Chassis. The four

Chassis. The four

Chassis. The four-link front axle. The rack and pinion steering

Chassis. The four-link front axle. The rack and pinion steering

November 15, 2017 | Author: Jürgen Bieber | Category: N/A DOWNLOAD PDF (2.4MB) Share Embed Donate Report this link

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1 Chassis The four-link front axle The FRONT AXLE is designed as four-link. It is the modified Fa…


Chassis The four-link front axle The FRONT AXLE is a four-link design. It is the changed vehicle dimensions. Adapted to the changed axle loads compared with the previous Passat.

Bearing block

Tubular subframe


Rack-and-pinion steering The new Passat has HYDRAULIC SERVOLENGING as standard .


Chassis The twist-beam rear axle On the twist-beam rear axle, the spring/damper tuning has been adapted to the changed axle loads.

Shock absorber

Wheel bearing unit coil spring


Rear axle bearing

Changed offsets The offsets of the rims have been reduced from 45 mm to 37 mm. This ensures that the wheel is flush with the outside of the vehicle body. Winter wheels may continue to be used with offset ET45. An exception is the Passat 2001 with the large brake disc. It has a winter wheel size 6Jx16 ET40.

Offset 37 mm


Offset 45 mm

Chassis The brakes The equipment of the front and rear disc brakes has been dimensioned so that the vehicle achieves very good deceleration values during braking. Therefore, with the new Passat, depending on the engine, new, larger brakes are used.

Front disc brakes ● 280 x 22 mm ● 288 x 25 mm ● 312 x 25 mm Rear disc brakes ● 245 x 16 mm ● 256 x 22 mm ● 269 x 22 mm


Anti-lock braking system Bosch 5.3 The new Passat also has the Bosch 5 antiblokki system.3 with ESP installed. This ensures that the driver can control the vehicle at all times, even in tricky driving situations.


Chassis The electronic vacuum pump The electric vacuum pump for brake booster is used for all gasoline engines with automatic transmission and exhaust emission standard EU4.

It is needed: Because not enough vacuum is provided for brake boosting via the intake manifold during the cold-start phase.


The electric vacuum pump ensures pneumatic brake boosting. For this purpose, it is controlled on demand via the engine control unit.


More detailed information is available in a separate SSP for the electric vacuum pump.

Chassis All-wheel drive The double-wishbone rear axle In the all-wheel-drive version of the Passat, a double-wishbone rear axle is installed with a closed tubular subframe to which the wishbones for wheel control and the differential gear are attached.

The flat design of the rear axle allowed a very good amount of space. This design has already proven itself on the predecessor model.

A good acoustic decoupling from the body was achieved by the insulating rubber-metal bearings.

Suspension strut

Subframe upper wishbone

Rubber bearing

Lower wishbone Gearbox


Cardan shaft

Torsen gear 251_093

Chassis notes

Electrical system The electrical system is decentralized, as in the Passat 97. The installation locations of the fuse holder, relay carrier, additional relay carrier and coupling stations have been adopted unchanged.

Control unit for airbag (transmission tunnel)

The wiring harnesses have been modified due to the use of new systems (solar roof, distance control, dynamic navigation with TV, etc.).) and the clutch stations have been rearranged accordingly.

Coupling station A-pillar right

RNS-D radio with dynamic navigation

Control unit for automatic transmission (footwell on right)

E-box in the water tank – engine sterer unit – relay station – coupling station – fuses plug connection front end

Window regulator motor with integrated door control unit Control unit for distance control (trunk right)

TV tuner CD changer DSP

Window lift motor with integrated door control unit


Switch panel insert with control unit for immobilizer and diagnostic interface (gateway)

Coupling station A-pillar left

Fuse holder switch panel left

Comfort control unit in footwell left

Electrical system Headlights Standard headlights Two types of headlights are available for the new Passat. Basic equipment consists of a DE headlight in clear-glass look with an H7 bulb as high beam.


DE = Three-axle ellipsoidal headlamp Turn signals

High beam (H7 lamp) Low beam

Gas discharge headlamps (GDL) with bi-xenon light As an optional extra, a bi-xenon headlamp is installed instead of the normal DE headlamp. In this headlight module, both the low beam and the high beam are generated by a gas discharge lamp. The high beam is boosted by an H7 lamp, which also bridges the time until the gas discharge lamp has reached its full luminous intensity. The H7 lamp is also used for the headlight flasher function.


H7 lamp (additional high beam)

Turn signal

For driving in countries with left-hand traffic, both headlamps can be switched from asymmetrical to symmetrical dipped beam light. Please note the information in the repair guide.


Gas discharge lamp (low and high beam)

Electrics More light for more safety The Passat model year 2001 features the bi-xenon headlamp system. The improved light output of the system increases active driving safety because hazards can now be detected earlier.

Wider and brighter illumination of the surroundings allows hazards to be detected earlier and the vehicle to be braked sooner. Thus, if the driver reacts in time, the braking distance ends before the source of danger, so that an accident is avoided.

Speeds: Car: 50 km/h Wheel: 25 km/h

Stopping distance 28m

A) Represents the time saved by bi-xenon. In this example exactly 1 s.


Without xenon light 251_020

Without Xenon light, the cyclist is seen much later.

With xenon light 251_021

With xenon light, the cyclist is seen earlier and the car driver can still brake in time.

Electrical system Structure of a bi-xenon headlamp module The headlamp module consists of: ● ● ● ● ●

The electronic ballast (EB) the servomotor for headlamp levelling the conventional bulbs the gas discharge lamp module the housing with bonded clear glass pane

251_006 251_067


Until now, it was not possible to produce both low and high beam with only one gas discharge lamp. It was not possible to change the cut-off line during operation. Xenon low beam and high beam is made possible by the use of a mechanical shutter, which is adjusted by an electromagnet.

This mechanism shields part of the light generated in the lamp for the low beam. In the high beam position of the mechanical system, all the light generated in the lamp is transmitted.

Reflector lens

Gas discharge lamp




The screen shields part of the generated light cone. (Cut-off line)


For high beam, the diaphragm is adjusted electromagnetically. The entire light cone becomes effective. In addition, the H7 lamp is also switched on.


Legal requirements If gas discharge headlamps are used in a vehicle, the following additional devices are mandatory to prevent other road users from being dazzled: ● a headlamp cleaning system ● an automatically operating headlamp levelling system

Electrics Automatic dynamic headlamp levelling (LWR) The Passat 2001 with bi-xenon headlamps is equipped with automatic dynamic headlamp levelling. Task The automatic-static headlamp leveling system is to adjust the headlamps due to a change in the body caused by the load.

With automatic dynamic headlamp leveling, headlamp leveling changes caused by dynamic vehicle changes, for example, during braking and acceleration, are also compensated for.

The headlamp levelling system consists of: Kl. 15 Kl. 31 Stepper motor right V49

Kl. 56 Control unit for headlamp leveller J431 in left trunk

Encoder for vehicle level G76 and G78


Stepper motor left V48

Speed signal Self-diagnosis Input signal Output signal

+ Mass

Function: The J431 headlamp levelling control unit receives signals from two level sensors (one on the front axle, one on the rear axle) and the speed signal. After evaluation of the signals, the servomotors in the headlights are controlled. Thus vehicle level changes are compensated.

The headlamp adjustment motors are stepper motors with an adjustment speed of approx. 1 second for the complete control range executed. The control unit is diagnosable. Can be addressed via address word 55.

Electrics The switchboard insert The switchboard insert is the familiar Group switchboard insert with blue illumination and red pointers in through-illumination technology.

The switch panel insert is offered in three variants. They differ mainly by the display options in the center display.

The modified design with instruments edged in chrome is conspicuous. The instruments are now operated by stepper motors.

Center display

Selector lever range indicator


New functions

● Integrated control unit for third-generation immobilizer (see immobilizer) ● Connection to CAN data bus, d.H. Shift panel insert is connected to CAN drive data bus. CAN comfort data bus connected. For example, the tachometer is controlled via signals from the CAN drive and the status of the doors/lids can be displayed in the control panel insert via CAN comfort.

● Diagnostic interface (gateway) as interface in the control panel insert is necessary for communication of the various CAN data buses. It is also used to convert diagnostic data via CAN to the K lines (see CAN networking).

Electrical system New indicator lamps: Designation

Selector lever lock K169

Serves to prompt the driver to apply the brake. This releases the selector lever lock on automatic transmissions

Indicator lamps for doors/cover open (K116/K123-K127)

Indicates open doors/lids. Is executed as a symbol on vehicles with multifunction display.

"Cruise control system switched on" K31

Lights up when the cruise control system (GRA) is switched on. Only for vehicles with cruise control system.

Exhaust gas warning light K83

If a fault occurs in the vehicle that worsens the exhaust quality, the fault is stored in the fault memory and the exhaust warning light is switched on. If the catalytic converter can be damaged by combustion misfires, the exhaust gas warning lamp flashes.

Electrical system Third-generation immobilizer function The first phase (key detection) is identical to the immobilizer II function. What has changed is the communication between engine control unit. Control unit for immobilizer. The engine control unit also randomly generates a number (change code).

In the engine control unit and the immobilizer control unit, the result is calculated on the basis of a formula table. The result is sent back from the immobilizer control unit. In engine control unit compared with own result. This communication is carried out via CAN data bus. If they match, engine start is enabled.

Control unit for immobilizer

CAN data bus 251_037

General notes:

● The keys are marked W3. ● For customer service, the process of teaching the keys has not changed. The keys are electronically locked during teach-in. Thus they cannot be used on any other vehicle. ● When replacing the individual components, the adjustment procedure has changed.

Electrics Networking of CAN systems

Engine control unit

Injection pump (V6-TDI)

Transmission control unit

Brake control unit (ABS, ESP,…)

CAN drive

Airbag control unit

Steering angle sensor (for ESP)

CAN comfort radio (double DIN US market)

Fuel tank sensor (B5-W8 only)



Multifunction steering wheel

Door control unit driver

Door control unit passenger

CAN comfort

CAN infotainment seat driver (memory)

Comfort control unit (ZM or ZV)

Rear left door control unit

Door control unit rear right


CAN infotainment on CAN comfort (physically the same CAN) ECUs are directly connected to the diagnostic connector. Control units are connected directly via the gateway to the diagnostic connector.

The diagnostic interface (gateway) is integrated in the control panel insert and has the following tasks: ● Converting diagnostic data from the CAN drive and CAN comfort data bus to the K-line so that it can be used by the self-diagnostics system. This allows self-diagnosis of certain systems in the first place (the memory seat, for example, does not have its own K-line). ● The communication/data exchange between the participants of a data bus. To enable between the participants of different data bus systems.

The gateway has to be informed about the CAN participants via the function "encode ECUs.

All control units from the drivetrain are connected to the CAN drive (Highspeed). All control units for comfort systems are connected to the CAN comfort and CAN infotainment (physically a data bus = low-speed). The transmission rate with CAN high-speed is 500 kBaud, with low-speed 100 kBaud, i.E. Per second 500 000 or. 100 000 bits transmitted.

The address word for the gateway controller is 19.

Electrics Comfort system The comfort system has been changed in the following points: ● Radio remote control as standard with additional button for remote trunk lid release (HDF) ● The locking cylinder on the passenger side has been omitted. ● New locking concept for the trunk lid The trunk lid is unlocked via: – the button in the new switch unit of the driver's door. This function can be disabled via the key switch. – the handle switch in the trunk lid. This function can be locked via the key switch in the trunk lid. – the radio remote control.

Switch unit of the driver's door


Closing concept for rear lid


The key switch in the non-visible area of the tailgate performs three tasks: 1. Basic position The trunk lid can be opened via the handle button.

2. Workshop position In this position, the tailgate cannot be opened via the handle switch.

3. Mechanical emergency opening


Grip switch

Key switch

The CAN data bus in the comfort system (low-speed) introduced in the Passat '97 has been modified in the following points: – The transmission rate has been changed from 62.5 kBaud to 100 kBaud. Connection to CAN comfort data bus. Thus also connection to the control panel insert. This allows, for example, an open door to be symbolically represented in the switch panel insert.

Electrical system Memory seat The electronic seat adjustment system has been improved in the following respects: ● The memory control unit is now equipped with a read-only memory, which means that the stored seat positions are retained when the battery is disconnected. ● After a disconnected battery, the seat does not need to be initialized again. ● The sound generator serves as a confirmation signal after the seat position has been saved. It is no longer installed in the memory control unit, but is activated via CAN data bus in the control panel insert. Electrical system sliding roof/solar roof The solar roof generates electricity via integrated solar cells. In conjunction with the vehicle's own fan, cools the interior by approx. 20°C from. The system works when the ignition is switched off and with the or. Raised sliding roof. A direct current converter (DC/DC converter) is mounted on the underside of the sliding roof. The DC/DC converter is used to match the current/voltage between the solar generator (solar module) and the vehicle blower motor. It converts the high voltage and low current supplied by the solar module into a low voltage and high current, since the vehicle blower motor requires a very high starting current.


An electronic circuit in the DC/DC converter supplies the blower motor only from the specified voltage of 2 volts onwards. This prevents bearing damage.

When the ignition is switched off, the contact is in this position so that the fresh air blower is supplied with voltage from the solar roof.


+ from the blower controller Kl.15 Contact switch for solar operation F288

Isolating relay for solar operation J309


Solar cells C20

Control unit for solar roof J355 Fresh air fan V2 Contact switch in sunroof F289 251_035

Electrics Distance distance control (ADK) Distance distance control (ADK) facilitates parking when the vehicle is reversing. Four ultrasonic transducers are installed in the bumper area for this purpose. The control unit is located in the left rear trunk, the sound generator is installed under the parcel shelf in the sedan and in the control unit in the Variant. Control unit

Ultrasonic transducer

Sound generator

The distance warning starts at a distance of 1.60 m to the obstacle with an acoustic signal. The frequency of the audio signal changes with decreasing distance to the obstacle. A continuous tone signal sounds below a distance of 20 cm.

Switch reverse


The system becomes active as soon as the ignition is switched on and reverse gear is engaged. 251_002

Continuous tone

Variable audio signal


Electrics Radio navigation system Explanation of terms

Radio navigation system MFD with dynamic route influence Basis of the traffic data used is the RDS-TMC service which is supported by radio broadcasting stations (soon Europe-wide). By using a RDS-TMC control unit, a radio station can be freely selected for receiving the data. This means that TMC data reception and normal radio reception are done with different receivers.

● MFD = Multifunction Display ● RDS = Radio Data System ● RNS – High/D = Radio Navigation with 5" screen and D for dynamic navigation ● TMC = Traffic Message Channel ● CAN = CAN bus with manufacturer specific protocol, is not compatible with VW specified CAN data bus protocol ● GPS = Global Positioning System

All traffic messages within a radius of approx. 200 km are taken into account. If the dynamic navigation function is activated due to the traffic situation, the driver will be informed by the announcement: "The route will be recalculated taking into account traffic information!" Informs. Traffic obstructions (closures, traffic jams, and gridlocked traffic) are visualized on the map and can be read as text messages.

3-wire bus

RNS High/D with tuner 251_096


RDS-TMC tuner control unit antenna

A radio navigation system with dynamic route guidance is also offered as a two-color display (low-end). With this device the RDS-TMC tuner is integrated in the radio navigation device.

Electrik radio navigation with dynamic route guidance Dynamic route guidance ● Automatic rerouting around traffic disruptions ● Evaluation of the traffic disruption (full closure, traffic jam, slow-moving traffic), the basis is the remaining travel time to the destination ● No driver intervention required, the driver can concentrate fully on the traffic.

Unlike older systems, which can only display the position of the vehicle on the selected route (static), the new navigation device additionally displays information on the traffic situation and updates the selected route accordingly (dynamic).

The unit constantly collects traffic data, even when the ignition is switched off. In this way, traffic information is constantly available and can be retrieved as needed. Traffic information is available in text form, graphically or as spoken information. Since the received traffic data is first converted into speech in the device, the traffic messages are available in different languages. The dynamic navigation is addressed with the same address word as the normal navigation system (37). For the vehicle navigation, a GPS receiver. A direction sensor installed in the vehicle. With the help of the acquired data and a digital map, the position of the vehicle is determined and displayed. The destination guidance function allows navigation to a previously entered destination. By processing the digital traffic information broadcast by radio stations, it is possible to avoid disruptions in the traffic flow. Only the destination input is required as a user intervention.

Electrical TMC services What is a TMC service??

Public and private

A TMC (Traffic Message Channel) service is the sum of all activities undertaken by a service provider to broadcast traffic messages. All the user needs on the road then is an RDS-TMC receiver.

TMC services for general traffic information are freely available in all European countries. These messages are related to traffic safety. Different traffic disturbances. Europe's free and public services will be grouped under the term "ALERT service. Other TMC services will not be free. These services refer to value-added information or messages for special user groups.

Services in Europe European TMC services – public and private – are already in operation. With the beginning of the year 2000, there is a network that covers the whole of Europe. Each service refers to a country in which it covers part of the country or the entire country. According to an agreement, all national or international service providers send cross-border messages for long-distance drivers. How the TMC services work ● All highway sections. Important federal roads have received identification numbers (TMC Location). ● Traffic events (blockage, congestion, stalled traffic) have event codes (TMC events) associated with an indication of the extent (z.B. Congestion length). ● The navigation computer can refer (map) the TMC locations and events via a conversion table to its map material used for navigation purposes. ● All data is sent in the same way throughout the country.


● As soon as parts of the route to be driven are affected by traffic disruptions, the performance of the route section is reassessed. During the following recalculation of the route, a bypass route is used if necessary.

Electrics Radio navigation system with TV The TV function is an advanced function of the navigation device. All terrestrial programs can be received. Terrestrial programs are all programs that are received by means of the normal antenna and not by satellite.

The device already includes a facility for connecting external devices, such as a video recorder or a notebook computer. This connection is however z. Zt. Not available to the user. The TV is inactive while driving.

The device knows all current broadcasting standards such as PAL, NTSC or Secam. The appropriate transmission standard for reception at the delivery location is set at the factory. Teletext is also possible.

The TV tuner has a self-diagnosis function via address word 57.

The current available stations are detected automatically. The device itself ensures the best possible reception. If the vehicle drives out of the transmission range, for example into a radio hole or a radio shadow, the device is automatically muted (automute). In the sedan, the antenna for the TV tuner is located in the rear window. In the Variant in the two side windows at the rear.


Electrics Telephone preparation For the Passat 2001 a preparation for cell phone is available. The holder for the cell phone is mounted on the dashboard. The cell phone is then connected to an interface box, which is installed under the armrest. The interface box is the interface between the cell phone, onboard network and antenna. If the cell phone is plugged into the cradle, calls can be made via the hands-free system. The radion is automatically muted during phone calls. Dialing can be done directly on the cell phone. If the cell phone has a corresponding device, voice dialing is also possible. The cradle is offered in two versions.


Electrics Heating and air conditioning The Climatronic air conditioning system has been given an additional temperature sensor compared with the predecessor model. The temperature sensor is installed in the air duct behind the evaporator. Is called G263 sensor for outlet temperature evaporator. It constantly reports to the Climatronic control unit the air temperature behind the evaporator.

Signal from the temperature sensor to the control unit

Climatronic control unit (behind the operating unit)

Another innovation for the Climatronic is: The Climatronic control unit gets a signal from the wiper motor. If the wiper motor is running, the blower output and the temperature are raised slightly to prevent the windshield from fogging up. Windscreen wiper system



Thus the outside temperature (G17 and G89) and the air outlet temperature behind the evaporator are checked and the control unit can control the compressor cut-off more accurately. The interior is better dehumidified since the air is dried more strongly. The fogging of the windows is prevented as far as possible.



Self-diagnosis If the temperature sensor is defective, an entry is made in the fault memory of the control unit. The signal from the sensor can be checked in the self-diagnostics measurement block.

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