2009 Volkswagen Routan Service and Repair Manual

This factory service and repair manual for the 2009 Volkswagen Routan addresses a 4-door mini passenger van with nine trims, from S, SE and SEL through Comfortline, Highline, Trendline, Execline, Exclusive and Prestige. Two gasoline V6 engines were offered, a 3.8L (231 cu in) pushrod OHV unit and a 4.0L (241 cu in) SOHC unit, both naturally aspirated. Procedures, specifications, torque values, wiring diagrams and diagnostics apply to the engine, fuel system, cooling, transmission, brakes, suspension, steering, electrical system and body.

Engines covered

• 3.8L V6 (231 cu in) — OHV, naturally aspirated, gasoline
• 4.0L V6 (241 cu in) — SOHC, naturally aspirated, gasoline

Body styles covered

• 4-door mini passenger van

Trims covered

• Comfortline
• Exclusive
• Execline
• Highline
• Prestige
• S
• SE
• SEL
• Trendline

Known issues on the 2009 Routan. The 2009 Routan carries 5 recalls. Certain 2009 Routan vans from an early build window had air bag control units that could corrode, failing to deploy or firing unexpectedly (1,037 vehicles). On certain others, a jolt could knock the ignition switch out of run and shut the engine off; dealers modified the switch, and the recall covered 18,526 vehicles. On certain 2009 Routan vans built within a set production window, a possibly misrouted sliding door harness could chafe and overheat the latch, a fire risk (15,902 vehicles). Owners lodged 294 complaints, 151 on the electrical system; 6 complaints reported a crash, 3 a fire and 9 an injury. Wiring diagrams and diagnostics for the ignition, air bag and electrical systems apply.