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Volkswagen Passat 2006 Service Training
Summary of Passat 2006
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Service training self-study programme 339 the passat 2006.
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2 the self-study programme portrays the design and function of new developments! The contents will not be updated. For current testing, adjustment and repair instructions, please refer to the customer service literature intended for this purpose. ● uncompromising safety ● generous amount of space an...
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3 in brief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 occupant protection . . . . . . . . . . . . . . . . . . . ....
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4 in brief the passat model year 2006 where will the new passat 2006 be built? Like its predecessor, the new passat will also be built in the emden and zwickau plants. Vw's emden plant the emden plant, in which the majority of the passat model vehicles will be built, was the first automobile product...
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5 emden zwickau s339_011 s339_003 vw's zwickau/mosel plant in zwickau/mosel, around 1150 golfs and passats are manufactured each day, in both left and right-hand drive versions, for all markets from japan to north america. In january 2003, the one millionth passat rolled off the assembly line in zwi...
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6 in brief the passat 2006 the passat 2006 will point the way forward in many disciplines, e.G. - design - vehicle dynamics - drive technology - spatial availability - safety - quality ● dual-zone climatronic ● light assist ● transversely mounted engine ● bluetooth premium mobile phone pre-installat...
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7 s339_006 ● tyre pressure monitor systems ● electromechanical parking brake ● rear lights with led technology ● boot lid easy opening ● 230v socket ● high-end sound system ● multi-link rear suspension.
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8 in brief length 4765 mm width 1820 mm height 1472 mm wheelbase 2709 mm roof load 100 kg trailed load (braked) 1300 kg front track 1552 mm rear track 1551 mm permissible gross vehicle weight 1950 kg unladen weight without driver 1391 kg drag coefficient 0.281 c d fuel tank capacity 70 litres s339_0...
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9 interior dimensions 1 headroom, front 973 mm 2 headroom, rear 961 mm 3 interior length 1797 mm 4 luggage compartment volume 565 litres* s339_012 s339_010 * including 80 litres in the spare wheel recess storage space.
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10 body the following assemblies are manufactured from ultra-high-strength steel panels: ● the inner a-pillar ● the seat brackets ● the outer sills ● the rear longitudinal members the following assemblies are manufactured from ultra-high-strength, hot-formed steel panels: ● the front bumper cross me...
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11 what are ultra-high-strength, hot-formed steel panels? These are steel panels which, as the name implies, are formed when hot at temperatures of between 900 °c and 950 °c. The steel panels are provided with their high strength thanks to a specific cooling process in the forming die. They are form...
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12 spot weld bonds ● in the area of the longitudinal member to the floor panel ● in the area of the lower sill ● in the area of the rear wheel housing laser soldered joints ● in the roof skin ● side panel/luggage compartment sealing duct body the following joining techniques are employed: laser weld...
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13 in the event of a lateral crash, the passenger survival space is ensured by means of a triple-shell side wall. This is supported on the underlying body structure. The side wall's main component is the b-pillar, comprised of hot-formed steel panels. In the floor panel, the b-pillar is supported on...
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14 body the seats the front seats seat guidance and adjustment are carried out via parallel seat rails. This results in finer adjustment in comparison with the predecessor's central adjustment rail. Mechanical 2-way and electric 4-way lumbar support adjustment are optionally available. All seat vari...
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15 the front passenger seat with through-loading function with this optional seat, the seat backrest can be folded horizontally forwards by actuating the release lever. This enables the vehicle's entire passenger compartment length to be used as transportation space. The seat occupied recognition sy...
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16 body the backrest locking mechanism the backrests are locked by means of a rotary latch lock. If the backrest is not locked, this is displayed via a red indicator. S339_028 rotary latch lock body bow indicator s339_026 the rear seats the rear seat bench is split 1/3 to 2/3. The seat backrests can...
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17 the integrated child seats a rear seat bench with two integrated child seats is optionally available. The seat cushions on the outer seats can be raised. This serves to raise the seat for small children. S339_029 seat cushion not raised seat cushion raised footrest handle for raising raising mech...
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18 lock cylinder not clamped … lock cylinder clamped … body the door lock the door locks are actuated by means of a bowden cable between the door handle and the door lock. The lock cylinder when installed, the lock cylinder is clamped into the lock actuation mechanism via a lever. To do this, the le...
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19 the rear window roller blind the rear window roller blind is available as either a mechanical or an electric version. ● in the mechanical variant, the roller blind is pulled up via a handle and is locked in this position. ● the electric variant is actuated using a button in the centre console. Th...
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20 occupant protection introduction the passat is equipped with the following airbags: ● two-stage driver and front passenger airbags ● head airbags ● side airbags (optional in the rear) the outer seats are fitted with seat belts with belt tension limiters. Front seat belt pre-tensioners are fitted ...
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21 s339_034 in the event of lateral collisions which exclusively affect the front of the vehicle, the vehicle lateral acceleration measured in the airbag control unit is used for crash detection purposes. Rear crash detection is carried out using the two vehicle longitudinal acceleration sensors in ...
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22 occupant protection the two-stage airbags two separate igniter circuits and charges are fitted within the two-stage airbags. Both stages are always deployed in the event of an accident. However, the deployment times are staggered depending on the accident severity. In a minor accident, the time b...
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23 structure: the belt strap is guided through the deflector in the lower area of the c-pillar. It is held by a cable which leads into the seat belt pre- tensioner. The cable is firmly anchored in the seat belt pre- tensioner. How it works: if the seat belt pre-tensioner receives the deployment sign...
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24 engines engine-gearbox combinations petrol engine 5-speed manual gearbox 0ah 5-speed manual gearbox 0a4 diesel engine 1.6l/75 kw petrol engine bse 1.6l/85 kw fsi engine blf 2.0l/147 kw fsi engine (turbocharged engine) axx 2.0l/110 kw fsi engine blr 2.0l/103 kw 4v tdi engine bkp 1.9l/77 kw tdi eng...
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25 6-speed manual gearbox 0aj 6-speed manual gearbox 02s 6-speed manual gearbox 02q direct- shift gearbox 02e 6-speed automatic gearbox 09g.
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26 engines the 1.6l/75 kw engine with 2-valve technology the 1.6l/75 kw engine is based on the familiar 1.6 l/ 75 kw engine with the engine code bgu, which is fitted in the golf 2004. Special technical features ● 2-valve roller rocker fingers ● aluminium engine block with ribbed oil pan ● secondary ...
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27 the 1.6l/85 kw fsi engine this engine originates from the golf 2004. It differs from this only due to its switch to lambda 1 operation and super unleaded ron 95. Special technical features stratified charge and homogeneous lean operation have been omitted due to the switch to lambda 1 (homogeneou...
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28 engines the 2.0l/110 kw fsi engine with 4-valve technology the 2.0l/110 kw fsi engine dispenses with stratified charging and the no x sensor system. The abbreviation fsi will be retained. Special technical features ● ethanol-resistant hitachi high-pressure pump ● two overhead camshafts with conti...
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29 the 2.0l/147 kw turbo fsi engine with 4-valve technology a further developed turbo fsi engine is to follow on the basis of the 2.0l/110 kw engine. The turbo fsi engine was first launched in 2004 in the audi a3 sportback and the golf gti. Special technical features ● single-branch exhaust system w...
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30 due to its underhood location, no fuel additive is required for soot combustion. In combination with a new engine oil, the diesel particulate filters are entirely maintenance-free. Engines information on these diesel particulate filters can be found in self-study programme 336 "the catalytically ...
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31 the 1.9l/77 kw tdi engine with 2-valve technology this tried-and-tested 1.9l/77 kw tdi engine is also installed in the current golf model and in other volkswagen models. For installation into the passat, it has been modified and adapted to the new vehicle. Special technical features ● switchable ...
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32 engines the 2.0l/103 kw tdi engine with 2-valve technology and diesel particulate filter the 2.0l/103 kw tdi engine has been developed from the 1.9l/96 kw engine. It was already installed in the passat model year 2001. Special technical features in comparison with the 2.0l engine in the passat 20...
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33 the 2.0l/103 kw tdi engine with 4-valve technology based on the 2.0l/103 kw 4v tdi engine fitted in the golf 2004 and touran, this engine has been further developed for the passat 2006. Vibrations and noise emissions have been reduced by a balancer shaft module and new unit injectors with piezo-e...
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34 engines the unit injector with piezo-electric valve the 2.0l/103 kw 4v tdi fitted in the passat 2006 will be equipped with unit injectors with piezo-electric valves for the first time. This new development offers the following advantages over the unit injector with solenoid valve: ● lower noise e...
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35 the fuel tank the fuel tank fitted in the passat 2006 is comprised of two half shells manufactured from a compound of several plastic, adhesive and barrier layers. The two half shells are welded together after the fuel tank's internal breather system has been installed. The fuel tank meets the fo...
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36 engines the fuel delivery unit the fuel delivery unit is installed in the fuel tank. The following components are contained within this unit: ● the fuel pump ● the fuel filter (not in the diesel engine) ● the fuel pressure regulator ● the suction jet pumps ● the potentiometer for the fuel gauge f...
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37 the fuel delivery unit supplies the engine with the precisely required quantity of fuel at the precisely required pressure. It is controlled by the engine control unit according to the fuel requirements. The fuel delivery units differ due to the fuel required by the individual mpi, fsi and diesel...
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38 the fuel delivery unit with integrated fuel pressure regulation fuel pump and fuel regulation initialisation depend on the engine which is installed. The mpi engines the engine's fuel supply is ensured by the constant- delivery fuel pump. The fuel is pumped, counter to the pressure regulator's pr...
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39 the suction jet pumps two suction jet pumps are located within the fuel delivery unit. These have the task of continuously filling the fuel pump's reservoir chamber with fuel. This reduces the fuel pump's intake consumption, and the fuel pump always has sufficient fuel at its availability. Front-...
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40 engines the fuel tank for 4motion vehicles the external shape of the fuel tank is determined by the available installation space, which is in turn determined by the double wishbone rear suspension and the haldex coupling. Its function is identical to the fuel tank fitted in front-wheel drive vehi...
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41 power transmission already fitted in the: technical features also see self- study programme no.: 5-speed manual gearbox 0ah caddy • further development of the 02t gearbox • shaft distance increased, final drive strengthened, housing adapted • without speedometer sender 328 5-speed manual gearbox ...
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42 the automatic gearbox with the code 09g has already proved its worth in the golf 2004, touran and new beetle. In design and functional terms, automatic gearbox 09m corresponds to automatic gearbox 09g. It has merely been reinforced to cope with higher torque transmission in the area of the coupli...
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43 the gearbox offers the following characteristics: ● six forward gears and one reverse gear ● standard and sports gearbox programmes ● tiptronic selector level and steering wheel switches ● mechatronics ● hill-holder function ● creep control ● pressure oil filter and oil cooler located on the gear...
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44 the ignition key withdrawal lock is comprised of the following components. ● the selector lever locked in position "p" switch f319 ● the steering column electronics control unit j527 and ● the ignition key withdrawal lock solenoid n376 in the entry and start authorisation switch e415 power transm...
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45 if the selector lever is set to a driving position or "n" position, switch f319 is closed. Due to the fact that switch f319 is closed, the current circuit to control unit j527 is made. Based on the made current circuit, control unit j527 detects the selector lever position. If the selector lever ...
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46 modern, lightweight mcpherson strut front suspensionand the state-of-the-art 4-link rear suspension therefore remain in use. The passat's handling behaviour, which is outstanding as a result of these components, is rounded off with the electromechanical power steering system familiar from the gol...
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47 however, there are also significant innovations in the passat's running gear, e.G. ● the electromechanical parking brake with auto hold function, ● the new abs/esp system from trw (thompson-ramo-wooldrigde) and ● the tyre pressure monitor system from hella. ● tyre pressure monitor system, optiona...
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48 running gear the rear axle the front-wheel drive passat's rear axle is a compact four-link rear suspension in lightweight design. The 4motion rear axle the 4motion rear axle is based on that fitted in the front-wheel drive vehicles and is linked to the body via large bonded rubber bushes. S339_05...
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49 the steering column the steering column fitted in the passat 2006 can be adjusted vertically by 60 mm and horizontally by 50 mm. It is equipped with an electric steering column lock. This has enabled the steering lock to be positioned in a crash- optimised area. The position of the steering colum...
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50 this encompasses: ● a new esp system from trw (thompson-ramo- wooldrigde) with vehicle/trailer stabilisation ● large wheel brakes ● a brake disc wiper ● a tandem brake master cylinder with brake light switch ● a brake servo with "dual rate characteristics" ● a hydraulic brake servo (hbv), for veh...
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51 the anti-lock brake system abs/esp trw ebc 440 a trw esp system will be fitted for the first time at volkswagen. In addition to a hydraulic brake assist system, this system includes an auto hold function as an interface to the electromechanical parking brake, plus a vehicle/trailer stabilisation ...
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52 by regularly applying the brake pads to the brake discs from time to time at low pressure, this displaces the water film and shortens the stopping distance. This is carried out by cyclical initialisation of the hydraulic pump, which builds up the low brake pressure in the brake system. This proce...
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53 the brake servo - dual rate booster all left-hand drive vehicles will be fitted with an 11" brake servo. The right-hand drive vehicles will be fitted with a 7/8" tandem brake servo. Implementation of the "dual rate characteristics" represents a significant innovation. S339_142 s339_144 a progress...
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54 running gear the brake light switch f the brake light switch f is bolted to the brake master cylinder. It is used to detect whether the brake pedal is actuated. When the brake pedal is actuated, the brake lights are switched on. Signal usage the brake lights are switched on via the vehicle electr...
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55 how it works: on actuation of the brake pedal, the push rod in the brake master cylinder pushes the piston with magnetic ring (permanent magnet). Brake pedal not actuated: when the brake pedal is not actuated, the piston and magnetic ring are at rest. The evaluation electronics of brake light swi...
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56 running gear engine front brake in mm rear brake in mm 75 kw to 118 kw as of 132 kw s339_140 Ø 312 x 25 bolted swivel bearing s339_138 Ø 286 x 12 s339_141 Ø 345 x 30 bolted swivel bearing s339_139 Ø 310 x 22 the brakes.
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57 the automatic levelling system the sachs automatic levelling system is a self-inflating shock absorber which will be installed on the passat's rear suspension instead of the conventional shock absorber. It will be available as an optional extra at a later point in time. The automatic levelling sy...
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58 running gear summer tyres wheel 205/55 r16 91 h/v steel alloy 6.5j x 16 et 42 mm 215/55 r16 93 h/v alloy 7j x 16 et 45 mm 235/45 r17 74 v alloy 7.5j x 17 et 47 mm winter tyres (suitable for snow chains) 205/55 r16 91 h/v steel alloy 6.5j x 16 h2 et 42 mm spare wheel mobility set comprised of a se...
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59 this is made possible by a special side wall reinforcement and innovative, extremely heat- resistant rubber compounds. A reinforced bead coil ensures that the tyre is securely seated on the wheel – even in the event of total pressure loss. One additional advantage is: bridgestone rft tyres do not...
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60 electrical system the fuse boxes and relay positions in the vehicle electrical system the installation locations the vehicle electrical system in the passat 2006 has a decentralised structure and is therefore comparable to that in the golf 2004. Due to the multitude of electrical consumers, the p...
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61 relay holder on the vehicle electrical system control unit relay holder on the vehicle electrical system control unit s339_062 fuse box, left of dash panel for more detailed information on the electrical system, please refer to self- study programme 340 "the passat 2006 electrical system"..
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62 electrical system the networking concept to ensure flawless data exchange between the individual control units, these are networked via various data bus systems. The data bus diagnostic interface j533 (gateway) acts as the interface for the following data buses: ● can powertrain data bus ● can co...
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63 legend d ignition/starter switch e221 operating unit in steering wheel g85 steering angle sender g273 interior monitoring sensor g384 vehicle inclination sender g397 rain and light detector sensor g419 esp sensor unit h8 anti-theft alarm system horn j104 control unit for abs j136 seat and steerin...
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64 electrical system the inverter an optional 230 v/50 hz european socket can be ordered for the passat 2006. An inverter, which is firmly connected to the socket, is installed in the vehicle to generate the alternating voltage. This unit is located in the rear centre console instead of the cup hold...
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65 the emergency key serves ● to mechanically unlock the driver's door if the vehicle cannot be opened using the radioremote control, ● to deactivate the front passenger airbag, ● to lock the glove box, ● to lock and release the rear seat bench and ● to activate the child safety lock in the rear doo...
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66 heater and air conditioner an identically designed air conditioner unit, which has been adapted to the relevant vehicle equipment, is used for both systems. The main difference is in air distribution flap actuation. 2c-climatronic is fitted with an additional fresh air/air flow flap. Climate cont...
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67 operation different control panel versions are available depending on the equipment fitted in the vehicle: ● with or without instant heat button for the auxiliarycoolant heater ● with or without potentiometer for the seat heating ● with or without potentiometer for the heated windscreen the clima...
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68 heater and air conditioner the 2c-climatronic system in the 2c-climatronic system, the interior is sub- divided into two climatic zones. This means that the temperatures desired on the driver and front passenger side can be set independently of each other in the range from 16 °c to 29.5 °c. The c...
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69 indirect ventilation 2c-climatronic is equipped with indirect ventilation. An adapter positioned on the top of the air conditioner unit enables air distribution between the vents in the centre of the dash panel and indirect ventilation via the electrically driven air flap for indirect ventilation...
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70 heater and air conditioner for basic information on auxiliary coolant heaters, please refer to self-study programme 280 "the phaeton – auxiliary coolant heater and additional heater thermo top c". Thermo top v auxiliary coolant heater s339_106 the thermo top v auxiliary heater the new passat can ...
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71 structure ● the auxiliary coolant heater control unit is integrated into the heater unit. The electrical contacts for the combustion air blower are inserted directly into the control unit. ● the auxiliary coolant heater is fitted with a second ntc temperature sensor for controlling and monitoring...
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72 the radio systems in the passat 2006 radio rcd 300 radio rcd 300 is available as the standard radio system for private customers. It offers the following functions: ● two or four loudspeaker channels (20 watts each) ● rds fm/am european radio (am without lw) ● indication of the stored stations wi...
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73 a radio system with an integrated navigation system is also available for the passat 2006. The operating sequences are similar to those of the radio/navigation system fitted in the touareg. It offers the following functions, etc.: ● multi-colour display (mfd) ● dynamic guidance ● four loudspeaker...
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74 notes.
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75.
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© volkswagen ag, wolfsburg all rights and technical changes reserved. 000.2811.54.20 technical status 03.2005 volkswagen ag service training vk-21 brieffach 1995 d-38436 wolfsburg ❀ this paper has been manufactured from cellulose bleached without the use of chlorine. 339.