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Glossary

Palmela

municipality

Portugal

Spain

S355_043

ALMELA

Palmela is a small town in the municipality of the same

name in the district of Setúbal. This historical and very

old town in the west of Portugal today has a

population of around 16000.

HERMOFORMED

SHEETS

In thermoforming (e.g. forging), the metal lattice is

recrystalised during the shaping process. The

recrystalisation prevents embrittlement and avoids a

reduction in the tenacity of the workpiece as occurs

during cold forming.

Summary of Contents for EOS 2006

Page 1: ...Service Training Self study Programme 355 The EOS 2006 ...

Page 2: ...st Beetle Cabriolet and continued in 1979 with the Golf Cabriolet and in 2003 with the New Beetle Cabriolet Unlike its predecessors the Eos is not derived from another model it is an independent development that unites the characteristics of different vehicle types and heads in a totally new direction in terms of roof technology Together with the values of quality comfort safety and engines the Eo...

Page 3: ...rief 4 Body 8 Occupant Protection 39 Engines 41 Transmission 47 Chassis 48 Heating and Air Conditioning 50 Electrical System 53 Convenience Electrics 55 Radio and Navigation 56 Service 58 Glossary 59 Contents ...

Page 4: ...anus every morning and travels ahead of Helios in his chariot as he rides across the sky to herald the new day Homer praises her beauty and her grace and describes her as a wonderful beautiful and curly haired goddess The Eos from Volkswagen combines the everyday and all year round suitability of a coupé with the classic open top driving characteristics of cabriolets without their disadvantages li...

Page 5: ...interior comfort thanks to 12 way electrically adjusted seat with electrical easy entry function Rear seat system with through load option Generous boot volume when roof closed Extensive safety concept with driver front passenger and head airbags and active rollover protection system High torsional stiffness Low level of wind noise High end sound system from Dynaudio ParkPilot with boot lid assist...

Page 6: ...Wheelbase 2578mm Track width at front 1545mm Track width at rear 1553mm Technical data Exterior dimensions and weights Weights when equipped with 3 2l 185kW V6 engine Maximum weight 2090kg Curb weight 1713kg Cd value as coupé 0 315 S355_003 S355_002 S355_001 4407 2578 1791 1545 1553 1443 ...

Page 7: ...ne Coupé boot volume 380l 358l Cabriolet boot volume 205l 183l Tank capacity 55l Interior dimensions Interior length 1684mm Front shoulder width 1390mm Front headroom 952mm Rear shoulder width 1055mm Rear headroom 909mm Interior dimensions S355_005 S355_004 S355_006 ...

Page 8: ...ponents are made from highest strength sheets Inner A pillar Seat consoles Sills Rear longitudinal members Highest strength tubes are fitted in the upper area of the doors and under the rear seat bench Thermoformed sheets are used in the front bumper cross members in the A pillar reinforcements and in the front windscreen frame in the door reinforcements Body structure Legend Normal sheets with a ...

Page 9: ...ent of the rear panel they are mainly in the introduction of a supporting front underbody capsule made from aluminium and diagonal struts mounted in the rear area The underbody capsule and diagonal struts are bolted The underbody capsule connects the front subframe to the longitudinal members Together with the diagonal struts this creates an additional reinforcing level and thus increases the tors...

Page 10: ...s The Eos has an additional cross member for pedestrian protection that has a deformation element made from foam The deformation element absorbs a large proportion of the energy in a collision so that the risk of severe leg injuries is reduced In terms of car crash safety we distinguish between three different load levels that have to absorb the forces in an accident The upper load level is formed...

Page 11: ... deformation at the point of impact is reduced as the forces affect a larger area On the Eos in frontal and side collisions the forces are distributed broadly across the centre and lower load levels thanks to the reinforcing and stiffening measures on the side and floor structure so that maximum protection for occupants is guaranteed even when the roof is open Absorption of force in side collision...

Page 12: ...nual 2 way lumbar support The next equipment version up is the mechanical 8 way seat with electrical 2 way lumbar support and manual easy entry function The top of the range version is the electrical 12 way seat with electrical 4 way lumbar support and electrical easy entry function On this front seat you can also adjust the seat tilt electrically S355_162 ...

Page 13: ... rear seat bench has two pairs of Isofix anchors and three point seat belts with belt force limiters as standard A lockable through load facility which is also standard allows you to transport skis for example Brackets for securing a first aid kit are integrated in the lid of the through load facility Once the lid has been removed you can reach the emergency boot release Rear seat bench S355_021 S...

Page 14: ...deflector fits into the mountings provided It covers the rear seat bench completely up to the head restraints Finally the partition section folds up towards the front seats and locks into place The wind deflector reduces the formation of turbulence It also helps keep the rear seat bench clean Wind deflector Unfolding wind deflector Airflow with wind deflector S355_018 S355_037 S355_019 ...

Page 15: ... place A microswitch checks if the cover is positioned correctly If the luggage cover is not closed a warning signal will sound and warning message will appear in the dash panel insert display to inform the driver about the problem Stickers on the left hand and right hand side of the boot and on the luggage cover inform you that nothing may be stowed there as the roof side members and roof mechani...

Page 16: ...er also provides ventilation and light when you are driving the car as a coupé The CSC roof and the externally running sunroof are operated using a switch in the centre console When the roof is operated the CSC roof segments are placed one on top of each other in a sandwich and are stored in the boot To support the driver when the roof is retracted the Eos Park Assist system is supplemented with t...

Page 17: ...id with the necessary locking and unlocking processes is also carried out by hydraulic cylinders The boot lid mechanism is basically made up of the following components the boot lid the boot lid hinges the mounting frame 2 hydraulic cylinders on each side of the car the boot lid lock All in all the complete movement procedure to open and close the CSC roof is a complex interaction of individual mo...

Page 18: ...ng frame 4 When the roof is operated different lids and flaps are opened or closed while the CSC roof is stowed away completely or closed again These movements like the locking and unlocking of roof components are also carried out by a clever system of mechanical couplings with the help of rods and Bowden cables via the Eos hydraulic cylinder When the roof is operated parts of the interior panelli...

Page 19: ... the M segment 3 Hydraulic cylinders in the boot lid hinges Carrying out the swinging movement of the boot lid Opening and closing the roof side member flaps via cables 4 Hydraulic cylinders in mounting frame Locking and unlocking the mounting frame to from the boot lid for roof movement Unlocking or locking the mounting frame from to the body when roof completely open or closed Opening and closin...

Page 20: ...lation position and stops there Pressing the switch again for less than 0 5 seconds starts a second automatic run that opens the sunroof completely If you press the switch for longer than 0 5 seconds when the sunroof is closed a manual run is started The sunroof opens manually for as long as the switch is pressed Once it passes the ventilation position the control unit switches to automatic mode a...

Page 21: ...t lid the sunroof is not driven by hydraulic cylinders but by an electric motor the sliding sunroof motor V1 It is located centrally at the rear of the M segment and is connected to the ESS module via two pairs of flexible shafts One shaft pair moves the sunroof upwards to the ventilation position The other pair of shafts opens the sliding inner headliner S355_054 Electrical drive in M segment Sli...

Page 22: ...at the bottom of the folded roof package that is transported to the boot by the main drive The sliding sunroof is on top of the M segment and the C segment is placed on top of that The roof package is only moved by the main drive once the sunroof and C segment have reached their final positions on top of the M segment and the boot lid along with all necessary flaps have been opened S355_053 S355_1...

Page 23: ...r windscreen The segment is connected to the roof frame via a four link mechanism The C segment is moved by two separate hydraulic cylinders one in the left hand roof side member and one in the right hand roof side member S355_051 Four link mechanism Rear windscreen S355_116 S355_111 ...

Page 24: ...cylinder in the boot lid mounting frame unlocks the C segment in the lower section The hydraulic cylinder in the roof side member unlocks the C segment in the top section The C segment is then swung over the M segment by the hydraulic cylinders in the roof side members Latch in top section open closed Latch in lower section open Latch closed Latch Striker on C segment Roof side member S355_148 S35...

Page 25: ...mponents as well as the boot lid The main drive is basically made up of the following components and modules on each side of the car the main hinge the hydraulic cylinder in the main hinge the roof side member incl various guide rails connecting rods and latches the hydraulic cylinder in the roof side member the roof side member panelling the sensors Main drive S355_059 Main hinge Hydraulic cylind...

Page 26: ...e the C segment is opened by the two hydraulic cylinders the two latches holding the roof side members to the A pillars are released desmodromically The boot lid is moved to the open position by its hydraulic cylinders The roof side member flaps are opened by this movement with the help of cables Lock roof side member to A pillar Unlock roof side member from A pillar S355_060 ...

Page 27: ...side member outwards If the roof package is raised out of the boot to close the roof the gate is pushed to the front again inside the roof side member by the lever system This movement swings the roof side members towards the inside again so that the roof side members can dock onto the A pillars S355_062 Outside of main drive Gate moves towards the front and pulls roof side member inwards Roof sid...

Page 28: ...e tail as show in the diagram This is possible thanks to the boot lid being connected to a mounting frame on each side A hydraulic cylinder is fitted on each side of the mounting frame The unit consisting of the boot lid and mounting frame is mounted on the body via the boot lid hinges There is a hydraulic cylinder in each boot lid hinge The boot lid is connected to the mounting frame via the boot...

Page 29: ...y space These two opposing movements are made possible by the two independent hinges Furthermore the covering flaps over the mounting frame mechanism are opened and closed The hydraulic cylinders in the boot lid hinges now carry out the movement of the boot lid and open or close the roof side member flaps with the aid of Bowden cables Boot lid hinge Boot lid hinge Open covering flap Mounting frame...

Page 30: ... lid can now be opened again normally During roof operation the boot lid cannot be opened When the roof is not being opened or closed the boot lid can be opened normally for example to stow away luggage The boot opens and closes manually closing is supported by a power latching system S355_058 S355_057 b a Boot lid connecting rods Boot lid during boot usage Boot lid during cabriolet roof operation...

Page 31: ...t the roof package is only stored away when the roof side member flaps are open These flaps close the opening that is occupied by the C segment latch to the boot lid when the roof is closed The covering flaps are on the boot lid and are each operated by the hydraulic cylinders in the mounting frame via a Bowden cable If the roof is closed the flaps will be in the open position They are covered by ...

Page 32: ...of the C pillars via a complex system of cables and deflector lugs The interior panels of the roof side members are also shortened by cables and deflector lugs S355_025 Panel for left hand roof side member Panel for right hand roof side member Tensioned headliner Roof side member panel Roof corner panel Sliding inner headliner Lower trim for rear windscreen frame Lower trim for rear windscreen fra...

Page 33: ...uide spring Moving tensioned headliner The tensioned headliner is folded in a controlled method when the CSC roof is opened The tensioning tapes 1 2 3 and 4 on each side of the car are used for this Rubber cord 5 is used as a guide for tensioning tape 4 Precise laying and fastening of the tensioning tapes is the requirement for perfect and lasting operation of the CSC roof Make sure you read the r...

Page 34: ...temperature sensor on the hydraulic pump monitors the temperature of the hydraulic fluid Legend Hydraulic cylinders 1 in left hand main hinge 2 in left hand roof side member 3 in left hand boot lid hinge 4 in left hand boot lid mounting frame 5 in right hand main hinge 6 in right hand roof side member 7 in right hand boot lid hinge 8 in right hand boot lid mounting frame a Sunroof module b M segme...

Page 35: ...se conditions are met the side windows will first start to lower This is necessary because the roof package would otherwise collide with the rear side windows when it is lowered At the same time as the side windows move the sunroof starts to open and move over the M segment S355_075 S355_076 C segment opens Once the side windows have passed a defined position the movement procedure of the C segmen...

Page 36: ...tors that the flaps are fully open Once the C segment opens the two roof side members are unlocked from the A pillars A sensor in each roof side member confirms that they are unlocked S355_077 S355_143 Boot lid and roof side member flaps open Unlock roof side members S355_079 S355_078 The main drive now swings the roof package to the rear The roof side members also swing outwards Two sensors in th...

Page 37: ...y in the open or close direction Once the roof package has reached its final position in the boot the boot lid and the roof side member flaps start to close Once the mounting frame is locked to the body and has been unlocked from the boot lid the boot can be opened normally again Upon completion of the roof operation the side windows are raised again S355_080 S355_082 Boot lid and roof side member...

Page 38: ... dash panel insert display The roof movement is interrupted The procedure can however be continued despite the warning if you press the roof switch again Just before the boot lid is lowered into the sensor scanning area the Boot Lid Assist is deactivated as it cannot distinguish between the boot lid and a real obstacle This means that if an obstacle appears after this point in time for example ano...

Page 39: ...sions The front passenger airbag can be deactivated with a key switch in the glove compartment The front seats have 3 point seat belts with belt force limiters and pyrotechnic belt tensioners The two rear seats have 3 point belts with belt force limiters but without belt tensioners The airbags and belt tensioners can only be activated for 150ms after the power supply fails In accidents in addition...

Page 40: ...doors Like the New Beetle Cabriolet there is an active rollover element behind each of the head restraints on the rear seat bench Together with the two A pillars they secure the crash survival space if the car rolls over The rollover protection is triggered by the airbag control unit in severe front side and rear collisions if the car rolls over or tilts extremely Rollover protection S355_161 Roll...

Page 41: ...on the 2 0l 103kW TDI engine with 2 valve technology and diesel particulate filter All of these engines have been further developed for use in the Eos All engines fulfil the EU4 emissions standard The TDI engine has a diesel particulate filter close to the engine You will find detailed information on the engines in the following self study programmes SSP 296 The 1 4l and 1 6l FSI engine with timin...

Page 42: ... in the intake manifold This prevents coking of the throttle valve to a great extent The engine control unit software has been adapted to the changes S355_084 Torque and power diagram Torque Nm Power kW 20 40 60 80 100 120 140 160 180 10 20 30 40 50 60 70 80 90 1000 3000 5000 Engine speed rpm S355_086 7000 Do not run the car with Normal unleaded RON 91 because the ignition retardation will reach i...

Page 43: ...e is made from plastic It uses a contact free sensor not a potentiometer There is no need for water cooling The engine control unit software has been adapted to the changes Engine code BVY Type 4 cylinder in line engine Displacement 1984cm3 Bore 82 5mm Stroke 92 8mm Valves per cylinder 4 Compression ratio 11 5 1 Maximum output 110kW at 6000 rpm Maximum torque 200Nm at 3500 rpm Engine management Bo...

Page 44: ...ith turbocharger is also used in the Golf GTI the Passat and the Jetta The following features have already been used in series production in these vehicles Technical features Single pipe exhaust system with starter and underbody catalytic converter mounted near engine Ethanol resistant Hitachi high pressure pump There is no fuel pressure sender for low pressure G410 The required fuel pressure is c...

Page 45: ... 95 9mm Valves per cylinder 4 Compression ratio 10 85 1 Maximum output 184kW at 6300 rpm Maximum torque 320Nm at 2500up to 3000 rpm Engine management Bosch Motronic ME 7 1 1 Fuel Super Plus unleaded at RON98 Super unleaded at RON 95 with reduction in performance Exhaust gas treatment Two three way catalytic converters with constant Lambda control Emissions standard EU 4 Technical features of engin...

Page 46: ...linder in line engine Displacement 1968cm3 Bore 81mm Stroke 95 5mm Valves per cylinder 2 Compression ratio 18 1 Maximum output 103 kW at 4000 rpm Maximum torque 320Nm at 1750 rpm to 2500 rpm Engine management Bosch EDC 16 with unit injector system Fuel Diesel min 51CN Exhaust gas treatment Exhaust gas recirculation and diesel particulate filter Emissions standard EU4 Technical data S355_085 Engine...

Page 47: ...d manual 0AJ 6 speed manual 02S 6 speed manual 02Q 6 speed Direct Shift Gearbox DSG 02E 1 6l 85kW FSI engine 2 0l 110kW FSI engine 2 0l 147kW TSI engine 3 2l 185kW V6 engine 2 0l 103kW TDI engine Engine gearbox combinations ...

Page 48: ...s and the stabilisers have been configured for sportiness The second generation electromechanical power steering is supplemented with the counter steer support function It allows stable straight running in cross winds or on roads that are inclined sideways The brakes have been optimised and have hydraulic brake assist and ABS with ESP function as standard Second generation electromechanical power ...

Page 49: ...programme SSP 321 The Golf 2004 Chassis Tyre Mobility Set Four link rear axle with high transverse stiffness and decoupled longitudinal and transverse dynamics Tyre pressure monitoring system optional Safety steering column height and reach adjustable S355_142 ...

Page 50: ...s achieved by among other things adapting the fan voltage taking the greater sunlight intensity into consideration adapting the air distribution in heating mode adapting the compressor regulation and the behaviour of the Climatronic S355_168 Compressor operation When the Eos is driven as a cabriolet the air conditioning compressor only needs to be run if the required outlet temperature is below th...

Page 51: ...n all occupants are exposed to more intense sunlight from all sides Therefore the values measured by the sun sensors in the instrument panel are used as a value for the air conditioning regulation The sunlight from the rear is also measured by a light sensitive diode in the air conditioning control panel The 2 zone air conditioning control is also available when the roof is open even though a larg...

Page 52: ...e inside temperature sensor and the outside temperature The settings that are present upon the respective switch over from cabriolet or coupé mode are stored by the 2C Climatronic system When the system returns to this operating mode the stored values are applied again Air distribution in heating mode To create a feeling of warmth when the outside temperature is low and the roof is open the heated...

Page 53: ...J393 Convenience system central control unit J400 Wiper motor control unit J412 Mobile telephone operating electronics control unit J446 Parking aid control unit J500 Power steering control unit J503 Control unit with display for radio and and navigation system J519 Onboard supply control unit J533 Data bus diagnostic interface J525 Digital sound package control unit J527 Steering column electroni...

Page 54: ...ox 80 to the car longitudinal axis Both functions are activated by turning the steering wheel or switching on the turn signals You will find more information on the cornering lights in self study programme SSP 335 Cornering Light System Taillights The taillights are divided by the boot lid The reverse lights and the rear fog lights are located in the respective boot lid sections The sidelight brak...

Page 55: ...n the storage compartment of the driver s door Electrical easy entry function The Eos sees an electrically activated easy entry function being used for the first time It has the function of moving the front seats electrically to make access to the rear seats easier It is operated with a rocker switch on the top side of the seat backrest Flicking the switch in one direction activates the easy entry...

Page 56: ...r 8 speakers As an alternative to the RCD 300 the RCD 500 with 4 20W speakers 8 speakers or with the Dynaudio sound package can be selected A 6 CD changer can be added to the Eos audio system The RNS 300 and the RNS MFD DVD are available as navigation systems You will find more detailed information on these audio systems in the user s manual or self study programme SSP 342 Radio Systems S355_034 ...

Page 57: ...ules for Telephone GSM Global System for Mobile Communications SDARS Satellite Digital Audio Radio Services and GPS Global Positioning System The radio amplifier module is accommodated on the right hand side of the boot lid It processes the signals from the AM FM1 and the FM2 aerial wire and has two Fakra interfaces The remote start aerial optional with auxiliary heating is integrated in the radio...

Page 58: ...ved or fitted VAS 6368 Key for barrel screw Adjusting tool for securing the roof side members VAS 6369 Clamp for C segment Locks the folded roof package VAS 6370 Gauge for guide rails For adjusting the guide rails on the sliding sunroof VAS 6371 Gauge for main bearing For checking and adjusting the main bearings of the CSC roof VAS 6372 Seal pliers For sealing the tensioning tapes for the side mem...

Page 59: ...as set up in 1991 in an agreement between Volkswagen and Ford The Palmela plant has been a hundred percent subsidiary of Volkswagen AG since 1999 IN SITU This term is Latin and literally means in original place or on site If for example you observe a metabolism process in situ this means that you observe the processes in living cells The opposite would be in vitro In this case you would remove the...

Page 60: ... Setúbal This historical and very old town in the west of Portugal today has a population of around 16000 THERMOFORMED SHEETS In thermoforming e g forging the metal lattice is recrystalised during the shaping process The recrystalisation prevents embrittlement and avoids a reduction in the tenacity of the workpiece as occurs during cold forming ...

Page 61: ...61 Notes ...

Page 62: ...rights to make technical alterations reserved 000 2811 69 20 Technical status 04 2006 Volkswagen AG Service Training VSQ 1 Brieffach 1995 38436 Wolfsburg This paper was manufactured from pulp that was bleached without the use of chlorine 355 ...

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