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Volkswagen Phaeton 2003 Manual - Table of Contents

Summary of Phaeton 2003

  • Page 1

    Self-study program course number 891303 the phaeton.

  • Page 2

    Volkswagen of america, inc. Service training printed in u.S.A. Printed 08/2003 course number 891303 ©2003 volkswagen of america, inc. All rights reserved. All information contained in this manual is based on the latest information available at the time of printing and is subject to the copyright and...

  • Page 3: Table of Contents

    I table of contents the self-study program provides you with information regarding designs and functions. The self-study program is not a repair manual. For maintenance and repair work, always refer to the current technical literature. Important/note! New ! Introduction ................................

  • Page 5: Introduction

    Introduction 1 volkswagen’s flagship the introduction of the volkswagen phaeton is the result of developments in the international market for luxury cars. Product quality alone is no longer sufficient to guarantee success in highly-developed markets. The prestige and value of the brand are also deci...

  • Page 6: Introduction

    Introduction 2 the phaeton name the name phaeton (or phaethon) originally derives from greek mythology. Phaeton (the “incandescent”) was the son of the sun god helios, who was the owner of the sun chariot. Derived from this, the word “phaeton” also refers to the four-wheeled horse-drawn walking coac...

  • Page 7: Introduction

    Introduction 3 phaeton’s place in automotive history since 1910, august horch endowed some of his models with the “phaeton” suffix. Some examples include the 1931 horch 18/90 hp 450 phaeton and the 1911 horch 12/28 hp phaeton, as well as the 1937 horch 853a parade phaeton only three of which were bu...

  • Page 8: Introduction

    4 introduction the transparent factory concept not only has the advent of the exclusive phaeton led to the building of an impressive production line in dresden, it has also engendered a polished and precisely-functioning logistics concept. The transparent factory represents a significant milestone f...

  • Page 9: Introduction

    5 introduction ssp270/130 logistics an automated system guides baskets containing the individual components used for the assembly of each vehicle through the factory. Each basket accompanies its corresponding vehicle throughout the assembly stage. This reduces wasted motion during assembly. The chas...

  • Page 10: Introduction

    6 introduction phaeton technical innovations this is an overview. Detailed descriptions of the individual topics can be found in this and other phaeton self-study programs. Ssp270/053 • rear window heated by practically invisible tungsten threads. • fenders and spare tire recess made of plastic. • e...

  • Page 11: Introduction

    7 introduction • xenon headlights with automatic headlight range control. Ssp270/054 • surrounding illumination with front, rear, and forward lighting simplifies orientation when getting out of the car in the dark. • air suspension with automatic control. • electro-mechanical high-pressure nozzles f...

  • Page 12: Introduction

    8 specifications introduction • length 203.74 inches (5175 mm) • width 74.92 inches (1903 mm) • height 57.09 inches (1450 mm) • wheelbase 118.15 inches (3001 mm) • fuel tank capacity 23.8 gallons (90 liters) • front track width 64.09 inches (1628 mm) 64.09 in (1628 mm) • rear track width 63.46 inche...

  • Page 13: Introduction

    9 aerodynamics the phaeton has a low drag coefficient of 0.32 c d . This level was achieved by combining several design elements: • the underbody has an extremely smooth design. • the windshield wipers are recessed. • the body gap dimensions are very narrow. • the front has an arrow-shaped design. •...

  • Page 14: Engines

    10 engines the 4.2-liter v8-5v gasoline engine emphasis was placed on the following development objectives: • compliance with future exhaust-emission regulations. • reduction of fuel consumption. • increase in torque and power. • improvement of comfort and convenience. • reduction of engine weight. ...

  • Page 15: Engines

    11 engines technical data – 4.2-liter v8-5v gasoline engine • type v8 engine with 90 degree v-angle, five valves per cylinder, and variable intake and exhaust valve timing • displacement 255 cu in (4172 cm 3 ) • bore 3.32 in (84.5 mm) • stroke 3.66 in (93.0 mm) • compression ratio 11:1 • maximum pow...

  • Page 16: Engines

    12 engines the 6.0-liter w12 gasoline engine with the w12 engine, volkswagen is offering a 12-cylinder engine in its lineup for the first time ever. It is the most powerful engine version available in the phaeton. Mechanical innovations • cylinder block made of aluminum. • bottom crankshaft bearings...

  • Page 17: Engines

    13 engines the specified power data is only possible if 91 aki fuel is used. A reduction in power output must be expected if lower grade fuel is used. Please refer to the w engine concept, self-study program course number 821203 and the phaeton w12 engine management system, self-study program course...

  • Page 18: Fuel Supply

    14 fuel supply fuel delivery system fuel tank the fuel tank is mounted on the vehicle underbody close to the rear axle. It has a capacity of 23.8 gallons (90 liters). Due to its external shape, it consists of a main fuel tank chamber and a secondary fuel tank chamber. Each fuel tank chamber has an e...

  • Page 19: Transmissions

    15 transmissions ssp270/105 automatic transmissions depending on the engine application and marketing area, the volkswagen phaeton is available with a five-speed automatic transmission or a six-speed automatic transmission. Both automatic transmissions are currently already in use in other volkswage...

  • Page 20: Transmissions

    16 transmissions six-speed automatic transmission 09f this specially-developed automatic transmission is used in phaetons equipped with the 4.2l v8-5v engine. Compared with the five-speed automatic transmissions, the six-speed automatic is especially characterized by: • improved driving performance....

  • Page 21: Transmissions

    17 transmissions lepelletier gear set simple planetary gear set lepelletier gear set concept the six automatic transmission gears are shifted by a ravigneaux planetary gear set with a series-connected simple planetary gear set. This arrangement is known as the lepelletier gear set concept. Ssp270/22...

  • Page 22: Transmissions

    18 transmissions automatic transmission selector lever positions the selector lever and tiptronic functions are the same in the five-speed automatic transmissions and the six-speed automatic transmission. P – parking in order to move the selector lever from the “p” position, the ignition must be tur...

  • Page 23: Transmissions

    19 transmissions shift program and gear indicator on display unit in instrument cluster y24 in both the “d” and “s” automatic shift programs, the engaged selector lever position and the gear being currently used are shown on display unit in instrument cluster y24. Ssp270/109 the gear being used is s...

  • Page 24: Transmissions

    20 tiptronic on the phaeton, tiptronic gear selection can be operated by the selector lever. The automatic transmission is switched to tiptronic mode by moving the selector lever to the right from the “d” position into the tiptronic notch. Gear change must then be made by moving the selector lever. ...

  • Page 25: Transmissions

    21 transmissions shift lock solenoid n110 shift lock solenoid n110 is located on the selector lever frame below the selector lever. It prevents the movement of the selector lever from positions “p” and “n” unless the brake pedal is pushed. How it works once the ignition has been turned on, the shift...

  • Page 26: Transmissions

    22 transmissions selector lever park position solenoid n380 selector lever park position solenoid n380 is also located at the selector lever. It prevents the selector lever from moving out of the “p” position when the ignition is turned off. The brake pedal must be pressed and the ignition turned on...

  • Page 27: Transmissions

    23 transmissions ssp270/157c effect of failure if one of the signals fails or the selector lever park position solenoid n380 is defective, then the selector lever cannot be moved out of the “p” position. The selector lever must be manually unlocked to allow towing of the vehicle. To manually unlock ...

  • Page 28: Transmissions

    Ignition switch key lock solenoid n376 the ignition switch key lock solenoid n376 is located within the access/start authorization switch e415. It prevents the ignition key from being removed when the selector lever is in a driving position. Previous versions of this ignition key removal lock featur...

  • Page 29: Transmissions

    Transmissions “selector lever in p” signal emergency release electrical circuitry if the ignition is turned off and the selector lever is in “p” position, a signal travels from the selector lever park position lock switch f319 to the access/start control module j518. The access/start control module ...

  • Page 30: Running Gear

    26 running gear phaeton chassis overview the phaeton chassis has air suspension at all four wheels. This system provides extremely sensitive activation of the suspension even on slightly uneven driving surfaces. Bosch 5.7 abs brakes with electronic stabilization program and brake assist assembled br...

  • Page 31: Running Gear

    27 running gear trapezoidal wishbone rear suspension ssp270/089-090 the chassis is described in detail in the phaeton chassis, self-study program course number 893303. Foot parking brake with hand-operated release lever all season tires alloy wheels.

  • Page 32: Body

    28 body body structure the focus of the body design was a high level of crash safety and body rigidity. The gap dimensions for the hood, luggage compartment lid, and doors could be designed to be relatively narrow due to the high rigidity of the main body structure. The doors, luggage compartment li...

  • Page 33: Body

    Body 29 ssp270/154-155 safety features • high energy absorption at the front and rear of the vehicle. • stable passenger compartment. • occupant protection in event of side impact due to: — bonding of the super high-strength steel b-pillar with the side member. — high-strength aluminum profiles in t...

  • Page 34: Body

    30 body glued-in-place plastic spare tire recess the following components are integrated in the spare tire recess: • compressor for air suspension. • evap canister with activated-charcoal filter. • spare wheel. Body attachments aluminum parts • engine hood • reinforced doors • luggage compartment li...

  • Page 35: Body

    Detailed view of spare tire cavity, from below. 31 body aluminum plastic ssp270/114-115 ssp270/004 reinforced laser-welded doors with high-strength die-cast inner sections..

  • Page 36: Body

    32 body ssp270/182 aluminum expansion foil sandwich, 0.18 inch (4.5 mm) bitumen plastic-foil, pressure-sensitive bonding, 0.08 inch (2 mm) bitumen plastic-foil, magnetized, thermoplastic bonding, 0.08 inch (2 mm) bitumen plastic-foil, thermoplastic bonding, 0.08 inch (2 mm) bitumen foil with aluminu...

  • Page 37: Body

    33 body glass high-insulation laminated glass the high-insulation laminated glass used on the phaeton reflects heat without reducing its ability to pass light through. This glass reduces ultraviolet radiation and contributes to an improved noise insulation. This is facilitated by two foils incorpora...

  • Page 38: Body

    34 body rear window with tungsten threads the rear window is heated by nearly invisible tungsten threads that are embedded between the inner and outer pane. All antennas are integrated in the upper third of the rear window. This lack of external antennas helps to maintain the streamlined quality of ...

  • Page 39: Body

    35 body power-assisted luggage compartment lid the phaeton is also available with a system allowing the driver to open and close the luggage compartment lid from inside the vehicle. Power-assisted closure is not only a convenience but is also an enhancement of the entire locking system. Retractable ...

  • Page 40: Body

    36 body function the power-assisted luggage compartment lid is operated by an electro-hydraulic mechanism. Hydraulic fluid is pumped through the hydraulic lines by an electric pump. The routing of hydraulic fluid to the piston crown sides or piston rod sides of the hydraulic cylinders facilitates th...

  • Page 41: Body

    37 body sunroof the phaeton is available with a tilt and slide sunroof with a separate electrically-actuated sunshade. Tilt and slide sunroof the tilt and slide sunroof has a sunshade and an electric wind deflector. A separate electric motor moves the sunshade at the same time as the glass roof is o...

  • Page 42: Occupant Protection

    Airbag triggering the four phaeton airbag systems have approximate filling volumes as follows: • driver airbag – 2.65 cubic feet (75 liters) • front passenger airbag 4.24 cubic feet (120 liters), • side airbag at front and rear 0.42 cubic feet (12 liters), • head airbag 1.09 cubic feet (31 liters). ...

  • Page 43: Occupant Protection

    Rear side airbag ssp270/024 side curtain protection ssp270/025 driver airbag ssp270/023 front passenger airbag ssp270/026 front side airbag ssp270/019 39 occupant protection.

  • Page 44: Occupant Protection

    40 occupant protection seat belt systems all seats on the phaeton have three-point retracting seat belts with belt tension limiters. All outside seats are equipped with pyrotechnical seat belt tensioners that are triggered by the airbag control module j234 if the accident is bad enough. The 18-posit...

  • Page 45: Occupant Protection

    41 occupant protection front automatic shoulder belt in the standard version – the 12-position seat – an automatic shoulder belt ensures optimal safety. This means that in the event of a collision, the belt is tightened from the b-pillar side at the occupant’s shoulder. The front automatic shoulder ...

  • Page 46: Occupant Protection

    42 occupant protection 18-position seat removal with optional automatic lap belt the optional automatic lap belt must be separated from the 18-position seat in order to remove the seat. To detach the automatic lap belt, the plastic cover on the buckle tongue and the metal pin that attaches the tongu...

  • Page 47: Occupant Protection

    43 occupant protection active headrest system the front seats in the phaeton are equipped with an active headrest system. In the event of a rear-end collision, the headrests are rotated forward and up. This reduces the relative differences in acceleration between the shoulders and the head, and lowe...

  • Page 48: Seats

    44 seats front seats the phaeton is available with air-conditioned seats. The seat belt mechanism integrated in the front seats give the phaeton an even greater level of comfort. The optional automatic lap belt available with the 18-position seat gives increased seat belt comfort and improved safety...

  • Page 49: Seats

    45 seats memory functions the memory package for the 12-position seats includes a range of savable functions. In addition to the seat settings, the memory function can also save the positions of the steering column, the mirror and the seat belts. Easy-entry function the easy-entry function facilitat...

  • Page 50: Seats

    46 seats 18-position front seats the phaeton can be equipped with even more luxurious optional 18-position front seats. The 18-position front seats can be equipped with optional automatic lap belts. Adjustment functions the 18-position front seats provide for these additional adjustments: • upper se...

  • Page 51: Seats

    47 seats rear seats the phaeton is available with three rear seat variations: • standard rear seat. • premium rear seat. • 10-position individual rear seats. Standard rear seat the standard rear seat can comfortably accommodate three people. Side air bags and manually adjustable headrests are provid...

  • Page 52: Seats

    48 seats 10-position individual rear seats the 10-position individual rear seats are available as an option only on phaetons equipped with the 18-position front seats. The following functions on the 10-position individual rear seats are electrically adjustable: • seat cushion backward and forward. •...

  • Page 53: Air Conditioning System

    49 air conditioning system on/dark help settings manual audio trip data nav nav set map vehicle climate reset fm am cd scan 1 2 3 4 5 6 bal/fad four-zone climatronic as a luxury-class sedan, the phaeton has a standard four-zone air conditioning system. Thanks to the four-zone climatronic, the driver...

  • Page 54: Air Conditioning System

    50 special functions of four-zone air conditioning • automatic and manual control for each air conditioning zone. • air conditioner synchronization – all air conditioning zones are tuned to the settings for the driver’s zone. • economy function. Air conditioning system • automatic and manual recircu...

  • Page 55: Air Conditioning System

    51 air conditioning system air distribution in the vehicle the blower draws fresh air in through the dust and pollen filter and routes it through the evaporator. The airflow in the air conditioner module is separated behind the evaporator: • most of the air flows through the heat exchangers. • some ...

  • Page 56: Air Conditioning System

    52 air conditioning system system overview the air conditioning system includes the following circuits and components: • cooling circuit with: — a/c pressure/temperature sensor g395. — evaporator temperature sensor g308. • heating circuit with: — pump valve unit. — two independent heat exchangers re...

  • Page 57: Air Conditioning System

    53 air conditioning system ssp270/208 ssp270/189 rear a/c control head (climatronic) e265 front information display control head j523 ssp270/159 climatronic control module j255 climate reset fm am cd scan nav nav set audio trip data settings manual on/dark help map vehicle bal/fad 6 5 4 3 2 1 welcom...

  • Page 58: Electrical System

    54 electrical system seat memory front information display control head j523 memory convenience electronics memory functions the phaeton offers a variety of memory functions that are saved and accessed by various operating panels. In addition to the functions controlled by the seat memory feature, u...

  • Page 59: Electrical System

    55 electrical system overview of memory components this illustration provides an overview of the controls and their associated memory function components. Please consult the external mirror appropriate pages for a more precise description of the front information display control head j523 controls a...

  • Page 60: Electrical System

    56 electrical system access and start authorization system the vehicle can be locked or unlocked without the active deployment of the radio remote key by using the optional convenience features of the access and start authorization system. The components and functions listed in the table are constit...

  • Page 61: Electrical System

    57 electrical system additional functions of the convenience features for access and start authorization ssp270/209 access/start control module j518 access/start authorization antenna (in rear bumper) r136 (2) luggage compartment access/start authorization antenna r137 interior access/start authoriz...

  • Page 62: Electrical System

    58 electrical system adaptive cruise control (late availability) adaptive cruise control (acc) is a driver assistance system that enhances cruise control operation. 62 mph (100 km/h) ssp270/197 50 mph (80 km/h) ssp270/198 62 mph (100 km/h) 佡 50 mph (80 km/h) delay when the acc-equipped vehicle appro...

  • Page 63: Electrical System

    59 effects the acc-equipped vehicle adapts its speed to the speed of the vehicle in front of it. Ssp270/199 50 mph (80 km/h) 50 mph (80 km/h) electrical system ssp270/200 50 mph (80 km/h) 佡 62 mph (100 km/h) 50 mph (80 km/h) acceleration the acc-equipped vehicle accelerates to the desired speed once...

  • Page 64: Electrical System

    60 electrical system ssp270/201 conditions for turning on the acc the acc system can be turned on at vehicle speeds between 19 and 112 mph (30 and 180 km/h). The control buttons have the following functions: • the set button adopts the current speed as the desired speed. Repeated pressing reduces th...

  • Page 65: Electrical System

    61 electrical system new acc components the acc function is made possible by the use of a control module for distance regulation j428 with a right distance regulation sensor g259 that employs the radar principle and the active abs system electronic brake booster control module j539. Important data r...

  • Page 66: Electrical System

    62 electrical system headlights the phaeton headlight design combines xenon lamps for the low beams and hb3 lamps for the high beams. The turn indicator lights are integrated in the headlight housings. To enhance appearance, the h21w bulbs are not visible under the lenses. The gas discharge headligh...

  • Page 67: Electrical System

    63 electrical system rear lights the rear lights are designed with light- emitting diodes (leds). Lower energy consumption, shorter response times and a longer service life are among the advantages of leds. Ssp270/236 the phaeton vehicle diagnostic system will detect a malfunction if an led becomes ...

  • Page 68: Electrical System

    64 electrical system battery all phaeton vehicle batteries are made using non-woven fabric containing latent sulfuric acid and are therefore maintenance free. The cell fill plugs cannot be opened. Ssp272/240 positive grid fabric plate group negative plate negative grid positive plate the battery gas...

  • Page 69: Electrical System

    65 electrical system phaeton battery systems the vehicle battery system has the task of guaranteeing the electrical energy for starting the engine and of feeding the various vehicle components that consume electricity. To ensure a sufficient energy supply for all of the electrical components as well...

  • Page 70: Electrical System

    66 electrical system two-battery system vehicles with w12 engines are equipped with two-battery systems. The two-battery system includes a starter battery, a separate on-board power supply battery, a parallel battery connection relay j581, and a battery monitoring control module j367. The starter ba...

  • Page 71: Electrical System

    67 electrical system emergency starting if the single battery in a one-battery system is discharged, or if both batteries in a two-battery system are discharged, the engine can be started using an external voltage source. The voltage source positive lead must only be connected at the vehicle jump-st...

  • Page 72: Electrical System

    68 electrical system using the front information display control head j523 for component service adjusting headlights the headlights must be locked in place in the “basic setting” function with the vehicle diagnosis, test and information system vas 5051 prior to adjustment. Mechanical access to the ...

  • Page 73: Electrical System

    69 electrical system ssp270/086 infotainment system the phaeton infotainment system includes a range of functions that can be controlled by the front information display control head j523, by buttons on the multi- function steering wheel, and by the rear information display control head j524. Please...

  • Page 74: Electrical System

    Electrical system 70 infotainment components in addition to the controls in the front information display control head j523, the multi-function steering wheel, and the rear a/c control head (climatronic) e265, the infotainment system includes the following components: • display unit in instrument cl...

  • Page 75: Electrical System

    Electrical system 71 control module for navigation with cd-mechanism j401 in the glove compartment ssp270/066 rear a/c control head (climatronic) e265 ssp270/077 multi-function steering wheel ssp270/076 ssp270/074 antennas in the rear window ssp270/073 microphone unit (in front roof module) r164 ssp...

  • Page 76: Electrical System

    Welcome on/dark help settings manual audio trip data nav nav set map vehicle map vehicle climate reset fm am cd 1 2 3 4 5 6 scan electrical system 72 front information display control head j523 the infotainment front information display control head j523 is integrated into the center console and is ...

  • Page 77: Electrical System

    Electrical system 73 display unit in instrument cluster y24 some phaetons are also equipped with a display unit in instrument cluster y24 with a 5-inch (127 mm) color display. This display can show seven different menus for the various infotainment functions. A menu is selected using the multi-funct...

  • Page 78: Service

    Service 74 special tools engine hoist vs 6100 engine and transmission bracket vas 6095 bracket for seat repair vas 6136 upholsterer tool set vas 6137 scissors lifting table vas 6131 adapter for v.A.G. 1342 exhaust gas analyzer probe vas 1787/7a exhaust gas analyzer probe vas 1788/13a adapter for rem...

  • Page 79: Notes

    75 notes.

  • Page 80: Notes

    Notes 76.

  • Page 81: Knowledge Assessment

    Knowledge assessment 77 an on-line knowledge assessment (exam) is available for this self-study program. The knowledge assessment may or may not be required for certification. You can find this knowledge assessment at: www.Vwwebsource.Com from the vwwebsource.Com homepage, do the following: – click ...

  • Page 83

    Volkswagen of america, inc. 3800 hamlin road auburn hills, mi 48326 printed in u.S.A. August 2003.