Service.
The Passat W8 S261_002 This Self-Study Programme presents the Passat W8. We will only explain the design and function where the items are totally new. All the changes described refer to the Passat model year 2001. The 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“ NEW This Self-Study Programme explains the design and function of new developments.
At a glance In a nutshell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Occupant protection . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Drive units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
In a nutshell The Passat W8 The top model of the Passat range is the first car from Volkswagen equipped with an 8-cylinder engine. The Passat W8 offers luxury class refinement in performance, comfort, safety, quality and equipment. It will be offered in saloon and estate versions. Innovations in the Passat W8 ● ● ● ● ● ● Special crash and acoustic measures W8 engine 4.
This high-quality car is based on the Passat launched in model year 2001. S261_003 The W8 engine is a totally new development. One of the technical features is its compact size. The engine 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.
In a nutshell The Estate All the innovations in the Passat W8 saloon are also in the estate. The bodies of both the estate and the saloon have been strengthened to improve the acoustics and increase crash safety. 6 But whether it is the estate or the saloon, the new Passat W8 is recognisable from the outside by its two chrome twin exhausts, the bi-xenon headlights, additional chrome trims and the 17 inch alloy wheels.
Inside, the standard equipment includes head airbags front and rear, high-class pillar and headliner trims, chrome and real wood 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 dynamic navigation system with audio, TV unit and Internet access, a digital sound pack and dark tinted rear windows.
In a nutshell The Saloon 100 kg S261_073 S261_005 2703 mm 1461 mm 4703 mm S261_006 S261_007 1746 mm Size and weight 8 Length 4703 mm Front track width 1511 mm Width 1746 mm Rear track width 1510 mm Height 1461 mm Perm. gross vehicle weight 2220 kg Wheelbase 2703 mm Kerb weight 1665 kg Turning circle 11.5 m Permitted roof load 100 kg Tank capacity 80 l Drag coefficient 0.
The Estate 100 kg S261_073 S261_008 2703 mm 1497 mm 4682 mm S261_009 S261_010 1746 mm Size and weight Length 4682 mm Front track width 1515 mm Width 1746 mm Rear track width 1510 mm Height 1497 mm Perm. gross vehicle weight 2290 kg Wheelbase 2703 mm Kerb weight 1725 kg Turning circle 11.5 m Permitted roof load 100 kg Tank capacity 80 l Drag coefficient 0.
Body Body modifications To fulfill the claims of greater luxury and safety, the body of the Passat W8 has been strengthened. By strengthening, we make a distinction between reinforcement to improve the acoustics 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 the rear seat bench is therefore not foldable.
Acoustic measures: Crash reinforcements: A cross strut is bolted between the front wheel housings. It is fixed to new supports welded to the wheel housings. An additional strut is welded to the front bulkhead near the front side member. The front footwell is reinforced by an additional cross-member.
Occupant protection Occupant protection Occupant protection is ensured by the airbag system with two front airbags, sidebags and head airbags, belts and belt tensioners as well as the child safety restraint system. The Passat W8 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 the tunnel.
The conventional inertia-reel seat belts are used on 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/pyrotechnical capsules.
Occupant protection Child safety restraint system Both the integrated child safety seats and the Isofix system are available on the Passat W8. Integrated child safety seats To use the integrated child safety seat, the swab elements must be raised and engaged. The correct belt run is corrected by an additional shoulder belt guide for children measuring 1.3 m to 1.5 m tall. A belt guide hook on the raised swab ensures that the belt runs safely across the child's lap.
Drive units The W8 engine in general The Passat W8 is fitted with one engine, the new W engine generation, the W8. The W layout is obtained by joining two V engines at an angle of 72°. This layout achieves a very compact 8-cylinder engine with very small dimensions. S261_015 S261_071 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.
Drive units Specifications Engine code BDN Displacement 3,999 cm3 Type W engine Valves per cylinder 4 Compression ratio 10.75±0.25:1 Bore 84.0 mm Stroke 90.2 mm Max. output 202 kW / 275 bhp 6000 rpm Max. torque 370 Nm 2750 rpm Engine management system Motronic M7.
The fuel delivery system The fuel delivery system of the Passat W8 has tank capacity of 80 litres. It consists of a 60 litre fuel tank as fitted to the Passat 2001 4Motion 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 reason. If the car has a puncture, there is an emergency wheel available in the reduced spare-wheel well.
Drive units The fuel pumps The 60-litre fuel tank contains an electrical fuel pump and a suction jet pump (entrainment pump). There is another electrical fuel pump in the 20-litre additional fuel tank. The different heights of the main tank and the additional tank require a controlled evacuation of the two tanks. The engine is always supplied with fuel by the pump in the 60 l tank. When the tank is full, fuel is first pumped from the 60 l tank.
Fuel pump control The fuel pump in the main fuel tank is controlled by the engine control unit. The fuel pump in the additional fuel tank is switched on by the fuel pump control unit. For this reason there are four fuel level senders in the entire tank and one sender G293 with a Reed contact. The signals from all the senders are sent to the fuel pump control unit. When 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.
Drive units Function diagram of fuel delivery system G6 G 293 G 292 G G 237 G 169 J 17 S228 Terminal 30 S J 538 CAN convenience G 23 S261_022 G 293 -Fuel level sender, additional fuel tank empty G 292 -fuel level sender, G J 17 - fuel pump relay G23 - fuel pump additional fuel tank J538 - control unit for fuel pumps - sender for fuel level indicator S228- fuse in the fuse box G 237 - sender 3 for fuel level indicator G 169 - sender 2 for fuel level indicator 20 G 6 - fuel pump (pre-suppl
The fuel level indicator Due to the different heights of the fuel tanks, four fuel level senders are required to calculate the remaining fuel amount correctly. The signals from all the senders are evaluated in the fuel pump control unit. The resulting signal runs via the CAN convenience bus to the dash panel insert and is used to control the fuel level indicator. The fuel pump control unit is self-diagnosable by address word 58.
Power transmission Gearbox The 6-speed manual gearbox 01E, four-wheel drive The 6-speed manual gearbox 01E from the Passat 2001 is also fitted to the Passat W8. As the Passat W8 is supplied with 4Motion four-wheel drive as standard, a Torsen differential is integrated in the gearbox to distribute the engine torque to all four wheels. The gearbox casing is adapted to fit the W8 engine. S261_024 The 5-speed automatic gearbox 01V The gearbox was adapted to fit the W8 engine, i.e.
The four-wheel drive 4Motion The main function of the four-wheel drive is to compensate the drive forces between the front and rear axles as a factor of positive engagement. S261_026 The Torsen differential detects wheel slip in one axle and distributes 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 processes.
Running gear The four-link front suspension The design of the front axle on the Passat W8 is identical to the Passat model year 2001.
The double wishbone rear suspension The proven double wishbone rear suspension with closed tubular subframe is fitted to the Passat W8. What is new are the wheel bearing housings with a modified attachment to the track rods.
Running gear The brake system The Passat W8 currently has the most powerful brake system of all Volkswagen car models. Despite high engine performance, it achieves excellent deceleration rates.
The hydraulic unit and ABS control unit The Passat W8 receives the Bosch 5.7 ABS system with ESP (Electronic Stability Programme) and the hydraulic brake assistant 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 electronic dynamics control V156. The pressure sensor G294 is contained in the hydraulic unit.
Running gear The ABS two-stage recirculating pump V39 is integrated in the Bosch 5.7 ABS system. When the ESP intervenes, it supplies the required preliminary pressure in the brake lines. The pistons of the two-stage recirculating pump operate at both sides. While pressure is building up in working chamber 1, the piston in working chamber 2 sucks brake fluid in. This creates a suction process with every piston stroke.
The hydraulic brake assistant system (BAS) is integrated in the ABS control unit. Accident research studies have shown that the majority of drivers do not press hard enough on the brakes in critical situations. This means that pressure build-up is insufficient to reach maximum vehicle deceleration. Pressure sensor G294 S261_034 The pressure sensor G294 detects the pressure rise in the brake system.
Vehicle electrical system The vehicle electrical system The electrical system on the Passat W8 has a similar design as on the Passat model year 2001. The following pages will describe modifications to components and functions compares with the Passat model year 2001. All components not described here are identical with the Passat 2001.
Window lifter motor with integrated door control unit Control unit for parking aid (luggage compartment, right) TV tuner CD changer DSP Window lifter motor with integrated door control unit S261_044 Dash panel insert with immobiliser control unit and diagnostic interface (gateway) Connector station A-pillar, left Fuse box, dash panel, left Convenience control unit in footwell, left 31
Vehicle electrical system The gas discharge headlight (GDH) with bi-xenon light The Passat W8 is only fitted with the bi-xenon headlight system. The improved light output of the system increases active driving safety as the driver can detect danger earlier. Due to the gas discharge headlights, all bi-xenon cars are equipped with automatic and dynamic headlight range control (refer to SSP 251). The bi-xenon headlight module produces the dipped beam and the main beam from a single gas discharge lamp.
Convenience and safety electronics Passat W8 with Internet access Networking a vehicle is no longer limited to the car's immediate surroundings but goes far beyond this. The in-car communications equipment now provides access to the worldwide data network, the Internet. The Internet interface is a device which is linked to the radio navigation system via the CAN bus.
Convenience and safety electronics The convenience system Interior monitor and anti-theft alarm system The Passat W8 anti-theft alarm system is equipped with a new function and a new alarm horn. The new alarm horn, designated the H12, is mounted in the plenum chamber. It has a separate power supply. Two lithium batteries integrated in the horn ensure that the horn operates independent of the car battery. The batteries have a life of approx. 5 to 7 years.
Function diagram of signal horn for anti-theft alarm system J393 30a H8 H12 F266 S261_048 F266 H8 H12 J393 30a -contact switch for bonnet, in lock part -signal horn for anti-theft alarm system -alarm horn -central control unit for convenience system -positive terminal The anti-theft alarm system has self-diagnostic capability.
Convenience and safety electronics The "Delta" radio system supplements the current radio generation. At first glance the differences to the other units are its larger size and a redesigned user interface.
MIX button In CD mode, tracks are played in random sequence. Rotary/push button for SCAN/TUNE SCAN Press in radio mode to search for a station or in CD mode to briefly play the start of the track. TUNE Rotate to tune the FM/AM station manually or to select the previous/next track 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 tracks.
Convenience and safety electronics Radio rear panel The rear panel of the radio contains the aerial sockets and the central connector. The aerial sockets Aerial input for FM/AM signal from control unit for aerial selection S261_050 Output to control unit for aerial selection The aerial sockets S261_051 To avoid plugging the aerial connectors in the wrong socket the connector housings have a plug coding and different colours. This means that a connector will only fit in its associated aerial socket.
Tuner The radio has two integrated FM/AM tuners. One of the tuners is only adjusted for receiving frequencies from FM/AM stations. The other tuner is used for setting the frequencies to receive TP/FM traffic radio stations. This allows selection of traffic radio messages from a TP station irrespective of the FM station setting. Example: You are listening to an FM station, e.g. NDR 2, which broadcasts supraregional traffic radio messages.
Convenience and safety electronics CAN bus networking To control functions and processes, the radio control unit and the dash panel insert exchange the following information over the CAN bus.
The radio aerial system FM/AM reception of the radio system on the Passat W8 has been considerably improved. This was achieved by fitting four independent FM/AM aerials (see SSP 147). If reception is poor, the aerial control unit switches to another aerial with a stronger signal. The aerials are in different locations on the 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.
Convenience and safety electronics Location of aerials on the estate On the estate, the aerials are located in the rear side windows. Viewed in the direction of travel there is a combined AM/FM aerial on the lefthand side and two FM aerials on the right-hand side. As on the saloon, each FM aerial is allocated to an aerial amplifier. Even on the estate, the amplifiers should not be wrongly allocated. As the aerials on the estate do not use the rear window heater, no suppressors are required.
Function The radio signal received from one of the four aerials runs via an aerial switch circuit inside the aerial selector control unit to the tuner. In the tuner, the signal quality is checked and the result is fed back to the control unit via an aerial output line. If the selected signal is too weak for tuner reception, the aerial switch switches automatically to the next of the four aerials. This process is repeated until an aerial is found with good reception.
Heating, air conditioning system Heating and air conditioning system The CLIMAtronic with fully automatic control is offered on the Passat W8.
The externally regulated compressor The compressor basically works on the principle of the swash plate.
Heating, air conditioning system The overload protection The V-belt pulley and the driven plate are positively joined by a shaped rubber element. When the compressor is operational, the two plates rotate in the same ratio to each other.
If the compressor is damaged internally, it may cause the drive shaft to block. The driven plate will also stop. This drastically increases the transfer forces between the belt pulley and the driven plate. The shaped rubber element is pressed by the belt pulley in the direction of rotation 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 unhindered.
Heating, air conditioning system The evaporator control circuit When the CLIMAtronic is ON and the driver enters the desired temperature, the refrigerant demand is determined and changed by a number of different influences. The components described below form a control circuit for regulating the desired temperature. CLIMAtronic control unit J255 The compressor regulating valve N280 The external regulating valve forms an interface between the suction and high pressure sides of the compressor.
Outlet temperature sender G263 Influencing parameters: The outlet temperature sender G263 is located in the air duct behind the evaporator. It detects the vent temperature downstream of the evaporator.
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261 For internal 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-bleached pulp.
