2009 Volkswagen Routan Service and Repair Manual

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Factory-Grade Data

2009 Volkswagen Routan service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you diagnose issues correctly, follow proven repair steps, and use wiring diagrams and system sections to track faults faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical diagnostics with wiring diagrams
  • Coverage across major systems: engine, transmission/driveline, brakes, steering, suspension, HVAC, and more

Trims covered

  • Prestige Mini Passenger Van 4-Door
  • Comfortline Mini Passenger Van 4-Door
  • Execline Mini Passenger Van 4-Door
  • SE Mini Passenger Van 4-Door
  • S Mini Passenger Van 4-Door
  • Exclusive Mini Passenger Van 4-Door
  • Trendline Mini Passenger Van 4-Door
  • Highline Mini Passenger Van 4-Door
  • SEL Mini Passenger Van 4-Door

Engines covered

  • 3.8L 3778CC 231Cu. In. V6 GAS OHV Naturally Aspirated
  • 4.0L 3952CC 241Cu. In. V6 GAS SOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2009 Volkswagen Routan Recalls & Complaints

NHTSA #16V08300011/02/2016Component: AIR BAGS:FRONTAL:SENSOR/CONTROL MODULE-INACTIVE

Volkswagen Group of America, Inc. (VW) is recalling certain model year 2009 Volkswagen Routan vehicles manufactured February 7, 2008, to August 28, 2008. In the affected vehicles, the air bag control

Consequence

If the air bag control unit fails, the air bags may not deploy in the event of a crash, increasing t

Remedy

VW will notify owners, and dealers will replace the air bag control unit, free of charge. The recal

NHTSA #14V05500011/02/2014Component: SUSPENSION:REAR:AXLE:NON-POWERED AXLE ASSEMBLY

Freedom Motors Inc., (Freedom Motors) of Savaria Vehicle Group (formerly The Liberty Motor Company) is recalling one model year 2009 Volkswagen Routan and certain model year 2008-2010 Dodge Grand Cara

Consequence

Failure of the rear axle may increase the risk of a crash.

Remedy

Freedom Motors will notify owners, and dealers will replace the affected axles, free of charge. The

NHTSA #10V25200010/06/2010Component: ELECTRICAL SYSTEM:WIRING

VOLKSWAGEN IS RECALLING CERTAIN MODEL YEAR 2009 ROUTAN VEHICLES MANUFACTURED FROM JUNE 2008 THROUGH JULY 2009. THESE VEHICLES MAY HAVE BEEN BUILT WITH AN IMPROPER ROUTED WIRE HARNESS THAT MAY HAVE A

Consequence

THIS COULD RESULT IN AN OVERHEATED LATCH AND A FIRE WITHIN THE REAR SLIDING DOOR COULD OCCUR.

Remedy

VOLKSWAGEN WILL INSPECT THE SLIDING DOOR WIRE TRACK WIRE ASSEMBLY AND THE SLIDING DOOR POWER DRIVE U

NHTSA #09V24400001/07/2009Component: EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

VOLKSWAGEN IS RECALLING 18,500 MY 2009 ROUTAN VEHICLES FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 208, "OCCUPANT CRASH PROTECTION." THE OWNER'S MANUAL WA

Consequence

ANY SUCH OBJECTS COULD CAUSE INJURY TO THE VEHICLE'S OCCUPANTS IN THE EVENT OF A CRASH SEVERE ENOUGH

Remedy

DEALERS WILL SEND AN OWNER'S MANUAL INSERT CONTAINING THE REQUIRED AIR BAG INFORMATION FOR OWNER INS

NHTSA #15V19400001/04/2015Component: ELECTRICAL SYSTEM:IGNITION:SWITCH

Volkswagen Group of America, Inc. (Volkswagen) is recalling certain model year 2009 Routan vehicles manufactured June 25, 2008, to July 8, 2009, and 2010 Routan vehicles manufactured October 1, 2009,

Consequence

If the ignition key inadvertently moves into the OFF or ACCESSORY position, the engine will turn off

Remedy

Volkswagen will notify owners, and dealers will replace the ignition switch and key FOBs, free of ch

TSB #11030847

This is a notice for software changes with the ODIS diagnostic program to correct the communication during vehicle programming function: A software fix is needed to correct the error message ERP0204E could occur during perform initial opera

TSB #11030829

This is a notice for software changes with the ODIS diagnostic program to correct the communication during vehicle programming function: A software fix is needed to correct multiple test plans: All basic settings test for the following comp

TSB #11028490

This is a notice for software changes with the ODIS diagnostic program to correct the communication during vehicle programming function: A software fix is needed to correct a test that is not reading any information from the battery data mo

TSB #11026184

What is and what is not a leaking suspension strut.

TSB #11021378

Fuel Additive

TSB #11021372

How to identify and when to replace a leaking strut

TSB #11014949

Identifying and Mixing Engine Coolant

TSB #11010011

Vehicle Concerns Before Recall Repair Available

Showing the 8 most recent of 356 technical service bulletins on file with NHTSA.

20240625Component: AIR BAGSCrash reported1 injured

The contact owned a 2009 Volkswagen Routan. The contact stated that while driving at 65 MPH, the contact suffered a medical emergency and lost control of the vehicle. The contact's vehicle crashed in

20101012Component: POWER TRAIN:AUTOMATIC TRANSMISSIONCrash reported1 injured

ON MONDAY, OCTOBER 4TH, 2010, I PULLED INTO MY DRIVEWAY AND PLACED THE 2009 VOLKSWAGEN ROUTAN IN PARK. THE ENGINE WAS STILL RUNNING WHILE I FINISHED UP A PHONE CALL THROUGH THE BLUETOOTH AND PROCEEDE

20090903Component: POWER TRAIN:AUTOMATIC TRANSMISSIONCrash reported1 injured

MY 2009 VOLKSWAGEN ROUTAN SLIPPED INTO REVERSE WHILE I WAS BEHIND IT TODAY RUNNING ME OVER AND CAUSING A LEG INJURY. *TR

20161107Component: AIR BAGSCrash reported

TL* THE CONTACT OWNS A 2009 VOLKSWAGEN ROUTAN. WHILE DRIVING APPROXIMATELY 35 MPH, THE CONTACT REAR ENDED THE PRECEDING VEHICLE. THE AIR BAGS DID NOT DEPLOY. THE DRIVER WAS SHAKEN UP AND WAS TAKEN TO

20140910Component: PARKING BRAKECrash reported

TL* THE CONTACT OWNS A 2009 VOLKSWAGEN ROUTAN. THE CONTACT STATED THAT THE EMERGENCY BRAKE WARNING INDICATOR ILLUMINATED, WHICH INDICATED THAT IT WAS LOCKED. THE VEHICLE VEERED TO THE RIGHT AND CRASHE

Showing the 5 most serious of 460 complaints filed with NHTSA.

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