Guidelines for Rescue Services

Information about accident rescue

regarding Volkswagen vehicles
with alternative drives
2
Contents

Preface 05

EcoFuel Natural Gas Drive 06

Vehicle identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08
Emergency service information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09
Physical properties of natural gas . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

BiFuel Autogas Drive 16

Vehicle identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Emergency service information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Physical properties of autogas . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Safety features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Hybrid Drive 24
Vehicle identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
High-voltage safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Emergency service information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
High-voltage components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Operating modes of hybrid drive . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Rescue cards
The rescue cards provide overviews of the equipment in
Volkswagen vehicles that is relevant to rescue operations
(item number: 002.2200.51.20).

3
Legal notice:
This guide has been produced exclusively for rescue service specialists who have been specially trained in the area of technical
assistance after road accidents and can thus have the qualifications to perform the activities described in this guide.
Furthermore the guide contains information on vehicles that are intended for sale in the European Union. The guide does not,
however, contain information on vehicles that are intended for sale outside the European Union.
The specifications and optional equipment for Volkswagen vehicles as well as the range of vehicles sold by Volkswagen AG
are subject to constant change. Volkswagen therefore expressly reserves the right to revise or modify the contents of this guide and the vehicles
described at any time without notice.

Please note:
The information contained in this guide is neither intended for customers nor for workshops and dealers.
Customers can refer to the vehicle wallet supplied with their respective vehicle from Volkswagen for information on the functions of their vehicle and
important safety information on vehicle and occupant safety. Workshops and dealers obtain repair information from their usual sources.

(Version: December 2010)

4
Preface
Driver, vehicle and environment the interplay of these
factors is decisive for driving safety.

In accident situations, the vehicle performs these functions among others:

Its rigid passenger cell helps to provide a survival space.

Its intelligent structural design includes elements that help to absorb the vehicle energy.
Its occupant restraint system has an optimised configuration of airbags, saftey belts with pretensioners
and belt force limiters to help protect occupants effectively.
Safety equipment helps to minimise the dangers from equipment or drive components.

Volkswagen vehicles have demonstrated in international tests that they are among the safest on the
road. However, accidents and the associated injuries cannot be entirely prevented.
The existence of a short, quick responding and efficient rescue chain therefore remains indispensable.

This guide is intended to help emergency service personnel perform their functions by providing them with the
necessary technical information on Volkswagen vehicles. The information is provided in particular for basic and
advanced training of emergency service personnel. Please also observe the separate guide for emergency
services: Information about accident rescue regarding Volkswagen vehicles with various safety systems
(item number 000.2200.50.20). Corresponding rescue cards (item number 002.2200.51.20) are available for
work at the scene of accidents involving Volkswagen vehicles.

You will find the latest versions at www.volkswagen-rettungsfahrzeuge.de. Changes to the vehicles in the rescue
guide may, however, be added later. This rescue guide was produced with the kind help of Moditech Rescue
Solutions (www.moditech.com).

Technical status: December 2010

5
EcoFuel
Natural Gas Drive
Vehicles with natural gas drive differ in a number of areas from
conventional vehicles and vehicles with autogas drive.
Knowledge of these differences is extremely important for emergency
service personnel at the scene of accidents.

6
 ECOFUEL NATURAL GAS DRIVE

Volkswagen offers certain models ex factory with
EcoFuel natural gas drive. The Golf 4 Estate was also
available in a BiFuel version with natural gas drive.
BiFuel was the designation for natural gas drive
systems at that time, but it is now used for vehicles that
run on autogas.
All natural gas drive vehicles from Volkswagen can be
run both on natural gas and petrol.
EcoFuel vehicles are powered primarily by natural
gas; the petrol tank functions purely as a reserve. The
BiFuel Golf 4 Estate had a conventional standard-
sized petrol tank in addition to its natural gas tank.
While vehicles powered by natural gas are no more
dangerous to handle than vehicles powered by petrol
or diesel fuel, they do differ in some areas.

Fig.: Touran EcoFuel natural gas vehicle

Filling connection

rlf_2010_062

Combustion engine
modified for natural gas
operation

High-pressure Natural gas

regulator tanks

Petrol tank

Tank valves

Natural gas tanks

High-pressure line

Natural gas (also known as compressed natural gas CNG) must not be confused with
liquid gas (also known as liquefied petroleum gas LPG). Liquefied petroleum gas (LPG) and liquid
gas systems differ from compressed natural gas (CNG) and natural gas systems in basic features.
See page 11 and page 21 for further informations about the physical properties of both gas types.

7
ECOFUEL NATURAL GAS DRIVE

Vehicle identification
EcoFuel vehicles and the Golf 4 Estate BiFuel EcoFuel

rlf_2010_065
can be distinguished from conventionally driven badge
(compressed natural
vehicles by the following features:
gas CNG)

EcoFuel badge on the tailgate

(or BiFuel on Golf 4 Estate). Gas filler neck

rlf_2010_064
Additional gas filler neck behind the tank flap or
on the rear right-hand side of the vehicle.

BiFuel

rlf_2010_066
badge on Golf 4
Estate
(compressed natural
gas CNG)

Fig.: Distinguishing features of

natural gas vehicles

The term BiFuel was also used for natural gas vehicles (CNG - compressed natural gas) upon the
introduction of gas-powered vehicles.
Since 2009, the term EcoFuel has been used for natural gas vehicles (CNG - compressed natural
gas) and the term BiFuel for autogas vehicles (LPG - liquefied petroleum gas).

8
Emergency service information
Refer to the rescue cards for the location of components of the compressed natural gas (CNG)
system relevant to rescue operations! The following symbols are used for these components on the
rescue cards:

Gas tank Safety valve

Vehicle fire

In the event of a vehicle fire in which the compressed
natural gas (CNG) tanks are exposed to heat, the
thermal releases open at a temperature of about
110 C causing a controlled release of compressed
natural gas (CNG), which ignites and is burned off.
If the compressed natural gas (CNG) tank is full, the
release of the compressed natural gas (CNG) takes
approx. 90 seconds until the tank is completely empty.
As soon as no more compressed natural gas (CNG) is
released, the emergency services can start to use
conventional firefighting methods. If the compressed
natural gas (CNG) tanks are not affected by the fire
(e.g. if the fire is in the engine compartment),
firefighting can also be started immediately.

If the vehicle is lying on its side or its roof, there may be a jet of flame when the thermal release is
activated. Keep a safe distance from the vehicle.
Approach it from the front if possible.

If the thermal releases have been triggered, the fire should not be extinguished in the area of the
gas tanks until the last gas from the tanks has been burnt off.
If it is necessary to extinguish the fire (e.g. to save lives), prevent the accumulation of compressed
natural gas (CNG) in enclosed spaces (e.g. take ventilation measures, disperse compressed natural
gas CNG).

A loud hissing sound indicates that a thermal release has opened.

9
ECOFUEL NATURAL GAS DRIVE

Road accident involving gas leak from a compressed natural gas (CNG) vehicle

The risk of compressed natural gas (CNG) escaping following an accident is extremely small because several
safety systems would have to fail simultaneously in order for this to happen.

Generally, the following steps should be taken after a
crash (as in the case of all Volkswagen vehicles):
Switch off ignition
Disconnect battery (or batteries)
Disconnect trailer power supply
If a release of compressed natural gas (CNG) is
detected at the accident scene (e.g. by the smell of
gas), the following steps should be taken:
Stop the engine
Switch off ignition
Clear and seal off the danger area
Do not switch on the ignition and never start the
vehicle engine; if it is in an enclosed space, push it
into an open area
Ventilate vehicle interior (open doors, windows,
bonnet and boot)
Determine where gas is concentrated, beware of
accumulation of gas in body cavities and other
spheres
Set up cross-ventilation if necessary, use fan to
disperse cmpressed natural gas (CNG)
Keep potential ignition sources well away from the
vehicle

Never disconnect a battery if critical gas concentrations (e.g. 20% LEL) are present.
The gas can ignite or explode causing serious bang and other serious personal injuries.

10
Physical properties of compressed natural gas CNG
Compressed natural gas (CNG) is a colourless,
combustible gas (fire class C). It is odourless in its Compressed natural gas is lighter than air (density
natural state. ratio natural gas/air approx. 0.6) and therefore
For use in e.g. vehicles, compressed natural gas evaporates quickly in the open air!
(CNG) is odorized, i.e. an odorant is added. This Explosive range between 4 % and 17 % by volume
allows a compressed natural gas (CNG) leak to be Ignition temperature approx. 640 C
detected before the lower explosive limit is
reached.

Notice the basic difference in the behavior of compressed natuarl gas (CNG) and liquefied
petroleum gas (LPG)

gas type behavior

CNG - lighter than air
compressed natural gas - evaporates quickly in the open air
- collects in body cavities and other spheres
LPG - heavier than air
liquefied petroleum gas - collects on the ground, in depressions, in shafts,
in body cavities and other spheres

11
ECOFUEL NATURAL GAS DRIVE

Safety features
The whole natural gas system is installed so that it is Fuel tank shut-
protected from damage in a wide variety of accidents. off valve

The gas tanks are extremely sturdy and can resist very
high temperatures. The high pressure lines and
connecting parts are made from seamless stainless Manual
shut-off tap
steel and, in the Touran, Caddy and Passat, run

outside the passenger compartment. The natural gas
Connecting thread for
system in the Golf 4 Estate is located under the natural gas line
luggage compartment floor.
The tanks are protected against damage and the

rlf_2010_063
elements in a wide variety of accident experiences.

The solenoid fuel tank shut-off valves automatically

cut off the supply of gas when the engine stops, in
petrol mode and in crashes.
In addition to the solenoid shut-off valves, the tank Connecting thread for Thermal release
valves have an integrated thermal release and a flow natural gas tank
restrictor, which helps to prevent uncontrolled gas Flow restrictor
leaks if a pipe is damaged. A non-return valve is also
Fig.: Example of tank valve (up to 2008)
built into the first tank valve, which helps to prevent
the gas flowing back from the tank into the filling line.

12
 Fuel tank shut-off valve
Spring
The fuel tank shut-off valve is a solenoid valve and is
opened by the engine control unit during natural gas
Magnetic field
operation.

The valve closes automatically upon switch-over to

petrol mode, when the engine is switched off, in
Valve accidents resulting in airbag and/or safety belt
pretensioner deployment and if the voltage supply
fails.
rlf_2010_096

Fig.: Function of fuel tank shut-off valve

Sealing cone
Flow restrictor
If there is a
constant high The flow restrictor is a safety valve and is located in
pressure, the connecting flange of the tank valve.
the flow restrictor
It helps to prevent unwanted, sudden flows of gas
will remain open.
from the natural gas tanks if the natural gas pipes or
the gas pressure regulator have been damaged.
The flow restrictor helps to prevent an uncontrolled
flow of fuel and limits leakage flow to max.
rlf_2010_093 0.05 Nm3/min at 100 bar.
Fully closing the manual shut-off tap (see page 10)
Sealing cone allows the fuel leak to be stopped completely.
If there is a
sudden fall in
pressure,
theflow restrictor
will close.

Cone seat

rlf_2010_092

Fig.: Function of flow restrictor

13
ECOFUEL NATURAL GAS DRIVE

Thermal release
Gas outlet
The thermal release is also part of the fuel tank shut-
The glass tube closes the
off valve. It helps to prevent the natural gas tanks gas outlet.
bursting if the pressure rises excessively because of
high temperatures. The thermal release is installed in
such a way that direct release of the natural gas into
Glass tube
the atmosphere is possible.
Flow outlet
rlf_2010_094
The Golf 4 Estate BiFuel has pressurised tanks made
from carbon-fibre composite material located in the
The glass tube
vehicle interior. A thermal release has been fitted on bursts and gas can
both sides of the tank in this vehicle. escape.

Effect of heat approx.
rlf_2010_095 110 C
Fig.: Function of thermal release

rlf_2010_139

Manual shut-off tap

The manual shut-off tap allows you to close the

natural gas tank with a conventional tool so it is gas-
tight. For safety reasons, this is necessary whenever
the natural gas tank is removed or fitted again. Fig.:
Manual
shut-off tap
The escape channel for the thermal release is also on the side
open when the shut-off tap is closed for safety (up to 2008)
reasons.
rlf_2010_140

Fig.:
Manual shut-off
tap
on foot
(from 2008)

14
15
BiFuel
Autogas Drive
Vehicles with autogas drive differ in a range of areas from conventional
vehicles.
Knowledge of these differences is extremely important for emergency
service personnel on rescue operations.

16
 BIFUEL AUTOGAS DRIVE

Volkswagen offers the Polo, Golf and Golf Plus While vehicles powered by autogas (liquefied
models with BiFuel autogas (liquefied petroleum gas petroleum gas LPG) are no more dangerous to handle
LPG) drive ex factory. Up to April 2010, the Sharan than vehicles powered by petrol or diesel fuel, they do
was offered with autogas (liquefied petroleum gas differ in some areas.
LPG) drive under the name Sharan 2.0 LPG.
All autogas-drive vehicles from Volkswagen can be
run both on autogas (liquefied petroleum gas LPG)
and petrol. The BiFuel vehicles use a bivalent
configuration, i.e. the conventional standard-size
petrol tank is fitted in addition to the autogas
(liquefied petroleum gas LPG) tank.

Fig.: Golf 6 BiFuel autogas vehicle

1. Liquid gas (liquefied petroleum gas LPG) filling connection

2. Liquid gas tank
3. Filling gauge and manual selector switch
4. Control unit for liquid gas
rlf_2010_067

5. Evaporator
6. Fuel rail with gas injectors
7. Liquid gas-compatible combustion engine

17
BIFUEL AUTOGAS DRIVE

Vehicle identification
BiFuel vehicles can be distinguished from BiFuel badge

rlf_2010_137
conventionally driven vehicles in the following points: on the tailgate
(liquefied petroleum
gas LPG)
BiFuel badge on the tailgate.
Additional gas filler neck behind the
tank flap or at the rear right-hand side of the
vehicle

Gas filler neck

rlf_2010_068
(liquefied petroleum
gas LPG)

Fig.: Distinguishing features of autogas vehicles

The term BiFuel was also used for natural gas vehicles (CNG - compressed natural gas) upon the
introduction of gas-powered vehicles.
Since 2009, the term EcoFuel has been used for natural gas vehicles (CNG - compressed natural
gas) and the term BiFuel for autogas vehicles (LPG - liquefied petroleum gas).

18
Emergency service information
Refer to the rescue cards for the location of components of the autogas system relevant to rescue
operations! The following symbols are used for these components on the rescue cards:

Gas tank Safety valve

Vehicle fire

In a vehicle fire where the autogas (liquefied
petroleum gas LPG) tank is also exposed to heat, the
pressure relief valve opens at a pressure of 27.5 bar
and there is a controlled release of autogas, which
ignites and is burned off.
If the autogas (liquefied petroleum gas LPG) tanks are
not affected by the fire (e.g. if the fire is in the engine
compartment), firefighting can also be started
immediately.

If the vehicle is lying on its side or its roof, there may be a jet of flame when the pressure relief valve
is activated. If the vehicle is standing on its wheels, the flow of gas underneath the tank is directed
vertically towards the ground. Keep a safe distance from the vehicle.
Approach it from the front if possible.

If possible, cool the gas tank from a safe position to prevent it heating up to the opening
temperature of the pressure relief valve. Continue to cool the tank even if the pressure relief valve
opens.

A loud hissing sound indicates that a pressure relief valve has opened.

19
BIFUEL AUTOGAS DRIVE

Road accident involving/gas leak from an

autogas (liquefied petroleum gas LPG) vehicle

The risk of autogas (liquefied petroleum gas LPG) escaping following an accident is extremely small because
several safety systems would have to fail simultaneously in order for this to happen.

Generally, the following steps should be taken after a If a release of autogas is detected at the accident
crash (as in the case of all Volkswagen vehicles): scene (e.g. by the smell of gas), the following steps
should be taken:

Switch off ignition Stop the engine

Disconnect battery (or batteries)
Disconnect trailer power supply
Switch off ignition
Clear and seal off the danger area
Do not switch on the ignition and never start the
vehicle engine; if it is in an enclosed space, push it
into an open area
Ventilate vehicle interior (open doors, windows,
bonnet and boot)
Determine where gas is concentrated, beware of
accumulation of gas in body cavities and other
spheres
Set up cross-ventilation if necessary, use fan to
disperse autogas
Keep potential ignition sources well away from the
vehicle

Never disconnect a battery if any gas concentrations (e.g. 20% LEL) are present.

20
Physical properties of autogas (liquefied petroleum gas LPG)
Autogas (liquefied petroleum gas LPG) consists of
easily liquefied hydrocarbons
with three or four carbon bonds (fire class C),
primarily propane (C3H8), butane (C4H10),
propene (C3H6) and butylene (C4H8).
Autogas (liquefied petroleum gas LPG) is odorized
for use in vehicles,
i.e. a strong-smelling odorant is added.
In its gaseous state, autogas (liquefied petroleum
gas LPG) is heavier than air (density ratio
autogas/air approx. 1.55) and therefore distributes
itself on the ground.
Autogas (liquefied petroleum gas LPG) is liquefied
at a pressure of 8 bar, in which state the volume is
reduced substantially
(1/260th part of original volume).
Explosive range between 1.4 and 10.9 % by volume
Ignition temperature approx. 460 C

Liquefied petroleum gas (LPG) must not be confused with compressed natural gas (CNG).
Liquefied petroleum gas (LPG) and liquid gas systems differ from compressed natural gas (CNG)
and natural gas systems in basic features. See page 11 for further informations about the physical
properties of compressed natural gas (CNG).

Notice the basic difference in the behavior of compressed natuarl gas (CNG) and liquefied
petroleum gas (LPG)

gas type behavior

CNG - lighter than air
compressed natural gas - evaporates quickly in the open air
- collects in body cavities and other spheres
LPG - heavier than air
liquefied petroleum gas - collects on the ground, in depressions, in shafts,
in body cavities and other spheres

21
BIFUEL AUTOGAS DRIVE

Safety features
The whole autogas (liquefied petroleum gas LPG) system is installed so that it is protected from damage in a
wide variety of accidents.
The gas tanks are extremely sturdy and resistant to heat. All high-pressure lines and connecting elements are
made of copper/stainless steel and are largely routed around the passenger compartment. The tank in the
vehicle interior is protected from damage and the elements in a wide variety of accidents.

The solenoid shut-off valves automatically cut off the supply of gas when the engine stops, in petrol mode and in
crashes. The tank has an integrated pressure relief valve in addition to the solenoid shut-off valve. Furthermore,
a non-return valve is built into the filling stop valve to help prevent gas flowing back from the gas tank into the
filler pipe.

Spring
Fuel tank shut-off valve

The fuel tank shut-off valve is a solenoid valve and is

Solenoid
opened by the gas control unit during liquid gas
operation.
The valve closes automatically upon switch-over to
Armature
petrol mode, when the engine is switched off, in
accidents with airbag and/or safety belt pretensioner Valve
deployment and if the voltage supply fails. To evaporator
rlf_2010_097
From tank
Fig.: Function of fuel tank shut-off
valves
Pressure relief valve

The pressure relief valve is also built into the tank. It Dust cap
helps to prevent the autogas (liquefied petroleum gas Escaping
Outlet aperture autogas
LPG) tank bursting due to an excessive rise in
pressure, e.g. as a result of high temperatures. The Valve spring
pressure relief valve is configured so that it is possible
to release the autogas outside the passenger
Valve disk
compartment. The pressure relief valve is pressure-
rlf_2010_098
controlled, i.e. it opens as soon as the pressure in the rlf_2010_099
tank exceeds 27.5 bar. The valve is designed to close Pressure in tank Pressure in tank greater
again once the excess pressure has been reduced. than 27.5 bar
Fig.: Function of pressure relief valve

22
Fig.: Autogas tank in spare wheel well under the load floor in the boot

23

Hybrid Drive
Volkswagen also offers the Touareg model with a hybrid drive (Volkswagen
Touareg Hybrid). Vehicles with hybrid drive differ in a range of areas from
conventional vehicles.
Knowledge of these differences is extremely important for emergency
service personnel.

24

Hybrid vehicles are powered by a combination of
combustion engine and an electric motor/generator,
which is supplied by a high-voltage battery. The
electric motor/generator takes on the function of a
conventional 12V starter motor and a generator and
allows the vehicle to be driven with the electric motor
(electric driving). It supports the combustion engine in
acceleration phases and operates as a generator
during braking phases to charge the high-voltage
battery (brake energy recouperation).
High-voltage cables
rlf_2010_069
High-voltage
battery
HYBRID DRIVE
The high-voltage battery is charged exclusively by the
electric motor in its function as a generator.
Since the combustion engine does not run during
electric driving, other engine components, e.g. the
vehicle coolant pump, are driven electrically and
supplied with power from the 12 V vehicle electrical
system. The air-conditioning compressor is powered
by the high-voltage battery due to its high power
consumption. It is therefore part of the high-voltage
system.
Combustion engine
Electric motor/
generator
Fig.: Touareg Hybrid
25
HYBRID DRIVE

Vehicle identification

The Touareg Hybrid can be clearly recognised from

the Hybrid badge. It is located:

on the tailgate

Fig.: Examples of Touareg Hybrid on the radiator grille

identification on the engine compartment cover
on the chrome strips on the rear doors near to the
rlf_2010_133
rear wheels

rlf_2010_089

rlf_2010_127

rlf_2010_128

rlf_2010_091

26
High-voltage safety

If not handled correctly, the high voltage in the high-voltage system is dangerous.
The vehicle therefore has an extensive safety concept. Repairing, maintaining and servicing high-voltage
components including the orange-coloured high-voltage cables must only be carried out by specialists with the
corresponding tools and training. Unauthorised work on the high-voltage system is forbidden and
dangerous.

Warning signs

All high-voltage components are labelled with clear warning stickers. The high-voltage cables are excluded
from this.
Basically two kinds of warning stickers are used:

- Yellow warning stickers with warning sign for electrical voltage

- Warning sticker with Danger written on red background

The yellow stickers refer to high-voltage components that are fitted close to the sticker or are hidden behind
covers. The warning stickers with the message Danger are on the actual high-voltage components.

Fig.: Fig.:
Warning sticker Warning sticker
on high-voltage on high-voltage
components battery

rlf_2010_101

Fig.:
Warning sticker on
plastic assembly
carrier in engine
compartment rlf_2010_102

rlf_2010_100

27
HYBRID DRIVE

Further information on high-voltage safety

The high-voltage battery is in the battery box
underneath the load floor in the luggage
compartment.
It is installed in such a way that it is protected
against damage in many kinds of accidents.
The high-voltage battery has protection relays on
both the positive terminal and the negative
terminal that are closed for driving, i.e. when
ignition is ON.
The high-voltage system is electrically insulated
from the vehicle ground.
All connections (plugs and flange sockets) on the
high-voltage components of the vehicle are touch
safe.
A fuse for overhead protection has been
integrated into the maintenance connector to
interrupt the flow of current when the fuse blows.

There is an orange-coloured maintenance The insulation resistance of the high-voltage

connector near to the high-voltage battery. system is periodically checked as part of
It is provided for repair, service and insulation monitoring. Faults are indicated on the
maintenance work only. combi-instrument by a warning message, a yellow
lamp switches on and an acoustic signal sounds.
In the high-voltage system, the discharge circuit
helps to ensure, in case of an accident or an
unforeseen fault, that the high-voltage system is
de-energized after approx. 20 seconds.

The high-voltage system is switched off when:

- the ignition is switched off or
- an accident resulting in deployment of airbags and/or safety belt pretensioners is detected or
- the 12 V connector on the electronics box for the high-voltage battery under the load floor
is disconnected.

Disconnecting the 12 V connector for the electronics box deactivates only the high-voltage system.
Safety systems like airbags or safety belt pretensioners are supplied with power from the
conventional 12 V vehicle electrical system.

28
Emergency service information

In incidents (road accident or vehicle fire) involving a Touareg V6 TSI Hybrid vehicle, emergency service
personnel must always observe the following points:

Identify drive type (see chapter Vehicle identification)

Secure vehicle so it cannot roll away
Deactivate the drive
Work with caution

Refer to the rescue cards for the location of components of the high-voltage system relevant to
rescue operations! The following symbols are used for these components on the rescue cards:

High-voltage battery High-voltage disconnecting point

High-voltage cable
High-voltage components

29
HYBRID DRIVE

Secure vehicle so it cannot roll away

In vehicles that are driven by electric motors, the readiness to drive cannot be recognised by the engine or
running noises. The electric motor is silent when the vehicle is not moving.

The vehicle may be ready to drive even if you cannot hear any engine noises.

The combustion engine can also start automatically when the gear selector lever is set to
P or N depending on the charge level of the high-voltage battery.

Emergency service personnel must always therefore:

rlf_2010_105

Place chocks under the wheels

Move gear selector lever to P position
Apply parking brake (electronic parking brake)

Fig.: Gear selector lever and parking brake in the

centre console

Switch for applying the parking brake

30
Deactivating drive and high-voltage system
(ignition and 12 V battery accessible)

In accidents that are recognised by the airbag control unit, the high-voltage system is switched off.

To ensure that the drive as well as the safety systems are deactivated, emergency service personnel must always
take the steps described below.

Deactivating vehicles with conventional ignition

rlf_2010_126

key:
If the engine is running, turn the ignition key from
the neutral position to the left or right.
The key will spring back to the neutral position by
itself and can be removed.
The high-voltage system is deactivated and the
voltage supply to the airbag control unit is
switched off.

You can turn the ignition key both to the left

and right to start and switch off the vehicle.

Fig.: Conventional ignition key

If engine is OFF:
Turn the key to the right or left = ignition on.
If engine is running:
Turn the key to the right or left = engine off.

Deactivating vehicles with locking and start system

rlf_2010_106

without keys (KESSY):

Press the start/stop button to the second step.
This deactivates the high-voltage system and the
voltage supply to the airbag control unit is
switched off.

If the ignition key is within the range of

KESSY, it is possible to switch on the drive
and the combustion engine again. Always
make sure that the remote control vehicle
key is kept a safe distance from the vehicle.

Fig.: Start/stop button in centre console

31
HYBRID DRIVE

Disconnecting normal 12 V battery

Disconnect the ground cable of the 12 V battery via
the access flap in the floor in front of the driver
seat.
This helps to prevent short-circuits during
spreading and cutting work (risk of airbag
deployment).
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Fig.: Flap for disconnecting the normal 12 V vehicle

electrical system battery in the floor in front of the driver
seat
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Fig.: Opening flap Fig.: Disconnecting earth cable at the screw connection
with spanner

The high-voltage system and the safety systems are only deactivated when the ignition is switched
off AND the normal 12 V battery is disconnected. Simply disconnecting the 12 V battery (without
switching off the ignition) deactivates neither the high-voltage system nor the airbags and safety
belt pertensioners while the hybrid system is switched on!

The high-voltage electrical system can cause electrocution, severe burns, and other serious injuries.
Air bag deployment can cause injuries to vehicle components and first responders who are too
close to them while they deploy.

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Deactivating high-voltage system
(Alternative method: ignition and 12 V battery NOT accessible)

If the ignition lock or the 12 V battery cannot be accessed, the high-voltage system can also be deactivated
using the 12 V connector on the electronics box in the luggage compartment.

Locate disconnecting point

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Fold up luggage compartment floor and locate the
12 V connector on the electronics box to the left of
the high-voltage battery.

Disconnecting connector

This measure deactivates only the high-voltage

system.
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Fig.: 12 V connector on electronics box

Disconnecting the 12 V connector for the electronics box deactivates only the high-voltage system.
Safety systems like airbags or safety belt pretensioners are supplied with power from the
conventional 12 V vehicle electrical system.

The high-voltage system is de-energized within approx. 20 seconds after deactivation.

Further deactivation measures, as described, for example, in the workshop manuals (e.g.
disconnecting the maintenance connector), may only be carried out by trained and qualified
personnel.

33
HYBRID DRIVE

Work with caution

Particular care should be taken when working on the high-voltage system:

Incorrect handling of high-voltage components puts lives at risk due to the high voltage and the
possible resulting flow of current through the human body.

There is voltage in the high-voltage battery even after the high-voltage system has been
deactivated. Never damage or open the high-voltage battery.

The insulation of the high-voltage cables is orange. High-voltage cables must not be damaged or
be disconnected from the high-voltage system by unqualified personnel.

If contact with high-voltage components cannot be avoided during operations on the vehicle, then
the work can only be carried out by qualified personnel.

Special information:
Vehicle fire

During firefighting, the normal necessary safety distances must be observed.

Vehicle in water

If a Volkswagen Touareg Hybrid is in water, there is normally no danger that the body is live.

After recovering the vehicle from the water, emergency service personnel must drain the water
from the interior. Work can then be carried out on the vehicle while following the listed emergency
service information and measures discribed above.

34
High-voltage components

Incorrect handling of the Touareg high-voltage system

can be dangerous. For this reason, the Touareg
Hybrid features an extensive safety concept that
includes all components of the high-voltage system in
the high-voltage safety system, i.e.:
- the electric motor/generator
- the power electronics,
- the high-voltage cables,
- the air-conditioner compressor and
- the high-voltage battery with electronics box

Electric motor/generator High-voltage battery

Combustion engine

Air-
conditioner rlf_2010_075
compressor High-voltage cables
Electronics box with protection relay and
Power electronics
control unit for battery regulation

Fig.: The high-voltage components of the hybrid drive

35
HYBRID DRIVE

High-voltage battery

The high-voltage battery is a nickel-metal hydride
battery (NiMH) that is located in the luggage
compartment under the load floor. The high-voltage
battery consists of 240 battery cells connected in
series and combined into modules of 4 cells each.
The electrolyte in the battery cells is a potassium
hydroxide solution and is contained in small quantities
in the battery cells. Small quantities of electrolyte may
leak out if the battery cells are damaged.
The high-voltage battery supplies a nominal voltage
of 288 volt.
The high-voltage battery has its own cooling system,
which draws in air from the interior below the rear
seat bench and directs it over the battery cells.
The warmed air is sent via the body structure to the
forced ventilation openings on the vehicle.
In an accident, the high-voltage battery is protected
by a battery box. This transfers the impact energy at
the rear to the vehicle structure.

Air ducts to

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the interior

Battery box

Electronics box

Battery module for

high-voltage battery

Cooling fan for

high-voltage battery

Fig.: High-voltage battery used in Touareg Hybrid

The Volkswagen Touareg Hybrid has a normal 12 V vehicle battery in addition to the high-voltage
battery.

36
Electronics box

A connection and distribution box, the electronics box,

Maintenance connector with cover removed is located to the left of the high-voltage battery. The
high-voltage battery is connected to the high-voltage
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system via this box. The electronics box contains safety

systems for the high-voltage system and the
monitoring system for the high-voltage battery. The
maintenance connector is located under an orange-
coloured cover.
There is a protection relay (circuit breaker) on each of
the battery poles, which is closed for operation of the
high-voltage system. In accidents resulting in airbag
and/or safety belt pretensioner deployment, these
protection relays are opened and the high-voltage
system is discharged. The high-voltage connections of
the high-voltage system are then de-energized.

Electronics box Battery box with

high-voltage battery
High-voltage cables

Fig.: Electronics box in luggage compartment next to

high-voltage battery

High-voltage cables

The orange high-voltage cables connect the high-
voltage battery at the rear of the vehicle to the other
high-voltage components in the engine compartment
as well as the components to each other (power
electronics, electric drive motor and air-conditioner
compressor). They are routed under the vehicle floor
and in the area of the high-voltage components in the
engine compartment.
All high-voltage cables have orange-coloured
insulation and provide optimum protection against
damage thanks to additional covers and sleeves.
The high-voltage system does not have electric
potential to the body ground like the conventional
12-volt vehicle electrical system.

37
HYBRID DRIVE

Power electronics

The power electronics are in the engine compartment

of the vehicle. They are protected by a cover plate.

The functions of the power electronics include the

energy converter for the electric drive. Among other
things, it converts the alternating current of the
electric motor/generator into a direct current for the
high-voltage battery and the high-voltage into a 12 V
direct current for the 12 V vehicle electrical system.
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Fig.: Power electronics and high-voltage cables with

cover plate removed

The electrical components in the vehicle, like the power electronics, the electric motor/generator, the
high-voltage battery and the electric air-conditioner compressor work in voltage ranges above 25 V
AC and 60 V DC. Since the voltage is above the normal vehicle system voltage of 12 volt in
conventional vehicles, the term high-voltage (HV) is used for this voltage range in vehicles.

High-voltage systems in the electric motor compartment and in other places on the vehicle can
cause electrical shocks or even electrocution, severe burns, other injuries, and even death!

Touching damaged orange high-voltage cables, the high-voltage battery or other parts of high-
voltage electrical system can cause fatal electric shock.

The high-voltage system may also be active even when the ignition is switched off!

38
Operating modes of hybrid drive

The Volkswagen Touareg hybrid drive is based on a The Touareg Hybrid has the following operating
parallel hybrid drive, in which the combustion engine modes:
and electric motor/generator are used via a common
drive train. Vehicle stationary
Because the electric motor/generator also takes on Electric driving
the function of a conventional 12 V alternator and 12 V Combustion engine mode
starter motor, these components are not required. At Electric boost
the same time, the components that are driven by the Brake energy recouperation
running combustion engine in conventional vehicles,
e.g. oil pump, coolant pump and power steering, The interaction of the hybrid components in the
need to be fitted with electric drives. different driving modes is illustrated in the following
diagrams.

Vehicle stationary
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The combustion engine is not running
The vehicle electrical system (e.g. air-conditioning
system) is supplied with power from the high-
voltage battery

Combustion engine Electric motor/ High-voltage

generator battery
Fig.: Hybrid vehicle stationary
Electric driving
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The combustion engine is not running
The electric motor/generator drives the vehicle
Electric
motor

Fig.: Hybrid vehicle during electric driving

39
HYBRID DRIVE

Combustion engine mode

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The combustion engine drives the vehicle.
The high-voltage battery is charged (depending
on its correct charging level). The operating point
Engine of the engine is shifted to the most efficient range.

Fig.: Hybrid vehicle driven with combustion engine

Electric boost
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The electric motor/generator supports the
combustion engine when there is a very high load
requirement.
Boost The torque and output of the combustion engine
and the electric motor/generator are combined for
a short time.

Fig.: Hybrid vehicle in electric boost mode

Brake energy recouperation

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The combustion engine is switched off.
The braking energy is converted into electrical
energy by the electric motor (which functions as a
Chargin generator). The electrical energy is then stored in
the high-voltage battery.

Fig.: Hybrid vehicle in brake regeneration mode

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 Volkswagen AG
Rckhaltesysteme
EKSR
Brieffach 1565
38436 Wolfsburg

Version: December 2010

Item no. 000.2200.56.20