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Volkswagen Passat 1997 User Manual
Summary of Passat 1997
Page 1
Service. The passat ‘97 construction and operation 191 640.2810.10.00 technical status: 09/96 the presentation only for internal use. © volkswagen ag, wolfsburg all rights reserved. Subject to modification. ` printed on chlorine-free bleached paper. Self study programme service department.
Page 2
2 the most remarkable features of the new passat are its: l high economy l dynamic body styling l high-quality interior equipment designed with great attention to detail l pioneering safety engineering in this booklet, we would like to provide you with an initial overview showing how we justify maki...
Page 3
3 page the passat ‘97 04 environmental protection and recycling 08 body 10 vehicle safety 15 engines and gearboxes 19 running gear 26 brakes 29 steering 30 electrics 31 extended systems 36 the self study programme is not a workshop manual. Please refer to the relevant service literature for all insp...
Page 4: The Passat ‘97
4 to avoid confusion, concise examples are used to illustrate the various aspects of this all-embracing vehicle concept. You can find detailed information in self study programme no. 192 passat ‘97 – the enginee- ring. The passat ‘97 191/86 191/73 ser vice . 192 der passat '97 die t echnik konstrukt...
Page 5
5 dimensions and weights 4675 mm 2707 mm 1740 mm track widths front rear 1498 1500 mm mm 191/71 weights unladen weight max. Permissible weight appr. 1200 appr. 1805 kg kg.
Page 6: The Passat ‘97
6 the platform - an advantage for workshops the term “platform” is frequently used in publications although its fundamental meaning is not explained. The result of this is that people are often unsure of what the term “platform” implies. The vehicle consists of a) the platform and b) the body. Desig...
Page 7
7 the advantages for workshops like yourself are: - more clarity as regards the spare parts situation - simplified inventory management - fewer different special tools and fixtures - easier assembly and repair platform the platform comprises both common parts and system parts. Common parts e.G. Slid...
Page 8
8 environmental protection and recycling the concept of eco-friendliness was pursued consistently throughout development of the new passat. We would now like to show you some aspects of this topic which are also of interest to work- shops. Recycling not least the recycling requirements present works...
Page 9
9 solvents even during production, every effort is made to keep environmental pollution to a minimum. To achieve this, the following measures were taken: l full galvanisation means much less wax and pvc underseal l water-dilutable paints including water-based clear coat l stringent requirements for ...
Page 10: Body
10 body the following will be of interest to you: l the passat in the wind tunnel l fully galvanised body l greater body rigidity l use of high-strength steel parts l strategy of using common platform for body parts l ease of repair demonstrated using door module as example l rear collision demonstr...
Page 11
11 fully-galvanised body for the first time, the passat has a fully galva- nised body which comes with an 11-year anti- corrosion perforation warranty. The drawing below shows you the parts which are hot-dip galvanised and those which are electrolytically galvanised. Surface patterns, which are also...
Page 12: Body
12 body stability and structure the passat leads its class in terms of torsional rigidity. This was achieved by using: l high-strength panels l different panel thicknesses l improved adhesive bonding techniques (e.G. Adhesive joints) adhesive joints increase rigidity and leakproofing while minimisin...
Page 13
13 the rear bumpers repairing damage to the rear bumpers previously involved expensive repair and welding work, even after minor accidents. The bumpers on the passat ‘97 have the capacity to absorb so much energy during a low-speed rear collision that only plastic parts have to be replaced. Time-con...
Page 14: Body
14 body body platform the floorpan assembly, side members and luggage compartment floor assembly were adopted from the audi a4 as a platform. To enhance ride comfort for rear-seat passengers, a steel floor plate 86 mmwide was inserted. +86 mm +86 mm new parts in passat ‘97 191/69.
Page 15: Vehicle Safety
15 vehicle safety as you will no doubt already know, we make a distinction between active and passive safety. Active safety braking systems steering running gear airbag systems restraint systems inside door panels and side trims with integral pelvis paddings safety body steering column the following...
Page 16: Vehicle Safety
16 vehicle safety crashworthiness the new passat offers the driver and front pas- senger more safety, particularly during a side impact. The inside door panel, which is fitted complete with built-in door fittings, is bolted to the door. To protect the occupants, the inside door panel has an enclosed...
Page 17
17 airbag systems in addition to the driver and front passenger airbags, the passat is equipped with side air- bags as standard. Depending on the side and angle of impact, only the airbags in the immediate vicinity of the danger zone are inflated. Therefore, an uninflated airbag on the side facing a...
Page 18: Vehicle Safety
18 vehicle safety the seat belt tensioner the pyrotechnical seat belt tensioner, together with the “belt fastened” sensor and belt force limiter, are combined in a single assembly. This compact design greatly simplifies replace- ment. The “belt fastened” sensor prevents the seat belt tensioner from ...
Page 19: Engines and Gearboxes
19 engines and gearboxes 1.6-ltr. Engine ahl displacement 1595 cc compression ratio 10.3 : 1 max. Torque 140 nm at 3800 rpm max. Power output 74 kw at 5300 rpm engine management simos 2 fuel 95 ron unleaded premium this engine is also used in the audi a3. It is mounted in the passat without a twin-p...
Page 20: Engines and Gearboxes
20 engines and gearboxes 1.8-ltr. 5v turbo engine aeb displacement 1781cc compression ratio 9.3 : 1 max. Torque 210 nm at 1750-4600 rpm max. Power output 110 kw at 5700 rpm engine management motronic m 3.8.2 fuel 95 ron unleaded premium this engine is also used in the audi a4. 2.8-ltr. V6 engine ack...
Page 21
21 2.3-ltr. Vr5 engine agz the new vr5 engine has a displacement of 2.3 litres. It is derived from the vr6 engine and is designed for in-line or transverse mounting. Power output is 110 kw. The engineering of the vr5 engine is explained in a separate self study programme. 191/53.
Page 22: Engines and Gearboxes
22 engines and gearboxes 1.9-ltr. Tdi engine ahu displacement 1896 cc compression ratio 19.5 : 1 max. Torque 202 nm at 1900 rpm max. Power output 66 kw at 4000 rpm fuel 45 cn diesel mixture preparation direct injection with electronically controlled distributor injection pump 1.9-ltr. Tdi engine afn...
Page 23
23 range of engines and gearboxes 012/01w 01n 01v syncro 1.6-ltr. 74kw 1.8-ltr. 5v 92kw 1.8-ltr. 5v turbo 110kw 2.3-ltr. Vr5 110kw 1.9-ltr. Tdi 66kw 1.9-ltr. Tdi 81kw 2.8-ltr. V6 5v 142kw 01v 01a manual gearbox engines automatic gearbox 191/64.
Page 24: Engines and Gearboxes
24 engines and gearboxes 5-speed manual gearbox 012/01w the 012/01w is a manual gearbox as used in the audi a4. This gearbox has a magnesium housing for installation in the 1.6-ltr./74kw aluminium engine block. 5-speed manual gearbox 01a the 01a is the manual gearbox for four-wheel drive vehicles as...
Page 25
25 4-speed automatic gearbox 01n the 01n is also installed in the audi a6, for example. You can find detailed information on this gearbox in self study programe no. 172. 5-speed automatic gearbox 01v you will also be familiar with the 01v from the audi a4. It is equipped with tiptronic control as st...
Page 26: Running Gear
26 running gear in addition to the four-link front suspension, we will show you on the following pages the newly developed torsion beam rear suspen- sion as well as the new double-wishbone rear suspension unique to syncro models. The four-link front suspension the four-link front suspension is stand...
Page 27
27 the torsion beam rear suspension single-tube damper coil spring 191/55 advantages of torsion beam rear suspension: - larger through-loading width due to the fact that the coil springs and shock absorbers are kept physically apart - use of single-tube dampers - downward-facing v-section of axle be...
Page 28: Running Gear
28 running gear the double-wishbone rear suspension the double-wishbone rear suspension was developed in order to provide a through-loading width of over 1000 mm. Engine power is transmitted to all four wheels by a torsen differential. 191/54.
Page 29: Brakes
29 brakes the passat is equipped with the bosch 5.3 anti- lock braking system as standard. Two different sizes of brake disc are available for the front axle. The rear suspensions also have disc brakes as standard. 280 x 22 mm brake disc the front disc brakes are vented. The smaller disc diameter is...
Page 30: Steering
30 steering height and reach adjustment of steering column the passat is equipped with power steering. The steering column can be adjusted manually 50 mm fore and aft and 28 mm for height. The steering column is attached to the body by a mounting pedestal with sliding guide. A damper element located...
Page 31: Electrics
31 electrics the following features will be of interest to you: l decentralised vehicle electrical system l dash panel insert l gas discharge headlights l washer jets decentralised vehicle electrical system advantages: - short wiring harnesses make cable connections easier to find and assign. - the ...
Page 32: Electrics
32 electrics dash panel insert the following features will be of interest to you: l electronic immobiliser integrated in dash panel insert l capable of diagnosis l can be encoded l fuel gauge the dash panel insert is available in two versions which differ from one another in terms of the displays in...
Page 33
33 fuel gauge in previous systems, the fuel gauge tended to fluctuate, e.G. When cornering. To counteract this, damping of the fuel gauge was increased using electronic devices. However, the drawback of this was that the fuel gauge took longer to display the correct fuel level after refueling. The n...
Page 34: Electrics
34 1 lux 1 lux 0 50 100 150 200 250 m electrics gas discharge headlights gas discharge headlights, which are integrated into the headlights, are available for the passat as an option. However, the use of gas discharge technology is limited to the dipped beam headlight because it takes up to three se...
Page 35
35 fan jet nozzle the passat features new fan jet nozzles for washing the windscreens. Advantages: - better fluid distribution over the entire surface of the windscreen - lower water consumption - better cleansing effect - no adjustment required mode of operation for the sake of simplicity, the mode...
Page 36: Extended Systems
36 extended systems various systems cater for ride comfort and ease of operation in the new passat. The following features will be of interest to you: l l l l extended central locking system – decentralised system concept l heater/air-conditioning – innovations in the air-conditioning l navigation +...
Page 37
37 fi fi functions of the extended central locking system the master control unit assumes the following functions radio remote control interface to vehicle electrical system anti-theft warning system with “interior monitor” function interior light control central locking of rear doors (only in combi...
Page 38: Extended Systems
38 extended systems the heater unlike predecessor models, the new heater is constructed in one piece. The air distributing housing and the air duct with shutoff flap are combined in a single component. The heater, which is controlled at the air intake side, permits fresh-air and air-recirculation mo...
Page 39
39 operating and display unit with control unit - the controls have been rearranged. - the temperature sensor dash panel and blower is integrated in the operating and display unit. - the photosensor measures incident sunlight over a large area. There is greater sensitivity for controlling the interi...
Page 40: Extended Systems
40 extended systems - the fresh-air/air-recirculation flap is combined with the back pressure flap. - fresh-air blower with integrated control unit. - the shape of the central flap has been modified to allow separate airflow to the central and side vents. - all flaps are electic-motor-operated. Air-...
Page 41
41 navigation the navigation system enables the driver to reach his (her) destination easily and safely. It replaces the road map and enhances road safety. This system employs a map stored on a cd-rom. The driver can select his (her) destination on this map. Directions for the driver are then given ...
Page 42: Extended Systems
42 extended systems navigation computer with cd-rom drive the navigation computer determines the posi- tion of the vehicle by means of the above-men- tioned sensors. It then compares the calculated position with the map stored on the cd-rom and the chosen destination. The computer then calculates di...
Page 43
43 however, this particular navigation system is not yet able to make allowance for traffic lights, one-way roads, building sites, traffic jams, etc. Abs wheel speed sensor the wheel speed sensors of the rear suspension are used to provide the navigation computer with iinfomation on distance travell...
Page 44: Extended Systems
44 extended systems advantage: - easy to install - no complex cable installation necessary - one roof aerial for all functions depending on equipment specification of the vehicle, three types of aerial can be installed: - radio only - radio and telephone - radio, telephone and navigation (gps) with ...
Page 45: Notes
45 notes.
Page 46: Notes
46 notes.
Page 47
47.
Page 48: The Passat ‘97
Service. The passat ‘97 design and function 192 640.2810.11.10 technical status: 11/96 the engineering for internal use only. Ó volkswagen ag, wolfsburg all rights reserved. Specifications subject to change. ` printed on chlorine-free bleached cellulose paper. Self study programme service department.
Page 49: The Passat ‘97
2 the passat ‘97 having provided you with an initial overview of the new passat in the self study programme entitled “the passat ‘97 – the presentation”, we now want to describe in detail how the car’s various components are designed and how they function. The subjects of the vr5 engine, convenience...
Page 50
3 page introduction 04 vehicle safety 06 1.8-ltr. 5v engine adr 20 1.8-ltr. 5v turbo engine aeb 22 2.8-ltr. V6 engine ack 26 1.9-ltr. Tdi engine afn 34 gearbox 38 drive shafts 40 running gear 43 abs/edl 48 electrics 55 air-conditioning 60 this self study programme is not a workshop manual! Please re...
Page 51: Introduction
4 engines given that the engine concepts used in the passat ‘97 are tried and tested, we will con- fine ourselves solely to special innovations such as the variable valve timing featured in the 2.8-ltr. V6 engine. Gearbox non-ferrous metals, such as aluminium or magnesium, are being used increasingl...
Page 52
5 running gear in addition to information about the torsion beam rear axle and the double wishbone rear axle, we will show you the new design of the new wheel bearing generation. Abs/edl as a part of the abs/edl system, we will present you the new hydraulic unit with an integrated control unit. Air-...
Page 53: Vehicle Safety
6 vehicle safety mode of operation of the restraint systems two different restraint systems are used in the new passat: l seat belts with belt tensioner and belt force limiter, used on all outer seats, l front and side airbags for the driver and front passenger. Airbag control unit central module of...
Page 54
7 effect of the restraint systems during minor accidents during minor accidents, the body only partially absorbs the impact energy of components such as bumpers and impact absorbers. The seat belts provide adequate protection; the belt tensioners restrain the car’s occupants in their seats. The belt...
Page 55: Vehicle Safety
8 vehicle safety the effect of the restraint systems during serious accidents during serious accidents, the car body absorbs the impact energy. The passenger compart- ment remains by and large intact and the airbags are triggered. In addition to the protection afforded by the seat belts, the restrai...
Page 56
9 when carrying out work on the airbag systems, always follow the instructions given in the workshop manuals. Side airbag the new side airbag system is integrated in the driver’s and front passenger’s seats. The side airbag is described as a thorax airbag. It mainly protects the thorax, and with it ...
Page 57: Vehicle Safety
10 vehicle safety side airbag design the side airbags are integrated in the front seat backrests. The folded airbag and gas generator are accommodated inside the plastic housing. When the side airbag is triggered, the gas cartridges in the gas generator are opened and the pyrotechnical charge ignite...
Page 58
11 a two-stage crash recognition system is used to ensure reliable side airbag activation. Crash sensors g179/g180 the crash sensors for the side airbags are located below the two front seats on the seat cross mem- bers. They are conditioned to respond to lateral force application. The crash sensors...
Page 59: Vehicle Safety
12 vehicle safety airbag control unit j234 in parallel to the crash sensors, sensors in the airbag control unit evaluate the severity of the crash. The relevant side airbag is not triggered until these sensors have also rcognised that an accident has occurred and a crash sensor sends an airbag trigg...
Page 60
13 belt tensioner the pyrotechnical belt tensioner combines with the force limiter and the seat belt recognition device in a single unit. It is only triggered if the mechanical seat belt fastened recognition system recognises an unreeled belt. Its compact design makes for much easier replacement. Wh...
Page 61: Vehicle Safety
14 functional description of front belt tensioner the belt tensioner is activated by balls moun- ted in a feed tube. When the belt tensioner is triggered, a pyro- technical propellant charge ignites. It sets the balls in motion and drives them into the ball retainer via a gearwheel. The belt reeling...
Page 62
15 rear belt tensioner the belt tensioner can be described in simpler terms as a “pyrotechnical wankel engine”. This “wankel engine” is driven by 3 propellant charges. They are ignited in succession. Belt tensioner triggering mechanism belt locking mechanism with child safety seat lock belt force li...
Page 63: Vehicle Safety
16 functional description of rear belt tensioner. The first propellant charge is ignited by a mechanical triggering device. The released gas causes the rotor to rotate. The belt is tightened. After a certain angle of rotation, the piston opens the inlet port of the second firing pin, thus igniting t...
Page 64
17 belt force limiter functional description of belt force limiter if, due to acceleration, the tensile force of the belt is so high that bruising or internal injuries can occur, the tensile force of the belt must be limited to a tolerable level. It is limited by the belt reeling device torsion shaf...
Page 65: Test Your Knowledge
18 1. Which components belong to the restraint system of the passat ‘97? 2. The side airbag has a capacity of a) 8 litres, b) 12 litres or c) 15 litres. 3. The side airbag crash sensors respond to the application of ................................. Force. Test your knowledge 4. What is the function...
Page 66
19 5. The rear belt tensioner a) operates according to the wankel engine principle, b) uses a diaphragm pump, c) is ball-activated. 6. Annotate the following drawing. Ssp 192/126 a) c) b) d) f) e).
Page 67: 1.8-Ltr. 5V Engine Adr
20 1.8-ltr. 5v engine adr the 1.8-ltr. 5v engine has a twin path intake manifold. The twin path intake manifold is designed so that it is possible to switch between long and short intake paths. Long intake path a long intake path permite optimum charging of the cylinder, and consequently high torque...
Page 68
21 electric circuit 30 15 x 31 30 15 x 31 n156 s j220 64 4 3 2 components j17 fuel pump relay j220 motronic control unit n156 intake manifold pressure change valve s fuse j17 in out ssp 192/106 the engine control unit sends a signal to the intake manifold pressure change valve. It uses the vacuum un...
Page 69: 1.8-Ltr. 5V Turbo Engine Aeb
22 1.8-ltr. 5v turbo engine aeb system overview sensors lambda probe g39 actuators air mass meter g70 knock sensors g61 + g66 intake manifold temperature sender g72 the 1.8-ltr. 5v turbo engine is equipped with the motronic m 3.8.2 engine management system. Hall sender g40 engine speed sender g28 co...
Page 70
23 function diagram 1.8-ltr. 5v turbo engine aeb colour code input signal output signal positive negative components f96 altitude sender g6 fuel pump g28 engine speed sender g39 lambda probe g40 hall sender g61 knock sensor i g62 coolant temperature sender g66 knock sensor ii g70 air mass meter g72 ...
Page 71
24 30 15 x 31 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 s n30 n31 n32 n33 g39 n80 n75 j33 g61 g62 g28 g72 g66 j220 n g70 15 64 65 58 80 73 4 3 1 j17 27 25 26 12 13 2 68 60 56 63 53 54 67 g6 in out.
Page 72
25 ssp 192/076 30 15 x 31 n122 50 50 50 50 50 50 50 50 n163 n158 n128 f96 g40 77 78 70 19 59 69 75 11 74 76 62 61 5 6 7 8 18 20 22 23 49.
Page 73: 2.8-Ltr. V6 Engine Ack
26 2.8-ltr. V6 engine ack variable valve timing it provides high torque when driving in low gears at low speeds, thus improving fuel economy and reducing exhaust emissions. High output is needed at high speeds. To achieve both, the cylinder must be well-filled in all speed ranges. At low speeds, the...
Page 74
27 the principle of variable valve timing: performance position in the “performance” position, the lower section of the chain is short while the upper one is long. The inlet valve closes late. The rapid air flow within the intake manifold ensures that the cylinder charge is high. The engine is thus ...
Page 75: 2.8-Ltr. V6 Engine Ack
28 2.8-ltr. V6 engine ack variable valve timer a hydraulic cylinder lifts and lowers the variable valve timer. Oil is supplied to the hydraulic cylinder via the engine oil circuit. The engine control unit controls the hydraulic cylin- der via the variable valve timing valve, which is bol- ted direct...
Page 76
29 the design of the v6 engine makes particularly heavy demands on variable valve timing. Viewed from above, the exhaust camshafts are arranged on the outside and the inlet cams- hafts on the inside. As a result, the variable valve timers of the left and right bank of cylinders have to operate in op...
Page 77: 2.8-Ltr. V6 Engine Ack
30 2.8-ltr. V6 engine ack system overview sensors actuators the 2.8-ltr. V6 engine is equipped with variable valve timing and is controlled by the motronic m 3.8.2 engine control unit. Lambda probes i+ii g39 + g108 air mass meter g70 knock sensors g61 + g66 sensor for intake manifold tempera- ture g...
Page 78
31 function diagram of 2.8-ltr. 6v engine ack colour code input signal output signal positive earth components g6 fuel pump g28 engine speed sender g39 lambda probe g40 hall sender g61 knock sensor i g62 coolant temperature sender g66 knock sensor ii g70 air mass meter g72 intake manifold temperatur...
Page 79
32 30 15 x 31 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 s n30 n31 n32 n33 n83 n84 g39 g108 n80 n156 n205 n208 g61 g40 g163 g66 s 15 26 39 40 44 11 76 68 60 64 55 79 72 65 58 80 73 4 3 j17 s g6 25.
Page 80
33 ssp 192/075 30 15 x 31 n152 50 50 50 50 50 50 j338 g62 8 g72 g70 3 56 53 54 67 66 59 69 75 62 74 14 12 13 70 71 78 19 2 0 5 6 7 8 18 20 22 23 45 49 in out.
Page 81: 1.9-Ltr. Tdi Engine Afn
34 1.9-ltr. Tdi engine afn radiator fan run-on electric circuit 30 15 x 31 30 15 x 31 s v7 j248 j397 n39 3 a radiator fan run-on facility controlled by the engine management system is being used in the 1.9-ltr. 81kw tdi engine for the first time. The advantage of this is that the radiator fan run-on...
Page 82: Test Your Knowledge
35 b) a) test your knowledge 1. Which of the following diagrams represents the “performance” position and the “torque” position in the 2.8-ltr. V6 engine? 2. Complete the following text. At low speeds, the piston moves so that the gas mixture in follows the movement of the piston. The inlet valve so...
Page 83: Gearbox
36 gearbox magnesium lightweight construction now plays a central role in vehicle development, due to the tough demands on performance, safety and fuel economy. Weighing roughly 34% less than aluminium, magnesium is, as a material, well-suited to meeting these demands. We will show you the advantage...
Page 84
37 electrochemical voltage series in the presence of water, an electric current develops between two different metals. The car battery operates according to a similar principle. The electric current causes one of the two metals to decompose. If a metal decomposes easily, it is termed a non-precious ...
Page 85: Gearbox
38 gearbox contact corrosion, using a bolted connection as an example in this example, a magnesium component is attached using a bolt made is an iron alloy. If the contact surface is wetted with water, an electric current occurs between the two metals. This leads to contact corrosion. The magnesium ...
Page 86: Test Your Knowledge
39 test your knowledge 1. What is the insertion depth for magnesium compared to that for iron? A) 2.0 times greater, b) 5.2 times greater, c) 2.5 times greater. 2. Assign the metals of gold, iron, magnesium, copper, aluminium and lead to the following drawing. A) b) c) d) e) f).
Page 87: Drive Shafts
40 drive shafts triple roller constant velocity joint the triple roller cv joint reduces the transmis- sion of vibrations and noise from the engine/ gearbox unit to the body. Triple roller joints are principally used in diesel and automatic cars. This is necessary due to the high vibrations which oc...
Page 88
41 triple roller joint pin drive shaft triple roller joints race function the principal task of the drive shafts is to transmit power from the gearbox to the wheels. They are also responsible for length compensa- tion. The engine/gearbox unit runs in elastic bearings. At certain speeds, the unit beg...
Page 89: Drive Shafts
42 drive shafts housing in addition to the vibrations of the engine/gearbox unit, the triple roller joints have to equalise wheel bump and rebound. The joint housing remains stationary in the process. The drive shaft is moved away from the gearbox by the rebound action of the wheels. At the same tim...
Page 90: Running Gear
43 the following pages describe the design modifications to the axles of the passat ‘97 as presented to you in self study programme ssp 191. Running gear torsion beam rear axle the anti-roll bar used in the new torsion beam rear axle is located in front of the axis of rotation. The rear axle mountin...
Page 91: Running Gear
44 conventional rear axles have a v section which is open facing forward. In this configuration, the shear centre of the axle is located behind the v section. The centre of rotation is an imaginary axis about which the axle rotates when the suspension experiences a bump on one side. If the shear cen...
Page 92
45 hub/wheel bearing unit the newly developed wheel bearing generation is used on the rear axle of front-wheel-drive vehicles. The twin-tracked ball bearing has a stationary outer race which is bolted to the rear axle mounting plate. The bearing inner race serves as the carrier for the brake disc an...
Page 93: Running Gear
46 running gear double wishbone rear axle the newly developed double wishbone rear axle allows the same through-loading width as the torsion beam rear axle. It has an enclosed subframe to which the transverse links are attached. The subframe is connected to the body by four large bonded rubber mount...
Page 94: Test Your Knowledge
47 test your knowledge 1. How is the high transverse rigidity of the torsion beam rear axle achieved? A) b) 2. The v section of the new torsion beam rear axle is open . 3. The advantages of the new wheel bearing generation are as follows: a) minimal wear, b) the abs speed sensor rotor is protected, ...
Page 95: Abs/edl
48 abs/edl system overview the anti-lock braking system is a 4-channel system. This means that two valves are assigned to each wheel (inlet and outlet valves). The hydraulic unit and the abs control unit are combined in a single module and can only be renewed as one unit. A self study programme rela...
Page 96
49 abs/edl hydraulic unit recirculating pump features of hydraulic unit: - one-piece cast iron housing. - abs/edl solenoid valves each with two hydraulic connections and operating positions. - noise-optimised recirculating pump, - accumulator size for each brake circuit: approx. 3 cm 3 , - two diaph...
Page 97: Abs/edl
50 abs/edl abs/edl control unit j104 features of control unit: - redundant computer concept with separate watchdog, - self-diagnosis capability, - 26-pin connector contact. Redundant computer concept in this case, redundant stands for a computer concept with several backups. In the control unit ther...
Page 98
51 abs speed sensor features of speed sensor: - it is inserted into the wheel bearing and is thus protected against external influences. - it generates signals contactlessly. Signal utilisation the signal supplied by the abs speed sensor is used to control the anti-lock braking system. The navigatio...
Page 99: Abs/edl
52 abs/edl function diagram 30 15 x 31 g44 s s n99 n100 n101 j105 v39 j106 15 3 1 17 18 16 in out components f brake light switch g44 rear right speed sensor 4 g45 front right speed sensor 2 g46 rear left speed sensor 3 g47 front left speed sensor 1 j104 control unit for abs with edl j105 abs recirc...
Page 100
53 45 g46 g47 30 15 x 31 j401 f k47 j220 j285 j104 n102 n133 n134 n135 n136 n166 n167 n168 n169 5 4 9 8 7 6 19 23 24 13 21 10 14 11 ssp 192/087.
Page 101: Test Your Knowledge
54 test your knowledge 1. How do you distinguish the abs/edl hydraulic unit from an abs hydraulic unit? A) by the diaphragm outlet damper, b) by the colour of the control unit, c) by the threaded holes for the master brake cylinder. 2. Where is the rotor for the speed sensor of the torsion beam rear...
Page 102: Electrics
55 electrics gas discharge lamp in the case of gas discharge lamps, light is generated by an electric arc between two electrodes in a pea-sized gas-filled glass tube. The lamp emits light with high green and blue components due to the composition of the gas in the lamp tube. This is the external dis...
Page 103: Electrics
56 electrics a gas discharge headlight comprises: l headlight housing, l gas discharge lamp ballast j426/j427 and l headlight range control actuator v48/v49. The gas discharge lamp requires a high-voltage pulse of several thousand volts to ignite the elec- tric arc. The voltage is produced in the ba...
Page 104
57 automatic headlight range control to prevent dazzling oncoming traffic, the gas discharge headlights have to be equipped with an automatic headlight range control. The control unit for automatic headlight range control determines the car’s load condition by two sensors located on the front and re...
Page 105: Electrics
58 electrics emergency operation: if an electrical fault occurs in the automatic head- light range control, the headlight range control actuator automatically sets the headlight to its lowest position. The driver is alerted to the malfunction. Self-diagnosis: the self-diagnosis is started using addr...
Page 106: Test Your Knowledge
59 test your knowledge 1. In the case of gas discharge lamps, light is produced by between two in a gas-filled glass tube. 2. The luminous efficiency with the same power consumption is: a) approx. Ten times higher, b) approx. Five times higher, c) approx. Three times higher. 3. A gas discharge headl...
Page 107: Air-Conditioning
60 air-conditioning refrigerant circuit the passat has an improved air-conditioning system. You can find out about its features and innovations on the following pages. High pressure hot air restrictor the compressed refrigerant is expanded and atomised in the restrictor. It cools down rapidly in the...
Page 108
61 temperature sensor fan v42 climatronic the operating and display unit is combined with the climatronic control unit as a single module. The installation location of the temperature sensor in the climatronic control unit is different in left- and right-hand drive cars. In left-hand drive vehicles,...
Page 109: Air-Conditioning
62 air-conditioning system overview sensors sunshine penetration photosensor g107 sender for central air outlet temperature g191 temperature sensor for fresh air intake duct g89 sender for footwell air outlet tempera- ture g192 dash panel insert temperature sensor g56 with temperature sensor fan v42...
Page 110
63 auto econ magnetic coupling n25 temperature flap actuator v68 with potentiometer ventilation flap actuator v71 with potentiometer central flap actuator v70 with potentiometer footwell/defrost flap actuator v85 with potentiometer actuators fresh air blower v2 with blower control unit j126 control ...
Page 111: Air-Conditioning
64 air-conditioning ventilation flap and the fresh/air recirculation flap the ventilation flap and the fresh/air recircula- tion flap are activated by a common motor. The flaps are adjusted separately by a drive disc with two guide paths. The vacuum unit and two-way valve previously used are no lon-...
Page 112
65 air recirculation mode in the air recirculation mode, the two flaps are in their upper positions. The fresh air supply is blocked. Air-conditioning only takes in air from the passenger compartment. Recirculated air fresh air ssp 192/021 ssp 192/025 above a speed of 160 kph, the ventilation flap i...
Page 113: Air-Conditioning
66 air-conditioning central flap at low outside temperatures and when the engine is cold, the central flap is fully closed. This prevents ice-cold air from being blown into the passenger compartment. The central flap controls the air flow to the cen- tral, side, footwell and defrost air outlets. Its...
Page 114
67 the blower control unit is integrated in the fresh air blower. The control unit cooling ribs are cooled by the blower airstream. Fresh air blower v2 blower control unit j126 air-conditioner fresh air blower v2 ssp 192/037 ssp 192/038.
Page 115: Air-Conditioning
68 air-conditioning sunshine penetration photosensor g107 the air-conditioning temperature control is affec- ted by the sunshine penetration photosensor. It measures the sunlight falling directly on the car’s occupants. How it works: the sunlight impinges on a photodiode through a filter and an opti...
Page 116
69 vertical sunlight penetration the optical element provides greater pro- tection from vertical sunlight penetration. Ssp 192/105 vertically incident sunlight is screened by the car’s roof. The optical element deflects less light onto the photodiode. Cooling can be reduced as the car’s occupants ar...
Page 117: Air-Conditioning
70 air-conditioning signal utilisation the control unit calculates a value from the signals provided by the two sensors. Effects of signal failure in the event of signal failure, the control unit calculates a substitute value on the basis of the outside temperature. With this sender, the temperature...
Page 118: Test Your Knowledge
71 test your knowledge 1. Which statements are true? A) the ventilation flap and the fresh/air recirculation flap are activated by a common electric motor drive. B) in the air recirculation mode, the ventilation flap is in its upper limit position and the fresh/air recirculation flap is in its lower...
Page 119
72 solutions: page 18/19 re. 1. Driver airbag, front passenger airbag, side airbags, front + rear belt tensioners, belt force limiter re. 2. B) re. 3. Side re. 4. Its purpose is to reduce the tensile force of the belt to an acceptable level so that persons wearing a seatbelt are not injured by the b...
Page 120: Notes
73 notes.
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75 notes.