Volkswagen Passat 2006 Service Training
  1. Manuals
  2. Brands
  3. Volkswagen Manuals
  4. Automobile
  5. Passat 2006
  6. Service training

Volkswagen Passat 2006 Service Training

Self-study programme 339
Hide thumbs Also See for Passat 2006:
Table of Contents

Advertisement

Quick Links

See also: Workshop Manual , Service Training
Service Training
Self-study programme 339
The Passat 2006

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Passat 2006 and is the answer not in the manual?

Questions and answers

Related Manuals for Volkswagen Passat 2006

Summary of Contents for Volkswagen Passat 2006

  • Page 1 Service Training Self-study programme 339 The Passat 2006...
  • Page 2 Passat 2006 already meets luxury class quality, safety and design standards. It continues to offer the economy traditional in the mid-size class. The drive concept fitted in the Passat 2006 has been redesigned to achieve these outstanding characteristics. The engine is mounted in the classic transverse configuration.

  • Page 3: Table Of Contents

    At a glance In brief ............4 Body .

  • Page 4: In Brief

    In brief The Passat model year 2006 Where will the new Passat 2006 be built? Like its predecessor, the new Passat will also be built in the Emden and Zwickau plants. VW's Emden plant The Emden plant, in which the majority of the Passat...
  • Page 5 Emden Zwickau S339_011 VW's Zwickau/Mosel plant In Zwickau/Mosel, around 1150 Golfs and Passats are manufactured each day, in both left and right-hand drive versions, for all markets from Japan to North America. In January 2003, the one millionth Passat S339_003 rolled off the assembly line in Zwickau/Mosel.
  • Page 6 In brief The Passat 2006 The Passat 2006 will point the way forward in many disciplines, e.g. Dual-zone Climatronic ● - Design - Vehicle dynamics - Drive technology - Spatial availability - Safety Light assist ● - Quality Transversely mounted engine ●...
  • Page 7 High-end sound system ● Boot lid easy opening ● Rear lights with LED technology ● S339_006 Multi-link rear suspension ● ● Electromechanical parking brake Tyre pressure monitor systems ● 230V socket ●...

  • Page 8: Technical Data

    In brief Technical data Passat saloon 2006 S339_007 S339_009 S339_008 Length 4765 mm Front track 1552 mm Width 1820 mm Rear track 1551 mm Height 1472 mm Permissible gross vehicle weight 1950 kg Wheelbase 2709 mm Unladen weight without driver 1391 kg Roof load 100 kg...
  • Page 9 Interior dimensions S339_010 S339_012 Headroom, front 973 mm Headroom, rear 961 mm Interior length 1797 mm Luggage compartment volume 565 litres* * Including 80 litres in the spare wheel recess storage space...

  • Page 10: Body

    Body The body structure The new Passat's body has been optimised in terms of the following focal points: A-pillar Passive safety ● Lightweight design ● Comfort ● Pedestrian protection ● This has been achieved by using high- and ultra-high- strength steel panels and ultra-high-strength, hot- formed steel panels.
  • Page 11 Centre tunnel Roof frame B-pillar Longitudinal member S339_018 Ultra-high-strength, hot-formed > 1000 MPa Steel panels < 140 MPa Ultra-high-strength 300 - 420 MPa Outer sills Inner sills S339_081 Seat brackets Higher-strength 260 - 300 MPa High-strength 180 - 240 MPa What are ultra-high-strength, hot-formed steel Yield strengths of the steel panels which are used: panels?
  • Page 12 Body The joining techniques Thanks to the use of laser welded and soldered joints and spot welded/bonded joints, the body structure is safeguarded in the event of a crash. S339_019 Laser welding Spot welding and bonding The following joining techniques are employed: Laser welds Spot weld bonds...
  • Page 13 The flow of force in a frontal crash In the event of a frontal crash, the forces which occur are guided into the floor panel and the roof longitudinal members via the upper and lower longitudinal members. Side view S339_020 View from below In the event of a lateral crash, the passenger survival The body colours correspond to the...
  • Page 14 Body The seats The front seats 4-way lumbar support S339_021 Seat rails Seat guidance and adjustment are carried out via parallel seat rails. This results in finer adjustment in comparison with the predecessor's central adjustment rail. Mechanical 2-way and electric 4-way lumbar support adjustment are optionally available.
  • Page 15 The front passenger seat with through-loading function Front passenger seat in through-loading position With this optional seat, the seat backrest can be folded horizontally forwards by actuating the release lever. This enables the vehicle's entire passenger compartment length to be used as transportation space.
  • Page 16 Body The rear seats The rear seat bench is split 1/3 to 2/3. The seat backrests can be individually folded. S339_026 The backrest locking mechanism The backrests are locked by means of a rotary latch lock. Indicator If the backrest is not locked, this is displayed via a red indicator.
  • Page 17 The integrated child seats A rear seat bench with two integrated child seats is optionally available. Seat cushion not raised Lateral bolsters, can be folded up Seat cushion raised Handle for raising Footrest S339_029 Raising mechanism The seat cushions on the outer seats can be raised. After raising the seat cushion, the lateral bolsters have to be raised manually.
  • Page 18 Body The door lock The door locks are actuated by means of a Bowden cable between the door handle and the door lock. Lock actuation Bolt mechanism Lever Lever fulcrum Bowden cable Door lock S339_118 The lock cylinder When installed, the lock cylinder is clamped into the lock actuation mechanism via a lever. To do this, the lever is pivoted around its fulcrum by turning the bolt.
  • Page 19 The rear window roller blind The rear window roller blind is available as either a mechanical or an electric version. Button In the mechanical variant, the roller blind is pulled ● up via a handle and is locked in this position. The electric variant is actuated using a button in the ●...

  • Page 20: Occupant Protection

    Occupant protection Introduction The Passat is equipped with the following airbags: Two-stage driver and front passenger airbags ● Head airbags ● Side airbags (optional in the rear) ● The outer seats are fitted with seat belts with belt tension limiters. Front seat belt pre-tensioners are fitted as standard.
  • Page 21 Belt buckles with belt buckle interrogation are fitted on the driver and front passenger side. The front passenger seat is additionally equipped with seat occupied recognition, which is carried out via a sensor on the seat padding. Belt buckle interrogation and seat occupied recognition serve as a seat belt prompt system.
  • Page 22 Occupant protection The two-stage airbags Two separate igniter circuits and charges are fitted within the two-stage airbags. Both stages are always deployed in the event of an accident. However, the deployment times are staggered depending on the accident severity. In a minor accident, the time between deployment of the two stages is greater than in the event of a severe accident.
  • Page 23 The seat belt pre-tensioners The outer, rear seats in the Passat 2006 are fitted with a new type of seat belt pre-tensioner. Structure: The belt strap is guided through the deflector in the lower area of the C-pillar. It is held by a cable which leads into the seat belt pre- tensioner.

  • Page 24: Engines

    Engines Engine-gearbox combinations Petrol engine 5-speed 5-speed manual gearbox manual gearbox Diesel engine 1.6l/75 kW Petrol engine 1.6l/85 kW FSI engine 2.0l/110 kW FSI engine 2.0l/147 kW FSI engine (turbocharged engine) 1.9l/77 kW TDI engine 2.0l/103 kW 4V TDI engine 2.0l/103 kW 2V TDI engine with diesel particulate filter...
  • Page 25 6-speed 6-speed 6-speed Direct- 6-speed manual gearbox manual gearbox manual gearbox Shift Gearbox automatic gearbox...
  • Page 26 Engines The 1.6l/75 kW engine with 2-valve technology The 1.6l/75 kW engine is based on the familiar 1.6 l/ 75 kW engine with the engine code BGU, which is fitted in the Golf 2004. Special technical features 2-valve roller rocker fingers ●...
  • Page 27 The 1.6l/85 kW FSI engine This engine originates from the Golf 2004. It differs from this only due to its switch to lambda 1 operation and super unleaded RON 95. Special technical features Stratified charge and homogeneous lean operation have been omitted due to the switch to lambda 1 (homogeneous operation).
  • Page 28 Engines The 2.0l/110 kW FSI engine with 4-valve technology The 2.0l/110 kW FSI engine dispenses with stratified charging and the NO sensor system. The abbreviation FSI will be retained. Special technical features ethanol-resistant Hitachi high-pressure pump ● two overhead camshafts with continuous intake ●...
  • Page 29 The 2.0l/147 kW turbo FSI engine with 4-valve technology A further developed turbo FSI engine is to follow on the basis of the 2.0l/110 kW engine. The turbo FSI engine was first launched in 2004 in the Audi A3 Sportback and the Golf GTI. Special technical features single-branch exhaust system with underhood ●...
  • Page 30 Engines The diesel engines All of the diesel engines fitted in the new Passat comply with the EU4 exhaust emission legislation. Optionally, vehicles with diesel engines can be Due to its underhood location, no fuel additive is equipped with a state-of-the-art particulate filter required for soot combustion.
  • Page 31 2-valve technology This tried-and-tested 1.9l/77 kW TDI engine is also installed in the current Golf model and in other Volkswagen models. For installation into the Passat, it has been modified and adapted to the new vehicle. Special technical features switchable exhaust gas recirculation cooler ●...
  • Page 32 Engines The 2.0l/103 kW TDI engine with 2-valve technology and diesel particulate filter The 2.0l/103 kW TDI engine has been developed from the 1.9l/96 kW engine. It was already installed in the Passat model year 2001. Special technical features In comparison with the 2.0l engine in the Passat 2001, this engine has the following special features: diesel particulate filter ●...
  • Page 33 Based on the 2.0l/103 kW 4V TDI engine fitted in the Golf 2004 and Touran, this engine has been further developed for the Passat 2006. Vibrations and noise emissions have been reduced by a balancer shaft module and new unit injectors with piezo-electric valves.
  • Page 34 The unit injector with piezo-electric valve The 2.0l/103 kW 4V TDI fitted in the Passat 2006 will be equipped with unit injectors with piezo-electric valves for the first time. This new development offers the following advantages over the unit injector with solenoid valve: lower noise emissions ●...
  • Page 35 The fuel tank The fuel tank fitted in the Passat 2006 is comprised of two half shells manufactured from a compound of several plastic, adhesive and barrier layers. The two half shells are welded together after the fuel tank's internal breather system has been installed.
  • Page 36 Engines The fuel delivery unit The fuel delivery unit is installed in the fuel tank. The following components are contained within this unit: the fuel pump ● the fuel filter (not in the diesel engine) ● the fuel pressure regulator ●...
  • Page 37 The fuel delivery unit supplies the engine with the precisely required quantity of fuel at the precisely required pressure. It is controlled by the engine control unit according to the fuel requirements. The fuel delivery units differ due to the fuel required by the individual MPI, FSI and diesel engine systems.
  • Page 38 Engines The fuel delivery unit with integrated fuel pressure regulation Fuel pump and fuel regulation initialisation depend on the engine which is installed. The MPI engines The engine's fuel supply is ensured by the constant- delivery fuel pump. The fuel is pumped, counter to the pressure regulator's pressure level, within the fuel delivery unit by the fuel pump.
  • Page 39 The suction jet pumps Suction jet pump Two suction jet pumps are located within the fuel To the additional delivery unit. These have the task of continuously fuel extraction point filling the fuel pump's reservoir chamber with fuel. This reduces the fuel pump's intake consumption, and the fuel pump always has sufficient fuel at its availability.
  • Page 40 Engines The fuel tank for 4MOTION vehicles The external shape of the fuel tank is determined by the available installation space, which is in turn determined by the double wishbone rear suspension and the Haldex coupling. Its function is identical to the fuel tank fitted in front-wheel drive vehicles.

  • Page 41: Power Transmission

    Power transmission The manual gearboxes - overview Gearboxes which are already in use within the Group are fitted as the mechanical, manual gearboxes. The gearboxes have merely been adapted for installation in the new Passat. As these gearboxes have already been described more exhaustively in other self-study programmes, they will only be shown in the form of an overview with a brief description here.
  • Page 42 Power transmission The 6-speed automatic gearboxes 09G and 09M The 6-speed automatic gearboxes set new standards The automatic gearbox with the code 09G has in terms of dynamics and economy in the segment of already proved its worth in the Golf 2004, Touran transversely mounted stepped automatic gearboxes.
  • Page 43 The 6-speed Direct-Shift Gearbox 02E Following its successful, initial launch in the Golf 2004 The gearbox offers the following characteristics: and Touran, the Direct-Shift Gearbox is now also being fitted in the Passat. Six forward gears and one reverse gear ●...
  • Page 44 Power transmission The ignition key withdrawal lock The ignition key withdrawal lock is fitted in vehicles The ignition key withdrawal lock is comprised of the with automatic gearboxes. following components. It prevents the ignition key from being removed if the The selector lever locked in position "P"...
  • Page 45 How it works: Ignition switched on, selector lever in driving position or "N" Driving position or "N" Selector lever S339_102 Resistor If the selector lever is set to a driving position or "N" It supplies solenoid N376 with current and thereby position, switch F319 is closed.

  • Page 46: Running Gear

    Running gear The running gear The running gear fitted in the Passat 2006 will be the Modern, lightweight McPherson strut front benchmark in the mid-size class vehicle segment. This suspensionand the state-of-the-art is achieved by consistent further development of the 4-link rear suspension therefore remain in use.
  • Page 47 However, there are also significant innovations in the The electromechanical parking brake with ● Passat's running gear, e.g. AUTO HOLD function, The new ABS/ESP system from TRW ● (Thompson-Ramo-Wooldrigde) and The tyre pressure monitor system from Hella. ● ● Four-link rear suspension S339_058 ●...
  • Page 48 Running gear The front axle The front axle is the familiar spring strut suspension with lower wishbones. The aluminium subframe is designed in one piece and is joined to the body with 4 bolts. S339_123 The rear axle The front-wheel drive Passat's rear axle is a compact four-link rear suspension in lightweight design. S339_059 The 4MOTION rear axle The 4MOTION rear axle is based on that fitted in the front-wheel drive vehicles and is linked to...
  • Page 49 The steering column The steering column fitted in the Passat 2006 can be adjusted vertically by 60 mm and horizontally by 50 mm. It is equipped with an electric steering column lock. This has enabled the steering lock to be positioned in a crash- optimised area.
  • Page 50 A hydraulic brake servo (HBV), for vehicles with ● 16.l/85 kW and 2.0l/110 kW FSI engines only in combination with automatic gearboxes S339_061 A new brake fluid will be introduced along with the Passat 2006. Please observe the notes in the workshop manual.
  • Page 51 The anti-lock brake system ABS/ESP TRW EBC 440 A TRW ESP system will be fitted for the first time at Volkswagen. In addition to a hydraulic brake assist system, this system includes an AUTO HOLD function as an interface to the electromechanical parking brake, plus a vehicle/trailer stabilisation system and a brake disc wiper.
  • Page 52 A vehicle/trailer stabilisation system will be launched The trailer's pendulum movements are passed on to in the Passat 2006 along with the TRW EBC 440 ESP the towing vehicle. This leads to yawing moments and system. lateral forces which are detected by the yaw rate This function is an ESP sub-system.
  • Page 53 The brake servo - dual rate booster All left-hand drive vehicles will be fitted with an 11" brake servo. The right-hand drive vehicles will be fitted with a 7/8" tandem brake servo. Implementation of the "dual rate characteristics" represents a significant innovation. S339_144 A progressive characteristic curve is achieved thanks to the brake servo's modified internal design.
  • Page 54 Running gear The brake light switch F The brake light switch F is bolted to the brake master cylinder. It is used to detect whether the brake pedal is Brake master cylinder actuated. When the brake pedal is actuated, the brake lights are switched on.
  • Page 55 How it works: On actuation of the brake pedal, the push rod in the brake master cylinder pushes the piston with magnetic ring (permanent magnet). Brake pedal not actuated: When the brake pedal is not actuated, the piston and magnetic ring are at rest. The evaluation electronics of brake light switch F transmit a signal voltage of 0 - 2V to the engine control unit and the vehicle electrical system control...

  • Page 56: The Brakes

    Running gear The brakes Engine Front brake Rear brake in mm in mm Ø 312 x 25 Ø 286 x 12 75 kW 118 kW S339_140 S339_138 Bolted swivel bearing Ø 345 x 30 Ø 310 x 22 as of 132 kW S339_141 S339_139...
  • Page 57 The automatic levelling system The Sachs automatic levelling system is a self-inflating shock absorber which will be installed on the Passat's rear suspension instead of the conventional shock absorber. It will be available as an optional extra at a later point in time.
  • Page 58 Running gear The wheels and tyres Summer tyres Wheel 205/55 R16 91 H/V Steel 6.5J x 16 ET 42 mm Alloy 215/55 R16 93 H/V Alloy 7J x 16 ET 45 mm 235/45 R17 74 V Alloy 7.5J x 17 ET 47 mm Winter tyres (suitable for snow chains) 205/55 R16 91 H/V...
  • Page 59 The self-supporting tyre Self-supporting tyres will be introduced in the This is made possible by a special side wall Passat 2006. These Bridgestone RFT tyres (Run Flat reinforcement and innovative, extremely heat- Tyre) remain stable even in the event of full pressure resistant rubber compounds.

  • Page 60: Electrical System

    The installation locations The vehicle electrical system in the Passat 2006 has a decentralised structure and is therefore comparable to that in the Golf 2004. Due to the multitude of electrical consumers, the Passat has an additional fuse box on the right-hand side of the dash panel.
  • Page 61 S339_062 Relay holder on the vehicle electrical system control unit For more detailed information on the Fuse box, electrical system, please refer to self- left of dash panel study programme 340 "The Passat 2006 electrical system".
  • Page 62 Electrical system The networking concept To ensure flawless data exchange between the individual control units, these are networked via various data bus systems. The data bus diagnostic interface J533 (gateway) acts as the interface for the following data buses: ● CAN powertrain data bus CAN comfort data bus ●...
  • Page 63 Legend Ignition/starter switch E221 Operating unit in steering wheel Steering angle sender G273 Interior monitoring sensor G384 Vehicle inclination sender G397 Rain and light detector sensor G419 ESP sensor unit Anti-theft alarm system horn J104 Control unit for ABS J136 Seat and steering column adjustment control unit with memory function J217...
  • Page 64 Electrical system The inverter An optional 230 V/50 Hz European socket can be ordered for the Passat 2006. An inverter, which is firmly connected to the socket, is installed in the vehicle to generate the alternating voltage. This unit is located in the rear centre console instead of the cup holder.
  • Page 65 Entry and start authorisation switch E415 The entry and start authorisation switch is part of the The emergency key serves drive authorisation system. to mechanically unlock the driver's door if the ● The ignition key is designed without a key bit, as the vehicle cannot be opened using the radioremote vehicle is started by pushing the key rather than control,...

  • Page 66: Heater And Air Conditioner

    The main difference is in air distribution flap actuation. 2C-Climatronic is fitted with an additional Two different systems are available in the fresh air/air flow flap. Passat 2006: The semi-automatic heater and air conditioner ● "Climatic" The heater and air conditioner 2C-"Climatronic".
  • Page 67 Operation Different control panel versions are available depending on the equipment fitted in the vehicle: with or without instant heat button for the auxiliarycoolant heater ● with or without potentiometer for the seat heating ● with or without potentiometer for the heated windscreen ●...
  • Page 68 Heater and air conditioner The 2C-Climatronic system In the 2C-Climatronic system, the interior is sub- divided into two climatic zones. This means that the temperatures desired on the driver and front passenger side can be set independently of each other in the range from 16 °C to 29.5 °C. The climatic zones are separated by two temperature flaps inside the air conditioner unit.

  • Page 69: Indirect Ventilation

    Indirect ventilation Manual actuation Indirect ventilation 2C-Climatronic is equipped with indirect ventilation. An adapter positioned on the top of the air conditioner unit enables air distribution between the vents in the centre of the dash panel and indirect ventilation via the electrically driven air flap for indirect ventilation.
  • Page 70 Heater and air conditioner The Thermo Top V auxiliary heater The new Passat can be fitted with the optional Thermo Top V auxiliary coolant heater. The auxiliary heater is installed in the front right wing below the headlight. This undertakes the following tasks: Acts as an auxiliary heater for heating the vehicle interior and defrosting the vehicle's windows ●...
  • Page 71 Structure ● The auxiliary coolant heater control unit is integrated into the heater unit. The electrical contacts for the combustion air blower are inserted directly into the control unit. The auxiliary coolant heater is fitted with a second NTC temperature sensor for controlling and monitoring the ●...

  • Page 72: Radio And Navigation

    Driving school function (indication of turn signal ● function and speed via the display) Radio RCD 500 Radio RCD 500 in the Passat 2006 offers the following functions: Four loudspeaker channels (20 Watts each) ● RDS FM/AM European radio (AM without LW) ●...
  • Page 73 Radio/navigation system MFD 2 A radio system with an integrated navigation system is also available for the Passat 2006. The operating sequences are similar to those of the radio/navigation system fitted in the Touareg. It offers the following functions, etc.: Multi-colour display (MFD) ●...
  • Page 74 Notes...
  • Page 76 © VOLKSWAGEN AG, Wolfsburg All rights and technical changes reserved. 000.2811.54.20 Technical status 03.2005 Volkswagen AG Service Training VK-21 Brieffach 1995 D-38436 Wolfsburg ❀ This paper has been manufactured from cellulose bleached without the use of chlorine.

Table of Contents