Volkswagen Phaeton 2003 Manual
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Volkswagen Phaeton 2003 Manual

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The Phaeton
Self-Study Program
Course Number 891303

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Summary of Contents for Volkswagen Phaeton 2003

  • Page 1 The Phaeton Self-Study Program Course Number 891303...
  • Page 2 Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.

  • Page 3: Table Of Contents

    Table of Contents Introduction ....................1 Volkswagen’s Flagship, The Phaeton Name, Phaeton’s Place in Automotive History, The Transparent Factory, Phaeton Technical Innovations, Specifications, Aerodynamics Engines ......................10 The 4.2-Liter V8-5V Gasoline Engine, The 6.0-Liter W12 Gasoline Engine Fuel Supply ....................14 Fuel Delivery System Transmissions ....................

  • Page 5: Introduction

    Introduction Volkswagen’s Flagship The introduction of the Volkswagen There are separate Self-Study Phaeton is the result of developments in Programs on the following topics: the international market for luxury cars. • The W Engine Concept Product quality alone is no longer sufficient...
  • Page 6 Introduction 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 coaches that became popular in the 18th century.
  • Page 7 Horch 853A Parade Phaeton only three of which were built, and the last remaining model of which recently sold for $334,000. The choice of the name “Phaeton” for the Volkswagen flagship links this vehicle to the tradition of employing superior SSP270/169 quality-control requirements in the...
  • Page 8 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 for Volkswagen’s customer-oriented manufacturing and delivery. In addition to these outstanding technical production details, purchasers of this...
  • Page 9 Introduction transported in glass elevators to a different level, where they are joined into a complete vehicle and the final assembly process takes place. Once the manufacturing process has been completed, each Phaeton is once again placed on the overlapping conveyor belt before receiving its finishing touches and its final check.
  • Page 10 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. • Rear window heated by practically invisible tungsten threads. • Fenders and spare tire recess made of plastic.
  • Page 11 Introduction • Xenon headlights with automatic headlight range control. • 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 for cleaning headlights. •...
  • Page 12 Introduction Specifications 57.09 in (1450 mm) 64.09 in 63.46 in (1628 mm) (1612 mm) 74.92 in (1903 mm) 118.15 in (3001 mm) 203.74 in (5175 mm) SSP270/118 • Length • Rear track width 203.74 inches (5175 mm) 63.46 inches (1612 mm) •...
  • Page 13 Introduction Aerodynamics The Phaeton has a low drag coefficient of Small features such as the retractable 0.32 C headlight cleaning nozzles, the antenna-free body, and the smooth This level was achieved by combining body transitions are also responsible for several design elements: this low drag coefficient.

  • Page 14: Engines

    Engines The 4.2-Liter V8-5V Gasoline Engine Emphasis was placed on the following Alloys are used extensively: development objectives: • The cylinder heads and oil sump top • Compliance with future section are made of aluminum. exhaust-emission regulations. • The valve covers are die-cast magnesium •...
  • Page 15 Engines Technical Data – 4.2-Liter V8-5V lbs-ft Nm Gasoline Engine 369 500 335 250 • Type 332 450 302 225 V8 engine with 90 degree V-angle, 295 400 268 200 five valves per cylinder, and variable intake and exhaust valve timing 258 350 235 175 •...
  • Page 16 Engines The 6.0-Liter W12 Gasoline Engine With the W12 engine, Volkswagen is Engine Management offering a 12-cylinder engine in its lineup for • Dual control module concept. the first time ever. It is the most powerful • Secondary air injection.
  • Page 17 Engines Technical Data – 6.0-Liter W12 Gasoline Engine • Type • Maximum torque W engine with four valves per cylinder 406 lbs-ft (550 Nm) @ 3500 rpm • Displacement • Engine management 366 cu in (5998 cm Motronic ME 7.1.1 •...

  • Page 18: Fuel Supply

    Fuel Supply Fuel Delivery System Fuel Tank Each electric fuel pump is assigned two senders for fuel supply: a fuel sender and a The fuel tank is mounted on the vehicle level sender. underbody close to the rear axle. It has a capacity of 23.8 gallons (90 liters).

  • Page 19: Transmissions

    Both automatic transmissions are currently • Tiptronic shift program. already in use in other Volkswagen vehicles. They have been modified and adapted for Five-Speed Automatic Transmission 01L installation in the Phaeton. An electro- hydraulic system is used to control them.
  • Page 20 Transmissions Six-Speed Automatic Transmission 09F Like the five-speed automatic, the six-speed automatic transmission 09F This specially-developed automatic also has: transmission is used in Phaetons equipped • Dynamic shift program and sport with the 4.2L V8-5V engine. shift program. Compared with the five-speed automatic •...
  • Page 21 Transmissions Lepelletier Gear Set Simple Planetary Lepelletier gear set concept Gear Set Internal Gear 1 The six automatic transmission gears are Planet Gear shifted by a Ravigneaux planetary gear set Sun Gear 1 with a series-connected simple planetary gear set. This arrangement is known as the Lepelletier gear set concept.
  • Page 22 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 CLIMATE AUDIO SETTINGS ON/DARK In order to move the selector lever from RESET VEHICLE NAV SET...
  • Page 23 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. 76.7 mi 54.1°F 76728 mi...
  • Page 24 Transmissions Tiptronic On the Phaeton, Tiptronic gear selection CLIMATE AUDIO SETTINGS ON/DARK can be operated by the selector lever. RESET VEHICLE NAV SET TRIP DATA MANUAL HELP The automatic transmission is switched to Tiptronic mode by moving the selector lever SCAN to the right from the “D”...
  • Page 25 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. Shift Lock Solenoid N110 SSP270/222 How it works E415...
  • Page 26 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 to enable movement of the selector lever from the “P”...
  • Page 27 Transmissions 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 the selector lever: •...
  • 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 feature are mechanical Extended Groove systems activated by cable control.
  • Page 29 Transmissions Electrical circuitry If the ignition is turned off and the selector lever is in “P” position, a signal travels E415 from the Selector Lever Park Position Lock Switch F319 to the Access/Start Control Module J518. The Access/Start Control Module J518 then sends current to the “Selector Lever in P”...

  • Page 30: Running Gear

    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. Electrically Adjustable Steering Column with Electrical Steering Column Locking Tandem Master Cylinder with Brake Booster Air Suspension with Continuously...
  • Page 31 Running Gear Trapezoidal Wishbone Rear Suspension Alloy Wheels All Season Tires Foot Parking Brake with The chassis is described in Hand-Operated Release Lever detail in The Phaeton Chassis, Self-Study Program Course Number 893303. SSP270/089-090...

  • Page 32: Body

    Body Body Structure The focus of the body design was a high Static Rigidity level of crash safety and body rigidity. The The extremely high static rigidity of the gap dimensions for the hood, luggage body structure is a prerequisite for: compartment lid, and doors could be •...
  • Page 33 Body Safety Features • The relatively soft external bodywork areas are designed to help reduce the • High energy absorption at the front and severity of injuries to other parties rear of the vehicle. involved in an accident. • Stable passenger compartment. •...
  • Page 34 Body Body Attachments Aluminum Parts Glued-in-place plastic spare tire recess • Engine hood The following components are integrated in the spare tire recess: • Reinforced doors • Luggage compartment lid • Compressor for air suspension. • EVAP canister with Plastic Parts activated-charcoal filter.
  • Page 35 Body SSP270/114-115 Reinforced laser-welded doors with high-strength die-cast inner sections. Detailed view of spare tire SSP270/004 cavity, from below. Aluminum Plastic...
  • Page 36 Body Sound Silencers Sound deadening was a major design issue compartment, tunnel, luggage when developing the body-in-white. Along compartment, and behind body panels has with the dynamic rigidity of the body reduced interior noise to significantly lower structure itself, the consistent use of sound levels than is normally achieved.
  • Page 37 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 incorporated into the glass.
  • Page 38 Body Rear Window with Tungsten Threads Heating Duration of Heated Glass The rear window is heated by nearly In order not to overload the electrical invisible tungsten threads that are system, the heating duration of heated embedded between the inner and outer glass depends on the ambient outside air pane.
  • Page 39 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.
  • Page 40 Body Function Closing The power-assisted luggage compartment The Rear Lid Lock Button (in Luggage lid is operated by an electro-hydraulic Compartment) E406 in the luggage mechanism. Hydraulic fluid is pumped compartment lid is used to close the lid. through the hydraulic lines by an Safety Features electric pump.
  • Page 41 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 opened or closed.

  • Page 42: Occupant Protection

    Occupant Protection Overview The Phaeton has sophisticated active and Airbag Triggering passive safety equipment. Volkswagen has The four Phaeton airbag systems have redefined safety standards in luxury class approximate filling volumes as follows: cars by employing lighter but high-strength • Driver airbag – 2.65 cubic feet (75 liters)
  • Page 43 Occupant Protection Driver Airbag Front Passenger Airbag SSP270/019 SSP270/026 Front Side Airbag Rear Side Airbag SSP270/023 SSP270/025 Side Curtain Protection SSP270/024...
  • Page 44 Occupant Protection Seat Belt Systems All seats on the Phaeton have three-point Shoulder Belt Tensioner retracting seat belts with belt tension Comfort Mechanism limiters. All outside seats are equipped with A force greater than that used in pyrotechnical seat belt tensioners that are conventional belt buckles is required for the triggered by the Airbag Control Module automatic seat belt roller to retract the...
  • Page 45 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 belt has a spherical tensioner.
  • Page 46 Occupant Protection 18-Position Seat Removal The metal pin is secured with a sheet metal with Optional Automatic Lap Belt lock. The lock must be disengaged and the pin must be removed to separate the belt The optional automatic lap belt must be from the buckle tongue.
  • Page 47 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 lowers the risk of neck injury.

  • Page 48: Seats

    Seats Front Seats The Phaeton is available with 12-Position Front Seats air-conditioned seats. Adjustment functions The seat belt mechanism integrated in The Phaeton comes with 12-position the front seats give the Phaeton an even seats standard. greater level of comfort. The optional automatic lap belt available with the The following functions are 18-position seat gives increased seat belt...
  • Page 49 Seats Memory functions Air conditioning function The memory package for the 12-position Air conditioning in the 12-position seats is seats includes a range of savable functions. provided by ventilators that are integrated In addition to the seat settings, the memory in the seats and feed temperate air through function can also save the positions of the the fine perforations in the leather.
  • Page 50 Seats 18-Position Front Seats Memory functions The Phaeton can be equipped with even In addition to the functions featured in the more luxurious optional 18-position front 12-position front seats, the memory seats. The 18-position front seats can be package for the 18-position seats also equipped with optional automatic lap belts.

  • Page 51: Rear Seats

    Seats Rear Seats The Phaeton is available with three rear positions that distinguish it from the seat variations: standard rear seat: • Standard rear seat. • Electrically adjustable lumbar support and massage. • Premium rear seat. • Seat ventilation and heating. •...
  • Page 52 Seats 10-Position Individual Rear Seats • Seat occupancy detection – the head restraints rise automatically when The 10-position individual rear seats are the seat is occupied and the seat heater available as an option only on Phaetons is enabled. equipped with the 18-position front seats. •...

  • Page 53: Air Conditioning System

    Air Conditioning System Four-Zone Climatronic As a luxury-class sedan, the Phaeton has Climate Control Row a standard four-zone air conditioning system. Thanks to the four-zone Climatronic, the driver and passengers can enjoy their own desired air conditioning settings independently of each other. The temperature adjustment range available is between 64°F and 82°F (18°C and 28°C).
  • Page 54 Air Conditioning System Special Functions of • Automatic and manual recirculating air Four-Zone Air Conditioning function with air quality monitoring. • Automatic and manual control for each air • Automatic and manual defrost function conditioning zone. with window fogging recognition. •...
  • Page 55 Air Conditioning System Air Distribution in the Vehicle The blower draws fresh air in through the The temperature of the air distributed to dust and pollen filter and routes it through the right and left sides of the vehicle is the evaporator.
  • Page 56 Air Conditioning System System Overview The air conditioning system includes the Right Left following circuits and components: Heater Core Heater Core Temperature Temperature • Cooling circuit with: Sensor G307 Sensor G306 — A/C Pressure/Temperature Sensor G395. — Evaporator Temperature Sensor G308. Heating Circuit SSP270/212 •...
  • Page 57 Air Conditioning System Welcome CLIMATE AUDIO SETTINGS ON/DARK RESET VEHICLE NAV SET TRIP DATA MANUAL HELP SCAN BAL/FAD Front Information Display Rear A/C Control Head Control Head J523 (Climatronic) E265 SSP270/189 SSP270/208 Climatronic Control Module J255 SSP270/159...

  • Page 58: Electrical System

    Electrical System Convenience Electronics Memory Functions These user profiles communicate via the Front Information Display Control The Phaeton offers a variety of memory Head J523 and the Access/Start Control functions that are saved and accessed by Module J518. various operating panels. In addition to the functions controlled by the seat memory feature, user profile settings can be created using the radio remote key.
  • Page 59 Electrical System Overview of memory components appropriate pages for a more precise description of the Front Information Display This illustration provides an overview of the Control Head J523 controls and for controls and their associated memory information regarding seat adjustments. function components.
  • Page 60 Electrical System Access and Start Authorization System The components and functions listed in the table are constituent parts of the access The vehicle can be locked or unlocked and start authorization system. without the active deployment of the radio remote key by using the optional For more information on access convenience features of the access and and start authorization, please...
  • Page 61 Electrical System Additional functions of the convenience features for access and start authorization f i t Interior Access/Start Authorization Antenna 3 R154 Access/Start Interior Access/Start Authorization Authorization Antenna 2 R139 Switch E415 Interior Access/Start Authorization Antenna 1 R138 Luggage Compartment Access/Start Authorization Antenna R137...
  • Page 62 Electrical System Adaptive Cruise Control (Late Availability) Adaptive Cruise Control (ACC) is a driver By reducing engine speed and applying assistance system that enhances cruise the brakes if necessary, an ACC-equipped control operation. vehicle is kept at a reasonable distance behind a slower-moving vehicle in front of it.
  • Page 63 Electrical System Effects The ACC-equipped vehicle adapts its speed to the speed of the vehicle in front of it. 50 mph (80 km/h) 50 mph (80 km/h) SSP270/199 Acceleration The ACC-equipped vehicle accelerates to 50 mph the desired speed once the vehicle in front (80 km/h) of it leaves the traffic lane or otherwise moves out of the detection area.
  • Page 64 Electrical System 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.
  • Page 65 Electrical System Control Module for Distance Regulation J428 New ACC components with Right Distance Sensor Regulation Sensor G259 Electronics 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...
  • Page 66 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.
  • Page 67 Electrical System Rear Lights The rear lights are designed with light- The Phaeton vehicle diagnostic system emitting diodes (LEDs). Lower energy will detect a malfunction if an LED consumption, shorter response times and a becomes defective. The driver receives longer service life are among the notification of the problem in the advantages of LEDs.
  • Page 68 Electrical System Battery The battery gases are released through a All Phaeton vehicle batteries are made side vent and a tube that expels using non-woven fabric containing latent sulfuric acid and are therefore maintenance them into the wheel housing. free. The cell fill plugs cannot be opened. Plate Group Fabric SSP272/240...
  • Page 69 Electrical System Phaeton Battery Systems The vehicle battery system has the task One-Battery System of guaranteeing the electrical energy for The various components that consume starting the engine and of feeding the electricity are all supplied by one battery in various vehicle components that all operating conditions.
  • Page 70 Electrical System Two-Battery System If either battery is discharged, the vehicle can still be started. The Battery Monitoring Vehicles with W12 engines are equipped Control Module J367 and the Parallel with two-battery systems. Battery Connection Relay J581 can The two-battery system includes a starter reroute current when necessary to enable battery, a separate on-board power supply the system components needed to start...
  • Page 71 Electrical System Emergency Starting If the single battery in a one-battery voltage only to the electrical components system is discharged, or if both batteries in relevant to the starting procedure. This a two-battery system are discharged, the method of connection protects other engine can be started using an external components in the on-board power supply voltage source.
  • Page 72 Electrical System Using the Front Information Display Control Head J523 for Component Service Adjusting Headlights Changing Wiper Blades The headlights must be locked in place in To change the wiper blades, they must the “basic setting” function with the first be moved into the service position Vehicle Diagnosis, Test and Information using the “Maintenance &...
  • Page 73 Electrical System Infotainment System The Phaeton Infotainment system includes • Travel data (TRIP DATA) a range of functions that can be controlled (distance data, consumption, fuel stop) by the Front Information Display Control • Air conditioning (CLIMATE) Head J523, by buttons on the multi- (regulating heating / air conditioning function steering wheel, and by the Rear system, solar roof function, auxiliary...
  • Page 74 Electrical System Front Information Display Control Head J523 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: •...
  • Page 75 Electrical System Control Module for Navigation Microphone Unit with CD-Mechanism J401 in (in Front Roof Module) Antennas in the Glove Compartment R164 the Rear Window SSP270/071 SSP270/073 SSP270/074 SSP270/066 SSP270/077 Rear A/C Control Head (Climatronic) E265 Multi-Function SSP270/076 Steering Wheel...
  • Page 76 Electrical System Front Information Display Main menu row with Control Head J523 Menu Selection Rotary Knob E460 The Infotainment Front Information Display The selection of the main menu is made Control Head J523 is integrated into the with this row of buttons. Menu items are center console and is subdivided into selected by turning the Main Selection four sections:...
  • Page 77 Electrical System Multi-Function Steering Wheel Control In addition to the horn and driver’s airbag, the multi-function steering wheel accommodates two keypads to control the following functions: • Cruise control system. • Adaptive Cruise Control. • Infotainment subfunctions. • Menu selection for the Display Unit in Instrument Cluster Y24.

  • Page 78: Service

    Service Special Tools Engine Hoist Cooling System Filling Device VS 6100 VAS 6096 Engine and Transmission Bracket Fill Plug Set VAS 6095 VAS 6122 Bracket for Seat Repair Upgrade Set for PAX Tires VAS 6136 VAS 6134/1 Upholsterer Tool Set Attachment Set VAS 6137 VAS 6130...
  • Page 79 Notes...
  • Page 80 Notes...

  • Page 81: Knowledge Assessment

    Knowledge Assessment 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 on the Certification tab –...
  • Page 83 Volkswagen of America, Inc. 3800 Hamlin Road Auburn Hills, MI 48326 Printed in U.S.A. August 2003...

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