Volkswagen Tiguan 2008 Manual

Service Training
Self-study Programme 404
The Tiguan 2008

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The Tiguan covers the market segment for compact SUVs (Sport Utility Vehicles) with its many special features. It is
often described as the little brother of the Touareg, but it is a true individual as it sets standards in terms of
suspension, engines and comfort. Details like, for example, off-road suspension functions, off-road navigation,
exclusive turbocharged engines and off-road front bumper with 28° approach angle will make the Tiguan a
success among customers.
The name has already caused quite a sensation. 350,000 readers of Germany’s AutoBild magazine chose the
name Tiguan, a combination of tiger and iguana. You will find out why it is true to its name in this self-
study programme.
We hope you enjoy reading.
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The 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.
NEW Warning
Note

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In Brief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Occupant Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Radio, Telephone and Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Heating and Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Contents

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In Brief
Where is the Tiguan manufactured?
●Halls 3a + 4 Body assembly
●Hall 10 Body assembly
●Hall 9 Paint shop
●Hall 8 Assembly
The Volkswagen Tiguan 2008 is produced at
Auto 5000 GmbH in Wolfsburg.
In addition to the successful Touran compact MPV, a
second model from Volkswagen is being
built by Auto 5000 GmbH – the Tiguan compact SUV.
The production at Auto 5000 GmbH ranges from
body assembly through the paint shop to assembly.
The latest in manufacturing and logistics processes
have proven themselves since the start of production
at Auto 5000 GmbH in November 2002 and are
constantly being improved through the
implementation of innovative concept ideas.
One result is the flexible assembly line that is now
being used for both Touran and Tiguan production.
Auto 5000 GmbH in the Volkswagen plant, Wolfsburg S404_061
Hall 8
Hall 9
Halls 3a + 4 Hall 10

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Auto 5000 GmbH is a subsidiary of Volkswagen AG.
Its production site is at Volkswagen Group
headquarters in Wolfsburg.
The rapid success story of Auto 5000 GmbH began in
Autumn 1999 with the project “5000 x 5000”
(5000 jobs at 5000DM).
Auto 5000 GmbH started out with the aim of proving
that it is possible in Germany to create new secure
jobs and, at the same time, build an internationally
competitive car. The subsequent success has proven
that the idea and Auto 5000 GmbH were right.
More than 750,000 Tourans have already
left the factory.
A decisive factor for the success is the close
networking of work and learning.
Consistent qualification and training of staff has even
been laid down in a separate qualification wage
agreement.
Inside the factory, there is a “learning factory” for
each area that serves as a learning and
communication centre and also gives staff the
opportunity to exchange experiences.
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In Brief
The Tiguan 2008 from Volkswagen
●Bumper versions with different
approach angles:
On-road version at 18°
Off-road version at 28°
●Electromechanical steering with
parallel axis drive
●Park Assist
●Brakes with
off-road functions
●B-pillar with 2 rigidity zones
●Tyre pressure monitor
●RCD 510 radio
●RNS 510 radio/navigation system

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●Reverse lights in rear bumper
●Panoramic sunroof
You will find information on the panoramic sunroof in self-study programme 400
“The Golf 2007 – Chassis”.
●Mechanical swivelling tow coupling
●Electromechanical parking brake with planetary gear
●Four-wheel drive coupling
generation IV

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In Brief
Technical data
Exterior dimensions and weights
4427mm
2604mm 898mm925mm
1570mm
1809mm
1570mm
1686mm
Exterior dimensions
* with on-road bumper
** Standard equipment with 1.4l 110kW TSI engine/
6-speed manual gearbox 0A6 (4Motion)
Length 4427mm *
Width 1809mm
Height 1686mm
Wheelbase 2604mm
Track width at front 1570mm
Track width at rear 1570mm
Weights/further data
*** 2.0l/103kW CR TDI engine/“Track & Field” equipment
**** with roof rail
Maximum weight 2170kg **
Curb weight without driver 1546kg **
Max. roof load 100kg ****
Towing capacity (braked) 2500kg
up to 12% gradient ***
Tank capacity 64 l
Drag coefficient 0.37
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Interior dimensions
Front headroom 992mm
Rear headroom 991mm
Front elbow room 1428mm
Rear elbow room 1398mm
30mm
991mm992mm
375mm
343mm 693mm1019mm 381mm
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847mm
735mm
771mm
2086mm
1053mm S404_013
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Interior dimensions and volumes
* depending on equipment and position of rear seat bench
** depending on equipment
Interior length max. 1758mm
Boot volume 360-600l *
Luggage compartment
volume with rear seat
backrest folded down
max. 1510l **

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Body
Body structure
The Tiguan body is based on the Passat body concept
at the front end and in the middle underbody areas.
The Golf concept has been used at the rear.
The structure is a completely new development.
The main focus in the design was placed on comfort
and crash performance without neglecting lightweight
construction. Reaching the objectives for on-road and
off-road use was a challenge.
The high standards reached are reflected in the
excellent static and dynamic stiffness and thus in the
lightweight construction quality.
Lightweight construction quality L = 2.4
(e.g. Golf 2004, L = 2.5)
The lightweight construction quality puts the vehicle
mass in proportion with the vehicle size and stiffness.
Body-chassis connection
The body has been raised so that the Tiguan has SUV
ground clearance. Also the connection points of the
front axle (31mm) and rear axle (41mm) are lower
which moves the body construction up.
In addition, the larger wheels also provide more
ground clearance.
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Steel panels (< 140MPa)
High-strength plates (180-220MPa)
High-strength plates (240-420MPa)
Highest-strength sheets, die-quenched
( > 1000MPa )
B-pillar
The special feature of the B-pillar is that it is made
from one part, but has two rigidity zones. The upper
part has a very high strength for extreme loads due to
partial die-quenching. The lower part has a lower
strength with higher deforming capability for
controlled deformation in crashes.
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Body
Front bumper versions
Two different bumpers can be fitted on the Tiguan. Depending on the equipment version, there is an on-road
bumper optimised for road use and an off-road bumper optimised for driving on uneven terrain. The off-road
bumper has a greater approach angle allowing large obstacles and steep banks to be tackled on uneven terrain
without damaging the front end. The wheel housing liners and front modules are adapted to the respective bumper
versions.
New body features
Off-road bumper
The off-road bumper version is fitted on the “Track & Field” version.
●Approach angle: 28°
●Front axle overhang: 955mm
On-road bumper
The on-road version is fitted in the “Trend & Fun” and “Sport & Style” equipment versions.
●Approach angle: 18°
●Front axle overhang: 925mm
925
18°
955
28°
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Tail lights
The tail lights are mounted with two securing bolts and a side guide, into which the tail lights are inserted and
lock in. There are two threaded bushes with hexagon sockets under the securing bolts that are used for correct
fitment.
Threaded bush for correct fitment
Door concept
The front and rear doors have a conventional door design and are made up of a basic door unit and a bolted
assembly carrier. The door locks, window regulators and loudspeakers are pre-assembled on the assembly carrier.
Front door with assembly carrier Rear door with assembly carrier
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Side guides
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Body
The storage concept in the Tiguan provides all occupants with sufficient storage space for large and small items all
around the interior.
Storage concept
●Cooled glove compartment with integrated
pen and notepad holder
●Storage compartments in dash panel
insert as well as under front seats
●Storage compartments in the front door panels for
large-format road atlases and drinks holders for
up to 1.5l bottles
●Storage compartment in the centre console (varies depending
on equipment):
up to four cup holders (2 front, 2 rear);
ashtray;
sockets;
armrest with extra large storage compartment;
armrest with small storage compartment and CD charger

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●Boot with different load platform heights and flexible
cargo space as well as a cargo management system
for storing a wide range of items
●Bins in the rear door panels and drinks holders for
up to 1.5l bottles
●Cup holders in through-load facility
●Roof console with glasses compartment and three
other compartments lined with rubber mats with
normal full roof
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For the first time, a mechanical swivelling tow
coupling is being used by Volkswagen.
Previously fixed, removable or electrically adjusted
versions were used.
The mechanical swivelling tow coupling is mounted
behind the rear bumper and is also simple to use
when the vehicle is fully loaded. Depending on the
engine, the Tiguan has a towing capacity of up to
2500kg (up to 12% gradient).
Body
Mechanical swivelling tow coupling
Operation
Release button in bumper
There is a release knob in the rear bumper under a
dust cap to extend and retract the tow coupling.
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Release knob

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Integrated socket
The connecting socket for the trailer is integrated in
the tow coupling in an easy to reach position.
Releasing and locking
To change the position of the tow coupling, pull the
release knob to unlock it. The release knob is
connected to the tow coupling via a cable.
After unlocking, the tow coupling automatically
swivels downwards to the unlocked position. Then it
needs to be either manually locked in the rest or
working position. The tow coupling locks into one of
the end positions with a clearly audible locking noise.
LED display for end positions
In addition to the locking noise, an LED illuminates
green when one of the two end positions is reached.
The LED extinguishes when the lock is released.
The LED is next to the release knob in the rear bumper
and is only activated when the tailgate is open.
Unlocked tow coupling Rest and working position
Rest position
Working
position
LED warning
lamp
Electrical socket
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Occupant Protection
●The passenger airbag can be deactivated using a
key switch in the storage compartment on the
passenger’s side.
Safety equipment
●Driver and front passenger airbag
●Driver and front passenger seat belt
warning light
●Belt tensioners and belt force limiters for
the front seats
●Optional rear side airbags in conjunction with
belt tensioners for the outer rear seats
●3-point seat belts on all seats
●Isofix anchoring points on outer rear seats
●Pressure sensors in the front doors
●Belt force limiters for the outer rear seats

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●Side airbags in the front seats
●Curtain airbags for front and rear occupants
●Acceleration sensors in C-pillar area
●The airbag trigger system consists of an airbag
control unit in the front area of the frame tunnel
with three internal acceleration sensors (two
sensors in vehicle longitudinal direction and one in
transverse direction) as well as four external
sensors for recognising side collisions. Two are
configured as pressure sensors and are in the two
front doors. Two transverse acceleration sensors
are in the C-pillar area.

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Engines
* The 6-speed automatic gearbox 09M has been adapted to the requirements of the Tiguan.
Petrol engine
1.4l/110kW TSI engine
with 4-valve technology
2.0l/103kW CR TDI engine
with 4-valve technology
Diesel engine
6-speed manual gearbox 0A6
(4Motion)
6-speed automatic gearbox 09M
(4Motion) *
Engine/gearbox combinations