Volkswagen Passat ‘97 User Manual
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Volkswagen Passat ‘97 User Manual

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Only for internal use.
© VOLKSWAGEN AG, Wolfsburg
All rights reserved. Subject to modification.
640.2810.10.00
Technical Status: 09/96
` Printed on chlorine-free
bleached paper.
Service.
The Presentation
Construction and operation
Self Study Programme
Service Department
191

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Summary of Contents for Volkswagen Passat ‘97

  • Page 1 Service. The Passat ‘97 The Presentation Construction and operation Self Study Programme Only for internal use. ` Printed on chlorine-free © VOLKSWAGEN AG, Wolfsburg bleached paper. All rights reserved. Subject to modification. 640.2810.10.00 Technical Status: 09/96 Service Department...
  • Page 2 191/01 The most remarkable features of the new In this booklet, we would like to provide you Passat are its: with an initial overview showing how we l High economy justify making these claims. l Dynamic body styling l High-quality interior equipment designed with great attention to detail l Pioneering safety engineering...

  • Page 3: Table Of Contents

    Page The Passat ‘97 Environmental Protection and Recycling Body Vehicle Safety Engines and Gearboxes Running Gear Brakes Steering Electrics Extended Systems Important ! / Note The Self Study Programme is not a Workshop Manual. Please refer to the relevant Service Literature for all inspection, adjustment and repair instructions.

  • Page 4: The Passat '97

    The Passat ‘97 To avoid confusion, concise examples are used You can find detailed information in Self Study to illustrate the various aspects of this Programme No. 192 Passat ‘97 – The Enginee- all-embracing vehicle concept. ring. 191/86 191/73...

  • Page 5: Dimensions And Weights

    Dimensions and Weights 2707 mm 4675 mm 191/71 1740 mm Weights Track widths Unladen weight appr. 1200 front 1498 Max. permissible weight appr. 1805 rear 1500...
  • Page 6 The Passat ‘97 The Platform - an Advantage for Workshops The term “platform” is frequently used in The vehicle consists of a) the platform and b) publications although its fundamental the body. meaning is not explained. The result of this is that people are often unsure of what the term Design and vehicle characteristics dictate what “platform”...
  • Page 7 Platform The platform comprises both common parts and system parts. Common parts System parts e.g. sliding sunroof, steel rim e.g. seat Common parts may only be used in platform Some system parts are identical. vehicles without change. They have to be adapted since they are the They do not influence the design of the interface between the platform and body.

  • Page 8: Environmental Protection And Recycling

    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 To achieve this, the following measures were workshops with problems such as identifying, taken:...
  • Page 9 Solvents To achieve this, the following measures were Even during production, every effort is made to taken: keep environmental pollution to a minimum. l Full galvanisation means much less wax and PVC underseal l Water-dilutable paints including water-based clear coat l Stringent requirements for materials ensure lower emissions in the vehicle interior Energy + Resources...

  • Page 10: Body

    Body The following will be of interest to you: l The Passat in the wind tunnel l Strategy of using common platform for body l Fully galvanised body parts l Greater body rigidity l Ease of repair demonstrated using door l Use of high-strength steel parts module as example l Rear collision demonstrated using bumper...
  • Page 11 Fully-galvanised Body Surface patterns, which are also visible after For the first time, the Passat has a fully galva- painting, emerge during the hot-dip nised body which comes with an 11-year anti- galvanisation process. corrosion perforation warranty. That is why the outer skin of the body is electrolytically galvanised to produce a The drawing below shows you the parts which smooth finish.
  • Page 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 minimising noise levels.
  • Page 13 High-strength Panels The Rear Bumpers High-strength panels are used to produce a body with greater stability and strength and therefore to provide more safety for the vehicle occupants. They also substantially reduce the weight of the body-in-white. As you can see, the high-strength steel com- ponents in the front section of the vehicle create a cage-type structure to protect the vehicle occupants.
  • Page 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. New parts in Passat ‘97 191/69...

  • Page 15: Vehicle Safety

    Vehicle Safety The following features will be of interest to you: l Driver, front passenger and side airbags l Active and passive safety as standard l ABS as standard l New seat belt tensioner with force limiter l The Passat already complies with the new l Inside door panels with pelvis paddings European standard for crashworthiness l Door module with enclosed subframe...
  • Page 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 surface to prevent intrusion of the built-in door fittings into the interior of the vehicle.

  • Page 17: Airbag Systems

    Airbag Systems The driver and front passenger airbags, which In addition to the driver and front passenger have filling volumes of roughly 65 ltr. and 120 airbags, the Passat is equipped with side air- ltr. respectively, conform to the new internatio- bags as standard.
  • Page 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 being activated when the seat belt is not worn.

  • Page 19: Engines And Gearboxes

    Engines and Gearboxes In addition to the six tried and tested engines listed below, the new VR5 unit will also be mounted in the Passat. 1.6-ltr. Engine AHL Displacement 1595 Compression ratio 10.3 : 1 Max. torque 140 Nm at 3800 rpm Max.
  • Page 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.
  • Page 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. 191/53 The engineering of the VR5 engine is explained in a separate Self Study Programme.
  • Page 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 191/28...
  • Page 23 Range of Engines and Gearboxes Manual gearbox Engines Automatic gearbox 1.6-ltr. 012/01W 74kW 1.8-ltr. 5V 92kW 1.8-ltr. 5V turbo 110kW 2.3-ltr. 110kW 1.9-ltr. 66kW 1.9-ltr. 81kW 2.8-ltr. V6 5V Syncro 142kW 191/64...
  • Page 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. 191/34 5-speed Manual Gearbox 01A The 01A is the manual gearbox for four-wheel drive vehicles as used in the Audi A4.
  • Page 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. 191/36 5-speed Automatic Gearbox 01V You will also be familiar with the 01V from the Audi A4.

  • Page 26: Running Gear

    Running Gear The Four-link Front Suspension In addition to the four-link front suspension, we will show you on the following pages the The four-link front suspension is standard in all newly developed torsion beam rear suspen- sion as well as the new double-wishbone rear front- and four-wheel drive vehicles.
  • Page 27 The Torsion Beam Rear Suspension 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 beam Self-aligning twin-grooved oblique ball bearings act as wheel bearings Single-tube damper Coil spring...
  • Page 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. 191/54 Engine power is transmitted to all four wheels by a Torsen differential.

  • Page 29: Brakes

    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. Disc brakes, front Disc brakes, rear 191/14 191/16 Rear brake caliper...

  • Page 30: Steering

    Steering Height and Reach Adjustment of Steering Column The Passat is equipped with power steering. A damper element located above the double universal joint prevents vibrations and noise The steering column can be adjusted manually from being transmitted to the body. 50 mm fore and aft and 28 mm for height.

  • Page 31: Electrics

    Electrics The following features will be of interest to you: l Gas discharge headlights l Decentralised vehicle electrical system l Washer jets l Dash panel insert Decentralised Vehicle Electrical System Advantages: The main feature of the decentralised vehicle Short wiring harnesses make cable electrical system is that the central electrics are connections easier to find and assign.

  • Page 32: Dash Panel Insert

    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 Self-diagnosis: versions which differ from one another in The diagnostic functions can be retrieved using...
  • Page 33 Fuel gauge In previous systems, the fuel gauge tended to The new fuel gauge eliminates this drawback. fluctuate, e.g. when cornering. To counteract this, damping of the fuel gauge was increased If the ignition is switched off and fuel tank using electronic devices.
  • Page 34 Electrics Gas Discharge Headlights Gas discharge headlights, which are integrated On acount of the greater danger of dazzling oncoming traffic, vehicles with gas discharge into the headlights, are available for the Passat as an option. headlights are equipped with dynamic head- light range control.
  • Page 35 Fan Jet Nozzle The Passat features new fan jet nozzles for washing the windscreens. Advantages: Engine bonnet Better fluid distribution over the entire surface of the windscreen Lower water consumption Better cleansing effect 191/82 No adjustment required Installation from below Mode of operation For the sake of simplicity, the mode of opera- A nozzle insert for producing the pendulum jet...

  • Page 36: Extended Systems

    Extended Systems Extended Central Locking System Various systems cater for ride comfort and ease of operation in the new Passat. The extended central locking system is based on The following features will be of interest to a decentralised system concept. you: It has a central control unit and a separate door control unit with a control panel for every door.
  • Page 37 Functions of the Extended Central Locking System The master control unit assumes the following functions Anti-theft warning system Central locking of boot lid with “interior monitor” function Interior light control Diagnosis Address word „46” fi Interface to vehicle electrical system Radio remote control Slide/tilt sunroof Central locking...
  • Page 38 Extended Systems The heater Unlike predecessor models, the new heater is constructed in one piece. The heater, which is controlled at the air intake The air distributing housing and the air duct side, permits fresh-air and air-recirculation with shutoff flap are combined in a single modes.
  • Page 39 Pleasant air-conditioning for comfort and safety in the Passat. The CLIMAtronic Operating and display unit with control unit Temperature sensor 191/47 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.
  • Page 40 Extended Systems The Air-conditioning Fresh-air/air-recirculation flap Back pressure flap 191/42 Fresh-air blower Central flap The following components are integrated in The fresh-air/air-recirculation flap is the refrigeration circuit: combined with the back pressure flap. Fresh-air blower with integrated - Plate evaporator control unit.
  • Page 41 Navigation The navigation system enables the driver to The system comprises the following elements: reach his (her) destination easily and safely. It replaces the road map and enhances The navigation computer with integrated road safety. CD-ROM drive The control unit with control and This system employs a map stored on a loudspeaker CD-ROM.
  • Page 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 directions for the driver from this comparison.
  • Page 43 ABS wheel speed sensor The wheel speed sensors of the rear suspension are used to provide the navigation computer with iinfomation on distance travelled. 191/84 Earth magnetic field sensor The earth magnetic field sensor determines the direction of travel relative to the north pole for the navigation computer.
  • Page 44 Extended Systems The Passat is available with a mobile phone or cellular phone provision as equipment variants. Cellular Phone Preparation Advantage: Scope of cellular phone provision: Easy to install Hands-free microphone integrated in left-hand No complex cable installation necessary A pillar One roof aerial for all functions VDA-standard cable Depending on equipment specification of...
  • Page 45 Notes...
  • Page 46 Notes...
  • Page 48 Service. The Passat ‘97 The Engineering Design and Function Self Study Programme For internal use only. ` Printed on chlorine-free ¶ VOLKSWAGEN AG, Wolfsburg bleached cellulose paper. All rights reserved. Specifications subject to change. 640.2810.11.10 Technical status: 11/96 Service Department...
  • Page 49 The Passat ‘97 SSP 192/107 Having provided you with an initial overview The subjects of the VR5 engine, convenience of the new Passat in the Self Study Programme electronics and navigation system are so wide- entitled “The Passat ‘97 – The Presentation”, ranging that it would be beyond the scope of we now want to describe in detail how the this Self Study Programme.
  • Page 50 Page Introduction Vehicle Safety 1.8-ltr. 5V Engine ADR 1.8-ltr. 5V Turbo Engine AEB 2.8-ltr. V6 Engine ACK 1.9-ltr. TDI Engine AFN Gearbox Drive Shafts Running Gear ABS/EDL Electrics Air-conditioning New! Important! / Note! This Self Study Programme is not a Workshop Manual! Please refer to the relevant Service Literature for all inspection, adjustment and repair instructions.
  • Page 51 Introduction Overview of topics 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 increasingly in...
  • Page 52 ABS/EDL As a part of the ABS/EDL system, we will present you the new hydraulic unit with an integrated control unit. Running gear In addition to information about the torsion beam rear axle and the double wishbone SSP 192/001 rear axle, we will show you the new design of the new wheel bearing generation.
  • Page 53 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.
  • Page 54 Effect of the restraint systems during minor accidents During minor accidents, the body only partially belt tensioners restrain the car’s occupants in absorbs the impact energy of components their seats. such as bumpers and impact absorbers. The belt force limiter reduces the risk of the belt causing injury.
  • Page 55 Vehicle safety The effect of the restraint systems during serious accidents During serious accidents, the car body absorbs In addition to the protection afforded by the the impact energy. The passenger compart- seat belts, the restraint systems protect the ment remains by and large intact and the front passengers from more serious injuries in airbags are triggered.
  • Page 56 Side airbag In terms of its appearance, the new airbag The new side airbag system is integrated in the control unit has a different connector driver’s and front passenger’s seats. housing code to the previous model. The side airbag is described as a thorax airbag. It mainly protects the thorax, and with it the lungs and pelvis, from lateral bruising.
  • Page 57 Vehicle safety Side airbag design The side airbags are integrated in the front While expanding, the gas cools and mixes with seat backrests. the hot gas of the pyrotechnical charge. The The folded airbag and gas generator are temperature of the gas mixture is therefore so accommodated inside the plastic housing.
  • Page 58 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.
  • Page 59 Vehicle safety Airbag control unit J234 In parallel to the crash sensors, sensors in the There is an additional energy storage device in the airbag control unit evaluate the severity of the airbag control unit for igniting the side airbags. If crash.

  • Page 60: Belt Tensioner

    Belt tensioner The pyrotechnical belt tensioner combines The mode of operation of the belt tensioner is with the force limiter and the seat belt very different to that of its predecessors. recognition device in a single unit. It is only triggered if the mechanical seat belt fastened recognition system recognises an unreeled There are two belt tensioner variants:...
  • Page 61 Vehicle safety Functional description of front belt tensioner Mechanical trigger unit The belt tensioner is activated by balls moun- ted in a feed tube. Propellant charge Belt Feed tube SSP 192/124 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.
  • Page 62 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 limiter SSP 192/066 Reeling mechanism...
  • Page 63 Vehicle safety Functional description of rear belt tensioner. SSP 192/009 The first propellant charge is ignited by a Mech. triggering device mechanical triggering device. Wankel rotor Firing pin Propellant charge 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 the second propellant charge.

  • Page 64: Belt Force Limiter

    Belt force limiter Functional description of belt force limiter If, due to acceleration, the tensile force of the It is limited by the belt reeling device torsion belt is so high that bruising or internal injuries shaft. The torsion shaft operates in much the can occur, the tensile force of the belt must be same way as a spring.
  • Page 65 Test your knowledge 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. 4.
  • Page 66 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...
  • Page 67 1.8-ltr. 5V Engine ADR On the following page, we will show you the new technical features of the 1.8-ltr. 5V engine, 1.8-ltr. 5V turbo, 2.8-ltr. V6 and TDI engines. Twin path intake manifold The 1.8-ltr. 5V engine has a twin path intake Long intake path manifold.
  • Page 68 The engine control unit sends a signal to the intake manifold pressure change valve. Engine control unit J220 It uses the vacuum unit to change over the intake manifold. Power is supplied via the fuel pump relay. IIntake manifold pressure change valve N156 Vacuum unit SSP 192/127...

  • Page 69: System Overview

    1.8-ltr. 5V Turbo Engine AEB The 1.8-ltr. 5V turbo engine is equipped with the Motronic M 3.8.2 engine management system. System overview Sensors Actuators Lambda probe Fuel pump G6 with fuel pump relay Air mass meter Injection valves N30, N31, N32, N33 Intake manifold Output stage Engine control unit...
  • Page 70 Function diagram 1.8-ltr. 5V turbo engine AEB Components Additional signals Altitude sender Pin 5 Actual engine torque (out) Pin 6 Speed signal (out) Fuel pump Pin 7 Throttle valve potentiometer Engine speed sender signal (out) Lambda probe Pin 8 Air-conditioner compressor signal Hall sender (in + out) Knock sensor I...
  • Page 71 J220...
  • Page 72 N163 N128 N158 N122 SSP 192/076...
  • Page 73 2.8-ltr. V6 Engine ACK Variable valve timing It provides high torque when driving in low gears High output is needed at high speeds. To at low speeds, thus improving fuel economy and achieve both, the cylinder must be well-filled reducing exhaust emissions. in all speed ranges.
  • Page 74 The principle of variable valve timing: The exhaust camshaft is driven by the With variable valve timing, the opening times of the inlet valves are adjusted depending on crankshaft by means of a toothed belt. engine speed. The drive chain therefore turns The inlet camshaft is driven by the exhaust the inlet camshaft.
  • Page 75 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 directly to the variable valve timer housing.
  • Page 76 Variable valve timing in the V6 engine Exhaust camshaft The design of the V6 engine makes particularly heavy demands on variable valve timing. Inlet camshaft Viewed from above, the exhaust camshafts are arranged on the outside and the inlet cams- hafts on the inside.
  • Page 77 2.8-ltr. V6 Engine ACK 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. System overview Actuators Sensors Fuel pump G6 with fuel pump relay Lambda probes I+II G39 + G108 Ignition transformer Air mass meter N152...
  • Page 78 Function diagram of 2.8-ltr. 6V Engine ACK Components Additional signals Fuel pump Pin 5 Actual engine torque (out) Engine speed sender Pin 6 Speed signal (out) Lambda probe Pin 7 Throttle valve potentiometer Hall sender signal (out) Knock sensor I Pin 8 Air-conditioner compressor signal Coolant temperature sender...
  • Page 79 N205 N208 N156 G163 G108...
  • Page 80 N152 J338 SSP 192/075...
  • Page 81 1.9-ltr. TDI Engine AFN Radiator fan run-on A radiator fan run-on facility controlled by the The run-on time is determined by the engine engine management system is being used in control unit via a characteristic map. Allowance the 1.9-ltr. 81kW TDI engine for the first time. is also made for the coolant temperature and The advantage of this is that the radiator fan engine load during the final minutes of car...
  • Page 82 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 that the fuel-air mixture is not forced back into the intake manifold.
  • Page 83 Gearbox Magnesium Lightweight construction now plays a central Density comparison role in vehicle development, due to the tough Iron: demands on performance, safety and fuel 7.873 g/cm3 economy. Weighing roughly 34% less than aluminium, Aluminium: magnesium is, as a material, well-suited to 2.699 g/cm3 meeting these demands.
  • Page 84 Electrochemical voltage series In the presence of water, an electric current An electrochemical voltage series is produced develops between two different metals. The by arranging the metals in a series extending car battery operates according to a similar from non-precious metal to precious metal. principle.
  • Page 85 Gearbox Magnesium Contact corrosion, using a bolted connection Water 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.
  • Page 86 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.
  • Page 87 Drive shafts Triple roller constant velocity joint Triple roller joints are principally used in diesel The triple roller CV joint reduces the transmis- and automatic cars. sion of vibrations and noise from the engine/ This is necessary due to the high vibrations gearbox unit to the body.
  • Page 88 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 begins to oscillate in its mountings.
  • Page 89 drive shafts In addition to the vibrations of the engine/gearbox unit, the triple roller joints have to equalise wheel bump and rebound. SSP 192/044 The joint housing remains stationary in the Housing process. SSP 192/045 The drive shaft is moved away from the gearbox by the rebound action of the wheels.
  • Page 90 Running Gear The following pages describe the design modifications to the axles of the Passat ‘97 as presented to you in Self Study Programme SSP 191. 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.
  • Page 91 Running Gear V section of torsion beam rear axle Conventional rear axles have a V section which SSP 192/117 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.
  • Page 92 Hub/wheel bearing unit The newly developed wheel bearing generation The advantages of the new wheel bearing is used on the rear axle of front-wheel-drive generation are as follows: vehicles. The twin-tracked ball bearing has a stationary outer race which is bolted to the rear l Minimal wear due to improved sealing.
  • Page 93 Running Gear Double wishbone rear axle The newly developed double wishbone rear The subframe is connected to the body by four axle allows the same through-loading width as large bonded rubber mountings. the torsion beam rear axle. It has an enclosed subframe to which the transverse links are attached.
  • Page 94 Test your knowledge 1. How is the high transverse rigidity of the torsion beam rear axle achieved? 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, c) It is self-adjusting,...
  • Page 95 ABS/EDL 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.
  • Page 96 ABS/EDL hydraulic unit Connection for: Diaphragm outlet dam- Front left brake caliper Front right brake caliper Brake master cylinder Secondary piston circuit Brake master cylinder Primary piston circuit Rear left brake caliper Rear right brake caliper Hydraulic block SSP 192/063 Recirculating pump Features of hydraulic unit: One-piece cast iron housing.
  • Page 97 ABS/EDL ABS/EDL control unit ABS/EDL control unit J104 Features of control unit: SSP 192/064 Redundant computer concept with separate watchdog, Self-diagnosis capability, 26-pin connector contact. Redundant computer concept In this case, redundant stands for a computer This third computer is known as the watchdog. concept with several backups.
  • Page 98 ABS speed sensor Features of speed sensor: Speed sensor Speed sensor rotor 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.

  • Page 99: Function Diagram

    ABS/EDL Function diagram Components Brake light switch Rear right speed sensor 4 Front right speed sensor 2 Rear left speed sensor 3 Front left speed sensor 1 J104 Control unit for ABS with EDL J105 ABS recirculating pump relay J106 Solenoid valve relay J220 Control unit for Motronic...
  • Page 100 N166 N167 N168 N169 N102 N133 N134 N135 N136 J104 J401 J220 J285 SSP 192/087...
  • Page 101 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.
  • Page 102 Electrics Gas discharge lamp In the case of gas discharge lamps, light is components due to the composition of the gas generated by an electric arc between two in the lamp tube. electrodes in a pea-sized gas-filled glass tube. This is the external distinguishing feature of gas discharge technology.
  • Page 103 Electrics The gas discharge lamp requires a high-voltage pulse of several thousand volts to ignite the elec- Gas discharge lamp tric arc. The voltage is produced in the ballast. After ignition, an increased electric current is applied to the gas discharge lamp for approx. 3 seconds.
  • Page 104 Automatic headlight range control To prevent dazzling oncoming traffic, the gas The control unit for automatic headlight range discharge headlights have to be equipped with control determines the car’s load condition by an automatic headlight range control. two sensors located on the front and rear axles on the left of the car.
  • Page 105 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 address word ”55”.
  • Page 106 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.
  • Page 107 Air-conditioning The Passat has an improved air-conditioning system. You can find out about its features and innovations on the following pages. Refrigerant circuit The refrigerant in the evaporator absorbs heat The refrigerant is circulated in a closed circuit. and dissipates it into the ambient air to cool The refrigerant circuit contains the the passenger compartment.
  • Page 108 CLIMAtronic The operating and display unit is combined The dash panel insert temperature sensor and with the CLIMAtronic control unit as a single the temperature sensor fan are integrated in module. the control unit. Temperature sensor fan V42 SSP 192/031 Dash panel insert temperature sensor G56 SSP 192/039...
  • Page 109 Air-conditioning System overview Sensors Sunshine penetration photosensor G107 Dash panel insert temperature sensor G56 with temperature sensor fan V42 Outside temperature sensor Temperature sensor for fresh air intake duct G89 Sender for footwell air outlet tempera- ture G192 Sender for central air outlet temperature G191 Air-conditioning pressure switch...
  • Page 110 Actuators Control unit for CLIMAtronic J255 Footwell/defrost flap actuator with potentiometer Central flap actuator with potentiometer Temperature flap actuator with potentiometer Ventilation flap actuator with potentiometer Fresh air blower V2 with blower control unit J126 Magnetic coupling N25 Additional signals Diagnostic connection SSP 192/030...
  • Page 111 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. SSP 192/036 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- ger required.
  • Page 112 Fresh air SSP 192/022 Above a speed of 160 kph, the ventilation flap is closed. A small amount of fresh air trickles into the passenger compartment through a narrow opening in the ventilation flap. SSP 192/026 Recirculated air Fresh air Air recirculation mode In the air recirculation mode, the two flaps are in their upper positions.
  • Page 113 Air-conditioning Central flap The central flap controls the air flow to the cen- tral, side, footwell and DEFROST air outlets. Its new shape allows it to be fully closed. It is also SSP 192/035 driven by an electric motor. footwell DEFROST Central flap At low outside temperatures and when the...
  • Page 114 Fresh air blower V2 The blower control unit is integrated in the fresh air blower. The control unit cooling ribs are cooled by the SSP 192/037 blower airstream. Fresh air blower V2 SSP 192/038 Air-conditioner Blower control unit J126...
  • Page 115 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. SSP 192/093 How it works: The sunlight impinges on a photodiode through a filter and an optical element.
  • Page 116 Diagonal sunlight penetration Particularly sunlight incident on the car’s occupants diagonally from the front, i.e. directly, increases the feeling of warmth. Filter The optical element deflects a large proportion Optical element of diagonally penetrating sunlight onto the photodiode. Cooling is increased to equalise Photodiode the effect of heat radiation on the body.
  • Page 117 Air-conditioning The temperature of the air streaming into the vehicle is now measured by two separate temperature sensors. Footwell outlet temperature sender G192 The temperature is measured by a temperature- dependent resistor. As temperature decreases, the electrical resistance increases. NTC resistor SSP 192/032 Central outlet temperature sender G191 With this sender, the temperature-dependent...
  • Page 118 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 limit position.
  • Page 119 Solutions: Page 18/19 Re. 1. Driver airbag, Front passenger airbag, Side airbags, Front + rear belt tensioners, Belt force limiter Re. 2. 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 belt during an accident.
  • Page 120 Notes...
  • Page 121 Notes...
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This manual is also suitable for:

Passat b5Passat 1997

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