Service.
The Passat, Model Year 2001 This Self-Study Programme summarises the design features of the Passat 2001. It provides you with information about the various engines and gearboxes, the front and rear axle configurations, the electronics and the modifications to the convenience system. The design and function of the various components and modules will not be explained in depth in this SSP. have previously been described in other Self-Study Programmes.
At a glance Concisely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Environmental protection . . . . . . . . . . . . . . . . . . . . . . 10 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 The engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Concisely Saloon Brief description of vehicle The Passat 2001 is based on the highly successful predecessor model. In revising the vehicle, Volkswagen's designers retained the characteristic basic shape of the saloon, with its distinctive dome roof. The front end of the Passat has been redesigned, and particularly the bonnet, the wings and the radiator grille. The bumpers now have full-length rubbing strips.
Concisely The rear end has been revised also, including the rear lights. ● Solar roof The headlights have clear lenses and the indicator lights are built into the headlights. BI-xenon headlights with dynamic headlight range control are also available.
Concisely Variant The Variant has been revised, too. In addition to the new front-end design, which is identical in the Variant and saloon, the rear end and the rear lights have been redesigned in the Variant. ● New locking concept with radio wave folding key (fob) built into the driver's door.
Concisely The Passat has a new locking concept. All models come with radio wave folding keys. There is no lock cylinder on the front passenger's door and the tailgate is separately released. ● Comfort-enhanced air conditioning system ● Distance control ● Spare wheel fitted with ready-for-road tyre 251_104 All technical modifications apply to saloon and Variant.
Concisely Saloon 251_018 2703 mm (2707) 1462 mm (1459) 4703 mm (4675) 1746 mm (1740) 251_016 Dimensions and weights 8 Model MY 2001 MY 1997 Length 4703 mm 4675 mm Width 1746 mm 1740 mm Height 1462 mm 1459 mm Wheelbase 2703 mm 2707 mm Turning circle 11.4 m 11.4 m Tank capacity 62 l 62 l Drag coefficient 0.27 cw 0.27 cw Weight (unladen) 1277 kg 1233 kg The figures quoted in brackets refer to the predecessor model.
Concisely Variant 251_054 2705 mm (2707) 1470 mm (1459) 4682 mm (4675) 251_055 251_056 1746 mm (1740) Dimensions and weights Model MY 2001 MY 1997 Length 4682 mm 4675 mm Width 1746 mm 1740 mm Height 1470 mm 1459 mm Wheelbase 2705 mm 2707 mm Turning circle 11.4 m 11.4 m Tank capacity 62 l 62 l Drag coefficient 0.27 cw 0.
Environmental Protection The water management plan Environmental protection is a matter of fundamental importance. Each and everyone of us should strive to protect the environment wherever possible, day by day. You are required to think pro-environmentally when you repair and service vehicles. And we must do likewise in vehicle manufacture.
Environmental Protection The Emden plant The Emden plant, where the majority of Passat models are built, was the first automobile manufacturing plant in Europe to be certified (in September 1995). The plant was re-audited and recertified in September 1998. 251_091 West combined heat and power station Procurement of drinking water Cyclator Chem.
Safety Occupant protection The front airbags Full-size airbags are fitted in the Passat 2001 on the driver's and front passenger's sides. As in the predecessor model, the airbags have filling volumes of approximately 64 and 120 litres respectively. The central airbag control unit is located behind the central console, above the tunnel. 251_082 The side and head airbags The side and head airbags afford excellent side impact protection.
Safety As before, the system has two lateral acceleration sensors, located beneath the seats. The lateral acceleration sensors are programmed with a vehicle-specific parameter when they are replaced. Where repair or replacement of defective parts is needed, it is important to specify the correct SP-number.
Safety The belt tensioner/belts Belts and BELT TENSIONERS round off the restraint system. Standard belt tensioner systems are used in the outer seat positions, front and rear. These systems deploy mechanically and pyrotechnically. Ball-type tensioner Ball-type tensioners are used in the front seating positions. In comparison with the predecessor model, they are rotated through 180°. The rear seating positions have rotary belt tensioners.
Safety Child restraint systems Integrated child safety seats To make use of the integrated child safety seats, the elements of the seat cushion have to be raised and locked in place. An additional shoulder belt guide corrects the belt position for children with a height from 1.3m - 1.5m. A belt guide hook on the booster cushion ensures an ideal belt position around the child's pelvis.
Body Body reinforcements The body of the Passat 2001 was reinforced in the zones described below. In other words, the body panels have been thickened and the spot welds have been supplemented with laser-welded seams.
Body B-pillar, left Side member, left Side member, top left Wheel housing, inner surface (sheet-metal reinforcements have been welded in on the left and right ) 251_041 Side member, top right Tunnel reinforcement Vehicle safety and natural body vibration (40 Hz) have been greatly improved as a result of these modifications.
The engines Engines in general On the following pages, you will find descriptions of the engines to be used in the new Passat. They include specifications, torque and performance curves, as well as details of technical features and engine modifications. In developing all engines, special emphasis was put on raising fuel economy and reducing exhaust emissions.
The Engines 1.6-litre 75 kW petrol engine The engine is an improved version of the 1.6-litre petrol engine developing 74kW.
The Engines 1.8-litre 110 kW petrol engine with 5 valves per cylinder and turbocharger The engine was adopted from the predecessor model and adapted to meet the applicable exhaust emissions regulations, as outlined below.
The Engines 2.0-litre 85 kW petrol engine The 2.0-litre engine was adopted from the predecessor model. In vehicles which have automatic transmission, an electrical vacuum pump produces the vacuum required for the brake booster (see page 43). 251_031 Specifications 251_026 Engine code AZM Displacement 1984 cm3 Type Row Number of cylinders 4 Number of valves per cylinder 2 Compression ratio 10.3:1 Bore 82.5 mm Stroke 92.8 mm Max. power 85 kW/110 bhp @ 5000 rpm Max.
The Engines The 2.3-litre 125 kW V-5 petrol engine with 4 valves per cylinder The following modifications have been made to this engine: ● ● ● ● 4 valves per cylinder ROLLER CAM FOLLOWER valve gear BUILT-UP CAMSHAFT CAMSHAFT TIMING CONTROL intake and exhaust camshafts ● Plastic twin-path intake manifold ● ELECTRIC THROTTLE DRIVE ● "TUMBLE" INTAKE PORT These modifications provide higher power output and torque, and hence better driving performance.
The Engines 2.8-litre 142 KW V-6 petrol engine with 5 valves per cylinder The Passat is still powered by the highperformance 2.8-litre V-6 petrol engine. The following improvements were made to this engine: ● 2 lambda probes were integrated in the exhaust line before the catalyst and ● after the catalyst. These modifications allow the engine to meet the stringent EU 4 exhaust emission standard.
The Engines 1.9-litre 74 kW TDI engine with pump injection system The 1.9-litre 74 kW TDI engine is based on the 1.9-litre TDI engine developing 85 kW. It differs from the basic engine in the following respects: ● The software used in the engine control unit was adapted to the lower engine power. ● The injectors have smaller nozzle holes.
The Engines The 1.9-litre 96 kW TDI engine with pump injection system The 1.9-litre 96 kW TDI engine differs from 1.9litre 74kW TDI engine with pump injection system in the following respects: ● The software used in the engine control unit was adapted to the higher engine power. ● The injectors have larger nozzle holes. ● The TURBOCHARGER is larger. ● The crankcase is made of stronger material. ● The crank pin diameter of the crankshaft has been enlarged. ● The conrods are made of stronger material.
The Engines The 2.5-litre V-6 TDI engine developing 110 kW The 2.5l V-6 TDI ENGINE DEVELOPING 110 KW has demonstrated its success in the predecessor model and will also be used in the Passat 2001 The following technical innovations were employed to improve mixture preparation and reduce exhaust emissions: ● The number of pump pistons in the radial-piston distributor injection pump was increased by 1, thereby raising the maximum INJECTION PRESSURE.
Power Transmission Manual gearboxes 5-speed manual gearbox 012/01W The 012 or 01W manual gearbox has a proven service record in the predecessor model. It will be installed as a 5-speed gearbox in combination with all petrol engines and also in the 74 kW diesel engine. 251_061 5-speed manual gearbox 01A The 01A four-wheel drive manual gearbox from the predecessor model will be installed as a 5-speed gearbox in combination with the 2.0-litre, 2.3-litre and 2.8-litre petrol engines.
Power Transmission Automatic gearbox The new Passat is available with the same automatic transmission as in the predecessor model. The design and function of both automatic transmissions have been adopted without change.
Power Transmission Engine/gearbox combinations Front 4 Motion 1.6-litre ALZ 012 / 01W 01N 1.8-litre AWT 012 / 01W 01N 2.0-litre AZM 012 / 01W 01 V 2.3-litre AZX 012 / 01W 01 V 01 A 01 A 2.8-litre AMX 01 V 1.9-litre AVB 012 / 01W 01N 1.9-litre AVF 01 E 01 V 01 A 2.
Running Gear The four-link front suspension The FRONT AXLE is a four-link front suspension. It has been is accomodated to the modified vehicle dimensions and axle loads, as compared to the previous Passat. Bearing bracket Tubular subframe 251_072 The rack-and-pinion steering system The new Passat has HYDRAULIC POWER STEERING as standard.
Running Gear The torsion beam rear axle In the TORSION BEAM REAR AXLE, the spring/ damper settings have been adapted to the modified axle loads. Shock absorber Wheel bearing unit Coil spring 251_074 Rear axle bearing Modified offset depth Rim offset depth was reduced to 37 mm from 45 mm, with the result that the wheel is now flush with the body exterior. Wheels fitted with winter tyres with ET45 offset depth can still be used, except on the Passat 2001 with large brake discs.
Running Gear The brakes The front and rear disc brakes are configured for excellent deceleration under braking. New, larger brakes will therefore be used in the new Passat depending on engine type. 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 251_095 Bosch 5.3 anti-lock braking system The new Passat still has a Bosch 5.3 anti-lock braking system with ESP.
Running Gear The electronic vacuum pump All petrol engines which have automatic transmission conforming to exhaust emission standard EU4 will have an electrical vacuum pump for brake servos. This pump is required: because not enough vacuum is provided for the brake booster via the intake manifold during the cold-starting phase. 251_058b The electrical vacuum pump makes for reliable pneumatic brake boosting. It is activated by the engine control unit as required.
Running Gear Four-wheel drive The double wishbone rear suspension The 4-wheel-drive version of the Passat has a double wishbone rear suspension with a closed tubular subframe attached to which are the track control arms for wheel location and the differential. The flat-type construction of the rear axle provides a spacious interior. This type of construction proved successful in the predecessor model. Insulating bonded rubber bushes provide good acoustic isolation from the vehicle body.
Running Gear Notes 35
The Electrics The vehicle electrical system is distributed, as in the Passat 97. The fitting locations of the fuse holders, relay carriers, auxiliary relay carriers and connector stations have been adopted without change. Airbag control unit (in gearbox tunnel) The wiring harnesses have been extended to include new systems (solar roof, distance control, dynamic navigation with TV etc.) and the connector stations have been reorganised accordingly.
The Electrics Window lifter motor with integrated door control unit Control unit for distance control (in luggage compartment on right) TV tuner CD changer DSP Window lifter motor with integrated door control unit 251_003 Dash panel insert with immobiliser control unit and diagnosis interface (Gateway) Connector station in left A-pillar Fuse holder dash panel left Convenience control unit in the footwell left 37
The Electrics Headlights Standard headlights Two types of headlights are available for the new Passat. The basic specification consists of a clear glass triaxial ellipsoid headlight with a H7 bulb as a high beam headlight. 251_005 High beam (H7 lamp) Indicator lights Low beam Gas discharge lamp (GDL) with BI-xenon bulb A BI-xenon headlight is available as an optional extra in place of the standard triaxial ellipsoid headlight.
The Electrics More light means more safety The Passat, model year 2001, uses the BI-xenon headlight system. The system's improved luminous efficiency provides higher active driving safety, because hazards can now be recognised sooner. The wider range and increased brightness of the light beam enable the driver to recognise hazards and reduce speed earlier. Provided the driver reacts in time, he will be able to stop the vehicle ahead of the hazard and thereby avoid a collision.
The Electrics Design of a BI-xenon headlight module The headlight module comprises: ● ● ● ● ● electronic ballast (EVG) headlight range control motor conventional light bulbs gas discharge headlight module housing with bonded clear glass lens 251_006 251_067 ballast In the high beam setting, the mechanism allows all of the light generated in the lamp to pass through. Until now, no single gas discharge headlight has been capable of producing both low and high beams.
The Electrics The shutter screens off part of the light cone generated. (light/dark boundary) 251_306 The shutter is electromagnetically adjusted to produce the high beam. The entire light cone now becomes effective. The H7 lamp is also switched on.
The Electrics Automatic dynamic headlight range control (LWR) The Passat 2001 with BI-xenon headlights has automatic headlight range control. Task The task of the automatic headlight range control is to adjust the headlights to compensate for variation in ride height as a function of payload. The automatic headlight range control also compensates for variation in headlight range caused by dynamic effects under braking and acceleration, for example.
The Electrics The dash panel insert The dash panel insert is the Group dash panel insert with blue backlighting and translucent red dials. The dash panel insert is available in three versions. They mainly differ with regard to the display options in the central display. The modified design and chrome-bezeled instruments stand out. The instruments are now operated by stepping motors.
The Electrics New warning lamps: Designation Symbol Function Selector lever lock K169 serves to remind the driver to depress the brake. The selector lever lock on automatic transmissions is released in this way Door/tailgate open warning lamps (K116/K123-K127) indicates open doors/tailgate. In vehicles with a multifunctional display, this warning is issued as a symbol. Cruise control system warning lamp K31 comes on when the cruise control system (CCS) is switched on.
The Electrics Third-generation immobilisation Function The first phase (key recognition) is identical to that of function immobiliser II. However, the mode of communication between the engine control unit and the immobiliser control unit has changed. The engine control unit generates a number (variable code) by means of a random-number generator. The engine control unit and the immobiliser control unit each calculate a result based on a table of formulae.
The Electrics Networking of CAN systems Engine control unit Injection pump (V-6 TDI) Gearbox control unit Brake control unit (ABS, ESP,...
The Electrics The diagnosis interface (Gateway) is integrated in the dash panel insert and has the following tasks: ● To transfer diagnosis data from the drivetrain CAN bus and convenience CAN databus to the K-wire so that they can be used by the self-diagnosis. This is a basic requirement for self-diagnosis of certain systems (the memory seat does not have its own Kwire, for example). ● To facilitate communication/data exchange between users of a databus and between users of different databus systems.
The Electrics Convenience system The convenience system was modified as follows: ● Standard radio wave remote control with additional button for tailgate remote release (RLR) ● The lock cylinder on the front passenger's side has been deleted. ● New tailgate locking concept The tailgate can be released: - by pressing the button in the new driver's door switch unit. This function can be disabled by key switch. - by means of the handle switch in the tailgate.
The Electrics Memory seat The electronic seat adjustment was improved in the following areas: ● The memory control unit now has a nonvolatile memory which retains stored seating positions while the battery terminals are disconnected. ● It is no longer necessary to initialise the seat after having disconnected a battery. ● The tone generator emits an acknowledgement signal after the seating position is stored.
The Electrics Sliding roof/solar roof The solar roof generates electric current via integrated solar cells. This powers the fresh air blower, which cools down the vehicle interior to approx. 20°C. The system operates when the ignition is off and when the sliding roof is open or tilted. 251_040 A DC/DC converter is mounted on the underside of the sliding roof. The DC/DC converter serves the purpose of current/ voltage adaptation between the solar generator (solar module) and the blower.
The Electrics Distance control (ADK) The distance control (ADK) aids parking in reverse. For this purpose, four ultrasound converters are built into in the rear bumper. The control unit is located in the luggage compartment on the rear left. The tone generator is under the rear window shelf in the saloon and built into the control unit in the Variant.
The Electrics The radio navigation system Glossary MFD radio navigation system with dynamic route guidance The traffic data used by the system is based on the RDS TMC service which is supported by radio stations and soon to be available throughout Europe. Use of a RDS-TMC control unit allows the driver to freely select a radio station for data reception. This means that TMC data and normal radio are received with different receivers. All traffic information available within a radius of approx.
The Electrics Radio navigation with dynamic route guidance Dynamic route guidance ● Automatic rerouting to avoid traffic delays ● The system assesses traffic delays (road closure in both directions, traffic jam, slow-moving traffic) on the basis of the driving time remaining to destination ● No driver intervention is necessary and the driver can concentrate fully on the road ahead.
The Electrics TMC services What is a TMC service? Public and private A TMC (Traffic Message Channel) service is the net result of the activities undertaken by a service provider to broadcast traffic information. To make use of these services, the road user only requires an RDS-TMC receiver. TMC services for broadcasting general traffic information are freely available in all European countries. These messages relate to road safety and various traffic delays.
The Electrics Radio navigation system with TV The TV function is an extended function of the navigation system. All terrestrial programs can be received with the TV tuner. Terrestrial programs are all programs that can be received using a normal antenna, and not programs that can only be received by satellite. The equipment includes a preinstalled wiring harness for connecting external equipment such as a video recorder or a notebook. However, this connection is currently unavailable to the user.
The Electrics Dynamic navigation with TV tuner The system which provides dynamic navigation and TV tuner includes the following components: ● radio navigation system (RNS) with multifunctional display ● window aerial with amplifier ● TV tuner with control unit in the luggage compartment on the left Global Positioning System (GPS) Antenna for radio and navigation RDS-TMC tuner Antenna for TV tuner Amplifier RNS TV tuner The antenna for the TV tuner is integrated in the rear window in the saloon and in
The Electrics Pre-installed wiring harness for telephone installation A wiring harness for connecting a mobile phone is available for the Passat 2001. The mobile phone rest is attached to the dash panel. The mobile phone is connected to an interface box fitted below the armrest. The interface box is the interface between the mobile phone, the vehicle electrical system and the antenna. When the mobile phone is placed in the rest, the driver can make a telephone call using the hands-free facility.
The Electrics The heating and air conditioning system The Climatronic air conditioning system has been provided with an additional temperature sensor, as compared to the previous model. The temperature sensor is built in the air duct on the outlet side of the evaporator. It is designated "Evaporator vent temperature sender G263". This sensor provides the Climatronic control unit with a continuous stream of data on the air temperature on the outlet side of the evaporator.
The Electrics This allows the ambient temperature (G17 and G89) and the air outlet temperature on the outlet side of the evaporator to be checked and the control unit to control compressor shutoff more precisely. Dehumidification of the vehicle interior is improved because the air is dried more quickly. Windscreen fogging is thereby largely eliminated. Compressor 251_012 Self-diagnosis A fault in the temperature sensor is entered in the control unit's fault memory.
Index Index A I ALUMINIUM CYLINDER HEAD WITH ROLLER CAM FOLLOWER (RSH) - SSP 196 INJECTION PRESSURE - SSP 241 INJECTOR - SSP 241 B ISOFIX - SSP 192 BELT TENSIONERS/BELTS - SSP 192 J BUILT-UP CAMSHAFT - SSP 243 K C KNOCK SENSORS - SSP 233 CAMSHAFT TIMING CONTROL - SSP 246 L CRANKCASE VENTILATION - SSP 241 M D N DOUBLE WISHBONE REAR SUSPENSION - SSP 194 O E P ELECTRIC THROTTLE DRIVE - SSP 210 PLANAR PROBE BEFORE CATALYST - SSP 231 F Q FIVE- AND SIX-HOLE INJECTORS - SSP 241 R FRONT AIRBAGS - SSP 192 RACK-
Index Index S T TORSION BEAM REAR SUSPENSION - SSP 102 TRAPEZOIDAL CONROD - SSP 209 TUMBLE INTAKE PORT - SSP 198 TURBOCHARGER - SSP 190 U V V-6 TDI ENGINE - SSP 183 W X Y Z 61
Notes 62
Notes 63
251 For internal use only © VOLKSWAGEN AG, Wolfsburg All rights reserved. Technical specifications subject to change without notice. 040.2810.70.20 Technical status: 09/00 ❀ This paper is produced from non-chlorine-bleached pulp.
