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Volkswagen Passat W8, Service Manual, Page: 1 / 52

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The Passat W8

Self-Study Programme 261

Service.

Summary of Contents for Passat W8

Page 1: ...The Passat W8 Self Study Programme 261 Service...

Page 2: ...subject of the W8 engine is described in two separate Self Study Programmes Self Study Programme No 248 The W Engine Concept Self Study Programme No 249 The W8 Engine Management This Self Study Progr...

Page 3: ...nce In a nutshell 4 Body 10 Occupant protection 12 Drive units 15 Power transmission 22 Running gear 24 Vehicle electrical system 30 Convenience and safety electronics 33 Heating and air conditioning...

Page 4: ...nt in performance comfort safety quality and equipment It will be offered in saloon and estate versions W8 engine 4 0 l 202 kW 275 bhp 4 valve per cylinder 6 speed manual gearbox or 5 speed automatic...

Page 5: ...ine power output is transferred to the road via a 6 speed manual gearbox with four wheel drive 4Motion Optionally there is a five speed automatic gearbox with Tiptronic and 4Motion The W8 engine is a...

Page 6: ...both the estate and the saloon have been strengthened to improve the acoustics and increase crash safety But whether it is the estate or the saloon the new Passat W8 is recognisable from the outside b...

Page 7: ...ood trims exclusive upholstery an on board computer and automatic air conditioning In the extensive list of the Passat W8 s optional extras we have included new luxury leather seats new sports seats a...

Page 8: ...eelbase 2703 mm Turning circle 11 5 m Tank capacity 80 l 2703 mm 4703 mm 1746 mm 1461 mm S261_006 S261_005 100 kg Front track width 1511 mm Rear track width 1510 mm Perm gross vehicle weight 2220 kg K...

Page 9: ...e and weight Length 4682 mm Width 1746 mm Height 1497 mm Wheelbase 2703 mm Turning circle 11 5 m Tank capacity 80 l Front track width 1515 mm Rear track width 1510 mm Perm gross vehicle weight 2290 kg...

Page 10: ...stics and reinforcement to increase crash safety We have modified the spare wheel well to attach the auxiliary fuel tank On the saloon the rear bulkhead is welded to the rear backrest The backrest of...

Page 11: ...o the wheel housings An additional strut is welded to the front bulkhead near the front side member Crash reinforcements The front footwell is reinforced by an additional cross member Body modificatio...

Page 12: ...8 has two full size front airbags on the driver s and front passenger s sides They have a filling volume of 64 and 120 litres The central airbag control unit is located behind the central console on t...

Page 13: ...the front and outer rear seats Ball type tensioners are fitted to the front seats The rear seats are fitted with Wankel belt tensioners The two types of belt tensioner are triggered by mechanical pyro...

Page 14: ...he raised swab ensures that the belt runs safely across the child s lap Integrated child safety seats Belt guide hook S261_014 S261_013 The Isofix System The new Passat W8 is fitted both with a standa...

Page 15: ...ry small dimensions Compared with other 8 cylinder engines the W8 is very lightweight due to the short size and through the use of aluminium slim conrods and short pistons S261_015 S261_071 Four valve...

Page 16: ...m Max torque 370 Nm 2750 rpm Engine management system Motronic M7 11 Fuel RON 98 reduced output with RON 95 Exhaust gas aftertreatment Three way catalytic converter with Lambda control The power outpu...

Page 17: ...tion and an additional tank containing 20 litres The two fuel tanks are connected by a connecting tube The additional fuel tank is located under the spare wheel well which is reduced in size for this...

Page 18: ...tank When the tank is full fuel is first pumped from the 60 l tank When the fuel level in the main tank drops to 40 litres the fuel pump in the additional fuel tank cuts in and pumps fuel from the add...

Page 19: ...en the sender in the main fuel tank signals a fuel level of 40 litres the control unit switches the pump in the additional fuel tank on It pumps fuel from the additional fuel tank to the main fuel tan...

Page 20: ...for fuel level indicator G 237 sender 3 for fuel level indicator G 169 sender 2 for fuel level indicator G 6 fuel pump pre supply pump J 17 fuel pump relay G23 fuel pump J538 control unit for fuel pu...

Page 21: ...ing the fuel pump G 23 in the additional fuel tank Controlling the tank warning lamp The fuel level indicator Due to the different heights of the fuel tanks four fuel level senders are required to cal...

Page 22: ...adapted to fit the W8 engine S261_024 Gearbox The 6 speed manual gearbox 01E four wheel drive The 5 speed automatic gearbox 01V The gearbox was adapted to fit the W8 engine i e the casing and gear rat...

Page 23: ...s the drive power to the wheels of an axle with better wheel grip The Torsen differential permits limited differences in speed between the front and rear axles and therefore allows ABS control process...

Page 24: ...r weight and the resulting axle loads the wheel bearing housing the wheel bearings the wheel hub and the tubular subframe Steering The four link front suspension Tubular subframe Wheel bearing housing...

Page 25: ...8 S261_029 Upper wishbone Lower wishbone Tubular subframe Differential New wheel bearing housing Wheel bearing housing made of aluminium Track rods guided at both ends Larger track width Guided at bot...

Page 26: ...321 mm x 30 mm 269 mm x 22 mm Front disc brake Rear disc brake The Passat W8 currently has the most powerful brake system of all Volkswagen car models Despite high engine performance it achieves exce...

Page 27: ...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 electro...

Page 28: ...As the full suction volume is pumped almost continuously the maximum suction flow is much smaller than on single stage recirculating pumps This reduces the pressure in the suction line and prevents ca...

Page 29: ...is insufficient to reach maximum vehicle deceleration ABS control range Emergency braking Normal braking Pressure sensor G294 S261_034 S261_043 Pressure rise in brake system Time t Brake pressure p Th...

Page 30: ...ox in plenum chamber Engine control unit Relay station Connector station Fuses Connector station A pillar right The electrical system on the Passat W8 has a similar design as on the Passat model year...

Page 31: ...gage compartment right TV tuner CD changer DSP Dash panel insert with immobiliser control unit and diagnostic interface gateway Window lifter motor with integrated door control unit Convenience contro...

Page 32: ...The H7 lamp is also used for the headlight flasher function The gas discharge headlight GDH with bi xenon light When driving in LHD countries the two headlights can be changed over from asymmetric to...

Page 33: ...he radio navigation system via the CAN bus Communication with the Internet outside world is by means of a mobile radio aerial GSM antenna which complies with the present day standard Internet access a...

Page 34: ...lling line are monitored in addition to the other functions of the anti theft alarm system When the car is unlocked by the radio wave remote control key the anti theft alarm system is deactivated If t...

Page 35: ...ddress word Convenience System Please always use the latest version of the Workshop Manual in the electronic Service Information System ELSA when fault finding J393 H8 H12 30a F266 F266 contact switch...

Page 36: ...rmation Memory aerial sockets for aerial selection compact connectors with central locking CAN bus convenience networking The important new button names and functions are summarised below TIM function...

Page 37: ...ck in CD mode SEEK TRACK button SEEK In radio mode hit to start station search SEEK in AM band In FM or TP band browse through storage list TRACK Hit briefly to skip forward or backward through CD tra...

Page 38: ...and locking clip S261_053 S261_054 The aerial sockets To avoid plugging the aerial connectors in the wrong socket the connector housings have a plug coding and different colours This means that a con...

Page 39: ...traffic radio messages select a TP station e g ANTENNE by pressing the TP button When the selected TP station broadcasts traffic radio messages they will cut into the current programme of the FM stat...

Page 40: ...cessing Radio convenience coding Control signals from the multifunction steering wheel Vehicle identification number For further Information on the subject of the radio system refer to the following S...

Page 41: ...e saloon and on the estate Location of aerials on the saloon On the saloon the AM medium wave aerial is above the rear window heater The four FM aerials are integrated in the rear window heater Outsid...

Page 42: ...rongly allocated As the aerials on the estate do not use the rear window heater no suppressors are required Side window right Side window left Amplifier 1 AM FM aerial Amplifier 4 FM aerial Amplifier...

Page 43: ...aerial is found with good reception Switchover is so fast that the car occupants do not notice it Side window left AM FM 1 FM 2 FM 3 FM 4 Side window right Function diagram for aerial system example...

Page 44: ...emperature G263 Externally regulated compressor with regulating valve N280 and integrated overload protection The interaction between these two components in conjunction with the entire CLIMAtronic re...

Page 45: ...pressor N 280 Depending on the parameters input desired temperature ambient and interior temperature evaporator temperature and refrigerant pressure in refrigerant circuit the pressure conditions on t...

Page 46: ...ment The overload protection Shaped rubber element Drive shaft Compressor Driven plate When the compressor is operational the two plates rotate in the same ratio to each other Shaped rubber element Be...

Page 47: ...n onto the blocked driven plate The projecting shapes on the rubber element shear off and the joint between the belt pulley and the driven plate is separated The belt pulley continues to rotate unhind...

Page 48: ...led by the CLIMAtronic control unit J255 When the control voltage is applied to the electromagnet control valve a plunger in the control valve moves The period of the control voltage applied determine...

Page 49: ...ownstream of the evaporator If fulfills two important tasks it ensures that the air conditioning system is switched off at 0 C downstream of the evaporator together with the externally regulated compr...

Page 50: ...50 Notes...

Page 51: ...51 Notes...

Page 52: ...al 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 bleache...

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