Service TrainingSelf-Study Programme 549ProCarManuals.comThe Touran 2016 Body and Safety Features Design and functionThe new TouranThe success story of the MQB is clear to see in the design of the Touran 2016. The intensive work on the proportions has continued impressively in the new expressive Volkswagen design vocabulary. The vehicle appears to have been stretched as its overall length has grown and it has a longer wheelbase. Consequently, the new Touran looks very modern and stands out with its harmonious MPV proportions and generous space. The D-pillar, being a typical, characteristic brand design element, has been configured to look considerably more powerful and also more dynamic than the previous model. The angle in the side window shape and the elegant sloping roof line make it look noticeably lower than before. The design and details at the front are very powerful and striking. The combination of “sportiness” and “prestige” is expressed very well in this area.ProCarManuals.coms549_001The Self-study Programme shows the design and function of new developments. The contents will not be updated.For current testing, adjustment and repair instructions, refer to the relevant service literature.Important note2ContentsBody . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Body structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Vehicle floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Body assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Front end design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Panoramic sliding roof. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Electrically operated tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Towing bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Dash panel and centre console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Front seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Centre seats (second seat row) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Rear seats (third seat row) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Luggage compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Stowage facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Safety features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Occupant protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Pedestrian protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Test your knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30ProCarManuals.com3BodyBody structureThe body is an all-new development. It is based on the modular transverse matrix platform. An increased usage of press-hardened steel sheets and ultra-high-strength hot-formed steels guarantees a high level of crash safety combined with a low body weight. Resistance spot welding is used in the lower area of the B-pillar reinforcement. The rear section of the centre tunnel has been flattened off. This has created more room in the second row footwell. The cross member with pedestrian protection has been made wider for the active pedestrian protection system.Proportion of steel sheets according to strengthProCarManuals.com17% 35% 5%19% 24% s549_020Cross member with pedestrian protectionStrengths of steel sheets 160 MPa soft steel 220 MPa high-strength steel 420MPa higher-strength steel 1,000MPa ultra-high-strength steel 1,000MPa ultra-high-strength hot-formed steel4There are three different versions of the roof: • Closed without roof rails • Closed with roof rails • With cut-out for panoramic sliding sunroof and with roof rails The fastening point for the seat belt and the belt guide for the centre seat on the second seat row are located on the roof cross member.Roof cross memberProCarManuals.comRoof frame for the panoramic sliding sunroof with mountings for the roof railsRear floor panels549_025Rear cross member Centre tunnel5BodyVehicle floorCompared with the Golf SV, the vehicle floor has been raised 31 mm inside the body. This enables a higher seat position. The Touran has a 110mm longer wheelbase than the Golf SV. This has been achieved by making the rear cross member 110 mm longer.The join area of the longitudinal member has been adapted for the raised vehicle floor.31mm Touran Golf SVExtension of longitudinal member Seat mounting Tunnel Seat cross memberProCarManuals.comBulkheadEngine mounting bracketCentre plenum chamberFront floor Gearbox mounting bracket Bulkhead plateGolf SV Additional components for the third seat row6Additional brackets with threaded holes are welded on and a reinforced centre cross member is fitted to mount the third seat row. The ultra-high-strength hot-formed rear longitudinal members have been softened in places to absorb energy in rear-end collisions.ProCarManuals.comAdditional welded brackets with threaded holes and reinforced centre cross member Spare wheel fastening pointTouran110mmTouran Side members made 23.3 mm deeperVehicle floor raised by 31 mmGolf SVGolf SV110 mm longer rear cross member due to longer wheelbase and increased vehicle length s549_1737Body assemblyFront end designThe design corresponds to that of the modular transverse matrix vehicles.Radiator grilleThe radiator grille with its covers is clipped from the front into the bumper.WingWheel housing linersThe front wheel housing liners are equipped with • Sound-insulating fleece • A cover for changing the front fog light bulbs • A clip-on spoiler to improve the drag coefficient • A brake cooling duct (guided brake cooling air)Retaining plate Lock carrier Bumper cross member Pedestrian protectionProCarManuals.comRadiator grille, upper air intakeBumper coverThe bumper cover is bolted on at the sides and from underneath. It is clipped into the retaining strip along the top. The sensors for the parking distance warning and the park assist steering systems, the headlight washer system and the front fog lights are installed in the bumper cover.Radiator grille, lower air intakeBumper cross memberThe wider bumper cross member with the widened pedestrian protection system is new. The pedestrian protection system is clipped onto the bumper cross member.Lock carrierThere are two different lock carriers depending on the installation position of the radiator.8Gas strutBonnet latchThe Bowden cable used to operate the bonnet lock can be disconnected behind the headlight on the driver’s side.Gas strutA gas strut is used to open the bonnet.ProCarManuals.comHingess549_125 Retaining strip for bumper cover and radiator grilleThe bonnet is secured to the body with two singlepivot hinges each using two bolts. It can be adjusted via the large screw holes.Bumper coverWingsThe wings are secured on separate retaining plates along the top. This creates a flexible wing edge. This is important for pedestrian protection.Front fog lights9Body assemblyDoorsThe doors consist of the outer panel, the inner panel and the door impact bars. A mounting bracket with a new design has been integrated into the door. The mounting bracket secures the door handle and holds it in position. The lock cylinder on the driver’s door is secured by a bolt with washer. A new special tool T10539 is used to remove the door handles without a lock cylinder. The door hinges can be detached by loosening a bolt. The exterior mirror is bolted to the door shoulder line. An integrated sun blind is available for the rear door trim.ProCarManuals.comMounting bracketLock cylinders549_123 Exterior mirrors Door handles549_121 Door impact bars10WindowsThe windows on the Touran can be made of green tinted glass or dark tinted glass from the B-pillar back. The windscreen has a sound-insulation film and can be equipped with windscreen heating. The windscreen heating uses tungsten wires. The front side windows, the rear side windows and the rear window are force-fitted and bonded. The following aerials are integrated into the rear window: • AM (amplitude modulation) • FM (frequency modulation) • TVProCarManuals.coms549_129The windscreen heating is used to prevent any fogging on the inside and outside of the glass surface. It can help defrost a layer of ice.11Body assemblyPanoramic sliding sunroofThe Touran can be equipped with a panoramic sliding sunroof measuring 1.34 m2 (+ 0.24 m2 compared with previous model) from Webasto. It also features ambient lighting. The front sunroof panel has a tilt and slide function. The rear sunroof panel is fixed.The sunroof panel has a tilt height of 32mm, which is considerably higher than before. The drive motors for the sunroof panel and the sun blind are identical. They are installed in the sunroof frame from below. The sunroof roller blind is made of opaque fabric and is installed from above. It automatically opens when the sunroof panel is opened.ProCarManuals.coms549_035Ambient lightingThe ambient lighting for the panoramic sliding sunroof, which can be dimmed via the infotainment system display, consists of light strips along the sides. They provide indirect lighting of the closed blind and use LED technology.Lights for ambient lighting in the panoramic sliding sunroofs549_06312Assembly overviewOuter sealSunroof panelRear sunroof panelWind deflectorTilting mechanism, right Rear sectionProCarManuals.comSunroof cableTilting mechanism, leftElectrical wiring Sunroof frame Sunroof roller blind control unit J394 Sunroof roller blindSliding sunroof adjustment control unit J245 Cross strut Cable for sunroof roller blind s549_14713Body assemblyTailgateThe tailgate is attached to the body by means of single-pivot hinges. It is opened with a button in the handle trim. The tailgate lock is equipped with an electric power latching system. The rear window is framed by the roof spoiler with side spoilers (flaps). The side spoilers are bonded directly to the tailgate. The tail light clusters are split between a fixed section and a section on the tailgate.Roof spoilerProCarManuals.comSide spoilers Power latching systems549_179 Button for opening Tailgate lock Tailgate section of tail light cluster Fixed section of tail light cluster14Electrically operated tailgateAn electrically operated tailgate is available for the Touran 2016. The system is made up of the following components:E406• • • • • • • •The remote control The tailgate remote release button E233 in the driver's door trim The tailgate handle release button E234 One spindle drive on each side The power latching system in the lock The button to close tailgate in luggage compartment E406 (located in the tailgate trim) The sensor strips The tailgate control unitSpindle driveProCarManuals.coms549_135The spindle drive ensures very quiet running and smooth movements. Combined with the power latching system in the tailgate lock, these features make the tailgate functions easy to use. You can open the tailgate via the tailgate handle release button E234 or the remote control key. You close it with the tailgate button in the luggage compartment E406 or the remote control key. The opening height of the tailgate can be programmed.Further information on the electrically operated tailgate can be found in Self-study Programme no. 449 “The Touareg 2011”.15Body assemblyEasy OpenThe “Easy Open” function is an extension of the Keyless Access system functions. It allows you to open the electrically operated tailgate without touching it as the system can detect a specific gesture. This function is achieved by installing a capacitive sensor, which recognises specific gestures in the area behind the vehicle, underneath the rear bumper. You stand behind the vehicle and sweep a leg quickly towards the bumper and back. Your shin will enter and exit the area in which the capacitive sensor can detect movement (tailgate power opening sender). The “Easy Open” function will then open the tailgate if: • A remote control key for authorisation is located within an area not exceeding 1.5m to the rear of the vehicle. • The vehicle is stationary. • The engine and ignition are off.ProCarManuals.coms549_077 Bracket with sensor and aerial in rear bumper cover.16Towing bracketThe Touran has a towing bracket with a manually operated hinged ball head.Motor for lowering towing bracket V452ProCarManuals.comTowing bracket extendedTowing bracket retracteds549_130The electric hinged tow coupling attachment button E474 is located in the right-hand luggage compartment trim. When you press it, the ball neck will fold out and will then need to be moved into the towing position manually (by hand/with your foot) and engaged (locking mechanism). Pressing the button again unlocks the ball neck and you then need to move it manually into its rest position (behind the bumper cover).Electric hinged tow coupling attachment button E474s549_132 Trailer detector control unit J345Towing bracket with trailer socket U1017Body assemblyDash panel and centre consoleThe dash panel in the Touran has been given a more driver-oriented layout compared with the previous model. The upper area of the dash panel features a soft surface produced using slush moulding. A storage compartment with a lid is located in this area. The chrome-edged vents have been integrated centrally. A storage compartment with interface for mobile telephone is located in the centre console that rises up towards the front. The mobile telephones placed there are connected to the external aerial.Centre ventsProCarManuals.comDriver side ventRear centre consoleInfotainment systemHeating and air conditioning operating units549_119Interface for mobile telephonesThe vents, the rear air conditioning operating unit and a drawer have been integrated into the rear centre console. You will also find a 12-V socket and a USB interface there.18There is an additional compartment with a lid on the front passenger side. This is used as a storage or media compartment according to the equipment.Media compartmentFront passenger side ventProCarManuals.coms549_115 Glove compartmentThe media compartment with the control unit J794 is located above the glove compartment.Storage/media compartmentCentre consoleCentre armrests549_117 Rear centre ventss549_018The multifunction centre console is equipped with: • Jumbo box • Net in front passenger footwell • Two cup holders • Large storage compartment in front of the gear lever including USB interface, AUX-IN and 12-V socketRear air conditioning operating unit19Body assemblyFront seatsManually or electrically adjustable front seatThe manually or electrically adjusted front seat has the following adjustments: 1. Longitudinal adjustment: optimum distance from pedal cluster 2. Backrest adjustment: straight spine position 3. Height adjustment: optimum view of the road 4. Seat rake adjustment: optimum straight spine position/circulation in the legs 5. Longitudinal and height adjustment of head restraint: optimum protection in an emergency Adjustment is either manual or electric. 6. The electrically adjusted front seat also has an electrical four-way lumbar function.56 2ProCarManuals.com4 1 3 s549_073Ergonomic active seatThe ergonomic active seat is available for the driver and front passenger. It has the following adjustments: 1. Longitudinal adjustment 2. Height adjustment 3. Seat rake adjustment 4. Seat depth adjustment: optimum support for the upper thighs 5. Backrest adjustment 6. Electric four-way lumbar support with electrical massage function (lumbar support height and depth electrically adjusted): ideal support for the spine 7. Longitudinal and height adjustment of head restraint76 5 34 1 2 s549_05920Centre seats (second seat row)The second seat row is made up of three free-standing, separately folding individual seats. The individual seats have the following adjustments: • Longitudinal adjustment (approx. 200mm) • Backrest tilt (five positions) • Backrests with luggage compartment floor function • Adjustable headrests The folding centre armrest is located in the centre seat. It is standard in the Comfortline equipment level and above. All seats in the second seat row can be folded into the luggage compartment floor position as standard. This creates a flat cargo area at the same height as the luggage compartment floor in the third seat row. The outer seats in the second seat row can be heated in the Comfortline and Highline equipment levels.Folding centre armrestProCarManuals.coms549_187Easy Package functionRelease leverMovementThe Easy Package function for the outer seats in the seven-seater makes it easier to climb in and out of the third seat row. The seat can be folded forwards with the release lever. At the same time, it moves forward and engages in the Easy Package position.s549_065Integrated child seat Side head restraintsThe outer seats are also available with integrated child seats, which have a seat cushion that folds upwards. This reveals a non-slip step for the child's feet. The child is provided with additional side support by the fold-out side bolsters and side head restraints.Fold-out side bolsterss549_189 Non-slip step21Body assemblyRear seats (third seat row)The third seat row is made up of two independently folding individual seats. A flat cargo floor that joins the cargo box and second seat row without any steps or gaps is created when you fold the seats down. You can detach the seat belts from the seats and store them in the D-pillar so that they do not get in the way when you are loading the vehicle.Head restraint Release leverCargo boxs549_071 Pull-loopProCarManuals.comThe seat is released in the middle of the vehicle using the release lever at the top of the backrest and folded forward. A special kinematic mechanism allows the seat cushion to move downwards and provide space for the head restraint so it does not need to be removed. You can therefore expand the cargo area by folding down the seats completely in next to no time. The backrest is not locked into the luggage compartment floor position.Tilt 19°Pull-loopLuggage compartment floor level 2°Lowered, not locked backrestBackrest lockeds549_196The seats can be unfolded again just as easily. They are unfolded with the pull-loop.22Luggage compartmentLuggage compartment volumeThe backrests for the second and third seat rows and the front passenger seat can be folded down individually or all at the same time. They then create an extensive cargo area.ProCarManuals.comSecond and third seat row not folded down (137 litres) s549_105Third seat row folded down (644 litres) s549_103Second and third seat row folded down (1,857 litres) s549_101Luggage compartment floor systemThe luggage compartment is equipped with a variable luggage compartment floor. It can be moved to an upper or lower position using one hand.Luggage compartment managementThere is a new rail system for luggage compartment management. It consists of a net hung between two rods that can be pushed to variable positions along side rails and be used as a bag or for storage. The luggage compartment light can be removed and used as a torch.s549_111 Luggage compartment light Rail system with net23Body assemblyStowage facilitiesThe interior has been designed to be functional. All available space has been utilised in an ideal way for stowage. The Touran can therefore have up to 47 stowage compartments.Storage compartments in all doors at front for 1.5-litre bottles at rear for 1-litre bottlesStorage net on the passenger side of the centre consoleDrawers at the front under the left and right front seatsRoof console with front and rear storage compartmentProCarManuals.comStorage compartment with lid on the dash panelStorage compartment with media interfaces in front of the gear leverOpen storage compartment at the top on the driver’s sideCup holders in the centre consoleStorage compartment in the centre armrest24Storage compartment between seats in third rowBag hook on right of luggage compartmentProCarManuals.coms549_137Storage pockets on backs of front seatsStorage compartment with two cup holders in the side trim for third seat row25Safety featuresOccupant protectionThe following occupant protection features are available for the Touran 2016: • • • • • • • • • • • • • • • Single-stage driver airbag Single-stage front passenger airbag with deactivation switch Front side airbags Rear side airbags in the rear seat backrests Curtain airbags for five- and seven-seater Knee airbag on driver side Three-point seat belts with tensioners on front seats Three-point seat belts with tensioners on outer seats of second seat row Three-point seat belts on third seat row Proactive occupant protection system Belt force limiters on front seats and outer second row seats Top tether system The seats on the second and third seat rows are equipped with ISOFIX child seat anchors. Seat belt reminder Crash sensorsProCarManuals.comKnee airbag Driver airbag Side airbagSeat belt reminderThe Touran has a seat belt reminder system for all seats. The seat belt reminder informs the driver visually and acoustically via the multifunction display in the dash panel insert whether the passengers in the rear compartment have fastened their seat belts.Evaluation of the belt buckle information “latch plate inserted”/“latch plate not inserted” for the second and third seat rows.s549_19126Crash sensorsThe following crash sensors are installed: • •The curtain airbag differs between the five- and seven-seater models.Front passenger airbag•Crash sensor for front airbag Crash sensors in the doors for side collision detection (pressure sensors) Crash sensors in the C-pillars for side collision detection (acceleration sensors)ProCarManuals.comSide airbags in the rear seat backrestss549_079Proactive occupant protection systemIf the proactive occupant protection system identifies a potential accident situation when full brakes are applied by the activated brake assist system, the seat belts for the driver and front passenger are automatically pretensioned to give the best possible protection from the airbag and belt systems. In highly critical and unstable driving situations, for example, during severe oversteering or understeering with ESC intervention, the side windows (up to a remaining gap) and the sunroof will also be closed. This allows the curtain and side airbags to provide optimum protection and achieve their full effect.27Safety featuresPedestrian protectionThe Touran has an active bonnet for pedestrian protection.Active bonnetThe active bonnet can reduce head injuries to pedestrians in frontal collisions with the bonnet. The bonnet is raised by the hinges, which increases the distance between the bonnet and the components in the engine compartment (e.g. cylinder block) and thus creates an additional “crumple zone”.Crash sensors for pedestrian protectionThe Touran has the following additional crash sensors to detect a collision with a pedestrian: • Driver side crash sensor for pedestrian protection G570 • Front passenger side crash sensor for pedestrian protection G571 • Centre crash sensor for pedestrian protection G693 The sensors are mounted on the back of the bumper cover. They are acceleration sensors. They monitor 80% of the vehicle width. The pressure hose system can detect a collision across the whole width of the cross member. It consists of a silicone hose that is closed off by two pressure sensors. When pressure is applied to the hose, the sensors detect a change in the pressure hose system and send a signal to the airbag control unit.ProCarManuals.coms549_021 G693 G571 G570s549_019 Pressure hose Pressure sensors549_198Triggers for pedestrian protectionThe triggers for pedestrian protection are pyrotechnical components consisting of an ignition unit and a cylinder containing a piston. The piston has a stroke of 44mm.Cylinder Firing unit Pistons549_02728FunctionNormal position of active bonnet hinge Connection to bonnetIf the sensors detect a collision with a pedestrian within a speed range of approximately 25 to 55 km/h, the airbag control unit J234 activates the two triggers for pedestrian protection G598 and G599 on the left-hand and right-hand side of the bonnet.s549_031ProCarManuals.comTriggers for pedestrian protection G598, G599Hinge connection to top of longitudinal memberThe gas pressure produced upon ignition of the pyrotechnical propellants moves the pistons inside the cylinders. The pistons are attached eccentrically to the hook. The longitudinal movement of the pistons causes the hooks to rotate. This releases the hooks against the spring pressure and the bonnet can be raised by the active bonnet hinges. The kinematics of the active bonnet hinges and a longer striker at the front of the bonnet allow the bonnet to be raised by approximately 40–60 mm. The hinge is held in the raised position by a detent lever.Active bonnet hinge triggeredHookSpring Rear side of active bonnet hinges549_029Detent levers549_19329Test your knowledgeWhich answers are correct? One or several of the given answers may be correct. 1. Which statement about the B-pillar reinforcement on the Touran 2016 is correct? a) The lower area of the B-pillar reinforcement is welded using wobble seams. b) MIG brazing is used in the lower area of the B-pillar reinforcement. c) Resistance spot welding is used in the lower area of the B-pillar reinforcement.❒ ❒ ❒2.Which statement about the options for the roof skin on the Touran 2016 is correct? a) There is a closed variant without roof rails, a closed variant with roof rails and a variant with a cut-out for the panoramic sliding roof with roof rails. b) All roof skins are supplied with mounting holes as the roof rails are standard equipment. c) There is a closed variant without roof rails, a closed variant with roof rails, a variant with a cut-out for the panoramic sliding roof with roof rails and a variant with a cut-out for the panoramic sliding roof without roof rails.❒ProCarManuals.com❒ ❒3.What is the special feature of the rear door trims? a) The rear door trims are installed with a double crash-proof clip. b) A folding armrest has been integrated. c) The rear door trim can be ordered with an integrated sun blind.❒ ❒ ❒4.How are the side spoilers secured to the tailgate? a) The side spoilers are bonded to the tailgate. b) The side spoilers are clipped to the rear window. c) The side spoilers are bolted to the tailgate.❒ ❒ ❒305.Within which speed range is the pedestrian protection system triggered? a) 10 to 50km/h b) 25 to 55km/h c) 30 to 60km/h❒ ❒ ❒6.Which seats have a seat belt reminder? a) The seats on the second seat row b) The seats on the third seat row c) All seats❒ ❒ProCarManuals.com❒7.Which sensors belong to the pedestrian protection system? a) Pressure sensors and acceleration sensors b) Acceleration sensor and CISS sensor c) Only the acceleration sensors❒ ❒ ❒Answers: 1. c); 2. a); 3. c); 4. a); 5. b); 6. c); 7. a)31549ProCarManuals.com© VOLKSWAGEN AG, Wolfsburg All rights reserved. Subject to technical modifications. 000.2813.06.20 Technical status 10/2015 Volkswagen AG After Sales Qualification Service Training VSQ-2 Brieffach 1995 D-38436 Wolfsburg❀ This paper was manufactured from pulp that was bleached without the use of chlorine.