Get Engine compartment Guide for Volkswagen California Van Third Generation (2015-2024)

NOTICE

The towing eye must always be screwed fully and securely into the mounting. Otherwise, the towing eye can be torn

out of the mounting when the vehicle is being tow-started or towed.

Safety notes on working in the engine compartment

The engine compartment of a motor vehicle is a hazardous area. You should only carry out work on the engine and in

the engine compartment if you know exactly how to perform the required tasks, are aware of the general safety

procedures and have access to the correct equipment, service fluids and suitable tools. Carrying out work incorrectly

can cause serious injuries. Have all work carried out by a correspondingly qualified workshop if necessary.

Always park the vehicle on a level and stable surface before carrying out any work in the engine compartment.

WARNING

Unintentional vehicle movements during service work can cause serious injury.

● Never work underneath a vehicle if it is not secured against rolling away. If you are working underneath the

vehicle while the wheels are on the ground, the vehicle must be on a level surface, the wheels must be blocked

and the ignition switched off.

● If you intend to work underneath the vehicle, you must use suitable stands to provide support for the vehicle. The

vehicle jack is not sufficient for this task and can fail, which can lead to serious injuries.

● Switch off the start/stop system.

WARNING

The engine/motor compartment of any motor vehicle is a dangerous area. Serious injuries can be sustained here.

● Always work with extreme care and caution and observe the general safety precautions. Never take any personal

risks.

● Never perform any work on the engine and in the engine compartment unless you know exactly how to do so. If

you are uncertain of what to do, have the work carried out by a correspondingly qualified workshop. Serious

injuries can result from work that has not been carried out properly.

● Never open or close the bonnet as long as steam or coolant is escaping. Hot steam or hot coolant can cause

serious burns. Always wait until you can no longer see or hear steam or coolant coming from the engine

compartment.

● Always allow the engine to cool down before opening the bonnet.

● Hot parts of the engine or exhaust system can burn the skin.

● Observe the following points before opening the bonnet when the engine has cooled down:

● Apply the handbrake fully and move the selector lever to positionP or move the gear lever to the neutral

position.

● Switch off the ignition.

● Always keep children away from the engine compartment and never leave children unsupervised.

● The cooling system is under pressure when the engine is hot. Never open the cap of the coolant expansion tank

when the engine is hot. Coolant may spray out and cause serious burns and other injuries.

● Turn the cap of the coolant expansion tank slowly and very carefully anticlockwise while exerting slight

downwards pressure on the cap.

● Always protect the face, hands and arms from hot coolant or steam with a large, thick cloth.

● When refilling, do not spill any service fluids onto engine components or onto the exhaust system. The spilt

service fluids can start a fire.

WARNING

There are rotating components in the engine compartment that can cause serious injury.

● Never reach into the radiator fan or into the area of the radiator fan. Touching the rotary blades can result in

serious injuries. The fan is temperature-controlled and could start automatically - even when the ignition is

switched off.

515

● If any work has to be performed when the engine is started or is running, there is an additional, potentially fatal,

safety risk from the rotating parts, such as the drive belts, alternator, radiator fan, etc., and from the high-voltage

ignition system. Always take extreme care.

● Always ensure that no body parts, jewellery, ties, loose items of clothing or long hair get caught up in rotating

engine components. Always remove jewellery and ties before starting work. Tie up long hair and pull clothes in

tightly to avoid them getting caught in engine parts.

● Always take due care and attention when depressing the accelerator. The vehicle could move even if the

handbrake is applied.

● Always ensure you have not left any objects, such as cleaning cloths and tools, in the engine compartment. Any

forgotten items can cause malfunctions, engine damage and fires.

WARNING

Additional insulating materials such as blankets in the engine compartment could disrupt the operation of the

engine, start fires and lead to severe injuries.

● Never cover the engine with blankets or other insulating materials.

WARNING

Service fluids and some materials in the engine compartment are highly flammable and can cause fires and serious

injuries!

● Never smoke in the vicinity of the engine compartment.

● Never work near naked flames or sparks.

● Never spill service fluids onto the engine. They could ignite on hot engine components and hence cause injuries.

● Please note the following when carrying out any work on the fuel system or the electrical system:

● Always disconnect the 12-volt vehicle battery. Ensure that the vehicle is unlocked when the 12-volt vehicle

battery is disconnected as otherwise the anti-theft alarm will be activated.

● Never work in the direct proximity of heating systems, water heaters or any other naked flames.

● Always have a fully functional and tested fire extinguisher to hand.

NOTICE

The use of incorrect service fluids could result in serious malfunctions and engine damage.

● When refilling or replacing service fluids, ensure that you pour the correct service fluids into the correct openings.

Service fluids leaks are harmful to the environment. For this reason, you should regularly check the ground

underneath your vehicle. If there are patches of oil or other fluids on the ground, the vehicle should be

inspected by a correspondingly qualified workshop. Any spilt service fluids must be disposed of properly.

Preparing the vehicle for working in the engine compartment

The following steps should always be carried out in the specified order before working in the engine compartment→

:

1. Park the vehicle on a level and stable surface.

2. Depress and hold the brake pedal until the engine has stopped.

3. Automatic gearbox: Move the selector lever to positionP (→ Automatic gearbox).

4. Manual gearbox: Move the gear lever into the neutral position (→ Manual gearbox).

5. Apply the handbrake firmly (→ Handbrake).

6. Switch off the ignition (→ Switching off the engine).

7. If necessary, remove the vehicle key from the vehicle and keep it in a separate location so that the vehicle

cannot be started accidentally.

8. Allow the engine to cool sufficiently.

516

9. Children and other people should be kept well away from the engine compartment.

10. Ensure that the vehicle cannot roll away unexpectedly.

WARNING

Ignoring the instructions important for personal safety can lead to severe injuries.

● Always follow the actions and observe the generally valid safety precautions.

Opening and closing the bonnet

Fig. 1 In the footwell: Bonnet release lever(illustration).

Fig. 2 On the front edge of the bonnet: Release lever

(illustration).

Opening the bonnet

1. Please ensure that the wiper arms are positioned on the windscreen before opening the bonnet→

2. Pull the release lever in the direction of the arrow→ Fig. 1.

.

The bonnet is released from the lock carrier catch by spring force→

3. Lift the bonnet using the release lever→ Fig. 2 and open fully.

The gas strut holds the bonnet in the open position.

.

517

Closing the bonnet

1. To close the bonnet, pull it down until it overcomes the pressure of the gas strut→

2. Let the bonnet drop into the catches –do not press it down!

.

3. If the bonnet has not closed, open it and then close it correctly.

The bonnet is flush with the body parts around it when it is closed properly.

WARNING

If the bonnet is not closed properly, it can open suddenly while you are driving and completely obscure your view of

the road. This can lead to accidents and serious injuries.

● After closing the bonnet, always check whether the catch is properly engaged in the lock carrier. The bonnet must

be flush with the surrounding body panels.

● If you establish while driving that the bonnet is not closed properly, stop immediately and close the bonnet.

● Open or close the bonnet only when there is no-one in its movement path.

NOTICE

Opening and closing the bonnet incorrectly can damage the bonnet or the wiper arms.

● Open the bonnet only when the wiper arms are flush to the windscreen and when they are switched off.

● Always fold the wiper arms back onto the windscreen before driving away.

Display

A symbol on the instrument cluster display indicates if the bonnet is open or is not closed properly→ Fig. 1.

Fig. 1 On the instrument cluster display: the bonnet is

open or not closed properly (illustration).

1.

Do not drive on!

2. If necessary, lift the bonnet and then close it again.

This symbol is also visible when the ignition is switched off and will go out a few seconds after the vehicle has been

locked when all doors are closed.

WARNING

Failure to observe warnings can cause your vehicle to break down in traffic, which can lead to accidents and serious

injuries.

● Never ignore warnings.

518

● Stop the vehicle as soon as it is possible and safe to do so.

The symbol can differ depending on the version of the instrument

cluster.

Service fluids and equipment

All service fluids and consumables, e.g. coolant, vehicle batteries and engine oils, are being constantly developed. For

this reason, service fluids and consumables should be replaced by a correspondingly qualified workshop.

WARNING

Unsuitable service fluids and consumables, and the incorrect use of these fluids and consumables, can cause

accidents, serious injuries, burns or poisoning.

● Store service fluids only in the closed original container.

● Never store service fluids in empty food containers, bottles or any other non-original containers as people finding

these containers could drink them.

● Keep children away from all service fluids and consumables.

● Always observe and follow the information and warnings on the service fluid packaging.

● When using products that give off harmful fumes, always work outdoors or in a well-ventilated area.

● Never use fuel, turpentine, engine oil, nail varnish remover or other volatile fluids for vehicle care. They are toxic

and highly flammable. They could cause fires and explosions.

NOTICE

● Refill only appropriate service fluids. Do not mix up the service fluids under any circumstances. Failure to observe

this warning can result in serious malfunctions and engine damage.

Leaking service fluids can pollute the environment. Collect any service fluids that escape or are spilled in

suitable containers and dispose of them correctly and with respect for the environment.

519

Windscreen washer fluid

Fig. 1 In the engine compartment: cap of washer fluid

reservoir

The windscreen washer fluid level should be checked regularly and topped up as necessary.

A filter can be found in the feed throat of the washer fluid reservoir. The strainer keeps larger dirt particles away from

the washer jets when refilling. The filter should only be removed for cleaning. If the filter is damaged or cannot be

found when refilling, dirt particles will reach the system and will block the washer jets.

1. Open the bonnet (→ In the engine compartment).

The washer fluid reservoir is identified by the symbol on the cap→ Fig. 1.

2. Check whether there is enough washer fluid in the reservoir.

3. To add fluid, mix clear water, but not distilled water, with suitable windscreen washer fluid→ . Observe the

dilution instructions on the packaging.

4. At low outside temperatures, add a special anti-freeze agent so that the fluid cannot freeze→

.

WARNING

If coolant additive or similar unsuitable additives are mixed with the washer fluid, this can result in an oily film on

the window that considerably impairs visibility.

● Use clean, clear water, but not distilled water, with a suitable windscreen washer fluid.

● Add a suitable antifreeze agent to the washer fluid if necessary.

NOTICE

Mixing cleaning agents incorrectly can cause the ingredients to separate and block the washer jets.

● Never use unsuitable cleaning agents.

520

Introduction

Engine oils are matched to the requirements of the engines, the emission purification systems, and the fuel quality.

Due to the operating principle of combustion engines, engine oil always comes into contact with combustion residues

and fuel, which has corresponding effects on the ageing process of the engine oil. The correct engine oil is important

for the function and service life of the engine. A special multigrade high-lubricity oil has been filled at the factory and

this can normally be used as an all-season oil.

Information on warning and indicator lamps that light up can be found in the troubleshooting sections at the end of

the chapter (→ Engine oil).

WARNING

Incorrect handling of engine oil can cause serious burns and other injuries.

● Always wear eye protection when handling engine oil.

● Engine oil is toxic. Always keep engine oil out of the reach of children.

● Store engine oil only in the closed original container. This also applies to used oil until it is disposed of.

● Regular contact with engine oil can damage the skin. Always wash skin that has been in contact with engine oil

thoroughly with water and soap.

● Engine oil becomes extremely hot when the engine is running and can scald skin severely. Always allow the

engine to cool down.

Leaking or spilt engine oil can pollute the environment. Collect any service fluids that escape or are spilled

and dispose of them correctly and with respect for the environment.

521

Engine oil standards

Vehicles with an engine oil sticker

If you need to top up the engine oil, use an oil with the prescribed engine oil standard and engine oil viscosity

→ Fig. 1.

Fig. 1 Sticker showing engine oil standard and engine oil

viscosity (illustration).

1

2

Information about the engine oil standard.

Information about the engine oil viscosity.

The sticker showing the prescribed standard is located at the front of the engine compartment, on the side next to

1

the bonnet release → Fig. 2

.

Fig. 2 In the engine compartment: sticker showing engine

oil standard and engine oil viscosity (illustration).

1

Sticker.

If the prescribed engine oil → Fig. 1 is used, the engine oil level can be corrected as often as necessary (→ Engine oil).

Vehicles without an engine oil sticker

Information on the prescribed engine oil standard and engine oil viscosity can be obtained from a correspondingly

qualified workshop. If the engine oil needs to be topped up, use an engine oil with the prescribed engine oil standard

and engine oil viscosity. If the prescribed engine oil is used, the engine oil level can be corrected as often as

522

necessary, as follows (→ Engine oil).

If no engine oil is available according to the prescribed standard, in an emergency you may refill once with a

maximum of 0.5 l (0.5 qt) of the following, deviating standards until the next regular oil change:

—Diesel engines: standards VW 507 00 and ACEA C3, viscosity 0 W-30.

We recommend having the work carried out by a correspondingly qualified workshop.

NOTICE

The use of approved engine oils in accordance with the relevant VW standard is recommended. The use of engine

oils that do not meet these quality requirements can cause engine damage.

Changing engine oil

The engine oil must be changed on a regular basis. Always observe the service intervals applicable to your vehicle .

The engine oil and filter change should be carried out by a correspondingly qualified workshop due to the special

tools and knowledge required. This also applies to the disposal of used oil.

Additives in the engine oil can cause new engine oil to discolour quickly. This is normal and does not mean that the

engine oil should be changed more frequently.

WARNING

If, in exceptional cases, you have to carry out an oil change yourself, please note the following:

● Always wear eye protection.

● Always allow the engine to cool down completely to avoid burns.

● Keep your arms horizontal when unscrewing the oil drain plug with your fingers to prevent the emerging oil from

running down your arm.

● Use a suitable container when draining the used oil. It must be at least large enough to hold the entire filling

quantity of engine oil.

● Never store engine oil in empty food containers, bottles or any other non-original containers as people finding

these containers may not know that they contain engine oil.

● Engine oil is toxic and must be stored out of the reach of children.

Before changing the engine oil, first find out where old oil can be disposed of properly near

you.

Dispose of old oil in accordance with regulations governing the protection of the environment. Never

dispose of old oil in locations such as gardens, woods, sewerage systems, on streets and roads, or in rivers

and waterways.

523

Engine oil consumption

Engine oil consumption can vary from engine to engine and can change during the working life of an engine.

The vehicle may consume up to 1 l of engine oil per 2,000 km, depending on how you drive and the conditions in

which the vehicle is used. In new vehicles, consumption is likely to be higher for the first 5,000 km. The engine oil

level must therefore be checked at regular intervals, preferably when refuelling and before long trips.

When the engine is working hard, the engine oil level must be in the upper permissible area (→ Engine oil), for

instance during extended motorway trips in summer or when climbing mountain passes

524

Checking the engine oil level and refilling engine oil

Fig. 1 Oil dipsticks with engine oil level markings(variants).

A

B

C

Engine oil level too high – observe the messages on the instrument cluster display or seek expert assistance.

Engine oil level within normal range.

Engine oil level too low – follow the messages in the instrument cluster display or add engine oil, if necessary.

Fig. 2 In the engine compartment: engine oil filler opening

cap (illustration).

Carry out the steps in the specified order→

, →

:

1. With the engine at operating temperature, park the vehicle on a level surface to ensure that the engine oil

reading is correct.

2. Switch off the engine and wait at least 5 minutes for the engine oil to flow back into the sump.

3. Open the bonnet (→ In the engine compartment).

4. Identify the engine oil filler cap and oil dipstick. The oil filler neck is indicated by the → Fig. 2 symbol on the

cap, and the dipstick by its coloured handle. If you cannot find the cap and oil dipstick, please contact a

correspondingly qualified workshop.

5. Pull the dipstick out of the guide tube and wipe it off with a clean cloth.

6. Re-insert the oil dipstick into the guide tube as far as it will go. If there is a marking on the oil dipstick, this

marking must fit in the corresponding groove at the top end of the guide tube when inserting.

525

7. Pull out the oil dipstick again and read the engine oil level on the dipstick as follows→ Fig. 1:

A

Engine oil level too high. Observe the messages on the instrument cluster display or seek expert assistance

as necessary →

.

B

Engine oil level within normal range. Engine oil can be topped up to the upper limit of this range, e.g. when

the engine is working hard . Continue to step 8 or 16.

C

Engine oil level is too low. Where applicable, follow any messages that are shown on the instrument cluster

display and make sure you add engine oil. Continue to step 8.

8. After reading off the engine oil level, push the oil dipstick back into the guide tube as far as it will go.

9. Unscrew the engine oil filler opening cap→ Fig. 2.

10. Gradually add engine oil in small quantities, no more than 0.5 l(0.5 qt) in total, or follow the recommendation in

the instrument cluster. The use of approved engine oils in accordance with the relevant VW standard is

recommended.

11. In order to avoid overfilling, wait for at least 1 minute after each refill step to allow the engine oil to flow into

the oil sump up to the marking on the engine oil dipstick.

12. Read the engine oil level from the dipstick again before refilling with a further small quantity of engine oil.

Never overfill with engine oil →

.

B

13. After filling, the engine oil level should be in the middle of the area→ Fig. 1

A

. The engine oil level must not

be in area → Fig. 1

→

.

A

14. If too much engine oil has been added unintentionally and the engine oil level is in area→ Fig. 1

start the engine. Seek expert assistance.

, do not

15. After refilling, screw the engine oil filler cap back on.

16. Insert the oil dipstick into the guide tube as far as it will go. If there is a marking on the upper end of the oil

dipstick, this marking must fit in the corresponding groove at the top end of the guide tube when inserting.

17. Close the bonnet (→ In the engine compartment).

WARNING

Engine oil can ignite if it comes into contact with hot engine components. It can cause fires, burns and other serious

injuries.

● Always ensure that the engine oil filler cap is securely tightened after refilling, and that the dipstick is properly

inserted back into the guide tube. This will prevent the engine oil from draining out on to hot engine components

when the engine is running.

● If engine oil is spilt on cold engine parts it can heat up and ignite when the engine is running.

NOTICE

● If the engine oil level is in area→ Fig. 1

A

, do not start the engine. Seek expert assistance.

● When refilling service fluids, ensure that you pour the correct service fluids into the correct openings. The use of

incorrect service fluids could result in serious malfunctions and engine damage.

Troubleshooting

Engine oil pressure too low

The warning lamp flashes red. A message is shown on the instrument cluster display.

Do not drive on! The engine could otherwise be damaged.

526

1. Stop the vehicle as soon as possible and when safe to do so.

2. Switch off the engine.

3. Check the engine oil level (→ Engine oil).

4. Do not drive on or leave the engine running if the warning lamp is flashing even when the engine oil level is

correct. The engine could otherwise be damaged. Seek expert assistance.

Engine oil level very low

The warning lamp flashes red. A message is shown on the instrument cluster display.

Do not drive on! The engine could otherwise be damaged.

1. Stop the vehicle as soon as possible and when safe to do so.

2. Switch off the engine.

3. Check the engine oil level (→ Engine oil).

4. If required, top up the engine oil gradually in small quantities, using no more than 0.5 (l0.5 qt) in total.

5. Do not drive on or leave the engine running if the warning lamp is lit even though the engine oil level is correct.

The engine could otherwise be damaged. Seek expert assistance.

Engine oil level too low

The indicator lamp lights up yellow. A message is shown on the instrument cluster display.

1. Stop the vehicle as soon as possible and when safe to do so.

2. Switch off the engine.

3. Check the engine oil level (→ Engine oil).

4. If required, top up the engine oil gradually in small quantities, using no more than 0.5 (l0.5 qt) in total.

5. Do not drive on or leave the engine running if the indicator lamp is lit even though the engine oil level is correct.

The engine could otherwise be damaged. Seek expert assistance.

Engine oil level too high

The indicator lamp lights up yellow. A message is shown on the instrument cluster display.

1. Stop the vehicle as soon as possible and when safe to do so.

2. Switch off the engine.

3. Check the engine oil level (→ Engine oil).

4. If the engine oil level is too high, do not drive on or allow the engine to run. The engine could otherwise be

damaged. Seek expert assistance.

or

Fault in the engine oil system

The indicator lamp flashes yellow. A message is shown on the instrument cluster display.

1. Seek expert assistance.

Introduction

527

You should carry out work on the cooling system only if you know exactly how to perform the required tasks, are

aware of the general safety procedures and have access to the correct equipment, service fluids and suitable tools.

Failing to carry out work correctly can cause serious injuries → . Have all work carried out by a correspondingly

qualified workshop if necessary.

WARNING

Coolant is toxic.

● Keep coolant only in the sealed original container and in a safe place.

● Never store coolant in empty food containers, bottles or any other non-original containers as people finding these

containers may then drink the coolant.

● Keep the coolant out of the reach of children.

● The amount of correct coolant additive used must be sufficient for the lowest ambient temperature that you

expect the vehicle to be exposed to.

● Coolant can freeze at extremely cold outside temperatures, causing the vehicle to break down. Vehicle occupants

with inadequate winter clothing could then freeze to death as the heating will also no longer function.

Coolant and coolant additives can pollute the environment. Collect any service fluids that escape or are

spilled and dispose of them correctly and with respect for the environment.

Coolant specification

The cooling system is filled at the factory with a mixture of specially prepared water and at least 40% coolant additive

G12evo (TL 774-L).

The proportion of coolant additive mustalways be at least 40% to protect the cooling system. If greater frost

protection is required in very cold climates, the proportion of anti-freeze additive can be increased. However, the

percentage of coolant additive should not exceed 55 %, as this would reduce the frost protection and the cooling

effect.

The coolant additive is dyed purple. The mixture of water and coolant additive provides anti-freeze protection down

to -25°C (-13°F), protects the alloy parts in the engine cooling system against corrosion, prevents limescale deposits

and significantly increases the boiling point of the coolant.

When refilling the coolant, a mixture of distilled water and at least 40% G12evo coolant additive must be used in

order to obtain the optimum corrosion protection →

.

WARNING

Insufficient anti-freeze in the coolant system can cause the engine to break down and cause serious injuries.

● The amount of correct coolant additive used must be sufficient for the lowest ambient temperature that you

expect the vehicle to be exposed to.

● Coolant can freeze at extremely cold outside temperatures, causing the vehicle to break down. Vehicle occupants

with inadequate winter clothing could then freeze to death as the heating will also no longer function.

NOTICE

If the liquid in the coolant expansion tank is not purple, the correct coolant has been mixed with another, unsuitable

coolant additive. Failure to observe this warning can result in serious malfunctions or damage to the engine and

cooling system.

● In this case, have the coolant changed immediately.

● Never mix genuine coolant additives with other coolants that have not been approved.

Coolant and coolant additives can pollute the environment. Collect any service fluids that escape or are

spilled and dispose of them correctly and with respect for the environment.

528

Checking the coolant level and refilling coolant

Preparations

Fig. 1 In the engine compartment: coolant expansion tank

cap

1. Park the vehicle on a firm and level surface.

2. Allow the engine to cool down→

.

3. Open the bonnet (→ In the engine compartment).

You can identify the coolant expansion tank by the symbol on the cap→ Fig. 1.

WARNING

Hot steam and hot coolant can cause serious burns.

Never open the bonnet if you can see or hear steam or coolant coming out of the engine compartment. Always wait

until no escaping steam or coolant can be seen or heard. Hot components can burn the skin.

● The cooling system is under pressure when the engine is hot. Never open the cap of the coolant expansion tank

when the engine is hot. Coolant may spray out and cause serious burns and other injuries.

● Turn the cap slowly and very carefully anticlockwise while exerting some downward pressure on the cap.

● Always protect your face, hands and arms from hot coolant or steam by placing a large, thick cloth on the cap

of the coolant expansion tank.

Warning lamp

The warning lamp for the engine coolant will light up if the engine coolant level is too low.

1.

Do not drive on! Stop the vehicle as soon as possible and when safe to do so.

2. Seek expert assistance immediately.

3. If the coolant level is too low and it is not possible to obtain expert assistance, check the coolant level and add

coolant →

.

Checking the coolant level

529

Fig. 2 In the engine compartment: mark on the coolant

expansion tank (illustration).

The engine coolant may be above the marked area when a new vehicle is delivered. This is normal. The coolant does

not have to be sucked off.

1. When the engine is cold, check the coolant level at the side markings of the coolant expansion tank→ Fig. 2.

The coolant level must be between the markings.

2. Refill coolant if the liquid level in the coolant expansion tank is below the minimum marking (“min”).

When the engine is warm, the engine coolant level may be slightly above the upper mark.

3. Do not add coolant if there is no longer any coolant visible in the coolant expansion tank→

.

Refilling coolant

1. Unscrew the lid carefully →

.

2. Only refill with new coolant that is compliant with the specifications (→ Coolant).

3. Add coolant up to the upper level marking.

4. The coolant level must be between the markings on the coolant expansion tank→ Fig. 2.

5. Close the cap tightly.

6. Check the coolant level after one day.

7. If the level drops below the minimum marking “min” again, visit a correspondingly qualified workshop and have

the cooling system checked.

8. If in an emergency you do not have access to coolant with the required specification, do not use any other

coolant additive →

.

NOTICE

● Do not fill coolant above the top edge of the marked area. Otherwise the excess coolant will be pressed out of

the cooling system when the engine is hot and could cause damage.

● If in an emergency you do not have access to coolant in the required specification, add only distilled water

initially. Then have the correct mixture ratio with the coolant additive restored by a correspondingly qualified

workshop as soon as possible.

● Do not top up with coolant if there is no more coolant in the coolant expansion tank! Air could have entered the

cooling system. Do not drive on. Seek qualified professional assistance. Failure to do so can result in engine

damage.

● When refilling service fluids, ensure that you pour the correct service fluids into the correct openings. The use of

530

incorrect service fluids could result in serious malfunctions and engine damage.

Emergency top-up of the cooling system

The vehicle must not be moved if large quantities of coolant have been lost. Failure to observe this can lead to engine

damage.

Work on the cooling system shouldalways be carried out by a correspondingly qualified workshop.

The cooling system can betopped upif it is not possible to visit a correspondingly qualified workshop.

This description of manual filling applies only to the engine codesDMZA, DNAA, DNAB and DNAC.

You can find information abut the engine code here (→ Type plate).

Requirements when filling the cooling system

✓ The vehicle must be stopped on a firm and level surface.

✓ The engine must have cooled down (→ Coolant).

✓ The cooling system is not damaged(water loss).

✓ A tool that is not included in the vehicle toolkit.

✓ A sufficient quantity of coolant is available, in an emergency water filtered through a clean cloth.

Emergency filling of the cooling system

The actions should only be carried out in the specified order:

1. Open the bonnet (→ In the engine compartment)

2. Open the coolant expansion tank.

3. Fill the cooling system up to the upper seam on the coolant expansion tank until the coolant level remains

constant (→ Coolant).

4. Wait around 5 minutes and add more coolant if necessary.

5. Switch on the ignition.

6. The automatic coolant bleeding process begins. This process takes around 5 minutes.

7. When automatic coolant bleeding is complete, refill the coolant up to the seam on the coolant expansion tank

(→ Coolant).

8. Start the engine and switch off the air conditioning system (→ Heating, ventilation and cooling).

9. Drive the vehicle at an engine speed above 2,000 rpm for around 30 minutes to get the engine to operating

temperature

10. Switch off the vehicle and allow it to cool down. Once it has done so, adjust the coolant level to around 3 cm

above the upper marking. Set the air conditioning system to your preferred temperature.

Have the engine cooling system checked, repaired and filled with engine coolant of the correct specification by a

correspondingly qualified workshop immediately.

531

Brake fluid

Fig. 1 In the engine compartment: brake fluid reservoir

cap.

Brake fluid will gradually absorb water from the surrounding air. The brake system will be damaged if there is too

much water in the brake fluid. The boiling point of the brake fluid is also considerably reduced by the water content.

Heavy use of the brakes may cause a vapour lock in the brake system if the water content is too high. Vapour locks

reduce levels of braking power, considerably increase braking distance and can even cause the brake system to fail

completely. Your own safety and that of other road users depends on having a brake system that functions properly

at all times →

.

Brake fluid specification

Volkswagen Commercial Vehicles has developed a brake fluid that has been optimised for the brake system in the

vehicle. To ensure the best possible operation of the brake system, Volkswagen Commercial Vehicles expressly

recommends the use of brake fluid compliant with VW standard 501 14.

Before using a particular brake fluid, check that the specifications printed on the container correspond to the vehicle

requirements.

Brake fluid that is compliant with VW standard 501 14 is available from Volkswagen Commercial Vehicles

dealerships.

If this brake fluid is not available and it is necessary to use another high-quality brake fluid instead, brake fluid that is

compliant with DIN ISO 4925 CLASS 6 or US standard FMVSS 116 DOT 4 can be used.

Not all brake fluids that are compliant withDIN ISO 4925 CLASS 6 or US standard FMVSS 116 DOT 4 have the same

chemical composition. Some of these brake fluids may contain chemicals that can damage or destroy brake system

components over time.

Brake fluid that is compliant with VW standard 501 14 fulfils the requirements ofDIN ISO 4925 CLASS 6 or

US standard FMVSS 116 DOT 4.

Brake fluid level

The brake fluid level must always be between the MIN and MAX markings on the brake fluid reservoir→

.

The brake fluid level cannot be checked accurately in all models as the brake fluid reservoir may be partially

concealed. If the brake fluid level cannot be read exactly, please seek assistance from a suitably qualified workshop.

The brake fluid level drops slightly when the vehicle is being used as the brake pads wear and the brakes are

automatically adjusted.

532

Brake fluid level

The indicator lamp lights up red.

Brake fluid level is too low.

1.

Do not drive on!

2. Check the brake fluid level.

3. Seek expert assistance if the brake fluid level is too low.

Brake fluid change

Have the brake fluid changed regularly. Information on the change interval for the brake fluid can be obtained from a

correspondingly qualified workshop. Only brake fluid that conforms with the required specification should be used.

WARNING

Brake failure or reduced braking efficiency can be caused by the brake fluid level being too low or by brake fluid that

is too old or unsuitable.

● Have the brake system and brake fluid level checked or the brake fluid changed on a regular basis.

● The refilled brake fluid must be new.

● Make sure that the correct brake fluid is used. Only use brake fluid that is explicitly compliant with VW standard

501 14. Any other brake fluid or a low-quality one can affect the functioning of the brakes and reduce their

effectiveness.

● If you do not have any brake fluid that is compliant with VW standard 501 14, use a high-quality brake fluid

compliant with DIN ISO 4925 CLASS 6 or the US standard FMVSS 116 DOT 4, but only in exceptional

circumstances.

WARNING

Brake fluid is toxic.

● In order to reduce the risk of poisoning, never use bottles or other containers to store brake fluid. These

containers could encourage other people to drink out of them, even if they are labelled otherwise.

● Always store brake fluid in its original sealed container and out of the reach of children.

NOTICE

Brake fluid that has leaked or been spilt can damage the vehicle paintwork, plastic parts and tyres.

● Wipe off brake fluid that has leaked or been spilled immediately from all parts of the vehicle.

Brake fluid can pollute the environment. Collect any service fluids that escape or are spilled and dispose of

them correctly and with respect for the environment.

Introduction

The 12-volt vehicle battery is a component of the electrical system in the vehicle.

Never carry out any work on the electrical system if you are not familiar with the necessary procedures and the

general safety requirements and only unsuitable tools are available → . Otherwise, have all work carried out by a

correspondingly qualified workshop if necessary. Serious injuries can be caused if work is carried out incorrectly.

Information on warning and indicator lamps that light up can be found in the troubleshooting sections at the end of

the chapter (→ 12-volt vehicle battery).

Number and location of the 12-volt vehicle battery

The 12-volt vehicle battery is located in the engine compartment. Depending on the vehicle equipment level, the

533

vehicle could also have two 12-volt vehicle batteries, while camper vans can have three 12-volt vehicle batteries. The

second 12-volt vehicle battery is located under the left front seat; the third battery in camper vans is located in the

wardrobe at the rear left of the vehicle.

Explanation of the warnings on the 12-volt vehicle battery

Always wear eye protection!

Electrolyte is very corrosive and caustic. Always wear protective gloves and eye protection!

No fires, sparks, naked lights or smoking!

A highly explosive mixture of gases is given off when the vehicle battery is charging!

Always keep children away from electrolyte and the vehicle battery.

Always observe the owner's manual!

WARNING

Any work on the 12-volt vehicle battery and the electrical system can cause serious chemical burns, fire or electric

shocks. Always read the following warnings and safety information before carrying out any kind of work:

● Switch off the ignition and all electrical consumers before carrying out any work on the 12-volt vehicle battery

and also disconnect the negative cable from the 12-volt vehicle battery.

● Children should always be kept away from electrolyte and the 12-volt vehicle battery.

● Always wear eye protection and protective gloves.

● Electrolyte is very aggressive. It can burn the skin and can cause blindness. When working with the 12-volt

vehicle battery, ensure that your hands, arms and face in particular are protected from acid spillage.

● Never smoke and work near naked flames or sparks.

● When handling cables and electrical equipment, avoid generating sparks and electrostatic discharge.

● Never short circuit battery terminals.

● Never use a damaged 12-volt vehicle battery. The 12-volt vehicle battery can explode. Replace a damaged 12-

volt vehicle battery immediately.

NOTICE

In vehicles with a second battery under the driver’s seat or a third battery in the luggage compartment, you must

ensure that the breather hose is connected properly to the 12-volt vehicle battery.

NOTICE

The 12-volt vehicle battery housing can be damaged by ultraviolet radiation.

● Do not expose the 12-volt vehicle battery to direct sunlight for an extended time.

NOTICE

The 12-volt vehicle battery can “freeze” and be destroyed if the outside temperature is very low and the vehicle is

stationary for a long time.

● Protect the 12-volt vehicle battery against frost if the vehicle is left standing for extended periods.

534

When you start the engine after the 12-volt vehicle battery has been totally discharged or changed, you may

find that system settings e.g. time, date, personal convenience settings and programming have been changed

or deleted. Check and correct the settings as necessary once the 12-volt vehicle battery has been sufficiently

charged.

Checking the electrolyte level of the 12-volt vehicle battery

The electrolyte level of the 12-volt vehicle battery should be checked regularly in high-mileage vehicles, in hot

countries and in older 12-volt vehicle batteries. The 12-volt vehicle battery is otherwise maintenance-free.

Preparations

1. Preparing the vehicle for working in the engine compartment (→ In the engine compartment).

2. Open the bonnet (→ In the engine compartment).

Checking the electrolyte level (12-volt vehicle batteries with battery window)

Fig. 1 Battery window on the top of the 12-volt vehicle

battery (general guide).

Depending on equipment, it may be necessary to remove an additional bracket in order to view the battery window.

An additional tool that is not included in the vehicle toolkit is required for this purpose.

Ensure that enough light is available for you to clearly see the colour indicator in the round window on the top of the

12-volt vehicle battery → Fig. 1.

The colour indicator in the round window changes according to the electrolyte level in the 12-volt vehicle battery.

Light yellow or without colour

The electrolyte level of the 12-volt vehicle battery is too low. The 12-volt vehicle battery should be checked

and replaced by a qualified workshop if necessary.

Black

The electrolyte level of the 12-volt vehicle battery is correct.

For technical reasons, you cannot check the electrolyte level of 12-volt vehicle batteries marked with . Go to a

correspondingly qualified workshop to have the 12-volt vehicle battery checked.

535

WARNING

Any work on the 12-volt vehicle battery can cause serious chemical burns, explosions and electric shocks.

● Always wear eye protection and protective gloves.

● Never use naked flames or glowing objects as a light source.

● Electrolyte is very aggressive. It can burn the skin and can cause blindness. When working with the 12-volt

vehicle battery, ensure that your hands, arms and face in particular are protected from acid spillage.

● Never tilt the 12-volt vehicle battery. Electrolyte may spill out of the battery vents and cause chemical burns.

● Never open a 12-volt vehicle battery.

● If acid is sprayed into your eye or onto your skin, rinse the affected area immediately for several minutes with

cold water. Then consult a doctor immediately.

● If electrolyte is swallowed, consult a doctor immediately.

Charging, replacing, disconnecting and connecting the 12-volt vehicle battery

If you suspect that the 12-volt vehicle battery is damaged or faulty, go to a suitably qualified workshop and have the

12-volt vehicle battery checked.

Charging the 12-volt vehicle battery

The 12-volt vehicle battery should always be charged by a correspondingly qualified workshop, as the technology

used in factory-fitted 12-volt vehicle batteries requires voltage-limited charging →

.

Replacing the 12-volt vehicle battery

The 12-volt vehicle battery has been developed to suit the conditions of its location and has special safety features.

If a 12-volt vehicle battery has to be replaced, the replacement part must be installed by a workshop qualified to do

this. For component information on size and the required maintenance, capacity and safety features, please contact a

correspondingly qualified workshop, which must have the necessary technical documentation and equipment. The

ventilation opening of the 12-volt vehicle battery must always be on the negative terminal side. The ventilation

opening on the positive terminal side must always be sealed.

Only maintenance-free 12-volt vehicle batteries compliant with the standards TL 825 06 and VW 7 50 73 should be

used. These standards must be dated October 2014 or later.

The 12-volt vehicle battery must always be replaced by a workshop qualified to do this, as the vehicle electronics

must be adapted as part of the replacement process. In addition, the battery parameters for functional safety were

determined only with the original equipment battery. Only correspondingly qualified workshops have the technology

required to carry out this adjustment and also the correct replacement batteries. The use of unsuitable batteries can

render the type approval invalid.

Disconnecting the 12-volt vehicle battery

Please note the following if the vehicle battery has to be disconnected from the electrical system in the vehicle:

1. Switch off all electrical consumers and the ignition.

2. Unlock the vehicle before disconnecting the battery in order to avoid triggering the anti-theft alarm(if fitted).

3. First disconnect the negative cable and then the positive cable→

.

Connecting the 12-volt vehicle battery

1. Switch off all electrical consumers and the ignition before reconnecting the vehicle battery.

2. First connect the positive cable and then the negative cable→

.

536

Various indicator lamps may light up after the 12-volt vehicle battery has been connected and the ignition is

switched on. They will go out if you drive a short distance at a speed of 15 km/h to 20 km/h (10 – 12 mph). If the

indicator lamps continue to light up, have the vehicle checked by a suitably qualified workshop.

If the 12-volt vehicle battery was disconnected for an extended period, the system may not able to calculate or

correctly display the time when the next service is due . Observe the maximum permissible service intervals .

Automatic switch-off for electrical consumers

The vehicle electrical system cannot always prevent the 12-volt vehicle battery from discharging.

—For example, when the ignition is switched on for an extended period with the engine off, or when the side or

parking lights are on when the vehicle is parked for an extended period.

To prevent the 12-volt vehicle battery from discharging, the intelligent onboard supply management system

automatically implements certain measures when the 12-volt vehicle battery is subjected to heavy loads:

—The idling speed is increased so that the alternator provides more electricity.

—The performance of large electrical consumers may be reduced or they may be switched off completely.

—The power supply to the 12-volt socket and the cigarette lighter may be interrupted temporarily while the engine

is being started.

12-volt vehicle battery is discharged

The 12-volt vehicle battery will discharge if you use electrical consumers when the engine is switched off.

WARNING

Incorrectly securing the battery and using incorrect 12-volt vehicle batteries can cause short circuits, fire and

serious injuries.

● Always use maintenance-free and leak-proof 12-volt vehicle batteries that have the same properties,

specifications and dimensions as the factory-fitted 12-volt vehicle battery.

WARNING

A highly explosive mixture of gases is given off when the 12-volt vehicle battery is being charged.

● Charge 12-volt vehicle batteries only in well-ventilated spaces.

● Never charge a 12-volt vehicle battery which is frozen or has been frozen. Discharged 12-volt vehicle batteries

can even freeze at temperatures of approx. 0°C (+32°F).

● The 12-volt vehicle battery must be replaced if it has ever frozen.

WARNING

Incorrectly connected cables can cause a short circuit.

● First connect the positive cable and then the negative cable.

NOTICE

● Never connect or disconnect 12-volt vehicle batteries if the ignition is switched on or the engine is running.

Never use a 12-volt vehicle battery that does not correspond with the vehicle’s specifications. This can damage

the electrical system or electronic components, which can cause electrical faults.

● Never connect equipment that supplies electric power, such as a solar panel or a battery charger, to the 12-volt

sockets or to the cigarette lighter to charge the 12-volt vehicle battery. This can damage the vehicle electrical

system.

537

Dispose of the 12-volt vehicle battery in accordance with the applicable regulations. 12-volt vehicle

batteries may contain toxic substances such as sulphuric acid and lead.

Electrolyte can pollute the environment. Collect any service fluids that escape or are spilled and dispose of

them correctly and with respect for the environment.

Troubleshooting

12-volt vehicle battery

The indicator lamp lights up red.

1. Do not drive on! Stop the vehicle as soon as possible and when safe to do so.

The 12-volt vehicle battery will not be charged while the vehicle is in motion.

1. Switch off any electrical consumers that are not required.

2. Seek expert assistance.

3. Have the electrical system checked.

There is a fault in the 12-volt vehicle electrical system.

1. Seek expert assistance.

2. Have the electrical system checked.

The start/stop system cannot start the engine .

538

Engine compartment for Your Volkswagen California Van Third Generation (2015-2024)

Related Topics

Popular Owner Manuals

Latest Owner Manuals