote AG.
light washer system
3 - Left trim panel
❑ Also with fog light
❑ Pull forwards out of de‐
tent.
4 - Spoiler attachment
❑ Engages in cover
5 - Centre air intake grille
❑ Only remove when
bumper cover -1- is re‐
moved
6 - Right trim panel
❑ Also with fog light
❑ Pull forwards out of de‐
tent.
7 - Cover
❑ For towing eye.
8 - Right cover
❑ For headlight washing system
❑ Instructions and work specifications for the headlight washer system ⇒ Electrical system; Rep. gr. 92 ;
Headlight washer system

1. Front bumper 211

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.6.5 Front bumper cover substructure parts

1 - Bumper carrier
2 - Bolt
❑ Qty. 2 on each side.
❑ Specified torque: 8 Nm.
3 - Hexagon nut
❑ Specified torque: 8 Nm.
4 - Foam element
5 - Guide bracket
❑ Removing: agen
AG. Volkswagen AG d
oes
lksw not
❑ On side of wing. byV
o gu
ara
ed
❑ Remove with bolts -6-. horis nte
eo
ut ra
❑ Left and right. ss a c

ce
le

6 - Bolt
un

pt
an
d
itte

❑ Qty. 2.

y li

satelettronica
erm

ab
❑ 2 Nm

ility
ot p

wit
is n

7 - Expanding nut

h re
ole,

❑ Qty. 2.

spec
urposes, in part or in wh

8 - Expanding nut

t to the co
❑ For bolting on front
bumper cover

rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

212 Rep. gr.63 - Bumpers

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2 Rear bumper

2.1 Tools
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783- wage
n AG. Volkswagen AG do
es n
olks ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co

satelettronica
♦ Torque wrench - V.A.G 1331-

rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
2.2 Repairing rear bumper cover
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Note

If bumper cover is damaged, determine whether plastic can be

repaired before renewing bumper.

⇒ General Information; Body Repairs, General Body Repairs ;

Work procedures; Plastic repair procedure

2.3 Installing brackets for parking aid sys‐

tem - vehicles 8.2010 ►

Note

♦ Bumper covers for vehicles ► 8.2010 are supplied with holes

and brackets.
♦ The holes and brackets cannot be retrofitted.

2.3.1 Tools
Special tools and workshop equipment required

2. Rear bumper 213

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

♦ Installation tool for PDC bracket - VAS 6614-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
♦ Cartridge gun - VAS 5155-

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

satelettronica
t to the co
rrectness of i
l purpos

2.3.2 Materials

nform
mercia

a
com

tion in
Note
r
te o

thi
s
iva

do
The part numbers of the materials can be found in the “electronic
r
rp

c
parts catalogue”.

um
fo

en
ng

t.
yi Co
op py
♦ Cleaning solution
C
5) 1 t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
5) Observe manufacturer's instructions enclosed in the packaging. Prote AG.

6) Observe minimum curing period ⇒ page 217 .

2.3.3 Installing brackets

Note

The brackets are installed after the bumper cover has been pain‐
ted.

214 Rep. gr.63 - Bumpers

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

satelettronica
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

The 4 markings for brackets -1- can be found on the inside of the
rrectness of i

bumper cover.
– If there are no markings, the centre point -2- must be deter‐
l purpos

mined.
nf

– The holes must be drilled from the inside to the outside with
ercia

the drill in the tool kit -3-.

rm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Rear bumper 215

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co

satelettronica
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Set hole punch in position with bolt head -1-, washer -2- and
thrust bearing -3- from inside bumper cover -5-.
– Screw on punch -4-, not quite as far as bumper cover.
– Press punch -4- against bumper cover.
– Tighten hole punch -1-.

Note

The punch -4- must not turn on the paint of the bumper cover.

– Pull the punch -4- through the material of the bumper cover
-5- -arrows- by turning the bolt head -1-.
– Remove hole punch and make the next holes.
– Thoroughly clean bumper cover and bracket with cleaning sol‐
ution.

216 Rep. gr.63 - Bumpers

 AG. Volkswagen AG d
agen oes
olksw not
yV gu
ed b Touran ar2003
an ➤
ris tee
th General body repairs, exterior - Edition 02.2015
o
o
au ra
c
ss

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi

satelettronica
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Thoroughly clean bonding surfaces on bumper cover -4-.

– Push bracket -2- onto centring pin -1-.
– Pull protective foil off double-sided adhesive tape -3- on brack‐
et.
– Insert centring pin -1- into hole until the bracket is touching the
bumper cover -4-.
– Press bracket forcefully against bonding surface -3-.
– Removing centring pin and repeat the procedure for all brack‐
ets.
– Further work can carried out on bumper cover only after min‐
imum curing period ⇒ page 217 .

2.3.4 Minimum curing period

Do not carry out any further work on the bumper cover or brackets
until the minimum curing period of 2 hours has expired.
The minimum curing period must be observed so that the adhe‐
sive tape can develop its full adhesive strength.
In this time, the bumper cover must remain where it is and should
not be moved.

2. Rear bumper 217

 n AG. Volkswagen AG do
lkswage es n
Vo ot g
Touran 2003 e➤ d by ua
ran
ir s
General body
tho repairs, exterior - Edition 02.2015 tee
or
au ac
ss
2.4 Rear bumper cover ▶ 07.2010

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
2.4.1 Assembly overview
ot p

wit
, is n

h re
hole

spec
Note
es, in part or in w

t to the co
Minor visual differences will be encountered during removal and installation depending on version of special
models.

rrectness of i
l purpos

1 - Rear bumper cover

❑ Material PP/EPDM.

nform
ercia

❑ Removing and installing

m

at
om

⇒ page 219

ion
c

in t
or

2 - Bolt

his
ate

do
riv

❑ Qty. 4.
p

cum
or

❑ 6 Nm
f

en
ng

t.

satelettronica
yi Co
op
3 - Spreader rivet C py
t. rig
gh ht
❑ Qty. 2. yri
p by
co Vo
by lksw
cted
4 - Bolt
agen
Prote AG.

❑ Qty. 4.
❑ 2 Nm
❑ Left and right.
5 - Guide bracket
❑ Left and right.
6 - Bolt
❑ Qty. 4.
❑ 6 Nm

218 Rep. gr.63 - Bumpers

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.4.2 Removing and installing

Note

♦ The removal and installation procedures may have to be modi‐

fied slightly depending on variations in equipment.
♦ For some repairs, it is unnecessary to remove the bumper
cover completely. It is enough to loosen the bolts and locking
hooks on the side needed and pull the bumper cover off the
guide.

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu

Removing
o

m
f

en
ng

t.
yi
– Remove tail lights ⇒ Electrical system; Rep. gr. 94 ; Lights,
Co
Cop py
bulbs, switches - exterior; Removing and installing tail lights . ht. rig
rig ht
py by
o Vo
– Remove bolts -4- in left and right wheel wells. by c lksw
cted agen
Prote AG.
– Loosen clips -3- on left and right in the wheel housings.
– Remove bolts -2- from below.
– Remove upper bolts -6-.

2. Rear bumper 219

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015
n AG. Volkswagen AG do
– Disconnect connectors from all electrical components.
olks
wage es n
ot g
byV ua
Instructions and work specifications for therisparking aid system
ed ran
tee
can be found in ⇒ Electrical system; Rep.u th gr. 94 ; Lights, bulbs,
o
or
switches - exterior; Parking aid system
ss .
a ac

ce
le
un
– With the help of a second mechanic, pull rear bumper cover

pt
an
d
out of guide brackets -5-.

itte

y li
erm

ab
Installing

ility
ot p

wit
is n

Install in reverse order of removal.

h re
ole,

spec
– Ensure gaps are parallel and specified dimensions are main‐
urposes, in part or in wh

tained. ⇒ Body Repairs; Rep. gr. 00 ; Body gaps/shut lines;

t to the co
Body, rear.

2.4.3 Rear bumper cover add-on parts ► 10.06

rrectnes
Note

s o
cial p

f inform
Minor visual differences will be encountered during removal and installation depending on version of special
mer

models.

atio
om

satelettronica
n
c

i
or

n thi
te

sd
a

1 - Rear bumper cover

iv

o
pr

cum
r

❑ Material PP/EPDM.
fo

en
ng

t.
yi
❑ Removing and installing
Co
Cop py
⇒ page 219 ht. rig
rig ht
py by
o Vo
2 - Towing eye cap by c lksw
cted agen
Prote AG.
❑ Engages in cover
3 - Spoiler
❑ Material PC/ABS
❑ Engages in cover
❑ Can be removed only
with bumper removed.

220 Rep. gr.63 - Bumpers

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015
olkswagen AG
en AG. V
2.4.4 Rear
yV
olks bumper cover add-on
wag does
not
g
parts 11.06 ►
b ua
ed ran
oris tee
th or
au
ss Note
ac

ce
e
nl

pt
du

Minor visual differences will be encountered during removal and installation depending on version of special

an
itte

models.

y li
erm

ab
ility
ot p

wit
, is n

h re
1 - Rear bumper cover
hole

spec
❑ Material PP/EPDM.
es, in part or in w

t to the co
❑ Removing and installing
⇒ page 219
2 - Towing eye cap

rrectness of i
❑ Engages in cover
l purpos

3 - Spoiler
❑ Material PC/ABS

nform
ercia

❑ Engages in cover
m

at
om

io
❑ Can be removed only

satelettronica
n
c

in t
r

with bumper removed.

o

his
ate

do
riv

4 - Reflector
p

cum
or

❑ Secured to spoiler with

f

en
ng

t.
yi
lock washers
Co
Cop py
.
❑ Can be removed only
t rig
gh ht
yri by
with bumper removed.
cop Vo
by lksw
cted agen
Prote
5 - Clip
AG.

❑ Qty. 2 on each side.

❑ Only for trim on “Cross
Touran”
6 - Front bumper cover trim
❑ Only for “Cross Touran”
❑ Removing ⇒ page 341
❑ Installing ⇒ page 342 .
7 - Retainer
❑ Qty. 2 on each side.

2. Rear bumper 221

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.4.5 Rear bumper substructure

1 - Securing strip
2 - Hexagon nut
❑ Qty. 10.
❑ 2 Nm
3 - Guide bracket
❑ Left and right.
4 - Bolt
❑ Qty. 4.
❑ 1.5 Nm
❑ Left and right.
5 - Expanding nut
❑ Qty. 4.
❑ Left and right.

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

222 Rep. gr.63 - Bumpers

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.4.6 Assembly overview - bumper carrier

1 - Cross member
2 - Foam element
❑ Self-adhesive.
3 - Bolt
❑ Qty. 7.
❑ 20 Nm

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

2.4.7 Assembly overview - bumper carrier

rrectness of i

(natural gas vehicles, vehicles with

l purpos

parking aid)
nf
ercia

DANGER!
rm
m

atio
om

n in

The bolts -4- function as plugs for the upper securing holes and
or c

seal the passenger compartment against exhaust fumes, and

thi
te

sd
a

must without exception be installed.

iv

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
Note yri
p by
o Vo
by c lksw
cted agen
Prote
This bumper carrier is fitted in natural gas vehicles and/or vehicles
AG.

fitted with parking aid.

2. Rear bumper 223

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1 - Cross member
2 - Bolt
❑ Qty. 3.
❑ 20 Nm
❑ For upper securing
holes of a cross member
not installed here.
3 - Longitudinal member
4 - Bolt
❑ Qty. 4.
❑ 50 Nm + turn 90° further
❑ Always renew bolts after
loosening.

satelettronica
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

224 Rep. gr.63 - Bumpers

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.5 Rear bumper cover 08.2010 ►

2.5.1 Assembly overview

Note

♦ Minor visual differences will be encountered during removal and installation depending on version of special
models.
n AG. Volkswagen AG do
wage es n
♦ The spreader rivet -4- may also be a screw in some
y Vvehicles.
olks ot g
ua
b
ed ran
oris tee
th or
au ac
1 - Rear bumper cover ss

ce
le
un

pt
❑ Material PP/EPDM.

an
d
itte

y li
❑ Removing ⇒ page 226
erm

ab
ility
❑ Installing ⇒ page 227 .
ot p

wit
is n

2 - Bolt

h re
ole,

spec
❑ Qty. 4.

satelettronica
urposes, in part or in wh

❑ Specified torque: 6 Nm.

t to the co
3 - Bolt
❑ Qty. 3 on each side.

rrectne
❑ Specified torque: 2 Nm.

s
❑ Bolted to wheel housing

s o
liner.
cial p

f inform
4 - Spreader rivet
mer

atio
m

❑ Left and right.

o

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Rear bumper 225

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.5.2 Removing

Note

The spreader rivet -4- may also be a bolt in some vehicles.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

satelettronica
pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Undo and remove bolts -3- on left and right in the wheel hous‐
ings.
– Loosen clips -4- on left and right in the wheel housings.
– Undo bolts -2- from below.
– Pull rear bumper cover -1- out of fasteners in lateral guides
-arrow a-.
Further dismantling requires the help of a second mechanic.
– Pull rear bumper cover -1- parallel off vehicle -arrows b-.
– Remove connectors of all installed electrical components.
Instructions and work specifications for the parking aid system
can be found in ⇒ Electrical system; Rep. gr. 94 ; Lights, bulbs,
switches - exterior; Parking aid system .

226 Rep. gr.63 - Bumpers

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.5.3 Installing

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i

– Fasten existing connectors in place.

l purpos

– Fit rear bumper cover -1- with the aid of a second mechanic
nform

-arrows a-.
mercia

a
com

tion in

Note
r
te o

thi
s
iva

do

When fitting the rear bumper cover, make sure that it runs parallel along the left and right guide profiles.
r
rp

cum
fo

en
ng

t.
– Push rear bumper cover -1- onto left and right guide profile
yi Co
op py
-4- -arrows b-, until they engage audibly. . C rig
ht ht
rig by
py
– Check that parts are parallel and gaps are even ⇒ Body Re‐
co Vo
by lksw
cted
pairs; Rep. gr. 00; Karosseriespaltmaße; Karosserie hinten .
agen
Prote AG.

– Fasten clip -4- on left and right.

– Tighten bolts -2- and -3- ⇒ page 225 .

2. Rear bumper 227

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.5.4 Rear bumper cover add-on parts

lksw
agen
AG. Volkswagen AG d
oes
n o ot g
yV ua
edb ran
ris tee
1 - Rear bumper cover aut
ho or
ac
❑ Material PP/EPDM. ss

ce
le
un

pt
❑ Removing ⇒ page 226

an
d
itte

y li
❑ Installing ⇒ page 227 .

rm

ab
pe

ility
2 - Towing eye cap ot

wit
, is n

❑ Engages in cover

h re
hole

spec
3 - Reflector
es, in part or in w

t to the co
❑ Left and right.
❑ Engages from inside in
rear bumper cover

rrectness of i
l purpos

nform
mercia

a
com

satelettronica
ion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

228 Rep. gr.63 - Bumpers

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.5.5 Rear bumper cover substructure parts

1 - Securing strip
2 - Hexagon nut
❑ Qty. 4.
❑ Specified torque: 2 Nm.
3 - Guide bracket
❑ Left and right.
4 - Hexagon nut
❑ Qty. 2.
❑ Specified torque: 2 Nm.
5 - Bolt
❑ Qty. 3.
❑ Specified torque: 1.5
Nm.
❑ Left and right.

satelettronica
6 - Expanding nut
❑ Qty. 3.
❑ Left and right.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2. Rear bumper 229

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.5.6 Assembly overview - bumper carrier

1 - Bumper carrier
2 - Bolt
❑ Qty. 4.
❑ Specified torque: 20
Nm.
3 - Bolt
❑ Qty. 2.
❑ Specified torque: 20
Nm.

satelettronica
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

230 Rep. gr.63 - Bumpers

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

3 Towing bracket

3.1 Tools
Special tools and workshop equipment required
♦ Torque wrench 5…50 Nm - V.A.G 1331-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte

satelettronica
ho eo
3.2 Assembly overview - towing bracket
ss aut ra
c

ce
le
un

pt
an
d

DANGER!
itte

y li
erm

ab
ility
ot p

The bolts -4- function as plugs for the upper securing holes and
seal the passenger compartment against exhaust fumes, and wit
is n

h re
must without exception be installed.
ole,

spec
urposes, in part or in wh

t to the co

Note
rrectne

♦ The torque specifications refer only to factory-installed towing

brackets.
ss o
cial p

♦ Request specified torques for other towing brackets from the

inform

manufacturers.
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

3. Towing bracket 231

 AG. Volkswagen AG d
agen oes
olksw not
V
Touran 2003 ➤ d by gu
ara
ise nte
General body repairs, exterior - Edition 02.2015
thor eo
au ra
ss c
1 - Towing bracket

ce
e
nl

pt
du
❑ Towing bracket with re‐

an
itte

y li
movable ball head is

erm

ab
shown in the illustration

ility
ot p

wit
, is n
2 - Ball coupling

h re
hole
❑ The removable ball

spec
hitch is stored in left-

es, in part or in w

t to the co
hand side compartment
in luggage compart‐
ment.

rrectness of i
3 - Bolt l purpos
❑ Qty. 4.
❑ 50 Nm + turn 90° further

nform
ercia

❑ Always renew bolts after

loosening.
m

at
om

ion
4 - Bolt
c

in t
or

his
e

❑ Qty. 3.
at

do
priv

c
❑ 20 Nm

um
for

en
g

❑ For upper securing

n

satelettronica
t.
yi Co
op
holes of a cross member C py
t. rig
not installed here.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

232 Rep. gr.63 - Bumpers

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

64 – Glazing
1 Flush bonded windows

1.1 Tools

Note

The removal of a bonded window is described using the Removal

kit for flush bonded windows - V.A.G 1474 A- . The respective
tools from Removal kit for flush bonded windows - VAS 6452- may
also be used.

Special tools and workshop equipment required

♦ Removal kit for flush bonded windows - V.A.G 1474 A- or Re‐
moval kit for flush bonded windows - VAS 6452-

satelettronica
♦ Suction lifter - V.A.G 1344-
♦ Cutting tool - V.A.G 1351-
♦ Windscreen removal kit - V.A.G 1755-
♦ Cartridge gun - V.A.G 1628-
♦ Cartridge heater - V.A.G 1939-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Flush bonded windows 233

 Touran 2003 ➤
. Volkswagen AG
General body repairs, exterior - Edition 02.2015kswagen AG does
n ol ot g
yV ua
edb ran
ris tee
tho or
au ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
a

satelettronica
iv

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ Electric cutter - V.A.G 1561 A-

♦ Cutting blade - V.A.G 1561/2-
♦ Cutting blade - V.A.G 1561/8-
♦ Cutting blade - V.A.G 1561/10-
♦ Cutting blade - V.A.G 1561/19-
♦ Double cartridge gun - VAS 5237-

234 Rep. gr.64 - Glazing

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

satelettronica
thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Flush bonded windows 235

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.2 Materials
♦ 2-K glass adhesive 8) 10)

♦ 1K glass adhesive 9) 11)

♦ Activator 7)

♦ Glass and paint primer 7)

♦ Cleaning solution 7)

♦ Primer applicator 7)

♦ Adhesive remover 7)

♦ Cutting cord

7) Observe instructions for use on the information sheet provided by the manu‐
facturer.

8) Observe minimum curing period ⇒ n AG. Volkswagen AG do page 251 .

lkswage es n
Vo ot g

satelettronica
9) Warm according to manufacturers instructionsdusing
by cartridge heater - V.A.G ua
ran
1939- . ir se tee
tho
u be used to apply these materials. or
10) Double cartridge gun - VAS 5237- must
a ac
ss

ce
le

11) Small cartridge, 110 ml, for sealing and/or when a 400 ml cartridge alone is
un

pt
not sufficient.

an
d
itte

y li
erm

1.3 Repairing windscreen

ab
ility
ot p

wit
is n

h re
ole,

Note

spec
urposes, in part or in wh

t to the co
Before renewing windscreen, explore possibilities of repairing
damage to glass. rrectne

Description can be found under ⇒ General Information; Body Re‐

pairs, General Body Repairs ; Work procedures; Glass repair .
ss

1.4 Assembly overview - windscreen

o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

236 Rep. gr.64 - Glazing

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1 - Windscreen
❑ Removing windscreen
⇒ page 240 .
❑ Installing windscreen
⇒ page 241 .
2 - Plenum chamber cover
❑ Must be removed from
windscreen seal by
hand only.
❑ Removing plenum
chamber cover
⇒ page 239 .
❑ Installing plenum cham‐ . Volkswage
AG
ber cover ⇒ page 240
ksw
agen.
n AG d
oes
n ol ot g
yV ua
3 - Windscreenisseal
ed
b ran
or tee
❑ Is part
au of windscreen.
th or
ac
ss
4 - Windscreen adjuster

ce
e
nl

pt
du

❑ 443 845 631 A

an
itte

y li
erm

ab

satelettronica
5 - PUR adhesive sealant

ility
ot p

❑ Cross section of bead:

wit
, is n

width = 7 mm, height =

h re
hole

11 mm (including pre‐

spec
coating, residual materi‐
es, in part or in w

t to the co
al on window glass and
window flange)
❑ Minimum curing period
rrectness of i

⇒ page 251 .
l purpos

6 - Water deflector
7 - Dimension a = 3.5 mm
nform
ercia

❑ Top and sides

m

at
om

8 - Sealing lip
on
c

in t
or

❑ If sealing lip is damaged

his
te

when it is cut out, a new windscreen must be installed.

a

do
priv

cum
or

9 - Windscreen adjuster
f

en
ng

t.
yi
❑ 443 845 631 A
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1. Flush bonded windows 237

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.5 Assembly overview - plenum chamber cover

1 - Plenum chamber cover

❑ Removing ⇒ page 239
❑ Installing ⇒ page 240 .
2 - Windscreen
3 - Plenum chamber bulkhead
4 - Seal
5 - Windscreen seal

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

y li

satelettronica
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

238 Rep. gr.64 - Glazing

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.5.1 Removing plenum chamber cover

n AG. Volkswagen A age G do
ksw es n
y Vol ot g
ua
b
ed ran
oris tee
th or
au ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

satelettronica
m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wiper

system; Removing and installing windscreen wiper system .
– Pull seal -4- off entire length of plenum chamber bulkhead
-3-.
– Beginning on right, carefully pull plenum chamber cover -1-
upwards out of windscreen seal -5-.

1. Flush bonded windows 239

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.5.2 Installing plenum chamber cover

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
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nl

pt
du

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itte

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erm

ab

satelettronica
ility
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wit
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
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orm
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or c

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te

sd
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rp

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en
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t.
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Cop py
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gh
– Spray windscreen seal -5- with a soapy solution so that the
ht
pyri by
Vo
o
plenum chamber cover -1- can be inserted more easily. by c lksw
cted agen
Prote AG.
– Position plenum chamber cover -1- on windscreen seal -5- and
clip it into windscreen seal beginning in the middle using light
pressure.
– Install seal -4- and windscreen wiper.

Note

An insert is installed in windscreen seal of new windscreens. Remove this insert before installing plenum
chamber cover.

1.6 Removing windscreen

– Remove A-pillar trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Trims, insulation; Pillars and side trims .
– Remove left and right sun visors ⇒ General body repairs, in‐
terior; Rep. gr. 68 ; Interior equipment; Compartments, covers
and trims .

240 Rep. gr.64 - Glazing

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Remove interior mirror ⇒ General body repairs, interior; Rep.

gr. 68 ; Interior equipment; Interior mirror .
– Starting at bonnet end, pull left and right water deflectors out
of retaining strip on A-pillar ⇒ Item 1 (page 307)
– Slide protective foil - V.A.G 1474/8- between windscreen -1-
and dash panel.
– Pull cutting cord -3- through adhesive sealing material into in‐
side of vehicle using awl - V.A.G 1474/2- -2-.

n AG. Volkswagen AG d
– Secure inside end of cutting cord against falling
olks
out
wageusing pull oes
not
handle - V.A.G 1351/1- -3-. db
y V gu
ara
e nte
ris
– Insert cutting cord -2- into window flange
ho with aid of tube -1-. eo

satelettronica
ut a ra
ss c
– Loosen sealing lip in upper area of windscreen with a plastic

ce
e
nl

wedge and spray in cleaning solution D 009 401 04 (as sub‐

pt
du

an
stitute for lubricant).
itte

y li
erm

ab
– If gap is too small, guide cutting cord further on outside and

ility
ot p

push under lip with plastic wedge.

wit
, is n

h re
– Place cutting cord along periphery of window.
hole

spec
es, in part or in w

– Ensure that cutting cord lies under window in corners.

t to the co
– Secure other end of cord to reel device - V.A.G 1654 A- .

rrectness of i
– Position reel device - V.A.G 1654 A- in “position I”.
l purpos

– Reposition reel device - V.A.G 1654 A- as necessary and cut

window free.

nform
ercia

– Use wedge to press cutting cord against window glass while

cutting in order to have clearance at window flange and dash
m

at
om

panel.
on
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
1.7 Installing windscreen
gh ht
pyri by
Vo
o
by c lksw
cted
Preparing old undamaged window for glazing ⇒ page 248
agen
Prote AG.

Preparing new window for glazing ⇒ page 248

Preparing body flange for glazing ⇒ page 250
Installation instructions ⇒ page 251
Minimum curing period ⇒ page 251

1.8 Assembly overview - rear window

1. Flush bonded windows 241

 agen AG olksw
Touran 2003 ➤ wage
n AG. V does
olks not
General body repairs,dexterior
by
V - Edition 02.2015 gu
a
e ran
ris tee
1 - Rear window utho or
a ac
ss
❑ Removing rear window

ce
e
nl
⇒ page 242 .

pt
du

an
itte

y li
❑ Installing rear window
erm

ab
⇒ page 243 .

ility
ot p

wit
, is n

2 - Seal

h re
hole

❑ For rear window wiper.

spec
es, in part or in w

3 - Spacing lip

t to the co
❑ Part of window.
❑ Application surface for

rrectness of i
PUR adhesive sealant.
l purpos

4 - Rear lid
5 - PUR adhesive sealant

nform
ercia

❑ Cross section of bead:

m

width = 6.5 mm, height =

at
om

io
10 mm (including pre‐

n
c

in t
r

coating, residual materi‐

o

his
te

al on window glass and

a

do
riv

window flange).
p

satelettronica
um
for

en
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❑ Minimum curing period

n

t.
yi Co
⇒ page 251 . t. Cop py
rig
gh ht
yri
6 - Trim p by
co Vo
by lksw
❑ Remove trim ⇒ General
cted agen
Prote AG.
body repairs, interior;
Rep. gr. 70 ; Trim, insu‐
lation; Rear lid trim/insu‐
lation .
7 - Window heater contact

1.9 Removing undamaged rear window

– Remove rear lid trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Trims, insulation; Luggage/load compartment trims .
– Pull off connections for heated rear window and press con‐
necting tabs onto window.
– Remove rear window wiper motor ⇒ Electrical system; Rep.
gr. 92 ; Repairing rear window wipe and wash system .
– Push trimming needle -2- from windscreen removal kit - V.A.G
1755- through adhesive bead using handle -1-.
Look for a place where the gap is the largest. Protect the paint‐
work at this place from damage.
– Unscrew handle -1- and thread cutting cord through eye of
needle.
– Pull trimming needle with cutting cord into interior. Use pliers
and gloves.

242 Rep. gr.64 - Glazing

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Secure end of cutting cord against falling out using handle

-1-.
– Lay cutting cord -3- around window and guide second end of
cord inwards into interior.

– Secure end of cord to reel device - V.A.G 1654- -2-.

– Position reel device - V.A.G 1654- -2- in “position I”.
– Reposition reel device - V.A.G 1654- -2- as necessary and cut
window free.
. Volkswage
– Secure end of cutting wcord
agen against fallingAG
AG n
out
doeusing
s no handle
-1-. Volks t gu
by a d ran
ise

satelettronica
– Use plastic ut
howedge to press cutting cord -3- against window
r tee
o
glass while
ss
a cutting in order to have clearance at window r ac
flange. ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

1.10 Removing broken rear window

wit
, is n

h re

– Protect body and interior from glass splinters.

hole

spec
es, in part or in w

– Remove pieces of glass up to adhesive sealing material.

t to the co

– Pull off connections for rear window heating and aerial.

– Cover flange -2- all round with textile-reinforced adhesive
rrectness of i

tape.
l purpos

– Cut through adhesive seal (with glass remains) in window cut-

out using electric cutter - V.A.G 1561 A- and U-shaped blade
nform
ercia

- V.A.G 1561- .
m

at
om

io

WARNING
n
c

in t
or

his
ate

Always wear safety goggles and leather gloves.

do
priv

cum
for

en
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t.
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Cop py
ht. rig
rig ht
py by
1.11 Installing rear window
co Vo
by lksw
cted agen
Prote AG.
Preparing old undamaged window for glazing ⇒ page 248
Preparing new window for glazing ⇒ page 249
Preparing body flange for glazing ⇒ page 250
Installation instructions ⇒ page 251
Minimum curing period ⇒ page 251

1.12 Assembly overview - rear side window

1. Flush bonded windows 243

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015
n AG. Volkswagen AG do
1 - Side window lkswage es n
o ot g
❑ Removing side window byV ua
d ran
⇒ page 245 . ir se tee
tho
u or
❑ Installing side window ss
a ac
⇒ page 247 .

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e
nl

pt
du

an
2 - Seal with spacing lip

itte

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erm

ab
❑ Part of side window.

ility
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wit
3 - C-pillar trim
, is n

h re
hole

❑ Removing C-pillar trim

spec
es, in part or in w

4 - Retaining clip

t to the co
❑ Qty. 3.
❑ Part of side window.

rrectness of i
5 - Locating pin
l purpos

❑ Qty. 2.
❑ Holds side window in in‐

nform
ercia

stallation position.
m

at
6 - PUR adhesive sealant
om

io

satelettronica
n
c

❑ Cross section of bead:

in t
or

his
e

width = 7 mm, height =

at

do
riv

12 mm (including resid‐
p

cum
or

ual material on window

f

en
g

glass and window

n

t.
yi Co
op
flange) C py
t. rig
gh ht
yri
❑ Minimum curing period p by
co Vo
⇒ page 251 .
by lksw
cted agen
Prote AG.

244 Rep. gr.64 - Glazing

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.13 Removing undamaged rear side window

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
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ce
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nl

pt
du

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itte

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erm

ab
ility
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wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
– Loosen luggage compartment trim in upper area ⇒ General
l purpos

body repairs, interior; Rep. gr. 70 ; Trims, insulation; Luggage

compartment trim
nf
ercia

– Remove upper D-pillar trim ⇒ General body repairs, interior;

rm
m

Rep. gr. 70 ; Trim, insulation; Pillar trim .

atio
om

n in
c

– Detach C-pillar trim ⇒ General body repairs, interior; Rep. gr.

or

thi

70 ; Trim, insulation, pillar trim: Detaching C-pillar trim from

te

sd
iva

fastenings
o
r
rp

cu
o

m
f

– Depending on vehicle equipment, disconnect connectors

en
ng

t.
yi
-1 and 2-.
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1. Flush bonded windows 245

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
– Push C-pillar trim -1- to rear -arrow a- and lever C-pillar trim
ot p

wit
out of clips -2- -arrow b-.
, is n

h re
hole

– Separate sealing lip from window flange all around and spray

spec
in cleaning solution D 009 401 04 (as substitute for lubricant).
es, in part or in w

– Pull end of cutting cord -1- through adhesive sealant into inside t to the co
of vehicle using awl - V.A.G 1474/2- . rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

246 Rep. gr.64 - Glazing

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Secure inside end of cutting cord against falling out using pull
handle - V.A.G 1351/1- -2-.
– Place cutting cord -3- around side window.
– Guide cutting cord -3- between sealing lip and window flange
using tube -1-. wage
n AG. Volkswagen AG do
es ks not
Vol gu
d by ara
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utho eo
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pt
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d
itte

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ab
pe

ility
ot

– Secure other end of cord to reel device - V.A.G 1654 A- and

wit
, is n

cut window free, repositioning reel device as necessary.

h re
hole

spec
– One suction cup can be removed from the reel device - V.A.G
es, in part or in w

1654 A- as shown in figure. This ensures that the reel device

t to the co
roller can be guided closer to the window flange.

rrectness of i

satelettronica
l purpos

nform
mercia

a
com

tion in
r

1.14 Removing broken rear side window

te o

thi
s
iva

do
r

A broken side window is removed in much the same way as a

rp

cum
fo

broken rear window.

en
ng

t.
yi Co
op
1.15 Installing rear side window
C py
t. rig
gh ht
pyri by
Vo
o
Preparing used undamaged window for glazing ⇒ page 248
c by lksw
cted agen
Prote AG.
Preparing new window for glazing ⇒ page 248
Preparing body flange for glazing ⇒ page 250
Installation instructions ⇒ page 251
Minimum curing period ⇒ page 251

1. Flush bonded windows 247

 Touran 2003 ➤ AG. Volkswagen AG d
agen oes
General body repairs, exterior - Edition 02.2015 Volksw not
gu
by ara
d
rise nte
1.16 Preparing old undamaged window for tho eo
au ra
s c
glazing s

ce
le
un

pt
an
d
itte

y li
erm

ab
Note

ility
ot p

wit
is n
♦ If an undamaged windscreen is being re-used, cut back the

h re
ole,
residual adhesive sealant material to 1 to 2 mm shortly before

spec
urposes, in part or in wh
bonding it back in. Cut back 2 mm; do not damage primer and

t to the co
ceramic coating when doing this.
♦ Remaining material serves as adhesion base for newly ap‐
plied adhesive sealing compound.

rrectness
WARNING

o
cial p

f inform
Do not prime bonding surface and do not treat with a cleaning
mer

solution. Keep bonding surface free of dirt and grease.

atio
om

n
c

i
or

n thi
te

sd
a

Exception: If bonding is not performed immediately after cutting

v

satelettronica
i

o
pr

c
back, the remaining residual material must be activated with ac‐

um
r
fo

tivator.

en
ng

t.
yi Co
Cop py
t. rig
1.17 Preparing new window without precoat‐
gh ht
pyri by
Vo
co lksw
by
ing for glazing cted agen
Prote AG.

No replacement part windows except for rear window are pre‐

coated. Only the PUR sealing lip -1- and the spacing lip -2- have
been sprayed onto these windows -3-.
1 - Sealing lip
2 - Spacing lip
3 - Window glass

Note

The area on which the adhesive bead is applied is not precoated

or primed.

– Clean a 20 mm wide strip all around edge of window using

cleaning solution.
– Then rub edge of window dry using a lint free cloth.

WARNING

Ceramic coating on window is not primer! It must be primed

before application of adhesive sealing compound! Use only
glass/paint primer D 009 200 02!

248 Rep. gr.64 - Glazing

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Now apply glass/paint primer -2- using applicator -1- evenly in

one stroke.
♦ Drying time approx. 10 minutes

1.18 Preparing new window with precoating

satelettronica
for glazing
A replacement part rear window is precoated. A PUR application
area for the adhesive bead is sprayed onto this window.
– Rub over the precoating with a dry lint-free cloth.

WARNING

Do not prime precoating and do not treat with cleaning agent.

AG. Volkswagen AG d
agen oes
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– Now, evenly d byand
V in one stroke, apply thin coat guof activator
ara
-2- using orisapplicator
e
-1-. nte
eo
th
u ra
Allow activator
ss a
to 'flash off' for approx. 10 minutes. c
ce
e
nl

pt
du

an
itte

y li

Note
erm

ab
ility
ot p

Activator must not come in contact with paint, or the paintwork will
wit
, is n

be damaged.
h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Flush bonded windows 249

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.19 Preparing body flange for glazing

– Cut back remaining material on body flange with u-shaped
blade - V.A.G 1561/3- , but do not remove completely.

Note n AG. Volkswagen AG do

lkswage es n
o ot g
byV ua
Remaining material serves as adhesion base for ir se newly applied
d ran
tee
adhesive sealing compound. Keep bonding usurfaces
tho free of dirt or
and grease. ss
a ac

ce
e
nl

pt
du

an
itte

y li
WARNING
erm

ab
ility
ot p

wit
Activator must not have contact with paint or the paintwork will
, is n

h re
be damaged.
hole

spec
es, in part or in w

t to the co
Exception: If bonding is not performed immediately after cutting
back, the remaining residual material must be activated with ac‐
tivator.

rrectness of i

satelettronica
♦ If the window flange has been repaired or partially renewed,
l purpos

the area concerned must be cleaned and primed again after

painting.

nform
mercia

at
Note
om

ion
c

in t
or

It is possible that a laser weld seam lies outside the area of the

his
ate

adhesive bead. In this case, the exposed weld seam must be

do
priv

c
sealed with glass adhesive before bonding the window.

um
for

en
ng

t.
yi Co
Cop py
. rig
– If laser weld seam -3- on panel flange -4- is not covered by
t
gh ht
yri by
existing adhesive bead -1-, coat laser weld seam -3- with cop Vo
by lksw
glass/paint primer -3- and fill laser weld seam with 1-pack cted agen
Prote AG.
glass adhesive -1-.

250 Rep. gr.64 - Glazing

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.20 Installation instructions

– Apply adhesive sealant all around window keeping at right an‐
gles to window.

WARNING
n AG. Volkswagen AG do
lkswage es n
Window must bedinstalled
by
Vo within 10 minutes, or adhesive
ot g
ua prop‐
erties of glassorisadhesive
e will be impaired. ran
tee
th or
au ac
ss

ce
le

♦ With help of two suction lifters (V.A.G 1344) install glass panel
un

pt
in window cut-out, centre and press in to spacing lip.

an
d
itte

y li
rm

ab
♦ Sizes of windscreen gaps ⇒ page 236 .
pe

ility
ot

wit
♦ Secure windscreen during minimum curing period with window
, is n

h re
adjusters (443 845 631 A).
hole

spec
♦ It is absolutely necessary to install the plenum chamber cover
es, in part or in w

t to the co
as described on page ⇒ page 238 .
♦ Replace stickers (e.g. for airbag) which may be installed.

rrectness of i

satelettronica
♦ Insert rubber seal for rear window wiper motor drive shaft into
rear window.
l purpos

♦ Sizes of rear window gaps ⇒ page 241 .

nform
ercia

♦ The activator must not come into contact with the window
heater bus bar.
m

a
com

tion in

♦ Marks have been made to the left and right on the rear window
r
te o

thi

to aid in applying adhesive material.

s
iva

do
r

♦ The sides of the rear window must not project above the con‐
rp

cum
fo

tour of the rear lid under any circumstances!

en
ng

t.
yi Co
op
♦ Secure rear window glass in position with adhesive tape dur‐
C py
t. rig
gh
ing minimum curing process.
ht
pyri by
Vo
co lksw
by
♦ If the adhesive bead is too thick and the adhesive expands cted agen
Prote AG.
onto the area of the window heater the excess adhesive must
be removed.

1.21 Minimum curing period

WARNING

Special standards must be adhered to when replacing bonded

windows. One of these standards is, for example, that a freshly
bonded windscreen must comply with the safety requirements,
even in an accident, following the minimum prescribed curing
period.

The minimum curing period for 2-component adhesive is 2 hours

for all windows.
Minimum curing period is the time from bonding the window until
vehicle may be used. During this time, the vehicle must stand on
a level surface at room temperature (at least 15 °C).

WARNING

Vehicle is safe to use only after the curing period is completed.

1. Flush bonded windows 251

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.22 Touching up paint damage

If paintwork is damaged, paint structure must be restored accord‐
ing to specifications in “Paint” workshop manual.

1.23 Cleaning off excess adhesive sealing

material
– Adhesive remover is recommended as a cleaning solution.
Observe the appropriate safety precautions when performing
this work.

WARNING

When cleaning freshly installed glass from the inside in the ve‐
hicle, do not press glass outwards.

– First clean painted surface as much as possible using a dry

cloth. Remove residual traces with adhesive remover.
– Cleaning plastic trim: allow adhesive sealant to cure (approx.
one hour) and then peel off.

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

252 Rep. gr.64 - Glazing

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2 Front door window

2.1 Tools
Special tools and workshop equipment required
♦ Torque wrench 2…10 Nm - V.A.G 1783-

satelettronica
♦ Torque wrench 5…50 Nm - V.A.G 1331-

n AG. Volkswagen AG do
lkswage es n
o ot g
2.2 Assembly overview
ir se
d byV ua
ran
tee
tho
u or
a ac
ss
Note
ce
e
nl

pt
du

an
itte

y li

The right side is shown. The left side is similar.

erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Front door window 253

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1 - Door window
❑ Removing and installing
⇒ page 255
2 - Window channel
❑ Pushed onto flange.
❑ Removing and installing wage
n AG. Volkswagen AG do
es n
s
⇒ page 259 yV
olk ot g
ua
d b ran
3 - Cross-head screw ir se tee
tho
u or
❑ Qty. 2. ss
a ac

ce
e

❑ 2 Nm
nl

pt
du

an
itte

y li
4 - Trim
erm

ab
❑ Removing ⇒ page 259

ility
ot p

wit
, is n

5 - Spring clip

h re
hole

❑ Qty. 2.

spec
es, in part or in w

t to the co
6 - Window slot outer seal
❑ Pushed onto flange.
❑ Removing ⇒ page 259

rrectness of i

satelettronica
7 - Spacer
l purpos

❑ Between door and trim.

nf
ercia

8 - Window slot inner seal

orm
❑ Pushed onto flange.
m

atio
om

n in
9 - Bolt
or c

thi
e

❑ For door lock

t

sd
iva

o
r
rp

❑ Qty. 2. cu
o

m
f

en
ng

❑ 20 Nm
t.
yi Co
Cop py
10 - Door
t. rig
gh ht
pyri by
❑ Removing and installing
co Vo
by lksw
cted
⇒ page 70
agen
Prote AG.

❑ Adjusting ⇒ page 72
11 - Assembly carrier
❑ Removing and installing ⇒ page 74
❑ Window regulator is part of assembly carrier
❑ Window regulator motor is bolted to assembly carrier from in front.
12 - Clamping brackets
❑ Qty. 2.
13 - Bolt
❑ Qty. 2.
❑ 8 Nm
14 - Cover
❑ Qty. 2.
15 - Bolt
❑ Qty. 10.
❑ 8 Nm
16 - Bolt
❑ Qty. 3.
❑ 8 Nm
❑ For retaining bracket.

254 Rep. gr.64 - Glazing

 n AG. Volkswagen AG do
lkswage es n
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ir se
tho tee
or Touran 2003 ➤
u
ss
a
General abody c repairs, exterior - Edition 02.2015

ce
e
nl

pt
du
17 - Connector

an
itte

y li
❑ On A-pillar.
erm

ab
ility
ot p

18 - Mounting bracket

wit
, is n

h re
❑ Removing ⇒ page 258
hole

spec
19 - Window regulator motor
es, in part or in w

t to the co
❑ Removing and installing ⇒ page 258
20 - Window regulator

rrectness of i
❑ Part of assembly carrier.
l purpos

21 - Textile adhesive tape

❑ Dimensions: 250 mm x 20 mm

nform
mercia

at
om

io
2.3 Removing and installing door window

n
c

in t
or

his
ate

do
priv

cum
or

Note
f

en
ng

t.
yi Co
op
Removal and installation are described only for the right door
py

satelettronica
t. C rig
gh
window. The removal and installation of the left door window is
ht
pyri by
Vo
o
similar.
c by lksw
cted agen
Prote AG.

2. Front door window 255

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.3.1 Removing

n AG. Volkswagen AG do
lkswage es n
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d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

satelettronica
spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove front door trim ⇒ General body repairs, interior; Rep.

gr. 70 ; Trim, insulation; Door trims .
– Lever out cover caps -3-.
– Lower door window until clamping bolts -1- for door window
are accessible.
– Loosen bolts -1- (do not remove) and press clamping brackets
-2- apart.

Note

If the work step cannot be carried out because there is a fault with the electric window motor, remove motor to
slide window down.

256 Rep. gr.64 - Glazing

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Lift rear of door window and swing out of door forwards, in

-direction of arrow-.

2.3.2 Installing
– Insert door window -1- in door in -direction of arrow-. Ensure
that door window is properly located in window channel.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
o

satelettronica
th or
au ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Front door window 257

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
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tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness

satelettronica
o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Press door window -1- into window channel -arrow- and tight‐
en clamping bolts -3- (Qty. 2) to a torque of 8 Nm.
– Then perform remaining installation in reverse order of remov‐
al.

2.4 Removing and installing window regula‐

tor motor

2.4.1 Removing
– Remove front door trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Trim, insulation; Door trims .
– Remove bolts -1- (Qty. 3) and remove retaining bracket -2-.

258 Rep. gr.64 - Glazing

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Secure door window against sliding down with adhesive tape.

– Disconnect all connectors -3-.
– Remove the three bolts -2-.
– Remove window regulator motor with control unit -1- from as‐
sembly carrier.

AG. Volkswagen AG d
agen oes
olksw not
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2.4.2 Installing ise nte
or eo
h
aut ra
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ce
e

WARNING
nl

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itte

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erm

If a new window regulator motor is installed (door control unit),

ab
ility
the additional functions and the excess force limitation feature
ot p

wit
have to be coded!
, is n

h re

satelettronica
hole

spec
es, in part or in w

– Position window regulator motor and gently pull door window

t to the co
up and down to facilitate motor and cable drum toothing inter‐
mesh.

rrectness of i
Specified torque: window regulator motor bolts 3.5 Nm
l purpos

– Secure connectors -3-.

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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rp

cu
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m
f

– Install mounting bracket -2-.

en
ng

t.
yi Co
op
Specified torque: bolts -1-, mounting bracket (8 Nm)
C py
t. rig
gh ht
yri by
For the new window regulator motor
op Vo
by c lksw
cted agen
Prote AG.
– A new window regulator motor is coded using vehicle diagno‐
sis, testing and information system - VAS 5051 A- .
For all window regulator motors
– Allow window regulators to move up onto stop once automat‐
ically. Then pull switch again for 2 seconds. This programs the
upper stop for the window regulator motor.
– Then perform remaining installation in reverse order of remov‐
al.

2.5 Removing and installing window chan‐

nel

Note

♦ Removal and installation is described only for the right window

channel. The removal and installation of the left window chan‐
nel is similar.
♦ Do not bend the window slot seal when lifting off!

2. Front door window 259

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.5.1 Removing

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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tho eo
au ra
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pt
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d
itte

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rm

ab
pe

ility

– Remove exterior mirror ⇒ page 282

ot

wit
, is n

– Remove door window ⇒ page 255

h re
hole

spec

– Lift window slot seal -4- carefully and evenly upwards off door
es, in part or in w

flange.
t to the co

– Pull window channel -3- out of mounting.

rrectness of i

– Remove screws -2- and pull trim -1- towards B-pillar

-direction of arrow-.
l purpos

– Pull window channel -3- all round off door flange.

nform
ercia

2.5.2 Installing
m

a
com

Install in reverse order of removal.

tion in
r
te o

Specified torque for bolts -2- 2 Nm.

thi
s
iva

do

• Test function before installing door trim.

r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

260 Rep. gr.64 - Glazing

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

Note

To prevent wind noise, ensure window channel seats evenly

when installing.

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
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ce
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nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2. Front door window 261

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

3 Rear door window

swa
gen AG
. Volkswagen AG
does
k not
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e nte
ris
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3.1 Tools ss
au ra
c

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e

Special tools and workshop equipment required

nl

pt
du

an
itte

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♦ Torque wrench 2…10 Nm - V.A.G 1783-
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm

satelettronica
m

♦ Torque wrench 5…50 Nm - V.A.G 1331-

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

3.2 Assembly overview

Note

The right side is shown. The left side is similar.

262 Rep. gr.64 - Glazing

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1 - Door window
❑ Removing ⇒ page 264
2 - Spring clip
AG. Volkswagen AG d
❑ Qty. 2. agen oes
olksw not
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d by ara
3 - Trim orise nte
h eo
❑ Removing ⇒ page 268 aut ra
ss c

ce
le
4 - Bolt
un

pt
an
d
❑ Qty. 2.
itte

y li
rm

ab
❑ 2 Nm
pe

ility
ot

wit
5 - Window channel
, is n

h re
hole

❑ With window.

spec
es, in part or in w

❑ Pushed onto flange.

t to the co
❑ Removing and installing
⇒ page 268

rrectness of i
6 - Window glass
l purpos

❑ Part of widow channel.

satelettronica
7 - Middle frame

nform
ercia

❑ Removing and instal‐

ling.
m

a
com

tion in
8 - Window slot outer seal
r
te o

thi
❑ Pushed onto flange.

s
iva

do
r
rp

c
9 - Window slot inner seal

um
fo

en
ng

❑ Pushed onto flange.

t.
yi Co
Cop py
t. rig
10 - Bolt opyri
gh by
Vo
ht

❑ For middle frame. by c lksw

cted agen
Prote AG.
❑ Qty. 2.
❑ 6 Nm
11 - Bolt
❑ For door lock
❑ Qty. 2.
❑ 20 Nm
12 - Door
❑ Removing and installing ⇒ page 98
❑ Adjusting ⇒ page 100
13 - Clamping bracket
14 - Spreader pin
❑ For securing door window
15 - Spreader plug
❑ For securing door window
16 - Cover
17 - Bolt
❑ Qty. 11.
❑ 8 Nm
18 - Window regulator motor
❑ Removing and installing ⇒ page 266

3. Rear door window 263

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

19 - Bolt
❑ Qty. 3.
❑ 3.5 Nm
❑ For crank drive or motor of window regulator
20 - Assembly carrier
❑ Removing and installing ⇒ page 102
❑ Window regulator is part of assembly carrier
21 - Crank drive for window winder handle
❑ Bolted to front of assembly carrier. agen
AG. Volkswagen AG d
oes
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3.3 Removing and installing door window ss au ra
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pt
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d
itte

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Note
erm

ab
ility
ot p

Removal and installation are described only for the right rear door

wit
is n

window. The removal and installation of the left rear door window

h re
ole,

is similar.

satelettronica
spec
urposes, in part or in wh

t to the co
3.3.1 Removing
– Remove rear door trim ⇒ General body repairs, interior; Rep.

rrectne
gr. 70 ; Trims, insulation; Door trims .
– Lever out caps -4-.

ss o
cial p

f
– Lower door window until spreader pin -2- and spreader plug

inform
-3- in cut-out of window regulator is accessible.
mer

atio
om

n
c

i
or

n
Note

thi
te

sd
iva

o
r

If the work step cannot be carried out because there is a fault with
p

cum
r
fo

the electric window motor, remove motor to slide window down.

en
ng

t.
yi Co
Cop py
t. rig
– Screw a 5 mm bolt (approx. 70 mm long) into the spreader pin
gh ht
yri by
-3- and pull out from spreader plug -2-.
cop Vo
by lksw
cted agen
Prote AG.
– Screw an 8 mm bolt (approx. 80 mm long) into spreader plug
-2-.

Note

Do not exert too great a pressure on the plug because otherwise

the plug will fall into the door.

– Pull spreader plug -2- out of window regulator guide -1- and
therefore out of door window.

264 Rep. gr.64 - Glazing

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Grip window slot inner seal -1- with pliers -2-. Then move pliers
in -direction of arrow- while simultaneously lifting window slot
seal -1- upwards from door flange.
– Use plastic wedge -3- to aid removal of window slot seal with
pliers.

AG. Volkswagen AG d
agen oes
olksw not
V gu
by
– Pull window channel -3- out of middle frame -1-risand
ed guide ara
nte
window channel outwards ut
ho eo
ra
s a c
– Remove bolts -2- and push middle frame -1- downwards s

ce
e
nl
-arrow a- until upper end of middle frame appears out of win‐

pt
du

an
dow frame.
itte

y li
erm

ab
– Then pull upper part of middle frame -1- off seal of fixed win‐

ility
ot p

dow and upwards -arrow b- out of window slot.

wit
, is n

h re

satelettronica
hole

spec
es, in part or in w

t to the co
rrectness of i
– Lift door window -5- upwards -arrow- towards inside of vehicle
and out of window slot.
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

3.3.2 Installing

Note

♦ For clarity the assembly carrier is not shown in the figure.

♦ When installing door window, always renew spreader plug and
spreader pin.
♦ Before inserting spreader plug -2- and spreader pin -1-, check
window -3- for damage.

3. Rear door window 265

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Centre spreader plug -2- and install when window -3- is re‐
moved.
– Press spreader pin -1- flush into spreader plug -2-.
– Guide door window -3- into door and insert door window into
slot of window regulator -4-.
– With light pressure from above -arrow-, engage window -3- in
window regulator -4-.
. Volkswagen AG
gen AG does
– Then perform remaining installation in reverse order of remov‐ Volkswa not
gu
al. ed
by ara
nte
ris
ho eo
• Test function before installing door trim. aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
3.4 Removing and installing window regula‐

satelettronica
tor motor

rrectness of i
l purpos

Note

The removal and installation sequence is only for the right window

nform
ercia

regulator motor. The removal and installation of the left window

m

a
regulator motor is similar.
com

tion in
r
te o

thi
3.4.1 Removing

s
iva

do
r
rp

cum
– Removing door trim ⇒ General body repairs, interior; Rep. gr.
fo

en
ng

70 ; Trims, insulation; Door trims .

t.
yi Co
Cop py
t. rig
– Secure door window against sliding down with adhesive tape. opyri
gh by
Vo
ht
by c
– Remove the three bolts -3-.
lksw
cted agen
Prote AG.
– Disconnect connector -2-.
– Remove window regulator motor with control unit -1- from as‐
sembly carrier.

3.4.2 Installing
– Position window regulator motor and gently pull door window
up and down to facilitate motor and cable drum toothing inter‐
mesh.
Specified torque: window regulator motor bolts 3.5 Nm
For the new window regulator motor
– A new window regulator motor is coded using vehicle diagno‐
sis, testing and information system - VAS 5051 A- .
For all window regulator motors
– Allow window regulators to move up onto stop once automat‐
ically. Then pull switch again for 2 seconds. This programs the
upper stop for the window regulator motor.

266 Rep. gr.64 - Glazing

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Then perform remaining installation in reverse order of remov‐

al.

3.5 Removing and installing window slot

outer seal

Note

The removal and installation sequence is only for the rear right
door window slot seal. The removal and installation of the rear left
door window slot seal is similar.

3.5.1 Removing
– Lever window slot seal carefully and evenly upwards off door
flange using a plastic wedge.

Note

Do not bend window slot seal!

satelettronica
AG. Volkswagen AG d
agen
3.5.2 y Volksw Installing
oes
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– Press window slot ise carefully and evenly, from above, onto
seal
r nte
tho eo
door flange. s au ra
c
s
ce
e

3.6 Assembly overview - window channel

nl

pt
du

an
itte

y li
erm

ab
ility
ot p

Note
wit
, is n

h re

The right side is shown. The left side is similar.

hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

3. Rear door window 267

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1 - Door seal
❑ Part of widow channel.
2 - Window channel
❑ Pushed onto door
flange and engages in
the upper and rear sides
areas of door.
3 - Fixed window
❑ Part of widow channel.
4 - Side window channel
5 - Door and door flange

AG. Volkswagen AG d
agen oes
olksw not
V

satelettronica
by gu
d ara
ise nte
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d
itte

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ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
3.7 Removing and installing window chan‐
ercia

nel
m

a
com

tion in
r
te o

thi
s
iva

Note
do
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rp

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fo

en
g

♦ The removal and installation sequence is only for the right

n

t.
yi Co
rearmost window channel. The removal and installation of the Cop py
t. rig
left rearmost window channel is similar. opyri
gh by
Vo
ht
by c
♦ Do not bend window channel when removing!
lksw
cted agen
Prote AG.
♦ The fixed window is part of window channel.

3.7.1 Removing
– Remove door window ⇒ page 264 .
– Remove window slot outer seal ⇒ page 267 .
– Pull door gap strip ⇒ Item 1 (page 268) off door flange.

268 Rep. gr.64 - Glazing

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Pull window channel -3- out of mounting.

– Remove screws -2- and pull trim -1- towards B-pillar
-direction of arrow-.
– Pull window channel -3- all round off door flange.
– Pull window channel along with fixed window out of door.

3.7.2 Installing
Install in reverse order of removal.
Specified torque: bolts -2- (2 Nm).
• Test function before installing door trim.

Note

satelettronica
To prevent wind noise, ensure window channel seats evenly
when installing.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
269
Prote AG.
3. Rear door window
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

4 Windows having threaded connec‐

tions

4.1 Tools
Special tools and workshop equipment required
♦ Torque wrench 2…10 Nm - V.A.G 1783-

satelettronica
4.2 Removing and installing front side win‐
dow

Note

The removal and installation sequence is only for the left side
window. The removal and installation of the right side window is
similar.

4.2.1 Removing
– Remove A-pillar trim ⇒ General body repairs, interior; Rep. n AG. Volkswagen AG do
gr. 70 ; Trims, insulation; Pillars and side trims . lkswage es n
Vo ot g
by ua
ed ran
– Remove hexagon nuts -2-. oris tee
th or
au
– Remove side window -1- from bolt holes. ss
ac
ce
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un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by

270
co Vo
by lksw
Rep. gr.64 - Glazing cted agen
Prote AG.
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

4.2.2 Installing
– Insert side window -1- in window aperture.
– Lightly tighten hexagon nuts -2-.
– Centre window in window aperture.
– Tighten hexagon nuts -2- to 4.5 Nm.
– Then perform remaining installation in reverse order of remov‐AG. Volkswagen
al. lksw
agen AG do
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4. Windows having threaded connections 271

 Touran 2003 ➤ agen
AG. Volkswagen AG d
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General body repairs, exterior - Edition 02.2015 by Vol
gu
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tho eo
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66 – Exterior equipment
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1 Wheel housing liners

erm

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1.1 Tools

spec
es, in part or in w

t to the co
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-

rrectness of i
l purpos

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1.2 Front wheel housing liner pyri by
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1.2.1 Assembly overview

Note

♦ Only the left side is shown. The right side is similar.

♦ Minor differences depending on model must be taken into account.

272 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1 - Front wheel housing liner

❑ Material: PP/EPDM
❑ Removing and installing
⇒ page 274
2 - Bolt
❑ Qty. 11.
❑ 2 Nm ± 0.5 Nm
❑ Qty. 1 in side panel, out‐
side
❑ Qty. 2 in front wing
❑ Qty. 1 in front wheel
housing
❑ Qty. 2 in longitudinal
member, below AG. Volkswagen AG d
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4 - Speed nut

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5 - Expanding nut
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❑ Qty. 6.
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❑ Qty. 1 in side panel, out‐
side
❑ Qty. 2 in front wing

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❑ Qty. 1 in front wheel
l purpos

housing
❑ Qty. 2 in longitudinal

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member, below
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by
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Prote AG.

1. Wheel housing liners 273

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.2.2 Removing and installing

Note

♦ Removal and installation is described for the front left wheel housing liner only. Removal and installation of
the right front wheel housing liner are similar.
♦ The removal and installation procedures may have to be modified slightly depending on model variants.

satelettronica
AG. Volkswagen AG d
agen oes
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nform
mercia

Removing
a
com

tion in

– Remove wheel ⇒ Running gear; Rep. gr. 44 ; Specified tor‐

r
te o

thi

ques for wheel bolts .

s
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Unscrew bolts -2-.

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t.
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– Remove front wheel housing liner -1- from wheel housing.
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Front wheel housing liner -1- installation is performed in the re‐ cted agen
Prote AG.
verse order of removal.
– Torque setting for bolts -2- ⇒ page 272

274 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.3 Rear wheel housing liner

1.3.1 Assembly overview

AG. Volkswagen AG d
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Note d by
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Only the left side is shown. ut side is similar.
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1 - Rear wheel housing liner
erm

ab
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❑ Material: PP/EPDM
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❑ Removing and installing

h re
⇒ page 276
hole

spec
es, in part or in w

2 - Bolt

t to the co
❑ Qty. 8.
❑ 2 Nm ± 0.5 Nm

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❑ Qty. 3 in longitudinal

satelettronica
member, wheel housing
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❑ Qty. 1 in side panel, in‐

side

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1. Wheel housing liners 275

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1.3.2 Removing and installing

Note

♦ Removal and installation are described for the left wheel housing liner only. Removal and installation of the
right wheel housing liner are similar. agen
AG. Volkswagen AG d
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♦ The removal and installation proceduresd bmayy V have to be modified slightly depending on model variants.
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a
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fo

en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Removing
– Remove wheel ⇒ Running gear; Rep. gr. 44 ; Specified tor‐
ques for wheel bolts .
– Unscrew bolts -2-.
– Remove rear wheel housing liner -1- from wheel housing.
Installing

Note

New wheel housing liners for vehicles ► 7.2010 require 2 cut-outs -4-.

276 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

Rear wheel housing liner -1- installation is performed in the re‐

verse order of removal.
– Torque setting for bolts -2- ⇒ page 275

satelettronica
AG. Volkswagen AG d
agen oes
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or

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for

en
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

1. Wheel housing liners 277

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2 Exterior mirrors - vehicles ► 7.2010

2.1 Tools
Special tools and workshop equipment required
♦ Removal lever - 80-200-

satelettronica
♦ Torque wrench - V.A.G 1783-

AG. Volkswagen AG d
agen oes
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2.2 Assembly overview - exterior mirror

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urposes, in part or in wh

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Only the left side is shown. The right side is similar.

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atio
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

278 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1 - Mirror mounting
❑ Removing and installing
⇒ page 282
2 - Bolt
❑ Qty. 2.
❑ 8 Nm
3 - Insulation
4 - Assembly part
❑ Removing and installing
⇒ page 281
5 - Bolt
❑ Qty. 2.
❑ 1 Nm
6 - Mirror glass
❑ Removing and installing
⇒ page 279
7 - Turn signal

satelettronica
❑ Removing and installing
⇒ page 281
8 - Bolt
❑ Qty. 2. AG. Volkswagen AG d
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❑ 1 Nm olksw not
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9 - Mirror housing horis nte
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❑ Removing ss aand installing c
⇒ page 280
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2.3 Removing and installing mirror glass

rrectness of i

Note
l purpos

The removal and installation sequence is only for the left mirror
glass. The removal and installation of the right mirror glass is
nf
ercia

similar.
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When doing this repair work, always wear safety goggles and
o

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leather gloves!
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pyri by
Vo
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by
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Prote AG.

2. Exterior mirrors - vehicles ► 7.2010 279

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.3.1 Removing
– Protect edge of housing -1- against paint damage and mask
with e.g. fabric-reinforced adhesive tape.
– Press bottom of mirror glass -3- into mirror housing.
– Using removal lever - 80-200- , press -arrow 5- mirror glass
-3- off bracket -2- and housing -1-.
– Swing mirror glass -3- upwards -arrow 6- and pull contacts
-4- for mirror heating off back of mirror glass.
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spec
es, in part or in w

2.3.2 Installing

t to the co
– Push contacts for mirror heating onto mirror glass.

rrectness of i
– Press mirror glass centrally onto bracket in housing.
l purpos

– Mirror glass engages audibly.

• Finally carry out a functional check.

nform
ercia

2.4 Removing and installing mirror housing

m

a
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tion in
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Note

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The removal and installation sequence is only for the left mirror

en
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2.4.1 Removing
agen
Prote AG.

– Removing and installing mirror glass ⇒ page 279 .

– Fold exterior mirror forwards to ease removal and installation.
– Remove the 2 bolts -2-.
– Pull mirror housing -1- upwards off mirror carrier -3-.

2.4.2 Installing
Install in reverse order of removal.
• Finally carry out a functional check.

280 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

2.5 Removing and installing turn signal re‐

peater

Note

♦ The removal and installation sequence is only for the left turn
signal repeater. The removal and installation of the right turn
signal repeater is similar. . Volkswag
AG en AG
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♦ The turn signal
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♦ aut
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ss the entire turn signal must be renewed. c

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2.5.1 Removing

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ab
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– Removing and installing mirror glass ⇒ page 279 .

wit
is n

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– Removing and installing mirror housing ⇒ page 280 .
ole,

spec
urposes, in part or in wh

– Disconnect connector -1-.

satelettronica
t to the co
– Pull off turn signal -2- in -direction of arrow-.

rrectness o
cial p

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mer

atio
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2.5.2 Installing
en
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Install in reverse order of removal. t. C rig
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• Finally carry out a functional check.
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Prote AG.
2.6 Removing and installing assembly
bracket

Note

The removal and installation sequence is only for the left assem‐
bly bracket. Removal and installation of the right section are
similar.

2.6.1 Removing
– Removing and installing mirror glass ⇒ page 279 .
– Removing and installing mirror housing ⇒ page 280 .
– Removing and installing turn signal ⇒ page 281

2. Exterior mirrors - vehicles ► 7.2010 281

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Remove the 2 bolts -2-.

– Pull off assembly bracket -1- in -direction of arrow-.

2.6.2 Installing
Install in reverse order of removal.
• Finally carry out a functional check.

2.7 Removing and installing exterior mirror

satelettronica
Note

The removal and installation sequence is only for the left exterior
mirror. The removal and installation of the right exterior mirror is
similar. n AG. Volkswagen AG age does
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y Vol gu
2.7.1 Removing
b ara
ed nte
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th
– Remove front sdoor
s trim on driver side ⇒ au General body repairs, ac
r

interior; Rep. gr. 70 ; Trim/insulation; Door trim; Removing and

ce
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nl

pt

installing front door trim, driver side .

du

an
itte

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erm

– Disconnect connections -1- for exterior mirror.

ab
ility
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wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Unscrew bolts -1-.

– Remove exterior mirror and thread cable through hole.
nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

2.7.2 Installing
Install in reverse order of removal.
– Specified torque: bolts -1- (8 Nm).
• Carry out functional test function before installing door trim.

282 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

3 Exterior mirrors - vehicles 8.2010 ►

3.1 Tools
Special tools and workshop equipment required
♦ Removal lever - 80-200-

satelettronica
♦ Torque wrench - V.A.G 1783-

AG. Volkswagen AG d
agen oes
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3.2 Assembly overview - exterior mirror

hole

spec
es, in part or in w

t to the co

Note
rrectness of i

Only the left side is shown. The right side is similar.

l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

3. Exterior mirrors - vehicles 8.2010 ► 283

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1 - Mirror mounting
❑ Removing and installing
⇒ page 292
2 - Insulation
3 - Bolt
❑ 10 Nm AG. Volkswagen AG d
agen oes
4 - Connector olksw not
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5 - Assembly part horis
eo
ut ra
❑ With side turn signal re‐ ss a c
peater.

ce
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nl

pt
du

an
❑ Removing and installing
itte

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⇒ page 290
erm

ab
ility
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6 - Entry light in exterior mirror

wit
, is n

h re
❑ Removing and installing
hole

⇒ page 290

spec
es, in part or in w

7 - Adjustment unit with motor

t to the co
❑ Removing and installing

satelettronica
⇒ page 287

rrectness of i
8 - Bolt
l purpos

❑ Qty. 3.
❑ 1 Nm

nform
ercia

9 - Mirror glass
m

at
om

❑ Removing and installing

ion
c

⇒ page 284

in t
or

his
ate

10 - Bolt
do
priv

cum
or

❑ Qty. 2.
f

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ng

t.
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❑ 1 Nm
Co
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11 - Frame
ht
pyri by
Vo
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❑ Removing and installing Prote
cted agen
⇒ page 288
AG.

12 - Mirror housing
❑ Removing and installing ⇒ page 289

3.3 Removing and installing mirror glass

Note

Removal and installation are described only for the left mirror
glass. The removal and installation of the right mirror glass is
similar.

284 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

3.3.1 Removing

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec

satelettronica
es, in part or in w

t to the co
rrectness of i
l purpos

nf
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orm
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or c

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sd
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f

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Note

Protect edge of housing from paint damage using, for example, fabric-reinforced adhesive tape.

– Press bottom of mirror glass -1- into mirror housing -3-.

– Push mirror glass -1- using assembly lever - 80-200- in
-direction of arrow a- off bracket -2- and housing -3-.
– Swivel mirror glass -1- to side -direction of arrow b- and detach
connector contacts -4- for mirror heating on back of mirror
glass -1-.

3. Exterior mirrors - vehicles 8.2010 ► 285

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

3.3.2 Installing

n AG. Volkswagen AG do
lkswage es n
o ot g
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satelettronica
d b ua
ran
ir se tee
tho
u or
a ac
ss

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pt
an
d
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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in

– Push connector contacts -3- for mirror heating onto mirror

r
te o

thi

glass -1-.
s
iva

do
r
rp

– Swing mirror glass -1- in -direction of arrow a-.

um
fo

en
ng

t.
yi
– Press centre of mirror glass -1- in -direction of arrow b- onto
Co
op py
bracket -2- in housing -4-.
t. C rig
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pyri by
Vo
o
– Mirror glass -1- engages audibly.
c by lksw
cted agen
Prote AG.

286 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

3.4 Removing and installing adjustment unit

with motor

3.4.1 Removing

satelettronica
AG. Volkswagen AG d
agen oes
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an
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itte

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ab
ility
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wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne

– Remove mirror glass ⇒ page 289

– Remove bolts -2- (Qty 3).
ss o
cial p

– Swing control element with motor -1- to one side and pull off
f in

connector -3-.
form
mer

atio

3.4.2 Installing
om

n
c

i
or

n thi

Install in reverse order of removal.

te

sd
iva

o
r

– Specified torque for bolts -1-: 2 Nm.

p

cum
r
fo

en
ng

• Carry out functional check before installing mirror glass.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

3. Exterior mirrors - vehicles 8.2010 ► 287

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

3.5 Removing and installing frame

Note

Removal and installation is described only for the left frame. Re‐
moval and installation of the right frame are similar.

3.5.1 Removing

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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ris nte
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un

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d
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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Remove mirror glass ⇒ page 289

– Unscrew bolts -2-.
nform
ercia

– Release locking hooks -arrows a- from mirror housing using a

m

screwdriver.
com

tion in
r

– Lever out locking mechanism -arrows b- from underneath us‐

te o

thi

ing a screwdriver.
s
iva

do
r
rp

cum

– Raise frame -1- on side using assembly lever - 80-200- .

fo

en
ng

t.
yi Co
– Remove frame -1-. Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

288 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

3.5.2 Installing

Note

Check catches or locking mechanisms of respective component

for damage and renew if necessary.

Install in reverse order of removal.

– Specified torque for bolts -2-: 1 Nm.
• Finally check function.

3.6 Removing and installing mirror housing

Note

Removal and installation are described only for the left mirror
housing. The removal and installation of the right mirror housing
is similar.

satelettronica
3.6.1 Removing
AG. Volkswagen AG d
agen oes
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aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

3. Exterior mirrors - vehicles 8.2010 ► 289

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Remove mirror glass ⇒ page 289

– Remove frame ⇒ page 288 .
– Lever out locking mechanism -arrows a- on mirror housing
-1- using a screwdriver.
– Push together detent hooks -arrows b- and remove mirror
housing -1- from turn signal -2-.

3.6.2 Installing

Note

Check catches or locking mechanisms of respective component

for damage and renew if necessary.

Install in reverse order of removal.

• Finally check function.

3.7 Removing and installing side turn signal lksw

agen
AG. Volkswagen AG d
oes
not
and entry light in exterior mirrorsed b Vo

satelettronica
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ara
n ri tee
ho
aut or
ac
ss
Note

ce
le
un

pt
an
d
itte

♦ The removal and installation sequence is only for the left turn

y li
rm

ab
signal repeater. The removal and installation of the right turn
pe

ility
signal repeater is similar.
ot

wit
, is n

h re
♦ The side turn signal is fitted with light-emitting diodes (LEDs)
hole

spec
instead of conventional bulbs.
es, in part or in w

t to the co
♦ Therefore, the bulbs cannot be changed. In case of damage,
the entire turn signal must be renewed.

rrectness of i
3.7.1 Removing
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

290 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

satelettronica
rm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Remove mirror glass ⇒ page 289

– Remove frame ⇒ page 288 .
– Remove mirror housing ⇒ page 289 .
Removing entry light in exterior mirror
– Push entry light in exterior mirror -3- out of turn signal -1- in
-direction of arrow-.
– Pull bulb holder -4- out of entry light in exterior mirror -3-.
Removing turn signal
– Detach connector -2- from turn signal -1-.

3.7.2 Installing

Note

Check catches or locking mechanisms of respective component

for damage and renew if necessary.

Install in reverse order of removal.

• Finally check function.

3. Exterior mirrors - vehicles 8.2010 ► 291

 AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
Touran 2003 aut➤
ho eo
ra
General body
ss repairs, exterior - Edition 02.2015 c

ce
e
nl

pt
du

an
3.8 Removing and installing exterior mirror
itte

y li
erm

ab
ility
ot p

wit
, is n

Note

h re
hole

spec
Removal and installation are described only for the left exterior
es, in part or in w

t to the co
mirror. The removal and installation of the right exterior mirror is
similar.

rrectness of i
3.8.1 Removing
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t.

satelettronica
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove front door trim on driver side ⇒ General body repairs,

interior; Rep. gr. 70 ; Trims, insulation; Removing and instal‐
ling front door trim on driver side .
– Open cable tie -3- and separate connector -4- for exterior mir‐
ror -1-.
– Unscrew bolt -2-.
– Remove exterior mirror -1- and guide line through aperture in
door.

292 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

3.8.2 Installing
Install in reverse order of removal.
– Specified torque for bolt -2-: 10 Nm
• Check function before installing door trim.

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

3. Exterior mirrors - vehicles 8.2010 ► 293

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015
AG. Volkswagen AG d
agen oes
olksw not
V gu
4 Radiator grille by ara
d
rise nte
tho eo
au ra
ss c

ce
le
4.1 Tools

un

pt
an
d
itte

y li
rm
Special tools and workshop equipment required

ab
pe

ility
ot
♦ Torque wrench - V.A.G 1783-

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in

satelettronica
r
te o

4.2 Radiator grille ► 10.06

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
4.2.1 Assembly overview
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

294 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1 - Radiator grille
❑ Material: ASA
2 - Company emblem
❑ Clipped into radiator
grille.
❑ Can be removed only
with radiator grille re‐
moved.
3 - Bolt
❑ Qty. 2.
❑ 6 Nm

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara

satelettronica
rise nte
tho eo
au ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4. Radiator grille 295

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

4.2.2 Removing

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Remove bolts -3-.

nf
ercia

– Release locking hooks from lock carrier using small screw‐

rm
m

driver -arrows-.
atio
om

n in
c

– Pull radiator grille -1- forwards out of bumper.

or

thi
te

sd
a

4.2.3 Installing
iv

o
r
rp

cu
o

m
f

en
ng

– Hold radiator grille in place against bumper, doing so evenly

t.
yi Co
op
on left and right, and then push grille into bumper until it en‐ C py
t. rig
gages.
gh ht
pyri by
Vo
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by
– Engage clips in lock carrier and screw in bolts. Prote
cted AG.
agen

296 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

4.3 Radiator grille 11.06 ►

4.3.1 Assembly overview

Note

Minor visual differences will be encountered during removal and installation depending on version of special
models.

1 - Radiator grille
❑ Material: ASA
❑ Removing ⇒ page 298
❑ Installing ⇒ page 299 .
❑ Removing and installing
emblem ⇒ page 302
2 - Locking lug AG. Volkswagen AG d
agen oes
ksw

satelettronica
ol not
yV gu
3 - Bolt ised b ara
nte
or
❑ Qty. 4. aut
h eo
ra
s c
❑ 6 Nm s

ce
e
nl

pt
du

4 - Bumper cover

an
itte

y li
erm

ab
5 - Guide wedge

ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

4. Radiator grille 297

 AG. Volkswagen AG d
agen oes
olksw not
yV gu
Touran 2003 ➤ ed b ara
nte
ris
General body repairs, exterior - Edition
ut
ho 02.2015 eo
ra
s a c
s
4.3.2 Removing

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi

satelettronica
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Remove bolts -3-.

– Release locking hooks -2- from bumper cover -4- using a small
screwdriver.
– Pull radiator grille -1- forwards out of bumper cover.

298 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

4.3.3 Installing

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

satelettronica
spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Insert radiator grille -1- evenly into bumper cover -4- until lock‐
ing hooks -2- are engaged in bumper.
– Screw in bolts -3-.

4.4 Removing and installing radiator grille

08.2010 ▶

Note

Only optical differences exist depending on model.

4. Radiator grille 299

 Touran 2003 ➤ AG. Volkswagen AG d
General body repairs, exterior - Edition 02.2015 agen oes
olksw not
byV gu
ara
ed
is nte
4.4.1 Removing or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
va

satelettronica
i

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Remove front bumper cover -2- ⇒ page 209 .

– Release locking hooks from the inside of the front bumper
cover -2-, using the removal wedge - 3409- .
– Remove radiator grille -1- in direction of -arrow- from front
bumper cover.

300 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

4.4.2 Installing

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un

pt
an
d
itte

y li

– Guide radiator grille -1- into front bumper cover -2- -arrows-.
rm

ab
pe

ility

– Apply slight pressure to make sure all locking hooks engage.

ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
301
agen
Prote AG.
4. Radiator grille
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

4.5 Removing and installing company em‐

blem 11.06 ►

4.5.1 Removing

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec

satelettronica
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Push 2 locking hooks -2- inwards.

– Turn emblem -1- slightly in -direction of arrow-.
– Remove emblem from radiator grille -3-.

302 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

4.5.2 Installing

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

satelettronica
wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
– Insert emblem -1- into radiator grille -2- -arrow a-.
c by lksw
cted agen
Prote AG.
– Turn emblem in -direction of arrow b- until all locking hooks
-3- are engaged behind the projections.

4. Radiator grille 303

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

4.6 Removing and installing company em‐

blem 08.2010 ▶

4.6.1 Removing

Note

The company emblem and the protective grid cannot be removed without damaging them.

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

– Use a pair of pliers -4- to grasp the company emblem -1- and
com

tio

forcibly pull it out of the catches -3-.

n in
r
te o

thi

– Lever protective grid -5- out of radiator grille -2-.

s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

304 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

4.6.2 Installing AG. Volkswagen AG d

agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

satelettronica
m

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Push the protective grid together with upper guide between

the radiator grille -2- and the basic support of the radiator grille
-1- -b-.
– Bend the protective grid together -arrows a- and push in the
lower guides.
– Place company emblem -5- on radiator grille -2- and align.
– Press the company emblem onto the radiator grille -arrow c-
until the locking pegs -4- engage audibly with the radiator
grille.

4. Radiator grille 305

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

5 Mouldings and trims

5.1 Tools n AG. Volkswagen AG do

lkswage es n
o ot g
Special tools and workshop equipment required ed by V ua
ran
ir s tee
♦ Torque wrench - V.A.G 1783- autho
or
ac
ss

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i

satelettronica
l purpos

♦ Pop rivet pliers - VAS 5072-

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Hot air blower - V.A.G 1416-

5.2 Assembly overview - water deflector

Note

The right side is shown. The left side is similar.

306 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1 - Water deflector
❑ Removing:
– Starting at bonnet end,
pull water deflector -1-
out of clips -4- and re‐
taining strip -2-.

2 - Retaining strip
❑ The retaining strip can
only be renewed after
windscreen has been
removed.
3 - Pop rivet
❑ Qty. 5.
❑ Insert with pop rivet pli‐
ers - VAS 5072- agen
AG. Volkswagen AG d
oes
olksw not
4 - Clip byV gu
ara
ed
ris nte
❑ Clipped into wing. ut
ho eo
ra
s a c
s
5 - Wing

ce
le

satelettronica
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

5. Mouldings and trims 307

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

5.3 Renewing protective side strips

Note

♦ Only the left side is shown. The right side is similar.

♦ Remove protective backing immediately before installation. Working temperature about 20 °C.
♦ Curing time after attaching protective side strip is about 4 hours at a room temperature of about 20° C.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

satelettronica
wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Heat side protective mouldings -1- and -2- before removal us‐
ing hot air blower - V.A.G 1416- and pull off.
Only use adhesive remover - D 002 000 10- to remove adhesive
residue.
– Pull protective backing off side protective mouldings -1- and
-2- before attaching.
– Bonding surfaces must be free of dust and grease.
– Position side protective mouldings -1- and -2- and press on
forcefully.

308 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

5.4 Removing and installing stone-chip pro‐

tection trim
AG. Volkswagen AG d
agen oes
olksw not
V gu
by ara
5.4.1 Removing ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

satelettronica
nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Guide a small screwdriver through the opening on the bottom

edge of the side trim and release the locking device -2-, by
pressing the screwdriver upwards -arrow a-.
– Slide stone-chip protection trim -1- forwards -arrow b- until
screwdriver contacts securing screw -3-. Now pull screwdriver
out. Slide stone-chip protection trim further until it can be re‐
moved from all securing screws.

5. Mouldings and trims 309

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

5.4.2 Installing

Note

♦ The stone-chip protection trim bolts are corrosion-resistant.

No further secondary treatment is required.
♦ If a bolt is overtightened it is essential to replace it with a
“black” oversize bolt.

satelettronica
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un

pt
an
d
itte

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rm

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pe

ility
ot

wit
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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
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iva

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cum
fo

en
g

– Measure holes according to the table below.

n

t.
yi Co
Cop py
– Centre holes for the securing screws.
t. rig
gh ht
pyri by
Vo
o
– Drill out holes with a 1.5 mm drill bit.
c by lksw
cted agen
Prote AG.

Note

Dimension -a- is measured including wheel housing liner -2-. The other dimensions -b to i- are always measured
from the centres of the holes.

The table follows.

310 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

Dimension -a- = 930mm

Dimension -b- = 822 mm
Dimension -c- = 617 mm
Dimension -d- AG =
. Volks411
wagemm
n AG d
agen oes
Dimension -e- olksw = 205 mm not
y V gu
d b ara
Dimension -f- orise
= 205 mm nte
eo
h
ut
Dimension -g- ss a = 411 mm ra
c
Dimension -h- = 617 mm

ce
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un

pt
an
d
Dimension -i- = 822 mm
itte

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rm

ab
Dimension -k- = 35 mm
pe

ility
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wit
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That was the table.

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

satelettronica
nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

• If all securing screw holes are pre-drilled.

– Screw in self-tapping screws -2- with cordless drill/driver - VAS
5036- , using the highest speed, until the screw bites. Remove
cordless drill/driver immediately.

5. Mouldings and trims 311

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Tighten screws with least possible torque so that screw is not

over tightened.

– Position openings on back of stone-chip protection trim -1-

evenly -arrow a- over all securing screws -2- until stone-chip
protection trim contacts side member -3-.
Use a second mechanic to ensure that all securing screws remain
in openings when sliding stone-chip protection trim.
– Slide stone-chip protection trim forcibly to rear -arrow b- to
stop.

5.5 Decorative trims

5.5.1 Fitting notes

♦ Before removing trims, heat them with a hot air blower - V.A.G
1416- .
♦ If a trim section is applied for the first time on a new vehicle
. Volkswagen AG
and newly painted surfaces, the waprocedure
gen AG in ⇒ Workshop
does
manual "Paint"; ⇒ Paintwork olks
y V repairs; ⇒ Paint finish; ⇒ Mould‐
not

satelettronica
b gu
ara
ings ⇒ Film should berisobserved.
ed
nte
tho eo
♦ If a trim section is
ss
aremoved
u
and reinstalled, only use adhesive ra
c
remover - D 002 000 10- to remove the adhesive remains. ce
le
un

pt
an
♦ Remove existing adhesive residue of adhesive tape using ad‐
d
itte

y li
hesive strip remover - VAS 6349- .
rm

ab
pe

ility

♦ Ensure that the adhesive surfaces are free of dust and grease.
ot

wit
, is n

h re

♦ The trim must be bonded in place immediately following clean‐

hole

spec

ing.
es, in part or in w

t to the co

♦ Remove protective backing immediately before installation.

♦ The working temperature is approx. 21 °C.
rrectness of i

♦ The trim cannot be removed without it being damaged.

l purpos

5.5.2 Decorative trims on door

nform
ercia

Note
m

a
com

tion in

Only the left side is shown. The right side is similar.

r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

312 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

satelettronica
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
Removing
AG.

– Heat trim panel -1- or -2- with hot air blower - V.A.G 1416-
before removing.
– Pull trim panel off front door -3- or rear door -4- forcefully.
Installing
– Follow installation instructions ⇒ page 312 .
– Remove protective backing before fitting.
– Position trim panel on door and press on forcefully.

5. Mouldings and trims 313

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

5.5.3 Rear lid trim

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

satelettronica
ce
le
un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

Removing
en
ng

t.
yi Co
op
– Heat trim -1- with hot air blower - V.A.G 1416- before remov‐ C py
ht. rig
ing. rig ht
py by
co Vo
by lksw
– Pull trim off rear lid -2- forcefully. cted agen
Prote AG.

Installing
– Follow installation instructions ⇒ page 312 .
– Remove protective backing before fitting.
– Position trim -1- on rear lid -2- and press on forcefully.

314 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

5.6 Wheel arch trim

1 - Front wheel arch trim

2 - Protective film
3 - Adhesive tape
4 - Bolt
5 - Rear wheel arch trim

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le

satelettronica
un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

5. Mouldings and trims 315

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

6 Removing and installing roof railing

6.1 Tools
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

satelettronica
6.2 Assembly overview - roof railing

Note

The right side is shown. The left side is similar.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw

316
cted agen
Prote AG.
Rep. gr.66 - Exterior equipment
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1 - Left roof railing

❑ Removing and installing
⇒ page 317
2 - Right roof railing
❑ Removing and installing
⇒ page 317
3 - Bolt
❑ Qty. 6.
❑ 20 Nm
4 - Front mounting bracket
5 - Hexagon nut
❑ Qty. 3.
❑ 20 Nm
6 - Middle mounting bracket
7 - Rear mounting bracket

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

6.3 Removing and installing roof railing

rrectness of i

Note
l purpos

Removal and installation sequence is only described for the right

roof railing. The removal and installation of the left roof railing is
nf
ercia

similar.
rm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

6. Removing and installing roof railing 317

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

6.3.1 Removing

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Remove moulded headliner ⇒ General body repairs, interior;

nf
ercia

Rep. gr. 70 ; Trims, insulation; Removing and installing moul‐

rm
m

atio

ded headliner .
om

n in
c

– Remove hexagon nuts -2- and remove roof railing -1-.

or

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

318 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

6.3.2 Installing

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

satelettronica rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Begin by mounting roof railing -1- with the front foot.

– Comply with specified tightening sequence for bolts of roof
railing -1-. Start with front, then rear and finally the middle.
– If dents develop in roof around the support feet when roof rail‐
ing -1- bolts -2- are tightened, bolts -3- of mounting brackets
must be loosened.
– Adjust roof railing -2- (free of stress) and tighten bolts -2-
again.

6. Removing and installing roof railing 319

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

6.4 Assembly overview - roof railing retaining bracket

Note

♦ The illustration shows the centre bracket. The procedures for the front and rear brackets are similar.
♦ The brackets must not be interchanged with one another.
♦ The various wedges must not be interchanged with one another.

1 - Retaining bracket
❑ There are different re‐
taining brackets for
front, centre and rear.
❑ Removing retaining
bracket ⇒ page 321
❑ Installing retaining
bracket ⇒ page 321
❑ Installing new retaining

satelettronica
bracket ⇒ page 322
n AG. Volkswagen AG do
2 - Bolt lkswage es n
o ot g
yV
❑ Qty. 2 per retaining d b ua
ran
ir se
bracket tho tee
or
u
❑ 20 Nm ss
a ac

ce
e
nl

3 - Upper wedge

pt
du

an
itte

y li
❑ In lower tolerance com‐
erm

ab
pensation

ility
ot p

wit
4 - Lower wedge
, is n

h re
hole

❑ In lower tolerance com‐

spec
pensation
es, in part or in w

t to the co
5 - Bracket for lower tolerance
compensation
rrectness of i

6 - Hexagon nut
❑ 23 Nm
l purpos

❑ To secure roof railing

nform
ercia

7 - Lower wedge
m

❑ In upper tolerance com‐

at
om

io

pensation
n
c

in t
or

his
e

8 - Upper wedge
at

do
riv

❑ In upper tolerance com‐

p

cum
or

pensation
f

en
ng

t.
yi Co
op
9 - Seal C py
t. rig
gh ht
yri by
10 - Roof railing cop Vo
by lksw
cted agen
Prote AG.

320 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

6.5 Removing and installing roof railing re‐

taining bracket

6.5.1 Removing retaining bracket

Note

♦ Ensure all the wedges in the tolerance compensation remain

in position if the retaining bracket is to be reinstalled.
♦ The various wedges must not be interchanged with one an‐
other.

– Remove roof railing - 5- ⇒ page 318 .

– Unscrew bolts -2-.
– Remove retaining bracket -1- together with tolerance com‐
pensation -3 and 4-.
If the retaining bracket is to be reinstalled, secure tolerance com‐

satelettronica
pensation with commercially available adhesive tape.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec

6.5.2 Installing retaining bracket

es, in part or in w

t to the co

Note
rrectness of i

The various wedges in the tolerance compensation -4 and 5- must

l purpos

not be interchanged with one another.

nf
ercia

Remove adhesive tape from tolerance compensation before in‐

rm
m

stalling, if previously secured with tape.

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

6. Removing and installing roof railing 321

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Ensure the individual wedges in the tolerance compensation

-4 and 5- are seated correctly.
– First position roof railing -6- on roof, then guide the retaining
bracket -1- over the studs until the wedges in the tolerance
compensation -4 and 5- are centred.
n AG. Volkswagen A
– Only tighten hexagon nut -2- until
olks
wthe
ageretaining bracketGsits
does on
not
roof. d by V gu
ar
e an
ris tee
– Tighten bolts -3-, specified
ut
ho torque: 20 Nm. or
a ac
ss
– Now tighten hexagon nut -2-, specified torque: 23 Nm.

ce
e
nl

pt
du

an
– If dents develop at support foot of roof railing, adjust retaining
itte

y li
bracket.
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
6.5.3 Installing new retaining bracket

satelettronica
l purpos

– Insert new retaining bracket -1- until locating cap -4- engages
in roof.

nform
ercia

– Tighten bolts -2-, specified torque: 20 Nm.

m

at
om

– Pull locating pin -3- out downwards and push locating cap

ion
c

-4- upwards.
in t
or

his
ate

– If dents develop at support foot of roof railing, adjust retaining

do
priv

bracket.
um
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

322 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

7 Special body kit, Cross Touran

AG. Volkswagen AG d
agen oes
olksw not
7.1 Safety requirements ised byV gu
ara
nte
or eo
th
♦ The side member extensions, the wheel arch
s autrims and the ra
c
bumper covers were developed especially for
s the technical

ce
e
requirements of the Cross Touran. The side member exten‐

nl

pt
du

an
sions and wheel arch trims should be replaced with the re‐

itte

y li
spective Original part in all cases.

erm

ab
ility
ot p
♦ Without the side member extensions, the wheel arch trims and

wit
, is n
bumper covers, the vehicle does not comply with regulations.

h re
hole

spec
7.2 Tools
es, in part or in w

t to the co
Special tools and workshop equipment required
♦ Double cartridge gun - VAS 5237-

rrectness of i
l purpos

satelettronica
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
7.3 Materials
co Vo
by lksw
cted agen
Prote AG.

♦ 2-K glass adhesive -DA 004 600 A2-

♦ Static mixer with tapered -D 002 001-

nozzle

♦ Activator -D 181 801 A1-

♦ Glass primer/paint primer -D 900 200 02-

♦ Plastic primer -D 009 600-

♦ Cleaning solution -D 009 401 04-

♦ Primer applicator -D 009 500 25-

♦ Adhesive remover -D 002 000 10-

♦ Plastic primer -D 009 600-

Note

Observe instructions for use on the information sheet provided by

the manufacturer.

Use double cartridge gun - VAS 5237- to apply 2-component ad‐

hesives.

7.4 Assembly overview - bolt-on components

7. Special body kit, Cross Touran 323

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1 - Roof railing
❑ Removing ⇒ page 318
❑ Installing ⇒ page 319 .
2 - Front bumper cover trim
❑ Removing ⇒ page 339
❑ Installing ⇒ page 340 .
3 - Front wheel arch trim
❑ Removing ⇒ page 333
❑ Installing ⇒ page 335 .
4 - Side member extension
❑ Removing ⇒ page 326
❑ Installing ⇒ page 328 .
5 - Side lettering
❑ Foil lettering
6 - Rear wheel arch trim
❑ Removing ⇒ page 336

satelettronica
❑ Installing ⇒ page 337 .
7 - Front bumper cover trim
❑ With reflector
❑ Removing ⇒ page 341
❑ Installing ⇒ page 342 .

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

324 Rep. gr.66 - Exterior equipment

 AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
aut
h
ra Touran 2003 ➤
s c
s General body repairs, exterior - Edition 02.2015

ce
le
un

pt
an
7.5 d Side member extension and wheel arch
itte

y li
rm

ab
trim
pe

ility
ot

wit
, is n

h re
hole

spec
7.5.1 Assembly overview - side member extension
es, in part or in w

t to the co
1 - Side member extension

rrectness of i
❑ Material PUR-RIM
l purpos

❑ Removing ⇒ page 326

❑ Installing ⇒ page 328 .

nform
ercia

❑ Installation instructions
⇒ page 344 .
m

a
com

tio
2 - Bolt

n in
r
te o

thi
❑ Qty. 3.

s
iva

do
❑ 2 Nm
r
rp

cum
fo

en
g

3 - Bolt
n

t.
yi Co
op
❑ Qty. 1.
C py
ht. rig

satelettronica
rig ht
❑ 2 Nm
py by
co Vo
by lksw
cted agen
4 - Double-sided adhesive
Prote AG.

tape
5 - Protective backing
❑ With removal aid
❑ For double-sided adhe‐
sive tape
6 - Bolt
❑ Qty. 1.
❑ 2 Nm
7 - Retaining clip
❑ Qty. 3 on each side
8 - Primer and bonding surface
on side member extension and
wheel arch trim
❑ Plastic primer D 009 600
❑ 2-component glass ad‐
hesive DA 004 600 A2
❑ Bead cross section:
width = 5 mm, height = 2 mm (including residual material)
❑ Minimum curing period ⇒ page 344 .
9 - Front wheel arch
❑ Installation instructions ⇒ page 343 .
10 - Additional PUR adhesive
❑ 2-component glass adhesive DA 004 600 A2
❑ To be complied with only during removal
11 - Front wheel arch trim
❑ Material PUR-RIM
❑ Removing ⇒ page 333
❑ Installing ⇒ page 335 .
❑ Installation instructions ⇒ page 344 .

7. Special body kit, Cross Touran 325

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

12 - Retaining strip
AG. Volkswagen AG d
❑ Removing ⇒ page 330 agen oes
olksw not
y V gu
❑ Installing ⇒ page 331 . d b ara
rise nte
ho eo
13 - Bolt aut ra
c
ss
❑ Qty. 9.

ce
e
nl

pt
du
❑ 1.5 Nm

an
itte

y li
erm

ab
14 - Wheel arch, rear

ility
ot p

❑ Installation instructions ⇒ page 343 .

wit
, is n

h re
15 - Bracket
hole

spec
❑ Qty. 2.
es, in part or in w

t to the co
16 - Bolt
❑ Qty. 2.

rrectness of i
❑ 1.5 Nm
l purpos

17 - Retaining strip
❑ Removing ⇒ page 330

nform
ercia

❑ Installing ⇒ page 331 .

satelettronica
m

at
om

18 - Rear wheel arch trim

ion
c

in t
r

❑ Material PUR-RIM
o

his
ate

❑ Removing ⇒ page 336

do
priv

cum
or

❑ Installing ⇒ page 337 .

f

en
ng

t.
yi
❑ Installation instructions ⇒ page 344 .
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
7.5.2 Removing side member extension
Prote AG.

Note

♦ The side member extension cannot be removed without being

damaged.
♦ When removing side member extension, use suitable gloves
and protective eyewear.

326 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

satelettronica
rm
m

atio
om

n in
or c

thi
te

sd
iva

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r
rp

cu
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m
f

en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Unscrew bolts -2 and 3-.

– Before removing, carefully heat side member extension -1- in
bonding surface area -4- with hot air blower - V.A.G 1416- .
– Detach adhesive tape -4- by carefully inserting wedge - 3409-
between side member and side member extension -1- and
pulling towards rear -arrow a-.
– As soon as adhesive tape comes loose, lift side member ex‐
tension -1- up -arrow b- out of retaining strip.

7. Special body kit, Cross Touran 327

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

7.5.3 Installing side member extension

Note

♦ Installation is described only for the left side. The right side is similar.
♦ Remove protective backing immediately before installation. Working temperature approx. 21 °C.
AG. Volkswagen
♦ Curing period after attaching side member extension
lksw
agenis about 4 hours ateas nroom temperature of about 21 °
AG do
C. db
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o ot g
ua
ran
se
ri tee
♦ Adhesive remover - D 002 000 10- must
ut
ho be used as cleaning agent. or
a ac
ss
♦ The side member extension must be bonded in place immediately after cleaning.

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
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, is n

h re
hole

spec
es, in part or in w

t to the co

satelettronica
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Immediately before bonding the side member extension, clean

bonding surface thoroughly with adhesive remover - D 002
000 10- .
– Insert brackets -5- in side member -2- and press in pins -6-.
– Set side member extension -1- from above -arrows- evenly
into retaining strip -3- and press side member extension -1-
onto rear retaining strip -4- until the two parts engage
-arrow b-.

328 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

satelettronica
i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Push side member extension towards rear -arrow a- until there

is no gap between side member extension and wing
-arrow b-.
– Tighten bolt -3- on wing.
– Now pull protective backing -4- off side member extension
-1- -arrow c-.
– Press side member extension on forcefully in bonding area
-5-.
– Now pull protective backing -6- off rear section of side member
extension -1- -arrow d-.
– Likewise press side member extension on forcefully in bond‐
ing area -7-.
– Tighten bolts -2-.

7. Special body kit, Cross Touran 329

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

7.6 Retaining strip for side member exten‐

sion

7.6.1 Removing retaining strip olkswage

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es n
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ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i

satelettronica
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Push retaining strip -1- in direction of travel -arrows a- from

securing bolts -2- and remove from side member -3- uniformly
-arrows b-.
– Push rear retaining strip -4- opposite direction of travel
-arrow c- from securing bolts -2- and remove from side mem‐
ber -3- -arrow d-.

330 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

7.6.2 Installing retaining strip

Note

♦ The securing screws for the retaining strip are corrosion-re‐

sistant. No further secondary treatment is required.
♦ If a bolt is overtightened it is essential to replace it with a
“black” oversize bolt.
♦ The holes for the rear retaining strip can only be located after
the front retaining strip has been secured.
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wage does
olks not
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ris
tho eo
au ra
c
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nl

pt
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itte

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ab
ility
ot p

wit
, is n

h re

satelettronica
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Measure holes according to the table below.

– Centre holes for the securing screws.
– Drill out holes with a 1.5 mm drill bit.

7. Special body kit, Cross Touran 331

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

Note

Dimension -a- is measured including wheel housing liner -2-. The other dimensions -b to i- are always measured
from the centres of the holes.

The table follows.

Dimension -a- = 868 mm
Dimension -b- = 822 mm
Dimension -c- = 617 mm
Dimension -d- = 411 mm
Dimension -e- = 205 mm
Dimension -f- = 205 mm
Dimension -g- = 411 mm
Dimension -h- = 617 mm
Dimension -i- = 822 mm
Dimension -k- = 37 mm

satelettronica
That was the table.

AG. Volkswagen AG d
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ab
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ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

332 Rep. gr.66 - Exterior equipment

 AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
orise Touran 2003
nte ➤
h eo
aut General body repairs, exterior - Edition 02.2015 ra
ss c

ce
e
nl
Installation of front retaining strip

pt
du

an
itte

y li
– Screw in self-tapping screws -2- with cordless drill/driver - VAS

erm

ab
5036- , using the highest speed, until the screw bites.

ility
ot p

wit
, is n
– Tighten screws with least possible torque so that screw is not

h re
over tightened.

hole

spec
es, in part or in w
– Position retaining strip -1- evenly -arrows a- with openings

t to the co
over all securing bolts -2- until retaining strip contacts side
member -3-.

rrectness of i
So that all securing bolts remain in the openings when sliding on,
position retaining strip with a second mechanic.

l purpos
– Slide retaining strip on to stop counter to direction of travel
-arrow b-.

nform
ercia
Installation of rear retaining strip
m

at
om

io
– To mark the holes, position the rear retaining strip according

n
c

in t
r

to the front retaining strip. There are no dimensions to be in‐

o

his
e

dicated.
at

do
priv

cum
– Drill the holes according to the work steps for the front retaining
for

en
g

strip.
n

t.
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satelettronica
Cop py
– Position rear retaining strip -4- evenly -arrows c- with openings
t. rig
gh ht
yri
over securing bolts -2- until retaining strip contacts side mem‐
p by
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ber -3-. Prote
cted AG.
agen

– Slide retaining strip onto stop opposite direction of travel

-arrow d-.

7.7 Front and rear wheel arch trims

7.7.1 Removing front wheel arch trim

WARNING

When removing wheel arch trim, do not use cutting wire due to
the risk of damage to painted surfaces.

7. Special body kit, Cross Touran 333

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

AG. Volkswagen AG d
agen oes
olksw not
yV gu

satelettronica
d b ara
ise nte
or eo
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aut ra
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ce
e
nl

pt
du

an
itte

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erm

ab
ility
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wit
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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

Note
at
om

ion
c

in t
or

Under certain circumstances, a continuous PUR adhesive bead may run directly next to the double-sided ad‐
his
te

hesive tape.
a

do
priv

cum
for

en
g

– Separate bumper -6- on the required side ⇒ page 203 .

n

t.
yi Co
Cop py
– Unscrew bolt -7-. ht. rig
rig ht
py by
o Vo
– Clean dirt from all joints so that no paintwork is damaged when by c lksw
cted agen
attached parts are removed.
Prote AG.

– Tape over all adjacent painted surfaces.

– Wrap cutting cord around front corner of wheel arch trim -1-
– Using pull handle - V.A.G 1351/1- -4- and cutting cord -4-, cut
through double-sided adhesive tape -3- and PUR adhesive
material -2-.
– Remove wheel arch trim -1-.

334 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
AG. Volkswagen AG d
lksw
agen General
oes
not body repairs, exterior - Edition 02.2015
Vo gu
d by ara
ise
7.7.2 Installing front wheel arch trim
r nte
ho eo
aut ra
ss c

ce
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un

pt
Note

an
d
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erm

ab
♦ Immediately before installing side protective moulding, clean bonding surface thoroughly with adhesive re‐

ility
ot p

mover - D 002 000 10- .

wit
is n

h re
♦ Working temperature about 20 °C.
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
a

satelettronica
iv

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Remove residual adhesive -5- from body using adhesive strip

remover - VAS 6349- and thoroughly clean surfaces -2- using
adhesive remover - D 002 000 10- .
– Transfer dimensions for primer surface -8- from attachments
-9 and 7- to body.
– Prime body part at bonding points -8- using glass/paint primer
- D 009 200 02- .
– Prime attachment -1- using plastic primer - D 009 600- and
allow glass/paint primer to dry for 10 minutes before applying
adhesive.

7. Special body kit, Cross Touran 335

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Apply adhesive -3- 2-component glass adhesive - DA 004 600

A2- to primed surfaces -4 and 7- using double cartridge gun -
VAS 5237- .
The adhesive bead should have a cross section with a height of
2 mm and a width of 5 mm. To achieve this, cut 7 mm off the tip
of the tapered nozzle.
– Position wheel arch trim -1- with glue applied to points
-4 and 7- on wheel arch -8- and align trim on arch.
– Remove protective backings -6 and 10- from double-sided ad‐
hesive tape -5- and press trim firmly onto wheel arch.
– Tighten bolts -2-.
Specified torque for bolts -2-: 1.5 Nm.

7.7.3 Removing rear wheel arch trim

WARNING

When removing wheel arch trim, do not use cutting wire due to
the risk of damage to painted surfaces.

satelettronica
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
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pt
du

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erm

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ility
ot p

wit
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spec
es, in part or in w

t to the co
rrectness of i
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ercia

orm
m

atio
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or c

thi
te

sd
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en
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t.
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Cop py
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gh ht
pyri by
Vo
co

336
by lksw
cted agen
Rep. gr.66 - Exterior equipment Prote AG.
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
Note ir se
d ran
tee
tho
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a a
Under certain circumstances, a continuous PUR adhesive bead may run directly next to thec double-sided
ss ad‐

ce
e
hesive tape.

nl

pt
du

an
itte

y li
erm
– Separate bumper -6- on the required side ⇒ page 219 .

ab
ility
ot p
– Clean dirt from all joints so that no paintwork is damaged when

wit
, is n
attached parts are removed.

h re
hole

spec
– Tape over all adjacent painted surfaces.
es, in part or in w

t to the co
– Wrap cutting cord around rear corner of wheel arch trim -1-.
– Using pull handle - V.A.G 1351/1- -3- and cutting cord, cut

rrectness of i
through double-sided adhesive tape -2- and PUR adhesive
material -5-.
l purpos

– Remove wheel arch trim -1-.

nform
ercia

7.7.4 Installing rear wheel arch trim

m

at
om

ion
c

satelettronica
in t
r

Note
o

his
ate

do
riv

♦ Immediately before installing side protective moulding, clean bonding surface thoroughly with adhesive re‐
p

cum
for

mover - D 002 000 10- .

en
ng

t.
yi Co
op
♦ Working temperature about 20 °C.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

7. Special body kit, Cross Touran 337

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

satelettronica
an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

– Remove residual adhesive -2- from body using adhesive strip

sd
iva

remover - VAS 6349- and thoroughly clean surfaces -8- using

r
rp

cu
o

adhesive remover - D 002 000 10- .

f

en
ng

t.
yi Co
op
– Transfer dimensions for primer surfaces -7- from attachments C py
t. rig
-1 and 7- to body.
gh ht
pyri by
Vo
o
by c lksw
– Prime body part at bonding points -7- using glass/paint primer cted agen
Prote AG.
- D 009 200 02- .
– Prime attachment -1- using plastic primer - D 009 600- and
allow glass/paint primer to dry for 10 minutes before applying
adhesive.
– Apply adhesive -5- 2-component glass adhesive - DA 004 600
A2- to primed surfaces -4 and 4- using double cartridge gun -
VAS 5237- .
The adhesive bead should have a cross section with a height of
2 mm and a width of 5 mm. To achieve this, cut 7 mm off the tip
of the tapered nozzle.
– Position wheel arch trim -1- with glue applied to points
-3 and 4- on wheel arch -8- and align trim on arch.
– Remove protective backings -6 and 9- from double-sided ad‐
hesive tape -2- and press trim firmly onto wheel arch.

338 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

7.8 Bumper trims

7.8.1 Removing trim from front bumper

Note

When removing the trims, ensure that the paintwork of the bumper cover is not damaged.

AG. Volkswagen AG d
agen

satelettronica
oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove front bumper cover -2- ⇒ page 203 .
– Release clip -4- from spoiler -5-.
– Carefully drill out spot welds -arrows a- with an 8 mm drill bit.
– Before removing, heat bonded area -3- using hot air blower -
V.A.G 1416- .
– Pull trim -1- off bumper cover -2- and spoiler -5-.

7. Special body kit, Cross Touran 339

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

7.8.2 Installing trim on front bumper

Note

♦ When installing the trims, ensure that the paintwork of the bumper cover is not damaged.
♦ When trims are bonded, the bumper must not be twisted or bent.
♦ When the trim is pressed on during bonding, a strong force must be applied evenly and simultaneously from
both inside and outside.

n AG. Volkswagen AG do
lkswage es n
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byV ua
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ir se tee
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du

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itte

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erm

ab
ility
ot p

satelettronica
wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Bumper without holes

– Drill holes -arrows a- for attaching trim with an 8 mm drill bit.
The upper, outer hole is the guide hole and is round The other
holes are to be elongated.
– Deburr holes.
Bumper with holes
– Remove adhesive residue from bumper cover using adhesive
strip remover - VAS 6349- and clean surfaces thoroughly with
adhesive remover - D 002 000 10- .

340 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Set trim against bumper cover and lay ends of protective back‐
ing for double-sided adhesive tape outwards.
– Align trim -1- and pull off protective backing.
– Press trim -1- hard against bumper cover -2- in bonding areas
-3-, exerting counterforce from inside.
– Press on lock washers -arrows a- with a socket.
– Drill hole -arrow b- in spoiler for clip -4- with an 8 mm drill bit
and secure the clip.

7.8.3 Removing trim from rear bumper

Note

When removing the trims, ensure that the paintwork of the bumper cover is not damaged.

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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ce
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d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Remove rear bumper cover -3- ⇒ page 219 .

– Release clips -6- from spoiler -4-.
– Release clips -outer arrows a- from bumper cover -4-.
– Lever off locking washers -7- and pull reflector -5- out of trim.

7. Special body kit, Cross Touran 341

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Carefully drill out both spot welds -inner arrows a- with an

8 mm drill bit.
– Before removing, heat bonded area -2- using hot air blower -
V.A.G 1416- .
– Pull trim -1- off bumper cover -3- and spoiler -4-.

7.8.4 Installing trim on rear bumper

Note

♦ When installing the trims, sensure

wage
n AGthat
. Volkthe paintwork
swagen AG
does of the bumper cover is not damaged.
k not
Vol
♦ When trims are bonded, the bumper must not be twisted
ua or bent.
by g
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or tee
♦ When the trimauis
th pressed on during bonding, a strong force must
or be applied evenly and simultaneously from
a
both inside and
ss outside. c

ce
e
nl

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erm

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ility
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satelettronica
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es, in part or in w

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rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

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ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Bumper without holes

– Drill holes -arrows a- for attaching trim with an 8 mm drill bit.
The upper, outer hole is the guide hole and is round The other
holes can be enlarged slightly if necessary.

342 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Deburr holes.
Bumper with holes
– Remove adhesive residue from bumper cover using adhesive
strip remover - VAS 6349- and clean surfaces thoroughly with
adhesive remover - D 002 000 10- .
– Set trim -1- against bumper cover and lay ends of protective
backing for double-sided adhesive tape outwards.
– Align trim and pull off protective backing.
– Press trim hard against bumper cover in bonding areas -2-,
exerting counterforce from inside.
– Secure trim to bumper cover using 3 clips -outer arrows a-.
– Press on lock washers -inner arrows a- with a socket.
– Press both locking washers -7- onto pins of reflector -5-
– Drill holes -arrows b- in spoiler for clips -6- with an 8 mm drill
bit and secure clips.

7.9 Preparing add-on parts for bonding

satelettronica
The attachments have 3 clips n Aand
G. VoalksPUR
wagenadhesive
AG do strip for the
wage
application of adhesive.
VolksThese areas must be free ofotdust
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– Soak clothhoin
ris silicon remover - LSE 020 100 A3- . tee
t or
au a
– Clean areas
ss twice thoroughly using cloth applied with solution
c
and allow to dry.
ce
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un

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d
itte

– Now apply plastic primer - D 009 600- using applicator - D 009

y li
erm

ab

500 25- equally in one stroke.

ility
ot p

♦ Drying time approx. 10 minutes

wit
is n

h re
ole,

– Adhesive sealant must be applied to the primed areas of the

spec
urposes, in part or in wh

add-on parts.
t to the co

7.10 Preparing body kit component for bond‐

ing
rrectnes

Note
s o
cial p

f inform

Remaining material serves as adhesion base for newly applied

mer

adhesive sealing compound. Keep dirt and grease off of bonding

atio
m

surfaces.
o

n
c

i
or

n thi
te

sd

Exception: If bonding is not performed immediately after cutting

iva

o
r

back, the remaining residual material must be activated with ac‐

p

cum
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fo

tivator - D 181 801 A1- .

en
ng

t.
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Cop py
ht. rig
WARNING rig ht
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by lksw
cted agen
Activator must not have contact with paint or the paintwork will
Prote AG.

be damaged.

Note

If the body kit part has been repaired or partially renewed, the
area concerned must be cleaned and primed again after painting.

7. Special body kit, Cross Touran 343

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

7.11 Installation instructions

The surfaces to be primed for the body kit parts must be com‐
pletely clean.
– Remove adhesive residue using adhesive remover - D 002
000 10- .
– Soak cloth in silicon remover - LSE 020 100 A3- .
– Clean area of application for adhesive bead twice thoroughly
using cloth soaked with solution and allow to dry.
– Now apply glass/paint primer - D 009 200 02- using applicator
- D 009 500 25- evenly in one stroke.
♦ Drying time approx. 10 minutes
– Adhesive sealant must be applied to the primed areas of the
add-on parts.

WARNING

Add-on parts should be installed within 10 minutes, or bonding

properties of adhesive will be impaired.

satelettronica
♦ Gaps/shut lines should be kept to an absolute minimum.
♦ Use adhesive tape to secure add-on parts in position during
minimum curing time.

7.12 Minimum curing period

The minimum curing period for newly bonded special body parts
is 3 hours.
The minimum curing time is the time from bonding the add-on
parts until the vehicle may be used. During this time, the vehicle
must stand on a level surface at room temperature (at leastG15 °
A . Volkswagen AG d
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WARNING ut
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Vehicle is safe to use only after the curing period is completed.
ce
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nl

pt
du

an
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erm

ab

7.13 Touching up paint damage

ility
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wit
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Paint structure must be restored according to specifications in the

hole

“Paint” workshop manual.

spec
es, in part or in w

t to the co

7.14 Cleaning off excess adhesive sealing

material
rrectness of i

– Use adhesive remover - D 002 000 10- as a cleaning solution.

Observe the appropriate safety precautions when performing
l purpos

this work.
– First clean painted surface as well as possible using a dry
nf
ercia

cloth. Remove residue using adhesive remover - D 002 000

rm
m

atio

10- .
om

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or c

thi
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344
Prote AG.
Rep. gr.66 - Exterior equipment
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

8 Lettering

8.1 Tools
Special tools and workshop equipment required
♦ Hot air blower - V.A.G 1416-

satelettronica
♦ Adhesive strip remover - VAS 6349-

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agen oes
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wit
is n

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ole,

spec
8.2 Fitting notes
urposes, in part or in wh

t to the co
♦ Before removing the lettering, heat it with a hot air blower -
V.A.G 1416- .
rrectne

♦ If lettering is applied for the first time on a new vehicle and

newly painted surfaces, the procedure in ⇒ Workshop manual
s

"Paint" ⇒ Paintwork repairs ⇒ Paint finish ⇒ Mouldings ⇒ Film

s o

should be observed.
cial p

f inform

♦ If lettering is removed and reinstalled, only use adhesive re‐

mer

atio

mover - D 002 000 10- to remove the adhesive remains.

om

n
c

♦ Remove existing adhesive residue of adhesive tape using ad‐

or

n thi
e

hesive strip remover - VAS 6349- .

t

sd
iva

o
pr

♦ Ensure that the adhesive surfaces are free of dust and grease.
um
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fo

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t.
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♦ The lettering must be bonded in place immediately after clean‐
Co
op py
ing.
. C rig
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♦ Remove protective film immediately before installation. by c lksw
cted agen
Prote AG.
♦ The working temperature is approx. 21 °C.
♦ Lettering cannot be removed without damage.

8. Lettering 345
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

8.3 Company emblem on rear lid

Note
AG. Volkswagen AG d
agen oes
ksw
When fitting the lettering, observe the fitting notes ⇒bpage 345
ol not
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ility
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wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne

satelettronica
ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
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fo

en
ng

t.
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Cop py
t. rig
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pyri by
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Prote AG.

Removing
– Warm company emblem -1- with hot air blower - V.A.G 1416-
before removing.
– Lift VW emblem off rear lid.
– Remove existing adhesive residues with adhesive remains re‐
mover - VAS 6349- .
Installing
– Immediately before bonding, clean bonding surface thorough‐
ly with adhesive remover D 002 000 10.
– Pull off protective film -2-.
– Using centring pins -3-, position company emblem -1- in in‐
dentations -4- on rear lid.

346 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

– Press company emblem on firmly.

8.4 Rear lettering - dimensions > 07.2010

Note

♦ The lettering “Touran” shown in the illustration is only an example.

♦ Various forms of lettering are used.
♦ The dimensions for all lettering are identical.

1 - Lettering
❑ Model designation.
❑ Side dimension -b-: 28
mm from outer edge of
rear lid to lettering.
❑ Height dimension -a-: 5
mm from edge in rear lid
to lettering.

satelettronica
2 - Lettering
❑ Engine designation.
❑ Side dimension -a-: 28 AG. Volkswagen AG d
mm from outer edge of agen oes
olksw not
rear lid to lettering. d by
V gu
ara
ise nte
❑ Height dimension -c-: 5 hor eo
ut
mm from edge in rear lid ss a ra
c
to lettering.

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un

pt
an
3 - Lettering
d
itte

y li
rm

ab
❑ Additional designation
pe

ility
❑ Side dimension -a-: is
ot

wit
, is n

aligned to upper letter‐

h re
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ing

spec
es, in part or in w

❑ Height dimension -c-:

t to the co
13 mm, from upper let‐
tering to lettering rrectness of i
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Prote AG.

8. Lettering 347
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

8.5 Rear lettering - dimensions 08.2010 >

Note

♦ The lettering “Touran” shown in the illustration is only an example.

♦ Various forms of lettering are used.
♦ The dimensions for all lettering are identical.

1 - Rear lid
2 - Lettering
❑ Model designation.
❑ Height dimension -a-:
118 mm from edge in
rear lid to lettering.
❑ Side dimension -b-: 23
mm from outer edge of
rear lid to lettering.

satelettronica
3 - Lettering
❑ Engine designation.
❑ Height dimension -a-:
118 mm from edge in
rear lid to lettering.
❑ Side dimension -b-: 23
mm from outer edge of swage
n AG. Volkswagen AG do
es n
rear lid to lettering. by
Volk ot g
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ed nte
4 - Lettering ris
utho e or
❑ Additional designation
ss
a ac
ce
e

❑ Height dimension -c-: 8

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mm, from upper letter‐

itte

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ing to lettering
erm

ab
ility
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❑ Side dimension -b-: 20

wit

mm from outer edge of

, is n

h re

rear lid to lettering.

hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
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orm
m

atio
om

n in
or c

thi
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sd
iva

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f

en
ng

t.
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t. rig
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Prote AG.

348 Rep. gr.66 - Exterior equipment

 AG. Volkswagen AG d
agen oes
olksw not
d by
V gu
ara Touran 2003 ➤
e nte
horis General body e repairs, exterior - Edition 02.2015
aut or
ac
ss
8.6 Dimensions for lettering on side

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pe

ility
8.6.1 Dimensions for special model “Style”
ot

wit
, is n

h re
hole

spec
1 - Lettering
es, in part or in w

t to the co
❑ Self-adhesive.
❑ Side dimension -a-: 12
mm from outer edge of

rrectness of i
trim to lettering.
l purpos

❑ Side dimension -b-: 12

mm from rear edge of
trim to lettering.

nform
ercia

❑ Height dimension -c-: 15

m

mm, from window slot

a
com

tio
seal to lettering

n in
r
te o

thi
2 - Door trim

s
iva

do
r
rp

c
3 - Protective film

um
fo

en
g

satelettronica
n

t.
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Cop py
t. rig
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pyri by
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Prote AG.

8.6.2 Dimensions of »R Line« wing lettering

Optional equipment Volkswagen R GmbH

Note

♦ The dimensions of the R-line Volkswagen R GmbH lettering for wings are described only for the left side.
The right side is similar.
♦ The dimensions -b- and -c- determine the inclination of the lettering.

8. Lettering 349
 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

1 - Dimension a = 91 mm
❑ From lettering to edge of
wing, dimension -c-
2 - Dimension b = 521 mm
❑ From front lower wing
corner to corner point of
lettering
3 - Dimension c = 519 mm
n AG. Volkswagen AG do
❑ From rear lower corner olkswage es n
ot g
of wing to edge of wing
db
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pt
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itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

satelettronica
t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
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by
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Prote AG.

350 Rep. gr.66 - Exterior equipment

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

9 Scuff protection film

9.1 Renewing scuff protection film

9.1.1 Tools
Special tools and workshop equipment required
♦ Hot air blower - V.A.G 1416-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
ut

satelettronica
a ra
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ce
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nl

pt
du

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erm

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9.1.2 Fitting notes

ility
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wit
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♦ If a scuff protection film is applied for the first time on a new

h re
vehicle and on newly painted surfaces, the procedure in ⇒
hole

spec
Workshop manual "Paint" ⇒ Paintwork repairs ⇒ Paint finish
es, in part or in w

⇒ Mouldings ⇒ Film should be observed.

t to the co
♦ If the scuff protection film is removed and reinstalled, only use
adhesive remover - D 002 000 10- to remove the adhesive

rrectness of i
remains in installation area.
l purpos

♦ Ensure that the adhesive surfaces are free of dust and grease.
♦ The scuff protection film must be bonded in place immediately

nform
ercia

following cleaning.
m

at
♦ Remove protective film immediately before installation.
om

ion
c

in t
r

♦ The working temperature is approx. 21 °C.

o

his
ate

do
riv

9.1.3 Scuff protection film at front and rear

p

cum
for

en
ng

t.
yi Co
Cop py
Note ht. rig
rig ht
py by
co Vo
by lksw
♦ Renewing front or rear scuff protection film is described only for the left side. The right side is similar.
cted agen
Prote AG.

♦ The front or rear scuff protection film cannot be removed without damage.

9. Scuff protection film 351

 Touran 2003 ➤
General body repairs, exterior - Edition 02.2015

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne

satelettronica
ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Removing
– Release inner door seal in front step area ⇒ page 86
– Release inner door seal in rear step area ⇒ page 113 .
– Heat front scuff protection film -1- or rear protection film -2-
using hot air blower - V.A.G 1416- and pull off from step area.
Installing
– Fitting notes ⇒ page 351
– Position scuff protection film at front -1- or rear -2-.
Front scuff protection film -1-
Rear scuff protection film -2-
– Smooth out the scuff protection film with a plastic rake with soft
paper wrapped around it.
Further installation is performed in the reverse order of removal.

352 Rep. gr.66 - Exterior equipment