1. DL manuals
  2. Volkswagen
  3. Automobile
  4. Passat W8
  5. Service

Volkswagen Passat W8 Service

Manual is about: Passat W8

Summary of Passat W8

  • Page 1

    The passat w8 self-study programme 261 service..

  • Page 2

    2 new caution important the passat w8 this self-study programme presents the passat w8. We will only explain the design and function where the items are totally new. All the changes described refer to the passat model year 2001. The subject of the w8 engine is described in two separate self-study pr...

  • Page 3

    3 at a glance in a nutshell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 occupant protection . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 drive units . . . . . . . . . . . . ...

  • Page 4

    4 in a nutshell the passat w8 innovations in the passat w8 the top model of the passat range is the first car from volkswagen equipped with an 8-cylinder engine. The passat w8 offers luxury class refinement in performance, comfort, safety, quality and equipment. It will be offered in saloon and esta...

  • Page 5

    5 this high-quality car is based on the passat launched in model year 2001. The engine power output is transferred to the road via a 6-speed manual gearbox with four-wheel drive (4motion). Optionally there is a five-speed automatic gearbox with tiptronic and 4motion. The w8 engine is a totally new d...

  • Page 6

    6 in a nutshell the estate all the innovations in the passat w8 saloon are also in the estate. The bodies of both the estate and the saloon have been strengthened to improve the acoustics and increase crash safety. But whether it is the estate or the saloon, the new passat w8 is recognisable from th...

  • Page 7

    7 inside, the standard equipment includes head airbags front and rear, high-class pillar and headliner trims, chrome and real wood trims, exclusive upholstery, an on-board computer and automatic air conditioning. In the extensive list of the passat w8's optional extras we have included new luxury le...

  • Page 8

    8 in a nutshell the saloon size and weight length 4703 mm width 1746 mm height 1461 mm wheelbase 2703 mm turning circle 11.5 m tank capacity 80 l 2703 mm 4703 mm 1746 mm 146 1 mm s261_006 s261_005 100 kg front track width 1511 mm rear track width 1510 mm perm. Gross vehicle weight 2220 kg kerb weigh...

  • Page 9

    9 the estate 2703 mm 4682 mm 1746 mm 1497 mm s261_008 s261_010 s261_009 100 kg size and weight length 4682 mm width 1746 mm height 1497 mm wheelbase 2703 mm turning circle 11.5 m tank capacity 80 l front track width 1515 mm rear track width 1510 mm perm. Gross vehicle weight 2290 kg kerb weight 1725...

  • Page 10

    10 body body modifications to fulfill the claims of greater luxury and safety, the body of the passat w8 has been strengthened. By strengthening, we make a distinction between reinforcement to improve the acoustics and reinforcement to increase crash safety. We have modified the spare wheel well to ...

  • Page 11

    11 acoustic measures: a cross strut is bolted between the front wheel housings. It is fixed to new supports welded to the wheel housings. An additional strut is welded to the front bulkhead near the front side member. Crash reinforcements: the front footwell is reinforced by an additional cross-memb...

  • Page 12

    12 occupant protection occupant protection occupant protection is ensured by the airbag system with two front airbags, sidebags and head airbags, belts and belt tensioners as well as the child safety restraint system. Front airbag front passenger airbag control unit front airbag driver front airbag ...

  • Page 13

    13 wankel belt tensioner seat with integrated side airbag head airbag head airbag module side airbag driver side airbag module the conventional inertia-reel seat belts are used on the front and outer rear seats. Ball-type tensioners are fitted to the front seats. The rear seats are fitted with wanke...

  • Page 14

    14 child safety restraint system to use the integrated child safety seat, the swab elements must be raised and engaged. The correct belt run is corrected by an additional shoulder belt guide for children measuring 1.3 m to 1.5 m tall. A belt guide hook on the raised swab ensures that the belt runs s...

  • Page 15

    15 drive units the w8 engine in general the passat w8 is fitted with one engine, the new w engine generation, the w8. The w layout is obtained by joining two v engines at an angle of 72°. This layout achieves a very compact 8-cylinder engine with very small dimensions. Compared with other 8-cylinder...

  • Page 16

    16 drive units 500 400 300 200 100 2000 4000 6000 [nm] rpm s261_017 torque and power output 200 150 100 50 [kw] torque curve output curve specifications engine code bdn displacement 3,999 cm 3 type w engine valves per cylinder 4 compression ratio 10.75±0.25:1 bore 84.0 mm stroke 90.2 mm max. Output ...

  • Page 17

    17 the fuel delivery system the fuel delivery system of the passat w8 has tank capacity of 80 litres. It consists of a 60 litre fuel tank as fitted to the passat 2001 4motion and an additional tank containing 20 litres. The two fuel tanks are connected by a connecting tube. The additional fuel tank ...

  • Page 18

    18 the fuel pumps the 60-litre fuel tank contains an electrical fuel pump and a suction jet pump (entrainment pump). There is another electrical fuel pump in the 20-litre additional fuel tank. The different heights of the main tank and the additional tank require a controlled evacuation of the two t...

  • Page 19

    19 fuel pump control the fuel pump in the main fuel tank is controlled by the engine control unit. The fuel pump in the additional fuel tank is switched on by the fuel pump control unit. For this reason there are four fuel level senders in the entire tank and one sender g293 with a reed contact. The...

  • Page 20

    20 g 293 g 292 g g 237 g 169 g 6 j 17 j 538 g 23 g 293 -fuel level sender, additional fuel tank empty g 292 -fuel level sender, additional fuel tank g - sender for fuel level indicator g 237 - sender 3 for fuel level indicator g 169 - sender 2 for fuel level indicator g 6 - fuel pump (pre-supply pum...

  • Page 21

    21 control unit for fuel pump j538 the fuel pump control unit is located in the spare-wheel well embedded in plastic. It is connected to the can convenience bus. The control unit is therefore connected to the dash panel insert. It has the following tasks: ● evaluating signals from the four fuel leve...

  • Page 22

    22 power transmission the 6-speed manual gearbox 01e from the passat 2001 is also fitted to the passat w8. As the passat w8 is supplied with 4motion four-wheel drive as standard, a torsen differential is integrated in the gearbox to distribute the engine torque to all four wheels. The gearbox casing...

  • Page 23

    23 the four-wheel drive 4motion the main function of the four-wheel drive is to compensate the drive forces between the front and rear axles as a factor of positive engagement. The torsen differential detects wheel slip in one axle and distributes the drive power to the wheels of an axle with better...

  • Page 24

    24 running gear the design of the front axle on the passat w8 is identical to the passat model year 2001. The following components have been modified to cope with the higher weight and the resulting axle loads: ● the wheel bearing housing ● the wheel bearings ● the wheel hub, and ● the tubular subfr...

  • Page 25

    25 the double wishbone rear suspension the proven double wishbone rear suspension with closed tubular subframe is fitted to the passat w8. S261_029 upper wishbone lower wishbone tubular subframe differential new wheel bearing housing: ● wheel bearing housing made of aluminium ● track rods guided at ...

  • Page 26

    26 running gear the brake system rear disc brake front disc brake hydraulic unit and control unit ● 334 mm x 32 mm ● 321 mm x 30 mm ● 269 mm x 22 mm front disc brake rear disc brake the passat w8 currently has the most powerful brake system of all volkswagen car models. Despite high engine performan...

  • Page 27

    27 the hydraulic unit and abs control unit the passat w8 receives the bosch 5.7 abs system with esp (electronic stability programme) and the hydraulic brake assistant system (bas). Special features of the bosch 5.7 abs system are: ● the hydraulic unit and the control unit form a single unit ● the ab...

  • Page 28

    28 running gear the abs two-stage recirculating pump v39 is integrated in the bosch 5.7 abs system. When the esp intervenes, it supplies the required preliminary pressure in the brake lines. The pistons of the two-stage recirculating pump operate at both sides. Tdc bdc tdc bdc working chamber 1 work...

  • Page 29

    29 the hydraulic brake assistant system (bas) you will find explanations on the design and function of the hydraulic brake assistant system (bas) in self-study programme no. 264. Is integrated in the abs control unit. Accident research studies have shown that the majority of drivers do not press har...

  • Page 30

    30 the vehicle electrical system vehicle electrical system automatic gearbox control unit (right footwell) connector front end airbag control unit (gearbox tunnel) radio with dynamic navigation rns-d electronics box in plenum chamber ● engine control unit ● relay station ● connector station ● fuses ...

  • Page 31

    31 window lifter motor with integrated door control unit control unit for parking aid (luggage compartment, right) tv tuner cd changer dsp dash panel insert with immobiliser control unit and diagnostic interface (gateway) window lifter motor with integrated door control unit convenience control unit...

  • Page 32

    32 the passat w8 is only fitted with the bi-xenon headlight system. The improved light output of the system increases active driving safety as the driver can detect danger earlier. The bi-xenon headlight module produces the dipped beam and the main beam from a single gas discharge lamp. The main bea...

  • Page 33

    33 passat w8 with internet access networking a vehicle is no longer limited to the car's immediate surroundings but goes far beyond this. The in-car communications equipment now provides access to the world- wide data network, the internet. Internet interface with gsm antenna and connected laptop th...

  • Page 34

    34 convenience and safety electronics interior monitor and anti-theft alarm system the passat w8 anti-theft alarm system is equipped with a new function and a new alarm horn. The new alarm horn, designated the h12, is mounted in the plenum chamber. It has a separate power supply. The horn communicat...

  • Page 35

    35 the anti-theft alarm system has self-diagnostic capability. You will find the self-diagnosis in the vehicle diagnostic testing and information system (vas 5051) in the guided fault-finding under body - body repairs and the address word convenience system. Please always use the latest version of t...

  • Page 36

    36 the "delta" radio system supplements the current radio generation. At first glance the differences to the other units are its larger size and a redesigned user interface. Other new features compared to the current radio systems are: ● integrated cd player ● two fm/am tuners ● improved tim functio...

  • Page 37

    37 rotary/push button for scan/tune scan press in radio mode to search for a station or in cd mode to briefly play the start of the track. Tune rotate to tune the fm/am station manually or to select the previous/next track in cd mode. Seek/track button seek in radio mode, hit to start station search...

  • Page 38

    38 radio rear panel the rear panel of the radio contains the aerial sockets and the central connector. The central modular connector groups all the individual connectors, such as connectors for the cd changer or loudspeakers. The individual connectors can be plugged separately in the central connect...

  • Page 39

    39 the radio has two integrated fm/am tuners. One of the tuners is only adjusted for receiving frequencies from fm/am stations. The other tuner is used for setting the frequencies to receive tp/fm traffic radio stations. This allows selection of traffic radio messages from a tp station irrespective ...

  • Page 40

    40 to control functions and processes, the radio control unit and the dash panel insert exchange the following information over the can bus. Can bus networking ● no contact ● terminal 15 ● road speed signal (gala) ● display lighting ● self-diagnosis processing ● radio convenience coding ● control si...

  • Page 41

    41 the radio aerial system fm/am reception of the radio system on the passat w8 has been considerably improved. This was achieved by fitting four independent fm/am aerials (see ssp 147). If reception is poor, the aerial control unit switches to another aerial with a stronger signal. The aerials are ...

  • Page 42

    42 location of aerials on the estate on the estate, the aerials are located in the rear side windows. Viewed in the direction of travel there is a combined am/fm aerial on the left- hand side and two fm aerials on the right-hand side. As on the saloon, each fm aerial is allocated to an aerial amplif...

  • Page 43

    43 function the radio signal received from one of the four aerials runs via an aerial switch circuit inside the aerial selector control unit to the tuner. In the tuner, the signal quality is checked and the result is fed back to the control unit via an aerial output line. If the selected signal is t...

  • Page 44

    44 heating and air conditioning system the climatronic with fully automatic control is offered on the passat w8. A combination of the following components forms the main difference with the previous fully automatic air conditioning system fitted to the passat: ● sender for evaporator outlet temperat...

  • Page 45

    45 the compressor basically works on the principle of the swash plate. The technical features of the externally regulated compressor are: ● one-sided swash plate compressor with 7 lifting pistons ● variable lifting volume to match the refrigerating capacity demand ● hollow pistons ● belt pulley driv...

  • Page 46

    46 the v-belt pulley and the driven plate are positively joined by a shaped rubber element. The overload protection shaped rubber element drive shaft compressor driven plate when the compressor is operational, the two plates rotate in the same ratio to each other. Shaped rubber element belt pulley b...

  • Page 47

    47 if the compressor is damaged internally, it may cause the drive shaft to block. The driven plate will also stop. This drastically increases the transfer forces between the belt pulley and the driven plate. The shaped rubber element is pressed by the belt pulley in the direction of rotation onto t...

  • Page 48

    48 when the climatronic is on and the driver enters the desired temperature, the refrigerant demand is determined and changed by a number of different influences. The evaporator control circuit the compressor regulating valve n280 the external regulating valve forms an interface between the suction ...

  • Page 49

    49 outlet temperature sender g263 influencing parameters: ● input of desired temperature ● ambient temperature ● interior temperature ● temperatures downstream of evaporator and air outlets ● pressure level in refrigerant circuit the outlet temperature sender g263 is located in the air duct behind t...

  • Page 50

    50 notes.

  • Page 51

    51 notes.

  • Page 52

    For internal use only © volkswagen ag, wolfsburg all rights reserved. Technical specifications subject to change without notice. 140.2810.80.20 technical status: 08/01 ❀ this paper is produced from non-chlorine-bleached pulp. 261.