Volkswagen Passat W8 Service Manual
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Volkswagen Passat W8 Service Manual

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Service.
Self-Study Programme 261
The Passat W8

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Summary of Contents for Volkswagen Passat W8

  • Page 1 Service. Self-Study Programme 261 The Passat W8...
  • Page 2 The Passat W8 S261_002 This Self-Study Programme presents the Passat The subject of the W8 engine is described in two W8. We will only explain the design and function separate Self-Study Programmes: where the items are totally new. All the changes described refer to the Passat model year 2001.
  • Page 3 At a glance In a nutshell ........4 Body .

  • Page 4: In A Nutshell

    In a nutshell 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 estate versions.
  • Page 5 This high-quality car is based on the Passat launched in model year 2001. S261_003 The W8 engine is a totally new development. The engine power output is transferred to the One of the technical features is its compact size. road via a 6-speed manual gearbox with four-wheel drive (4Motion).
  • Page 6 The Estate But whether it is the estate or the saloon, the new All the innovations in the Passat W8 saloon are Passat W8 is recognisable from the outside by its also in the estate. The bodies of both the estate...
  • Page 7 Inside, the standard equipment includes head In the extensive list of the Passat W8's optional airbags front and rear, high-class pillar and extras we have included new luxury leather headliner trims, chrome and real wood trims, seats, new sports seats, a dynamic navigation...
  • Page 8 In a nutshell The Saloon 100 kg S261_073 S261_005 2703 mm 4703 mm S261_006 S261_007 1746 mm Size and weight Length 4703 mm Front track width 1511 mm Width 1746 mm Rear track width 1510 mm Height 1461 mm Perm. gross vehicle weight 2220 kg Wheelbase 2703 mm...
  • Page 9 The Estate 100 kg S261_073 S261_008 2703 mm 4682 mm S261_009 S261_010 1746 mm Size and weight Length 4682 mm Front track width 1515 mm Width 1746 mm Rear track width 1510 mm Height 1497 mm Perm. gross vehicle weight 2290 kg Wheelbase 2703 mm...

  • Page 10: Body

    To fulfill the claims of greater luxury and safety, We have modified the spare wheel well to attach the body of the Passat W8 has been the auxiliary fuel tank. On the saloon, the rear strengthened. By strengthening, we make a bulkhead is welded to the rear backrest.
  • Page 11 Acoustic measures: Crash reinforcements: A cross strut is bolted between the front wheel The front footwell is reinforced by an additional housings. It is fixed to new supports welded to cross-member. the wheel housings. An additional strut is welded to the front bulkhead near the front side member. Cross-member Support for cross strut...

  • Page 12: Occupant Protection

    Occupant protection Occupant protection Occupant protection is ensured by the airbag The Passat W8 has two full size front airbags on system with two front airbags, sidebags and the driver's and front passenger's sides. They head airbags, belts and belt tensioners as well as have a filling volume of 64 and 120 litres.
  • Page 13 The conventional inertia-reel seat belts are used The rear seats are fitted with Wankel belt on the front and outer rear seats. tensioners. Ball-type tensioners are fitted to the front seats. The two types of belt tensioner are triggered by mechanical/pyrotechnical capsules.
  • Page 14 Occupant protection Child safety restraint system Both the integrated child safety seats and the Isofix system are available on the Passat W8. Integrated child safety seats 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...

  • Page 15: Drive Units

    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.
  • Page 16 Drive units Specifications Engine code Displacement 3,999 cm Type W engine Valves per cylinder Compression ratio 10.75±0.25:1 Bore 84.0 mm Stroke 90.2 mm Max. output 202 kW / 275 bhp 6000 rpm Max. torque 370 Nm 2750 rpm Engine management system Motronic M7.11 Fuel RON 98...
  • Page 17 The fuel delivery system The fuel delivery system of the Passat W8 has The two fuel tanks are connected by a connecting tank capacity of 80 litres. It consists of a 60 litre tube. The additional fuel tank is located under...
  • Page 18 Drive units The fuel pumps The 60-litre fuel tank contains an electrical fuel When the tank is full, fuel is first pumped from pump and a suction jet pump (entrainment the 60 l tank. When the fuel level in the main pump).
  • Page 19 Fuel pump control The fuel pump in the main fuel tank is controlled When the sender in the main fuel tank signals a by the engine control unit. The fuel pump in the fuel level of 40 litres, the control unit switches the additional fuel tank is switched on by the fuel pump in the additional fuel tank on.
  • Page 20 Drive units Function diagram of fuel delivery system G 293 G 292 G 237 G 169 J 17 S228 Terminal 30 J 538 CAN convenience G 23 S261_022 G 293 -Fuel level sender, G 6 - fuel pump (pre-supply pump) additional fuel tank empty J 17 - fuel pump relay G 292 -fuel level sender,...
  • Page 21 The fuel level indicator Due to the different heights of the fuel tanks, four fuel level senders are required to calculate the remaining fuel amount correctly. The signals from all the senders are evaluated in the fuel pump control unit. The resulting signal runs via the CAN convenience bus to the dash panel insert and is used to control the fuel level indicator.

  • Page 22: Power Transmission

    Gearbox The 6-speed manual gearbox 01E, four-wheel drive 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.
  • Page 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. S261_026 The Torsen differential detects wheel slip in one The Torsen differential permits limited differences in axle and distributes the drive power to the speed between the front and rear axles and wheels of an axle with better wheel grip.

  • Page 24: Running Gear

    Running gear The four-link front suspension 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:...
  • Page 25 The double wishbone rear suspension The proven double wishbone rear suspension What is new are the wheel bearing housings with with closed tubular subframe is fitted to the a modified attachment to the track rods. Passat W8. Tubular subframe Upper wishbone Differential Lower wishbone...
  • Page 26 Running gear The brake system The Passat W8 currently has the most powerful Despite high engine performance, it achieves brake system of all Volkswagen car models. excellent deceleration rates. S261_031 261_031 Rear disc brake Front disc brake Hydraulic unit and control unit...
  • Page 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 ABS two-stage recirculating pump V39 replaces the hydraulic pump for electronic dynamics control V156.
  • Page 28 Running gear The ABS two-stage recirculating pump V39 is integrated in the Bosch 5.7 ABS system. While pressure is building up in working When the ESP intervenes, it supplies the required chamber 1, the piston in working chamber preliminary pressure in the brake lines. 2 sucks brake fluid in.
  • Page 29 The hydraulic brake assistant system (BAS) is integrated in the ABS control unit. Accident research studies have shown that the Pressure sensor G294 majority of drivers do not press hard enough on the brakes in critical situations. This means that pressure build-up is insufficient to reach maximum vehicle deceleration.

  • Page 30: Vehicle Electrical System

    Vehicle electrical system The vehicle electrical system The electrical system on the Passat W8 has a similar design as on the Passat model year 2001. The following pages will describe modifications Airbag control unit to components and functions compares with the (gearbox tunnel) Passat model year 2001.
  • Page 31 Control unit for Window lifter motor parking aid with integrated (luggage compartment, right) door control unit TV tuner CD changer Window lifter motor with integrated door control unit S261_044 Dash panel insert with immobiliser control unit and diagnostic interface (gateway) Convenience control Fuse box, dash panel, Connector station...
  • Page 32 Vehicle electrical system The gas discharge headlight (GDH) with bi-xenon light The Passat W8 is only fitted with the bi-xenon Due to the gas discharge headlights, all bi-xenon headlight system. The improved light output of cars are equipped with automatic and dynamic the system increases active driving safety as the headlight range control (refer to SSP 251).

  • Page 33: Convenience And Safety Electronics

    Convenience and safety electronics Passat W8 with Internet access Networking a vehicle is no longer limited to the The Internet interface is a device which is linked car's immediate surroundings but goes far to the radio navigation system via the CAN bus.
  • Page 34 Convenience and safety electronics The convenience system Interior monitor and anti-theft alarm system The Passat W8 anti-theft alarm system is Two lithium batteries integrated in the horn equipped with a new function and a new alarm ensure that the horn operates independent of the horn.
  • Page 35 Function diagram of signal horn for anti-theft alarm system J393 F266 S261_048 F266 -contact switch for bonnet, in lock part -signal horn for anti-theft alarm system -alarm horn J393 -central control unit for convenience system -positive terminal 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.
  • Page 36 Convenience and safety electronics 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 function (Traffic Information Memory)
  • Page 37 Rotary/push button for SCAN/TUNE SCAN Press in radio mode to search for a station or in CD MIX button mode to briefly play the start of the track. In CD mode, tracks are played in random sequence. TUNE Rotate to tune the FM/AM station manually or to select the previous/next track in CD mode.
  • Page 38 Convenience and safety electronics Radio rear panel The rear panel of the radio contains the aerial sockets and the central connector. The aerial sockets Aerial input for FM/AM signal from control unit for aerial selection S261_050 Output to control unit for aerial selection The aerial sockets S261_051 To avoid plugging the aerial connectors in the...
  • Page 39 Tuner The radio has two integrated FM/AM tuners. Example: You are listening to an FM station, e.g. NDR 2, One of the tuners is only adjusted for receiving which broadcasts supraregional traffic radio frequencies from FM/AM stations. The other messages. To receive current regional traffic tuner is used for setting the frequencies to radio messages, select a TP station e.g.
  • Page 40 Convenience and safety electronics CAN bus networking To control functions and processes, the radio control unit and the dash panel insert exchange the following information over the CAN bus. NO contact Terminal 15 Road speed signal (GALA) Display lighting Self-diagnosis processing Radio convenience coding Control signals from the multifunction steering wheel Vehicle identification number...
  • Page 41 The radio aerial system FM/AM reception of the radio system on the If reception is poor, the aerial control unit Passat W8 has been considerably improved. This switches to another aerial with a stronger signal. was achieved by fitting four independent The aerials are in different locations on the FM/AM aerials (see SSP 147).
  • Page 42 Convenience and safety electronics Location of aerials on the estate On the estate, the aerials are located in the rear As on the saloon, each FM aerial is allocated to side windows. Viewed in the direction of travel an aerial amplifier. Even on the estate, the there is a combined AM/FM aerial on the left- amplifiers should not be wrongly allocated.
  • Page 43 Function The radio signal received from one of the four If the selected signal is too weak for tuner aerials runs via an aerial switch circuit inside the reception, the aerial switch switches aerial selector control unit to the tuner. In the automatically to the next of the four aerials.

  • Page 44: Heating And Air Conditioning System

    Heating, air conditioning system 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:...
  • Page 45 The externally regulated compressor 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 drive with no magnetic clutch and integrated overload protection External regulating valve N280 to regulate the pressure conditions in the compressor...
  • Page 46 Heating, air conditioning system The overload protection The V-belt pulley and the driven plate are When the compressor is operational, the two positively joined by a shaped rubber element. plates rotate in the same ratio to each other. Compressor in function Belt pulley Shaped rubber element Drive shaft...
  • Page 47 If the compressor is damaged internally, it may The projecting shapes on the rubber element cause the drive shaft to block. The driven plate shear off and the joint between the belt pulley will also stop. and the driven plate is separated. The belt pulley This drastically increases the transfer forces continues to rotate unhindered.
  • Page 48 Heating, air conditioning system The evaporator control circuit When the CLIMAtronic is ON and the driver The components described below form a control enters the desired temperature, the refrigerant circuit for regulating the desired temperature. demand is determined and changed by a number of different influences.
  • Page 49 Outlet temperature sender G263 Influencing parameters: The outlet temperature sender G263 is located in Input of desired temperature the air duct behind the evaporator. It detects the Ambient temperature vent temperature downstream of the evaporator. Interior temperature Temperatures downstream of evaporator and air outlets If fulfills two important tasks: Pressure level in refrigerant circuit it ensures that the air conditioning system is...
  • Page 50 Notes...
  • Page 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.

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