New VW Touran - In Depth

VW Touran

92 new photos added to album

February 20, 2003 1:04 PM
Filed Under: Volkswagen

Press Release

Page 1 - Overview of facts and figures
Page 2 - Positioning
Page 3 - Interior
Page 4 - Body
Page 5 - Transmission
Page 6 - Running Gear
Page 7 - Equipment
Page 8 - Auto 5000 GmbH

New VW Touran - In Depth

Overview of facts and figures -Touran: a third Volkswagen van joins the Sharan and Multivan
 -An A-segment MPV in compact format with a multivariable interior
 All the data and equipment details in this press information apply to the model programme offered for sale in Germany, but may differ on other national markets. Subject to amendment; errors and omissions excepted. Page 1 - Overview of facts and figures
Page 2 - Positioning
Page 3 - Interior
Page 4 - Body
Page 5 - Transmission
Page 6 - Running Gear
Page 7 - Equipment
Page 8 - Auto 5000 GmbH

New VW Touran - In Depth

1.) Positioning Multivariable family, leisure and business transport In the first quarter of 2003, Volkswagen is adding the innovative Touran compact van to its model range. In addition to the Sharan and the latest Multivan model generation just introduced, Europe’s largest automobile manufacturer now has a third attractive van model line to offer its customers. It s 53 years since Volkswagen began to build its first-ever “van�, the Type 22, which became world-famous as the “VW Bus� and can be regarded as the ancestor of all today’s MPVs. Volkswagen’s aim with the Touran has been to produce a thoroughly well-planned form of multivariable transport for the family, leisure and business purposes The body, the interior, the running gear and the driveline concept are totally new developments; the Touran has five separate seats, but another two are available as an optional extra. Among this van’s most significant features are its multivariable interior layout, which makes exceptionally good use of the available space, its high quality standard, its pioneering suspension design and an innovative driveline concept. The Touran’s character as an all-rounder makes it ideal as highly versatile transport for family, leisure and business transport. Within Western Europe’s ‘A’ market segment comprising the lower midsize or ‘Golf’ car category, the multipurpose vehicles (MPVs) represent the second-largest group, with sales of approximately 1,200,000 in 2001, equivalent to a 22.4 percent share of this segment. In the long term, forecasts state that the MPVs could even account for a 50 percent share of this segment. They achieve their highest sales volume in Germany and France, followed by Italy, Great Britain and Spain. Although series production will only start in 2003, Volkswagen plans to deliver some 130,000 Tourans by the end of the year. From 2004 onwards, there will be production capacity for up to 200,000 of these compact vans annually in Wolfsburg. The Touran reaches the market with the most innovative interior layout, the most modern engines and the highest quality Many of its features elevate the Touran to the status of ‘best in class’. As a new model line, this van will make its conquests from two existing vehicle categories in this class. The first is the traditional ‘estate car’, which will lose sales to the much more versatile MPV. The second and more important group consists of direct competitors. The Touran is superior to them on account of its exceptionally intelligent interior layout, its higher perceived quality, its more advanced engines and transmissions and its remarkable agile, safe running gear. 72 percent of the Touran’s potential customers in Europe have growing children To the extent that market research can determine, the typical Touran purchaser will have the following characteristics: 72 percent of the potential customers in Europe have children under the age of 18, the customers’ average age is 42, 60 percent run a second car and their average net household income is approximately 3,000 Euro. It is interesting to note that for about 60 percent of potential customers in Europe, functional efficiency and versatility lie ahead of available space as the most important reason for purchase, followed by size and available space (33 percent) and price/value for money (28 percent). Incidentally, there is no other type of new vehicle for which the purchase decision is taken as frequently by the complete family (70 percent). The bottom line of the socio-demographic analysis is that the main groups of people who choose the Touran are families, active people who need plenty of carrying capacity for their sport and leisure interests, customers looking for greater functional efficiency and versatility and self-employed people who will run the Touran privately and/or for business purposes. Page 1 - Overview of facts and figures
Page 2 - Positioning
Page 3 - Interior
Page 4 - Body
Page 5 - Transmission
Page 6 - Running Gear
Page 7 - Equipment
Page 8 - Auto 5000 GmbH

New VW Touran - In Depth

2.) Interior Multiple variability achieved by brilliant detail design Best-sellers such as the Golf or Polo have always demonstrated that the vehicle class to which they belong is determined solely by their overall dimensions. Inside the car, a pleasant ambience is assured by installing seats of excellent ergonomic design, equipping and trimming the driver’s area to high standards and ensuring that the occupants enjoy a generous sense of space. The Touran has more interior height than any other model in its class (1.02 metres at the front seats, 0.99 m for occupants of the second row of seats). Its interior length from the pedals and the second-row seat back is 1.68 m and its width at elbow height is 1.46 m at the front and 1.48 m at the rear. The maximum load-area length is 1.75 m, and up to 1,989 litres of load volume (5-seater) are available to the Touran’s owners for a variety of load carrying purposes. Up to three rows of seats make the Touran highly versatile and vastly increases its potential benefit to the owner. This is achieved not only by the variable seating arrangements in the second row and the fully retracting third-row seats (optional extra) but also by the sheer size and carefully planned layout of the Touran’s interior. 1st row of seats The Touran’s interior: the front-seat area; passenger’s airbag shutdown, pedals that move away from the feet in a crash Like all the seats in the Touran, those at the front are of highly ergonomic design. They are an entirely new concept: the occupant sits slightly higher (at 631 millimetres) than in a conventional passenger car, and the headroom of 1,020 mm already mentioned is the best value in this class. The result is a quite exceptionally relaxed sense of space. The front seats have 254 mm of forward-and-back adjustment, and in addition the driver’s seat can be varied in height by 61 mm. Standard protective features for the front seat occupants include active head restraints and also front, side and side head-level airbags. If a small child travels at the front in a ‘reboard’ child’s seat, the passenger’s airbag system can be de-activated at a key-operated switch in the glove box. An easily visible telltale display under the hazard warning switch between the central ventilation outlets acts as a reminder that the front passenger’s airbag is out of action. For additional safety in the event of a frontal crash, the brake and clutch pedals are arranged to move down forwards. Since the Touran driver has a particularly comfortable, more upright seated position, Volkswagen’s design engineers have modified the accelerator pedal: instead of the usual ‘pendant’ layout, it is bottom-hinged so that the foot adopts a more relaxed position, particularly on long journeys. Plenty of storage space makes day-to-day driving more convenient and safer too. Everything important is immediately to hand, for example the first aid box under the driver’s seat The generous storage facilities in the front-seat area are a highly practical feature. The Touran has a storage compartment under each front seat as a standard feature, for example, and with Trendline equipment and upwards, a drawer for larger items. The first aid box (an optional extra) is easily accessible in the storage compartment on the driver’s side. There is a further compartment at the top, on the fascia, with a lid to conceal the contents from inquisitive eyes. If the Touran is ordered without a sunroof, there is further storage space in the form of a large roof console with three swing-down compartments, one of which can be used to hold a pair of sunglasses safely. A further lockable storage compartment has been provided in the centre console between the driver’s and front passenger’s seats. In front of the armrest, next to the handbrake lever, there are two easily accessible cup holders. The large storage bins in the doors are equally easy to use, and are capable (as in the rear doors too) of holding a one-litre bottle. To add further to the practical value of the Touran’s interior for front-seat occupants there is a compartment under the radio console, another to the left of the steering wheel and a glove box that can be cooled if the air conditioning is fitted (this depends on the chosen equipment level). The fascia has been completely redesigned; all functions can be selected intuitively in the Touran All the main design features inside the car, from the driver’s area through the door trims and controls – have been newly developed. Where the driver finds a familiar element, for example the headlight switch, he or she can be sure that it is of effective, mature design and can be operated intuitively without having to rethink the situation. But there are also details that greatly enhance the occupants’ comfort and convenience without this being immediately apparent: for instance the ventilation switches automatically to the recirculated-air mode when reverse gear is selected. The heating, ventilation and air conditioning are a good example of this principle. Whereas the ‘Climatic’ system that is standard in the Touran Highline retains the familiar layout, the optional-extra two-zone ‘Climatronic’, with its automatic regulating system and separate temperature and ventilation settings for the driver’s and front passenger’s sides of the interior, has an entirely new set of controls that are self-explanatory and, like the familiar ‘Climatic’ system, can be operated intuitively, without risk of confusion. Climatronic functions are controlled by three rotary knobs with integral pushbuttons. The two outer knobs are used to select the preferred temperatures on the driver’s and front passenger’s sides of the vehicle. The central rotary knob varies the blower speed and has an integrated switch that shuts down the entire system. The left control includes buttons for the heater rear window and the defrost function; the right control has buttons for the fully-automatic operating mode (Auto) and operation without cooling (Econ). To make them easier to read, the digital interior temperature setting displays, the recirculated-air button and the ventilation controls are on a separate panel above the three rotary knobs, together with the two knurled thumbwheels for the front seat heating, another optional extra. Information and entertainment as a standard feature: the RCD 300 radio with integral CD player Easily accessible and legible below the heating and air conditioning controls is the RCD 300 radio with CD player, which is a standard item even at Basic equipment level. Potential thieves are less likely to be interested in this 2 x 20 Watt audio system, since its design has been specially matched to the Touran. The controls and appearance of this new-generation radio match the other systems in the Touran. The operating functions are clearly laid out with three buttons at the left and right for the menu functions, CD player operation and radio-station memory. A large monochrome display provides the necessary visual information. Radio stations, CD titles and changeover between radio and CD player are selected, as is customary in Volkswagen models, at a further row of buttons below the display. With the Highline equipment level and above, or as an optional extra, an audio system with a rated output of 4 x 20 Watts can be obtained. In addition to a 6-CD changer, Volkswagen offers a combined radio and navigation system (RNS) for the Touran, which can also be prepared for the installation of a mobile phone including handset holder, hands-free operation and a new dual-band roof-mounted aerial. 2nd row of seats The Touran’s interior: the second row is far superior to the customary bench seat, and consists of three separate, removable seats that can be folded, slid forward-back and moved sideways The three separate seats that make up the second row can, in a few easy movements, be slid forwards and back, moved sideways, folded or taken out completely. They are extremely light in weight: 15.9 kilograms for the outer seats, 15.7 kg for the centre seat. The relatively high position (676 millimetres) of the seats provides good thigh support and an excellent standard of comfort even on long journeys. Headroom is the second row is 989 millimetres. Occupants of the second row of seats benefit from the same careful attention to detail. there are pockets and folding tables with cup holders on the backs of the front seats (Trendline or higher), the centre seat can be used as a table, there are storage compartments in the floor in front of the seats and storage bins of ample size in the doors (here too specially shaped to hold one-litre bottles). Even the kids’ favourite toys can be accommodated without difficulty. The seats’ adjusting and removal mechanisms are particularly easy to operate and practical. A high-grip handle is pulled up to slide the seat forwards or back. Easily reached and operated loops are pulled to fold the seat back or the complete seat forwards or release it for removal from the vehicle. Safety for the younger, smaller passengers: Isofix mountings for matching children’s seats are standard at the outer second-row seats, and even the centre seat has a lap-and-shoulder seat belt Every passenger in the Touran enjoys the best possible level of protection. There are head-level side airbags for the second row of seats as well, and all three seats have lap-and-shoulder seat belts and head restraints. When not needed, the centre seat belt retracts automatically into the roof lining and is anchored there. The two outer seats have integrated Isofix child’s seat mountings. The raised seated position not only improves the view through the fully retracting side windows but also makes it easier for parents to fasten the child’s seat belt. In this respect in particular the van is superior to classic saloons and estate cars, since hunting for the low-mounted seat belt buckles is no longer necessary. For the Touran’s occupants, both large and small, there is a special cup holder at the end of the centre console, capable of holding even a large bottle securely. Another feature until now largely reserved for midsize and large cars is the provision of two additional ventilation outlets and another 12-Volt power socket in this area. The latter will not only be of interest to young people with MP3 players but also supplies power to the optional cold-store box that can be attached firmly to the vehicle’s floor in place of the centre seat. There is another 12-Volt power socket in the load area. 3rd row of seats The Touran’s interior: an optional third row of separate seats that retract into the floor; plenty of shelf and compartment space and lap-and-shoulder seat belts As an optional extra, the Touran can be equipped with a third row of seats. They have been made available as an option because not every owner will need them. The five-seat version of the Touran avoids the additional weight of the third-row seats and the slight reduction in load space that they entail. But if the seven-seat version is chosen, Volkswagen provides even adults with a comfortable, safe means of transport entirely suitable for medium-distance travel on the sixth and seventh seats. By moving the second-row seats forwards, additional legroom can be provided for those seated behind when necessary. If they are not needed, the third-row seats are simply folded away by a simple-to-use retracting mechanism, revealing a flat load-area floor. Each seat can be folded separately, and is then only 183 millimetres high. The third-row seats are also equipped with lap-and-shoulder seat belts and head restraints that extend a long way. Before the third-row seats are folded away, these head restraints are removed and can then be kept clean and safe in a separate compartment in the load-area floor. Depending on its decor line and equipment level, the Touran has up to 39 means of storing items during the journey. In addition to the compartments and pockets provided for the occupants of the first two rows of seats, those at the back enjoy a similar standard of convenience, with lockable storage compartments and cup holders in the side panel trims. Load area The Touran’s interior: the load area holds 695 litres in the five-seat version, and total capacity can be as high as 1,989 litres Optimum use of the interior space includes the load area. There are storage compartments in the side panel and the floor to accommodate all those items that normally lie around loose. Even the warning triangle has its own compartment in the tailgate trim, where it can still be easily reached even if the vehicle is fully laden. As an optional extra, the five-seat version of the Touran can be ordered with a reversible load-area floor. The load area is altogether highly adaptable and efficient in layout. With the classic five-seat configuration in use for passenger carrying, its maximum capacity is 695 litres. Depending on which version of the Touran is ordered, the maximum payload is up to 660 kilograms. The seven-seater Touran still has a 121-litre luggage space behind the third row of seats. If all the second-row seats are taken out and the third row retracted, the maximum load volume rises to 1,913 litres. In the five-seat version, removing the second row of seats yields the remarkable load area of 1,989 litres, a best-in-class value. The seven-seat Touran’s load-area cover can be attached safely and without risk of rattling behind either the second or the third row of seats Further evidence of perfection in detail: the pull-out load-area cover (standard equipment with Trendline or higher). It can be attached behind either the second or the third row of seats. In this way, even with six or seven people on board, the cover does not have to lie around loose in the load area. A load retaining net, a pull-out bag hook in the right side panel and an additional 12-Volt power socket round off the picture of a new type of car that has been developed with no compromises to be entirely suitable for every practical day-to-day driving need. Page 1 - Overview of facts and figures
Page 2 - Positioning
Page 3 - Interior
Page 4 - Body
Page 5 - Transmission
Page 6 - Running Gear
Page 7 - Equipment
Page 8 - Auto 5000 GmbH

New VW Touran - In Depth

3.) Body Maximum space, minimum area The Touran looks considerably larger than a classic lower midsize car. And so it is – inside! Comparison with the Golf Variant estate car reveals how Volkswagen has obtained a most impressive amount of interior space within the same compact road space. The Touran (4,391 millimetres) is similar in overall length to the Golf Variant (4,397 mm), and six centimetres wider (1,794 mm). The most obvious difference, as one would expect, is in overall height: without roof rails, the Touran is 1,652 millimetres high, about 16 centimetres more than the Golf Variant. Bodyshell structure 69.5 metres of laser-welded seams and high-strength grades of steel make up the Touran’s safe, high-quality body The Touran’s bodyshell, many areas of which are galvanised, is a composite steel structure fabricated by laser welding. No fewer than 69.5 metres of laser-welded seams combine the steel elements into a crash-optimised structure of high torsional rigidity. High-strength steels are used where necessary to increase rigidity and crash safety. 62 percent of the body consists of these extra- or high-strength sheet steel grades. Careful attention to construction details avoids unwanted body shake and creaking noise on the one hand and provides a firm basis for accurate suspension control on the other. Form and function Form follows function: this new Volkswagen’s body styling reflects its high level of functional efficiency Immediately obvious Touran styling elements are the short body overhangs (front 877 millimetres, rear 836 millimetres) and the 2,677-mm wheelbase. A practical design feature aimed at enhancing the car’s practical value are the large doors which extend well down into the sill panels. Their wide openings (front 837 mm, rear 887 mm) make entering and leaving particularly easy at all seats. Wide side rubbing strips in the same colour as the body (black on the Basic version) protect against minor damage, for instance when parking. The outside mirror housings with their integral flashing turn indicator repeaters and the pull-action door handles are also painted in body colour (Trendline equipment level and higher). The Touran is notable for its smooth body surfaces and unity of design, emphasised by the continuous window areas at the sides and also by the flared wheel arches. The roof rails that are standard on the Touran Trendline and Highline not only look attractive but are highly practical too. They are black with the Trendline equipment and trim option and chrome-anodised on the Highline version. Also with a chromed surround on Trendline cars and upwards: the characteristic Volkswagen radiator grille. The headlights too have chromed surrounds. Their ‘free-form’ reflectors provide the low and high beams and also accommodate the flashing turn indicators and the parking lights. If a bulb should fail, the ‘One-Touch’ system enables it to be renewed extremely quickly and easily. The failure is also shown on the cockpit display. The optional-extra fog lights (standard with Highline) are in the lower section of the front apron panel. Bi-xenon headlights are another Touran optional extra. The Touran’s rear-end styling has visual parallels with the Multivan, another very recent design. The rear lights are unusually large, with circular light units integrated into their surfaces as on the Passat. This results in a particularly striking effect after dark. The rear window is comparatively wide and deep: this too is a styling element but also a practical design feature, since it improves the view to the rear. The tailgate has a large opening with a loading edge only 557 millimetres from the ground. An unusual technical feature of this ‘fifth door’ is that it opens in two stages: the ‘Inter-Stop’ gas-filled support spring raises it initially to a height of 1,822 millimetres (measured at the lock), then to its final height of 1,958 millimetres. Tall people may wonder why this two-stage mechanism has been provided, but those who are not so tall will appreciate being able to reach the handle more easily when closing the Touran’s tailgate. The wipers are recessed when parked, and clean a particularly large area of the windscreen The innovative character of many seemingly mundane details of the Touran’s design is exemplified by the windscreen wipers. The opposed movement of the two wiper arms cleans and dries a glass area that is particularly large on the front passenger’s side. Every second time the wipers are switched off, the linkage moves them slightly upwards to reverse the angle of the rubber blades and thus prolong their working life. The same effect is achieved by arranging for the wipers to move briefly to their parked position after every 15th cycle. Another feature that is not by any means common in the Touran class: when the vehicle comes to a halt in traffic, the wiper speed is automatically reduced to the next-lower setting. As soon as road speed rises above 8 km/h again, the original wiper speed is restored. There are also four intermittent-wipe settings with intervals that are partly influenced by the vehicle’s speed. As soon as the engine compartment is opened, the wipers are switched off. If reverse gear is selected with the windscreen wipers in use, the rear –window wiper is automatically switched on. The often irritating process of drying the windscreen after it has been washed is also taken care of by these ‘intelligent’ wipers: five seconds after the final wipe, the typical remaining droplets are wiped away automatically. If the driver operates the windscreen washer jets for more than two seconds, the wipers then operate at the second, faster speed. Page 1 - Overview of facts and figures
Page 2 - Positioning
Page 3 - Interior
Page 4 - Body
Page 5 - Transmission
Page 6 - Running Gear
Page 7 - Equipment
Page 8 - Auto 5000 GmbH

New VW Touran - In Depth

4.) Engines / transmissions Direct injection and six speeds The Touran is being launched with a choice of two turbocharged direct injection diesels and a direct petrol injection engine. New options are an advanced 2.0-litre TDI with four valves per cylinder and an innovative, more powerful 1.6-litre FSI (direct petrol injection) engine. This develops 85 kW (115 bhp), the TDI engines either 74 kW (100 bhp) or 100 kW (136 bhp). All the Touran’s engines comply with the EU 4 limits and qualify for a tax concession on the German market. A 1.6-litre spark-ignition engine rated at 75 kW (102 bhp) can be ordered from May 2003 onwards and another FSI engine, of 2 litres’ displacement and with an output of 110 kW (150 bhp), somewhat later. Apart from the low fuel consumptions, all these engines are also notable for their extended maintenance intervals. Tourans with a spark-ignition engine need an oil change and maintenance only after up to 30,000 kilometres; the diesels can cover up to 50,000 km before a service is due. All models can run for two years at a time before an oil change and routine maintenance has to be carried out, provided that they only cover relatively short annual distances. A unique offer in this market segment is that all FSI and TDI models have a six-speed gearbox as standard equipment. At a later date, TDI-engined versions will be available with the new, highly innovative direct-shift gearbox (DSG), which also has six forward ratios. It combines the advantages of a conventional automatic transmission with the agility and economy of a manual gearbox in a totally new, fascinating manner. This gearbox was first used in the 177 kW (241 bhp) Golf R32. With the FSI engine, a new convenience-oriented six-speed automatic transmission (Tiptronic) will also be available. 1.6 FSI The Touran 1.6 FSI in detail: an innovative 85 kW (115 bhp) direct petrol injection engine An innovative direct petrol injection engine of the latest design generation powers the Touran 1.6 FSI. Compared with the unit already installed in the Golf and Bora, it has been modified technically for its new task. Whereas the FSI in the Golf and Bora develops 81 kW (110 bhp) at 5,800 min-1, the peak output of the unit installed in the Touran is 85 kW (115 bhp) at the same engine speed. The Touran FSI reaches its maximum torque of 155 Nm at 4,000 min-1 (Golf and Bora: 4,400 min-1). There is no denying that since the FSI principle was introduced in the Golf as well during 2002, this new, forward-looking range of engines has achieved a major breakthrough. Like the abbreviation TDI, familiar today the world over for the Group’s exceptionally dynamic, economical turbocharged diesel engine, the three letters FSI stand for a new alliance between economy and dynamism, this time in the form of a spark-ignition engine. Following the Lupo, Polo, Golf and Bora, the Touran is now the Volkswagen brand’s fifth model line to use this new type of engine. The 1.6-litre Touran engine, now with an aluminium block, has extremely good acoustic properties. The valve gear, for example, is driven by a noise-optimised toothed chain. The timing case has also been modified to achieve an improved noise pattern. Other modifications relate to the cylinder head cooling, the oil pump (redesigned to lower its energy consumption still further), the oil-cooler, the continuous camshaft control system and the actual combustion process including the two-stage fuel injection. The engine-management control unit is new, the air intake system has been optimised for maximum power and torque, the fuel supply system is demand-regulated and the catalytic converter has been further developed to ensure that the 1.6 FSI is one of the supreme spark-ignition engines in this size and performance category. The Touran 1.6 FSI reaches 100 km/h from a standing start in 11.9 seconds and has a top speed of 186 kilometres an hour. The total fuel consumption according to the EU standard test values is an outstandingly low 7.4 litres of super (premium) petrol per 100 kilometres. The extra-urban test figure is 6.2 l/100 km. Since its engine complies with the EU 4 exhaust emission limits, the Touran 1.6 FSI qualifies for a tax concession on the German market. 1.9 TDI The Touran 1.9 TDI in detail: 250 Newton-metres of torque, EU 4 compliance and an action radius of 1,000 kilometres Already used with great success, the 1.9 TDI engine is another extremely innovative unit. From a displacement of 1,896 cc it develops 74 kW (100 bhp) at 4,000 min-1. Its maximum torque of 250 Newton-metres is reached at only 1,900 min-1. Like the 2.0 TDI, this engine’s exhaust passes through a two-way oxidating catalytic converter, so that the Touran complies with the EU 4 exhaust emission limits; for this reason, the version with this TDI engine is granted a road-tax concession. The 1.9 TDI accelerates this new van from 0 to 100 km/h in 13.5 seconds and gives it a top speed of 177 km/h. Fuel consumption is as low as would be expected from the Polo or Golf versions that use this engine: no more than 5.9 litres of diesel oil per 100 kilometres according to the total EU-test figure. Thanks to a fuel tank that holds 60 litres, a theoretical action radius of 1,000 kilometres before refuelling is attainable. The 1.9 TDI consumes as little as 5.2 l/100 km in the extra-urban test. Among its main technical components are a turbocharger with variable blade geometry, a charge-air intercooler, direct pump-injector high pressure fuel injection, a cooler for the exhaust gas recirculation system, an electrically operated regulating flap and injector nozzles of special conical pattern. 2.0 TDI The Touran 2.0 TDI in detail: green light for a new generation of Volkswagen TDI engines The refined 2.0-litre, four-cylinder TDI engine in the Touran initiates a new era for the world’s most successful manufacturer of diesel engines. It is the first Volkswagen turbocharged diesel to combine the innovative pump-injector fuel supply principle with four valves per cylinder. This first example of the new generation of TDI engines has a displacement of 1,968 cc and develops 100 kW (136 bhp) at 4,000 min-1. The impressive torque of 320 Newton-metres is available all the way from 1,750 to 2,500 min-1. This is the key to the Touran 2.0 TDI’s notable performance figures. It reaches 100 km/h from a standing start in only 10.6 seconds and, with its standard six-speed gearbox, needs only 9.5 seconds to accelerate from 80 to 120 km/h in fifth gear. This new Volkswagen model has a top speed of 197 km/h. The fuel consumption is particularly moderate in the light of these performance figures: a miserly 6.0 litres per 100 km is the total figure achieved on the EU test cycle. Even on the urban part of the test, the consumption is only 7.6 l/100 km, falling to an average of 5.2 l/100 km on the extra-urban test. These are impressive values for a luxuriously equipped van with a high safety standard and an unladen weight excluding the driver of 1,558 kilograms according to the DIN standard test. The principal design features of the new 2.0 TDI engine: double overhead camshafts, valves operated by low-friction roller cam followers with hydraulic clearance adjusters and pump-injector elements actuated by roller-ended rockers from the exhaust camshaft. As previously, a turbocharger with variable turbine blade geometry is used. The crossflow cylinder head is a new development, with two tangential inlet ports per cylinder and “rotated valve star�, the term used for the special arrangement of the four valves in relation to the crankshaft, which ensures the best possible port geometry and an optimum combination of swirl and cylinder filling. The Touran 2.0 TDI is the first diesel-engined car in this performance category that complies with the EU 4 standard A combination of four valves per cylinder and high-pressure pump-injector fuel supply has made it possible for the first time for a diesel engined car to comply with the EU 4 exhaust emission limits. A central role is played by the six-hole injector nozzles located centrally in each combustion chamber, which have conical, flow-optimised holes. Equally important is the central bowl-in-piston combustion chamber with its new emission-optimised geometry. To lower emissions of oxides of nitrogen still further, Volkswagen has installed an EGR cooler (EGR = exhaust gas recirculation) that can be switched into and out of circuit in order to ensure the best possible response from the two-way oxidating catalytic converter. The quantity of recirculated exhaust gas is precisely controlled by an electric throttle valve. In addition, a new generation of pump-injector elements has been developed for the four-valve engine. They are compact in construction, have a part-load injection pressure that has again been raised by a moderate amount and incorporate measures to reduce injection noise. These injectors make a significant contribution below the line to overall engine quality. The fuel consumption of the four-valve engine is normally as much as eight percent lower than that of a two-valve engine with a similar power rating. In addition to the further reduction in noise emanating from the pump-injector elements, acoustically optimised pistons a cylinder head reinforced both longitudinally and laterally and an insulated toothed belt cover help to ensure a quiet, pleasant sound from the engine. The noise level of 78 dB recorded by the Touran 2.0 TDI when at a standstill is even lower than that of the 1.9 TDI. Even at arctic temperatures: no pre-heating interval for the 2.0 TDI The diesel engine’s rapid starting system with temperature-controlled metal glowplug is an entirely new departure. It permits instant starting without a lengthy pre-heating period in almost all climatic conditions. In conjunction with the six-hole injector nozzles which supply a jet of fuel specially intended for good ignition, the new-generation TDI engine has excellent cold starting and warming-up characteristics and not only offers a pioneering level of refinement but also exceptional driving pleasure, extremely low exhaust emissions and low fuel consumption. Six-speed manual-shift gearbox All FSI- and TDI models have a six-speed manual gearbox as standard Touran versions with an FSI or TDI engine will have a six-speed gearbox as standard equipment – an absolute novelty in this market segment. This ultra-modern gearbox has a magnesium shift housing, is cable operated and has very short lever movements. Three-cone synchromesh for the lower gears ensures a pleasant shift action. Detail optimisation such as reduced-friction bearings have further increased the gearbox’s efficiency and reduced the engines’ fuel consumption. Front-wheel drive is used, and there is a hydraulically actuated single dry plate clutch with a double-mass flywheel to suppress unwanted vibration. 6th gear is a normal ratio rather than an extra-high overdrive. Although the greater spread of ratios permitted by the six-speed gearbox benefits fuel consumption, it also makes the Touran more agile. These gearboxes are filled with lifetime oil and need no routine maintenance. Six-speed automatic (Tiptronic) Innovative transmission in this segment: the Touran is the only model in its class available with a six-speed automatic transmission The six-speed automatic (Tiptronic) transmission available as an optional extra for the Touran 1.6 FSI is a most significant new departure. The Volkswagen Group is so far the only manufacturer anywhere in the world to offer a transversely mounted six-speed automatic transmission. The shift programmes vary to take driving conditions into account, for instance when climbing a gradient or towing a trailer. The Tiptronic function (with + and – lever movements) is an alternative for those who wish to select gears manually. A specially sport-oriented shift program (‘S’) is also provided for even greater agility. Compared with automatic transmissions having only four or five gears, the wider spread of ratios in the six-speed unit improves the car’s acoustics, cuts fuel consumption and ensures more lively acceleration. The new six-speed automatic transmission contains a Ravigneaux planetary gear set combined with a simple planetary gear set and five electro-hydraulically actuated friction shift elements. For smooth starting, there is a hydrodynamic torque converter with a free-shift lock-up clutch that helps to reduce emissions and fuel consumption. A separate electronic control unit looks after transmission functions and communicates with the engine and the rest of the vehicle. The automatic transmission’s maximum input torque is more than 300 Newton-metres. With a view to achieving the best possible ease of servicing, it is filled with a ‘lifetime’ grade of oil that does not need to be replaced. Direct-shift gearbox (DSG) No other van on the world market can be obtained with a double-shift gearbox (DSG) The direct-shift gearbox (DSG) is currently the most advanced passenger-car transmission available anywhere. It has been developed by the Volkswagen Group and can now be specified in the Gold R32 sports saloon and the Audi TT V6. In future, it will also be available for the first time in conjunction with TDI engines – in the Touran 1.9 TDI and 2.0 TDI. The DSG , which also has six forward gears, is a fascinating combination of the convenience of an automatic transmission with the agility and economy of a manual gearbox. Among the outstanding design features of this transversely installed gearbox are the two wet-type clutches (which withstand higher thermal loads than conventional dry-plate clutches); their contact pressure is regulated hydraulically. Clutch 1 is used for the odd-numbered gear ratios and reverse, clutch 2 for the even-numbered ratios. Basically speaking, one can therefore speak of two gearboxes in one. How the ingenious clutch management system works: the breaks in the power flow that are typical of even an automatic-shift manual gearbox no longer occur. The gear shifts take place in a smooth, refined but also highly dynamic manner. This is achieved by, on the one hand, an intelligent hydraulic and electronic (mechatronic) gearbox control system, the two wet-type clutches and the two input and out shafts in each half of the gearbox. This combination enables the next-higher gear ratio to remain engaged but ‘in reserve’, so to speak, until it is selected, which then takes place unbelievably quickly. In other words, if the car is being driven in third gear, fourth gear is already selected but not yet activated. As soon as the ideal shift point is reached, the clutch on the third-gear side opens, the other clutch closes and fourth gear takes effect. Since the opening and closing actions of the two clutches overlap, a smooth, continuous gear shift is carried out. The entire gear shift process is completed in only three to four hundredths of a second, no longer than the ‘blink of an eye’. In addition to its fully-automatic shift mode, DSG has a ‘Tiptronic’ function to permit manual gear selection. In either case the response to gear shift decisions is not only exceptionally refined but also gives the driver a strong sense of satisfaction. The enthusiastic driver can for the first time experience perfect gear shifts ‘at the touch of a button’. To make sure that, for example, upshifts are suppressed when the car is being cornered, information on wheel rotating speeds is supplied by the ABS sensors to the transmission control unit. The engine that drives the car though a DSG gearbox always runs in the best possible torque range, since full traction is available immediately in every gear. Another decisive advantage is that this new type of gearbox permits the car to be driven in a vigorous manner, but with a fuel consumption as good as a conventional manual-gearbox car would normally achieve. The acceleration figures and the top speed are also almost unchanged. Gearboxes of this type were used in motor sport some years ago, but in those days the mechanical and electronic components were not sufficiently advanced to ensure the necessary smooth changes for passenger-car use. Volkswagen has now tackled these challenging design problems successfully by developing many new hydraulic components and in particular the complex mechatronic assembly without which the DSG would be impracticable. Page 1 - Overview of facts and figures
Page 2 - Positioning
Page 3 - Interior
Page 4 - Body
Page 5 - Transmission
Page 6 - Running Gear
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New VW Touran - In Depth

5.) Running gear Start of a new era in suspension design It is the new suspension that gives the driver of this latest Volkswagen model such a direct feel for the road and makes it so agile and safe in its road behaviour. The front suspension uses the spring and shock absorber strut, using a triangulated lower wishbone and spring and the strut for wheel location. At the rear, an entirely new four-link suspension layout brings the car’s handling even closer to perfection. It consists effectively of three lateral control arms and a trailing arm for the precise location of each wheel. These new suspension ensures the best possible dynamic stability and ride quality, but this is not all: they also set new standards for agile handling in this vehicle class. Front suspension The Touran’s strut-type front suspension in detail; extremely precise location of components on the subframe Each front road wheel is located by a spring strut and a single lower wishbone attached to the central subframe. The settings chosen are aimed at improving the concept’s excellent basic features still further and achieving optimum ride comfort allied to excellent dynamics. The key front suspension element is an aluminium subframe, attached to the body at six points; it optimises both the acoustic and dynamic properties of the Touran. The lateral control arms, anti-roll bar and steering system are pre-assembled on this subframe during production, so that their precise positioning can be guaranteed. The lateral control arms pivot on rubber bushings with new settings that permit a controlled degree of lateral compliance at the wheel and thus also help to optimise ride quality. However, they are much firmer across the car, which improves wheel location and makes the steering more responsive. The chosen spring and shock absorber settings represent a satisfactory blend of ride comfort and dynamic road response. This is aided by the new type of suspension strut pivots, which transfer loads from the spring and the shock absorber separately to the bodyshell. This enables the shock absorbers’ damping rates to be optimised. The suspension strut pivot bushings have different stiffness ratings along and across the vehicle’s centreline, which improves the ride and makes road behaviour more dynamic. The front anti-roll bar is attached directly to the suspension struts, which has the effect of greatly reducing the body roll from which a van can otherwise suffer when cornering. Thanks to this, roll has been restricted to the same level as a good conventional saloon car achieves, without any sacrifice in ride comfort. Rear suspension The Touran’s four-link rear suspension in detail; a combination ofdynamism and ride quality never before achieved in this market segment A completely new development, the Touran’s four-link rear suspension is innovative in every respect. In conjunction with the thoroughly revised and improved strut-type front suspension, the running gear achieves a combination of dynamism and ride comfort previously unmatched in this market segment. The compact four-link layout has three lateral control arms (the spring mounting, the track rod and the upper control arm) and a trailing link at each wheel. This layout enables longitudinal and lateral dynamics to be tuned independently; the results are immediately evident as a very high level of dynamic stability and ride comfort. The suspension assemblies are attached to the body by way of a rear-axle subframe. As at the front, rubber-and-metal mountings that are soft in torsion but stiff radially are used to ensure that the anti-roll bar responds immediately and suppresses body roll effectively. The spring and the shock absorber on each side are located separately; the spring bears directly on the trailing link and the shock absorber is attached to the wheel hub assembly. The carefully chosen suspension geometry on the compression stroke generates a toe steering effect that maintains neutral behaviour or slight understeer in all driving and load-carrying situations. The rubber-and-metal mountings on the body for the trailing arms have a high degree of fore-and-aft compliance, as a contribution to ride quality. The shock absorbers are spaced well apart, which also permits the through-loading width in the load area to be as wide as possible. Steering Electro-mechanical power steering saves fuel and distinctly reduces driveline feedback; power assistance dependent on road speed is a standard feature For the first time on a Volkswagen model and new to this market segment, electro-mechanical power steering is a standard fitting. Compared with conventional power steering systems, it can save as much as 0.2 of a litre of fuel per 100 kilometres, depending on driving style. The degree of power assistance is always dependent on road speed, and the system is easier to tune to the needs of specific car models. A most welcome feature is that effectively no driveline influences are transmitted. This steering system varies the ‘feel’ at the steering wheel to suit the driving situation, something that previous electro-mechanical systems have not been able to do: firm and direct when driving hard, effortless when parking. Individual vehicle characteristics can be programmed into its electronics, for example to take the weight of the car’s equipment into account, so that optimum steering response can be assured on every version of the Touran. Other advantages of this steering system is its mild self-centring action after the steering wheel has been turned, and its ability to ‘adapt’: crosswinds or a steeply cambered road surface are identified after a certain distance has been covered and the effective steering ratio changed to compensate for these effects. The driver does not have to apply additional effort at the steering wheel but can continue to drive straight ahead in a relaxed manner. Wheels and tyres Wheels and tyres: basic version with 15-inch wheels and size 195 tyres, Trendline and Highline with 16-inch wheels and size 205 tyres The basic version of the Touran has 15-inch wheels and tyres of size 195/65 R 15 as standard equipment. High-strength dual-phase steel grades are used for the wheels, so that each weighs under 7.6 kilograms but can withstand a wheel load of 600 kilograms. For the Trendline equipment level, 16-inch pressed-steel wheels and size 205/55 R16 tyres are fitted. The distinguished Touran Highline has “Hockenheim� pattern alloy wheels with the same dimensions. Brakes Disc brakes all round and ESP with integral Brake Assist as standard equipment The Touran is braked by discs at all wheels. The front discs, with a diameter of 288 millimetres, are of ventilated pattern; the rear discs have a diameter of 260 millimetres. The handbrake acts on the rear wheels. Standard equipment for all Tourans is the electronic stability program (ESP), which includes the anti-lock braking system (ABS), the electronic differential lock (EDS), traction control (ASR) and Brake Assist. Page 1 - Overview of facts and figures
Page 2 - Positioning
Page 3 - Interior
Page 4 - Body
Page 5 - Transmission
Page 6 - Running Gear
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New VW Touran - In Depth

6.) Equipment Basic version with numerous comfort, convenience and safety features The new Volkswagen van is available with three levels of equipment: Touran, Touran Trendline and Touran Highline. The 2.0 TDI Touran has the Trendline equipment package as standard, but Volkswagen has given even the Basic version such features as six airbags, ABS, ESP including Brake Assist, central locking with radio-operated remote control, electric windows at front and rear and a radio with integral CD player. The list below shows the principal details of the three equipment levels. Touran – basic version The Touran: extensive comfort, convenience and safety equipment even in the five-seat Basic version Touran Trendline Touran Trendline (5 seats): additional sports-style equipment items compared with the Basic version Touran Highline Touran Highline (5 seats): additional details at the most exclusive equipment level compared with the Trendline version Page 1 - Overview of facts and figures
Page 2 - Positioning
Page 3 - Interior
Page 4 - Body
Page 5 - Transmission
Page 6 - Running Gear
Page 7 - Equipment
Page 8 - Auto 5000 GmbH

New VW Touran - In Depth

7.) Auto 5000 GmbH Regional job security with a new “factory within a factory� Just as advanced in its concept as the Touran is the production scheme planned for it at a new facility in Wolfsburg. The company is known as ‘Auto 5000 GmbH’ and will recruit no fewer than 3,500 new employees. They will receive nine months of advance training so that they possess general qualifications as automobile construction workers, and will then be integrated into an innovative production, sales, marketing, logistics and quality assurance concept. These measures are intended to give a lasting boost to Volkswagen AG’s ability to compete. The ‘5000 x 5000’ project Project 5000 x 5000 – a fine example of how to promote Germany as an industrial location The new production facilities for the Touran and the working conditions associated with this project have already been praised as a fine example of how jobs can be safeguarded in German industry. Auto 5000 GmbH company has been set up by Volkswagen AG is intended to show that vehicles can still be built by German industry at competitive prices and to the very highest quality standard. The crucial aspect is for the plant to be competitive when compared with those operating in other countries. To achieve this, all the business processes associated with a car’s production and sale must be optimised. Innovative concepts help to achieve significant cost savings. This applies to the working structure as well: based on pay and terms negotiated for the project, Volkswagen’s Auto 5000 GmbH has achieved one of the most innovative labour and pay models in use anywhere in the automobile industry. This pilot project envisages the assumption of the highest possible degree of direct responsibility by the employees on the ‘shop floor’ for the programmed production volumes and agreed quality targets. From unemployment to a job with further education for enhanced qualifications: Volkswagen and the regional Chamber of Commerce have compiled the “Automobile construction worker (C of C)� certificate A parallel process and an essential element in the labour model is the employee’s ability to acquire ongoing qualifications. Every week, Auto 5000 GmbH’s workforce attends three hours of training. A special cooperation agreement has been signed for this purpose with the Chamber of Commerce in the Lüneburg-Wolfsburg region. The aim is for every employee to gain a C of C certificate after absolving the two-year training programme. The certificate records the working and study processes into which the employee is integrated at Auto 5000 GmbH as part of the learning process. It represents a new form of qualification geared specifically to the automobile industry’s needs. “We use the term ‘workholder value’�, says Dr. Peter Hartz, a member of the Volkswagen AG Board of Management, when summing up the project as a whole. “Creative employment and payment processes, equal opportunities and the promotion of study during work and the employee’s career are the tools we have chosen as a means of boosting workholder value. Integration of labour, added value, qualifications and communication has the effect of making every Auto 5000 GmbH employee a businessperson with his or her own personal responsibilities and objectives.� 35 hours of work and three hours of study every week; including all bonus payments, salaries are higher than the general negotiated levels The average working week at the new factory has 35 hours. A three-shift model (early, late and night shifts) is to be operated. If demand is high at the new “factory within a factory� in Wolfsburg, however, the working week can be increased to 42 hours. The overtime thus worked is credited to the employees’ time accounts and normally settled by those concerned taking additional leave. In addition to the actual working hours, the agreement includes the three-hour weekly study period already mentioned. Of this, an hour and a half are credited to the employee; he or she invests the remaining time as a personal career contribution. The project’s name – “5000 x 5000� – is derived from the total number of new jobs (5,000 if 1,500 at the Volkswagen plant in Hanover are included, where the new Microbus will begin production in 2005) and the basic salary (5,000 German Marks, since the project was conceived before the Euro took over from the Mark). The actual sum is now 2,301 Euro. In addition, employees receive a minimum annual bonus of 3,068 Euro, a personal performance bonus when the profit threshold is crossed and also participate in the company’s results at a level depending on the previous year’s business success. With their basic pay and all bonuses, employees’ earnings can in fact be higher than the amount envisaged in the general wage agreement that would normally be applicable. The personnel selection process, with applications submitted by Internet, began on March 1, 2002 and will continue until Spring 2003. The ‘factory within a factory’ Wolfsburg is home to the largest automobile production complex in the world in terms of surface area; now a new “factory within a factory� has been created there – Auto 5000 GmbH Auto 5000 GmbH has been set up at Volkswagen AG’s headquarters in Wolfsburg, Germany. On the existing site, buildings 8, 9 and 10 are being used to house a modern “factory within a factory�. New production equipment and technologies are being installed in these buildings where other Volkswagen models were formerly built. The new company concerns itself only with three of the core processes in industrial-scale automobile manufacturing: construction of the body, painting and assembly. The remaining business activities support the core production process and are undertaken by either internal or external providers. New ideas and concepts are also being realised in the merchandising of the Touran. A new distribution and warehousing concept optimises the delivery processes and costs across national borders in Europe. The Internet website has been redesigned to provide comprehensive product information and extensive dialogue and advisory services. All sales, marketing, technical, logistic and procurement, quality, finance and human affairs processes are subject to close scrutiny. The topics of internal communication and the introduction of new media are of particular importance throughout Auto 5000 GmbH. There are good reasons for this: the very latest technologies are essential in automobile manufacturing if efficiency and quality are to be boosted, but these technologies can only be adopted successfully if the workforce also develops its knowledge and skills at the same time.