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38

Gearbox

Contact corrosion, using a bolted connection
as an example

In this example, a magnesium component is
attached using a bolt made is an iron alloy. If
the contact surface is wetted with water, an
electric current occurs between the two
metals. This leads to contact corrosion. The
magnesium is decomposed at the same time.

Contact corrosion can be prevented by inhibiting
the electric current between the two metals by
coating the bolt with an insulating layer. This
insulating layer is composed of a special
non-conductive coating.

A special coating is applied to all add-on parts which come into direct contact with
magnesium. Please follow the instructions given in the Workshop Manual.

Water

Special coating

Magnesium

Water

Corrosion

SSP 192/097

SSP 192/061

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Содержание Passat '97

Страница 1: ...operation 191 640 2810 10 00 Technical Status 09 96 The Presentation Only for internal use VOLKSWAGEN AG Wolfsburg All rights reserved Subject to modification Printed on chlorine free bleached paper S...

Страница 2: ...igh economy l Dynamic body styling l High quality interior equipment designed with great attention to detail l Pioneering safety engineering In this booklet we would like to provide you with an initia...

Страница 3: ...le Safety 15 Engines and Gearboxes 19 Running Gear 26 Brakes 29 Steering 30 Electrics 31 Extended Systems 36 The Self Study Programme is not a Workshop Manual Please refer to the relevant Service Lite...

Страница 4: ...ous aspects of this all embracing vehicle concept You can find detailed information in Self Study Programme No 192 Passat 97 The Enginee ring The Passat 97 191 86 191 73 Service 192 Der Passat 97 Die...

Страница 5: ...5 Dimensions and Weights 4675 mm 2707 mm 1740 mm Track widths front rear 1498 1500 mm mm 191 71 Weights Unladen weight Max permissible weight appr 1200 appr 1805 kg kg...

Страница 6: ...lt of this is that people are often unsure of what the term platform implies The vehicle consists of a the platform and b the body Design and vehicle characteristics dictate what form the body takes I...

Страница 7: ...es both common parts and system parts Common parts e g sliding sunroof steel rim Common parts may only be used in platform vehicles without change They do not influence the design of the vehicle Syste...

Страница 8: ...ials l Reduction in fine sealing through the use of laser welding l No parts containing CFCs are used Take bumpers for example Bumpers were previously manufactured from composites What the term compos...

Страница 9: ...en l Less energy consumption during production through the use of new joining techniques e g laser welding and complete assemblies e g side section of body l Full galvanisation and an 11 year warranty...

Страница 10: ...using door module as example l Rear collision demonstrated using bumper as example The Passat in the Wind Tunnel As you can see from the streamlines the body of the new Passat is very aerodynamic No...

Страница 11: ...g below shows you the parts which are hot dip galvanised and those which are electrolytically galvanised Surface patterns which are also visible after painting emerge during the hot dip galvanisation...

Страница 12: ...ass in terms of torsional rigidity This was achieved by using l high strength panels l different panel thicknesses l improved adhesive bonding techniques e g adhesive joints Adhesive joints increase r...

Страница 13: ...rength panels are used to produce a body with greater stability and strength and therefore to provide more safety for the vehicle occupants They also substantially reduce the weight of the body in whi...

Страница 14: ...ssembly side members and luggage compartment floor assembly were adopted from the Audi A4 as a platform To enhance ride comfort for rear seat passengers a steel floor plate 86 mmwide was inserted 86mm...

Страница 15: ...integral pelvis paddings Safety body Steering column The following features will be of interest to you l Active and passive safety l ABS as standard l The Passat already complies with the new Europea...

Страница 16: ...the interior of the vehicle The side impact beams made of pressed sheet metal are arranged diagonally and glued to the outer panel to increase door rigidity Impact energy can therefore be better abso...

Страница 17: ...ch have filling volumes of roughly 65 ltr and 120 ltr respectively conform to the new internatio nal standard airbag sizes The volume of the standard side airbag is roughly 12 litres Side impact right...

Страница 18: ...h the belt fastened sensor and belt force limiter are combined in a single assembly This compact design greatly simplifies replace ment The belt fastened sensor prevents the seat belt tensioner from b...

Страница 19: ...he Audi A3 It is mounted in the Passat without a twin path intake manifold 1 8 ltr 5V Engine ADR Displacement 1781 cc Compression ratio 10 3 1 Max torque 173 Nm at 3950 rpm Max power output 92 kW at 5...

Страница 20: ...00 rpm Engine management Motronic M 3 8 2 Fuel 95 RON unleaded premium This engine is also used in the Audi A4 2 8 ltr V6 Engine ACK Displacement 2771cc Compression ratio 10 3 1 Max torque 280 Nm at 3...

Страница 21: ...engine has a displacement of 2 3 litres It is derived from the VR6 engine and is designed for in line or transverse mounting Power output is 110 kW The engineering of the VR5 engine is explained in a...

Страница 22: ...ly controlled distributor injection pump 1 9 ltr TDI Engine AFN Displacement 1896 cc Compression ratio 19 5 1 Max torque 235 Nm at 1900 rpm Max power output 81 kW at 4150 rpm Fuel 45 CN diesel Mixture...

Страница 23: ...s and Gearboxes 012 01W 01N 01V Syncro 1 6 ltr 74kW 1 8 ltr 5V 92kW 1 8 ltr 5V turbo 110kW 2 3 ltr VR5 110kW 1 9 ltr TDI 66kW 1 9 ltr TDI 81kW 2 8 ltr V6 5V 142kW 01V 01A Manual gearbox Engines Automa...

Страница 24: ...W is a manual gearbox as used in the Audi A4 This gearbox has a magnesium housing for installation in the 1 6 ltr 74kW aluminium engine block 5 speed Manual Gearbox 01A The 01A is the manual gearbox f...

Страница 25: ...detailed information on this gearbox in Self Study Programe No 172 5 speed Automatic Gearbox 01V You will also be familiar with the 01V from the Audi A4 It is equipped with Tiptronic control as stand...

Страница 26: ...ed torsion beam rear suspen sion as well as the new double wishbone rear suspension unique to Syncro models The Four link Front Suspension The four link front suspension is standard in all front and f...

Страница 27: ...s of torsion beam rear suspension Larger through loading width due to the fact that the coil springs and shock absorbers are kept physically apart Use of single tube dampers Downward facing V section...

Страница 28: ...Double wishbone Rear Suspension The double wishbone rear suspension was developed in order to provide a through loading width of over 1000 mm Engine power is transmitted to all four wheels by a Torsen...

Страница 29: ...o have disc brakes as standard 280 x 22 mm brake disc The front disc brakes are vented The smaller disc diameter is based on a smaller vehicle mass and lower power output 282 5 x 25 mm brake disc This...

Страница 30: ...ody by a mounting pedestal with sliding guide A damper element located above the double universal joint prevents vibrations and noise from being transmitted to the body A clamped connection links the...

Страница 31: ...Example of the arrangement of control units ABS control unit Fuse carriers located on side of dash panel Airbag control unit Master control for extended central locking system Engine control unit The...

Страница 32: ...tem this display is complemented by the Auto Check System with a multi function display The immobiliser is an integral feature of the dash panel insert However the matching functions of the immobilise...

Страница 33: ...iminates this drawback If the ignition is switched off and fuel tank capacity increases by four litres or more the new fuel level is recalculated and displayed straight after the ignition is restarted...

Страница 34: ...adlights Greater luminous efficiency than conventional headlights Better brightness distribution by virtue of a lens Fog light is no longer necessary On acount of the greater danger of dazzling oncomi...

Страница 35: ...of operation For the sake of simplicity the mode of opera tion can be compared to that of a garden hose when it is swung from side to side Moving the garden hose quickly produces a fan jet A nozzle in...

Страница 36: ...l locking system is based on a decentralised system concept It has a central control unit and a separate door control unit with a control panel for every door Self diagnosis Diagnosis is initiated usi...

Страница 37: ...unction Interior light control Central locking of rear doors only in combination with mech window lifters at rear Central locking of boot lid 191 45 Diagnosis Address word 46 Slide tilt sunroof Electr...

Страница 38: ...controlled at the air intake side permits fresh air and air recirculation modes A main shutoff flap is therefore no longer required Central flap Fresh air air recirculation flap By virtue of the stepp...

Страница 39: ...the operating and display unit The photosensor measures incident sunlight over a large area There is greater sensitivity for controlling the interior climate Average outflow temperature is registered...

Страница 40: ...e central and side vents All flaps are electic motor operated Air conditioning without back pressure flap is installed in right hand drive vehicles The following components are integrated in the refri...

Страница 41: ...nd via the loudspeaker built into the control unit The system comprises the following elements The navigation computer with integrated CD ROM drive The control unit with control and loudspeaker The di...

Страница 42: ...to the navigation computer The system is switched on or off and the destination is entered by ope rating the control In addition to the display integrated in the dash panel insert a voice out put can...

Страница 43: ...field sensor The earth magnetic field sensor determines the direction of travel relative to the north pole for the navigation computer GPS sensor GPS stands for Global Positioning System a global navi...

Страница 44: ...rovision only mobile phones with a VDA standard connection can be operated Cellular Phone Preparation Scope of cellular phone provision Hands free microphone integrated in left hand A pillar VDA stand...

Страница 45: ...45 Notes...

Страница 46: ...46 Notes...

Страница 47: ...47...

Страница 48: ...2 640 2810 11 10 Technical status 11 96 The Engineering For internal use only VOLKSWAGEN AG Wolfsburg All rights reserved Specifications subject to change Printed on chlorine free bleached cellulose p...

Страница 49: ...e Presentation we now want to describe in detail how the car s various components are designed and how they function The subjects of the VR5 engine convenience electronics and navigation system are so...

Страница 50: ...r V6 Engine ACK 26 1 9 ltr TDI Engine AFN 34 Gearbox 38 Drive Shafts 40 Running Gear 43 ABS EDL 48 Electrics 55 Air conditioning 60 This Self Study Programme is not a Workshop Manual Please refer to t...

Страница 51: ...e Gearbox Non ferrous metals such as aluminium or magnesium are being used increasingly in vehicle construction In this booklet we will explain the advantages and special features of magnesium compone...

Страница 52: ...ing generation ABS EDL As a part of the ABS EDL system we will present you the new hydraulic unit with an integrated control unit Air conditioning The latest developments and the special fea tures of...

Страница 53: ...elt tensioner and belt force limiter used on all outer seats l Front and side airbags for the driver and front passenger Airbag control unit Central module of convenience central locking system Side a...

Страница 54: ...components such as bumpers and impact absorbers The seat belts provide adequate protection the belt tensioners restrain the car s occupants in their seats The belt force limiter reduces the risk of th...

Страница 55: ...tion to the protection afforded by the seat belts the restraint systems protect the front passengers from more serious injuries in the upper body and head areas The car s central locking system is ope...

Страница 56: ...nd front passenger s seats The side airbag is described as a thorax airbag It mainly protects the thorax and with it the lungs and pelvis from lateral bruising In terms of its appearance the new airba...

Страница 57: ...pened and the pyrotechnical charge ignites The highly pressurised gas contained inside the cartridge expands instantaneously inflating the airbag While expanding the gas cools and mixes with the hot g...

Страница 58: ...spond to lateral force application The crash sensors are known as intelligent sensors They operate independently of each other In addition to an electronic acceleration sensor the entire electronics a...

Страница 59: ...gs can be displayed via the self diagnosis The airbag control unit also indicates when a fault may possibly have occurred in the crash sensors or the side airbags via the airbag warning lamp There is...

Страница 60: ...occurs the belt tensioners reel in the belt and thus take up any slack clearance between belt and body The mode of operation of the belt tensioner is very different to that of its predecessors There a...

Страница 61: ...ro technical propellant charge ignites It sets the balls in motion and drives them into the ball retainer via a gearwheel The belt reeling device is driven by the kinetic energy of the balls thus reel...

Страница 62: ...rms as a pyrotechnical Wankel engine This Wankel engine is driven by 3 propellant charges They are ignited in succession Belt tensioner triggering mechanism Belt Locking mechanism with child safety se...

Страница 63: ...tion the piston opens the inlet port of the second firing pin thus igniting the second propellant charge The released gas makes the rotor rotate until the next inlet channel is opened The third charge...

Страница 64: ...shaft operates in much the same way as a spring Depending on its tensile force the belt gives Both types of belt tensioner use the same system Belt reeling device The end of the slot limits the distan...

Страница 65: ...raint system of the Passat 97 2 The side airbag has a capacity of a 8 litres b 12 litres or c 15 litres 3 The side airbag crash sensors respond to the application of force Test your knowledge 4 What i...

Страница 66: ...19 5 The rear belt tensioner a operates according to the Wankel engine principle b uses a diaphragm pump c is ball activated 6 Annotate the following drawing SSP 192 126 a c b d f e...

Страница 67: ...path permite optimum charging of the cylinder and consequently high torque in the low speed range Short intake path Switching over to the short intake manifold permits high power output in the upper s...

Страница 68: ...ifold pressure change valve S Fuse J17 IN OUT SSP 192 106 The engine control unit sends a signal to the intake manifold pressure change valve It uses the vacuum unit to change over the intake manifold...

Страница 69: ...sender G28 Coolant tempera ture sender G62 Altitude sender F96 Additional signals Throttle valve con trol valve J338 Injection valves N30 N31 N32 N33 Output stage N122 Ignition coils N N128 N158 N163...

Страница 70: ...N31 Injection valve cylinder 2 N32 Injection valve cylinder 3 N33 Injection valve cylinder 4 N75 Charge pressure limitation solenoid valve N80 Activated charcoal system solenoid valve N122 Output sta...

Страница 71: ...24 30 15 X 31 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 S N30 N31 N32 N33 G39 N80 N75 J33 G61 G62 G28 G72 G66 J220 N G70 15 64 65 58 80 73 4 3 1 J17 27 25 26 12 13 2 68 60 56 63 53 54 67 G6 IN OUT...

Страница 72: ...25 SSP 192 076 30 15 X 31 N122 50 50 50 50 50 50 50 50 N163 N158 N128 F96 G40 77 78 70 19 59 69 75 11 74 76 62 61 5 6 7 8 18 20 22 23 49...

Страница 73: ...the movement of the piston The inlet valve must be closed early so that the fuel air mixture is not forced back into the intake manifold At high speeds the flow rate inside the intake manifold is so h...

Страница 74: ...inlet camshafts therefore rotate in relation to the exhaust camshaft The exhaust camshaft cannot rotate at the same time since it is restrained by the toothed belt The inlet valve closes early In thi...

Страница 75: ...linder via the engine oil circuit The engine control unit controls the hydraulic cylin der via the variable valve timing valve which is bol ted directly to the variable valve timer housing Variable va...

Страница 76: ...n opposite directions Variable valve timing in the V6 engine Idling When the engine is idling the inlet valves are closed late Torque position The inlet valves are closed early above an engine speed o...

Страница 77: ...nder G28 Coolant tempera ture sender G62 Additional signals Throttle valve con trol unit J338 Hall sender II G163 Injectors N30 N31 N32 N33 N83 N84 Ignition transformer N152 Throttle valve con trol un...

Страница 78: ...N33 Injection valve cylinder 4 N83 Injection valve cylinder 5 N84 Injection valve cylinder 6 N75 Charge pressure limitation solenoid valve N80 Activated charcoal system solenoid valve N152 Ignition tr...

Страница 79: ...31 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 S N30 N31 N32 N33 N83 N84 G39 G108 N80 N156 N205 N208 G61 G40 G163 G66 S 15 26 39 40 44 11 76 68 60 64 55 79 72 65 58 80 73 4 3 J1...

Страница 80: ...33 SSP 192 075 30 15 X 31 N152 50 50 50 50 50 50 J338 G62 8 G72 G70 3 56 53 54 67 66 59 69 75 62 74 14 12 13 70 71 78 19 2 0 5 6 7 8 18 20 22 23 45 49 IN OUT...

Страница 81: ...of the engine The run on time is determined by the engine control unit via a characteristic map Allowance is also made for the coolant temperature and engine load during the final minutes of car opera...

Страница 82: ...speeds the piston moves so that the gas mixture in follows the movement of the piston The inlet valve so that the fuel air mixture is not forced back into the intake manifold At high speeds the flow r...

Страница 83: ...ty comparison Iron 7 873 g cm3 Aluminium 2 699 g cm3 Magnesium 1 738 g cm3 The strength of a material depends on its density among other things Low density goes hand in hand with low strength This los...

Страница 84: ...precious metal If a metal does not decompose easily it is termed a precious metal An electrochemical voltage series is produced by arranging the metals in a series extending from non precious metal t...

Страница 85: ...The magnesium is decomposed at the same time Contact corrosion can be prevented by inhibiting the electric current between the two metals by coating the bolt with an insulating layer This insulating l...

Страница 86: ...is the insertion depth for magnesium compared to that for iron a 2 0 times greater b 5 2 times greater c 2 5 times greater 2 Assign the metals of gold iron magnesium copper aluminium and lead to the...

Страница 87: ...omatic cars This is necessary due to the high vibrations which occur in diesel engines and the preten sioning forces which occur in automatic drive trains Design The triple roller joint has three sphe...

Страница 88: ...lastic bearings At certain speeds the unit begins to oscillate in its mountings This movement is compensated by the triple roller joints whereby the tripod star together with the rollers slide within...

Страница 89: ...bump and rebound The joint housing remains stationary in the process The drive shaft is moved away from the gearbox by the rebound action of the wheels At the same time the rollers are displaced in on...

Страница 90: ...trailing arms When designing the rear axle comfort was a major consideration The rear axle mountings and the large rubber bases of the coil springs minimise noise transmission from the axle to the bo...

Страница 91: ...on beam rear axle has a V section which is open downwards The shear centre is located above the V section The axle has different rotational characteristics as a result SSP 192 116 SSP 192 114 SSP 192...

Страница 92: ...the need for an axle pivot The ABS speed sensor is inserted into the wheel bearing and secured with a clip to prevent it from falling out The advantages of the new wheel bearing generation are as fol...

Страница 93: ...cted to the body by four large bonded rubber mountings Single tube gas filled shock absorbers are used on the double wishbone rear axle Their diameter is smaller than that of twin tube shock absorbers...

Страница 94: ...torsion beam rear axle is open 3 The advantages of the new wheel bearing generation are as follows a Minimal wear b The ABS speed sensor rotor is protected c It is self adjusting d It has to be adjus...

Страница 95: ...newed as one unit A Self Study Programme relating to the ABS 5 3 system is in preparation Braking system warning lamp ABS recirculating pump V39 Hydraulic unit with solenoid valves N99 102 N133 136 N1...

Страница 96: ...brake circuit approx 3 cm3 Two diaphragm outlet dampers are connected upstream of the EDL hydraulic blocks They help improve the low temperature performance of the EDL control system Diaphragm outlet...

Страница 97: ...ontrol unit there are two computers which work with the same program independently and check one another The two computers are in turn monitored by a third computer which assumes the task of controlli...

Страница 98: ...The navigation system is de energised The brake warning lamp comes on This is how it works The rotor is integrated and the speed sensor inserted in the wheel bearing The speed sensor comprises a perma...

Страница 99: ...splay unit in dash panel insert J401 Control unit for navigation system with CD ROM drive K 47 ABS warning lamp N99 Front right ABS inlet valve N100 Front right ABS outlet valve N101 Front left ABS in...

Страница 100: ...53 45 G46 G47 30 15 X 31 J401 F K47 J220 J285 J104 N102 N133 N134 N135 N136 N166 N167 N168 N169 5 4 9 8 7 6 19 23 24 13 21 10 14 11 SSP 192 087...

Страница 101: ...BS hydraulic unit a By the diaphragm outlet damper b By the colour of the control unit c By the threaded holes for the master brake cylinder 2 Where is the rotor for the speed sensor of the torsion be...

Страница 102: ...ventional lamp technology are as follows l Up to three times higher luminous efficiency same power consumption A 35W gas discharge lamp is sufficient to provide twice the illumination of a 55W lamp l...

Страница 103: ...n why the main headlight is still equipped with a halogen lamp which is connected to the headlight as required Once the gas discharge lamp has reached its nominal brightness the ballast regulates the...

Страница 104: ...e car s load condition by two sensors located on the front and rear axles on the left of the car It continuously adjusts the headlight via the actuator to ensure that the road is always illuminated op...

Страница 105: ...the headlight to its lowest position The driver is alerted to the malfunction Self diagnosis The self diagnosis is started using address word 55 The high voltage applied to the gas discharge lamps ca...

Страница 106: ...ame power consumption is a approx ten times higher b approx five times higher c approx three times higher 3 A gas discharge headlight comprises 4 The voltage applied to the gas discharge lamp is a ver...

Страница 107: ...ent The refrig erant absorbs the heat Condenser The passing outside air cools the hot gaseous refrigerant in the con denser The refrigerant is liquefied in the process Compressor The compressor draws...

Страница 108: ...temperature sensor is located behind the cover grille on the left For right hand drive cars the temperature sensor is installed on the right Using this layout drinks in the can holder have less effec...

Страница 109: ...temperature G191 Temperature sensor for fresh air intake duct G89 Sender for footwell air outlet tempera ture G192 Dash panel insert temperature sensor G56 with temperature sensor fan V42 Outside tem...

Страница 110: ...lation flap actuator V71 with potentiometer Central flap actuator V70 with potentiometer Footwell defrost flap actuator V85 with potentiometer Actuators Fresh air blower V2 with blower control unit J1...

Страница 111: ...to flow into the car unobstructed Recirculated air Recirculated air SSP 192 024 SSP 192 028 Ventilation mode At high speeds the ventilation flap prevents too much fresh air from entering the passenge...

Страница 112: ...nger compartment Recirculated air Fresh air SSP 192 021 SSP 192 025 Above a speed of 160 kph the ventilation flap is closed A small amount of fresh air trickles into the passenger compartment through...

Страница 113: ...ully closed It is also driven by an electric motor As coolant temperature increases the flap opens and air reaches the side air outlets The air duct leading to the central air outlets is still closed...

Страница 114: ...trol unit is integrated in the fresh air blower The control unit cooling ribs are cooled by the blower airstream Fresh air blower V2 Blower control unit J126 Air conditioner Fresh air blower V2 SSP 19...

Страница 115: ...ffect as sunglasses and prevents sublight from damaging the photodiode The photodiode is a light sensitive semiconduc tor element When it is not illuminated only a small electric current can flow thro...

Страница 116: ...ault message Open circuit short circuit to positive Short circuit to earth Photodiode Optical element Filter Diagonal sunlight penetration SSP 192 092 Particularly sunlight incident on the car s occup...

Страница 117: ...this way the temperature is not determined at a measuring point but along a measuring section The central air outlet temperature is measured in this way Central outlet temperature sender G191 Self dia...

Страница 118: ...lap is in its upper limit position and the fresh air recirculation flap is in its lower limit position c The central flap controls the air flow to the central side footwell and DEFROST air outlets d T...

Страница 119: ...the axis of rotation Re 2 downward Re 3 a b c Re 4 a within b a low load floor and large through loading width Page 54 Re 1 a Re 2 Er is inserted into the wheel bearing and secured by a clip Re 3 a AB...

Страница 120: ...73 Notes...

Страница 121: ...74 Notes...

Страница 122: ...75 Notes...

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