February 2002 3800 Hamlin Road Volkswagen of America, Inc

The Passat W8

Volkswagen of America, Inc.3800 Hamlin RoadAuburn Hills, MI 48326Printed in U.S.A.February 2002

Self-Study ProgramCourse Number 822203

Volkswagen of America, Inc.Service TrainingPrinted in U.S.A.Printed 2/2002Course Number 822203

©2002 Volkswagen of America, Inc.

All rights reserved. All information contained inthis manual is based on the latest informationavailable at the time of printing and is subjectto the copyright and other intellectual propertyrights of Volkswagen of America, Inc., its affiliatedcompanies and its licensors. All rights arereserved to make changes at any time withoutnotice. No part of this document may bereproduced, stored in a retrieval system, ortransmitted in any form or by any means,electronic, mechanical, photocopying, recordingor otherwise, nor may these materialsbe modified or reposted to other sites withoutthe prior expressed written permission ofthe publisher.

All requests for permission to copy andredistribute information should be referred toVolkswagen of America, Inc.

Always check Technical Bulletins and theVolkswagen Worldwide Repair InformationSystem for information that may supersede anyinformation included in this booklet.

Trademarks: All brand names and product namesused in this manual are trade names, servicemarks, trademarks, or registered trademarks; andare the property of their respective owners.

i

Table of Contents

The Self-Study Program provides you with informationregarding designs and functions.

The Self-Study Program is not a Repair Manual.

For maintenance and repair work, always refer to thecurrent technical literature.

Important/Note!

New !

Introduction ...............................................................................1

The Passat W8

Engine ........................................................................................8

The W8 Engine

Fuel Supply ..............................................................................11

Fuel Delivery System, Fuel Delivery SystemFunctional Diagram

Transmissions .......................................................................... 16

Six-Speed Manual Transmission 01E with 4MOTIONAll-Wheel Drive, Five-Speed Automatic Transmission01V with 4MOTION All-Wheel Drive

Final Drive ................................................................................17

4MOTION All-Wheel Drive

Running Gear........................................................................... 18

Four-Link Front Suspension, Steering,Double-Wishbone Rear Suspension, Brake System

Body .........................................................................................24

Body Modifications

Occupant Protection ...............................................................26

Airbags and Seat Belts

Air Conditioning System ........................................................ 28

Heating and Air Conditioning System, ExternallyControlled A/C Compressor, Evaporator Control Circuit

Electrical System.....................................................................36

Vehicle Electrical System, Bi-Xenon Headlights,Automatic Dynamic Headlight Range Control,Instrument Cluster, Comfort/Convenience System,Functional Diagram for Anti-Theft System Alarm Horns,Entertainment and Communications,Functional Diagram for Antenna System

Knowledge Assessment .........................................................57

Introduction

1

The Passat W8

This Self-Study Program presents thePassat W8, new to the North-Americanmarket for 2002. We will only explain thedesign and function of items that are totallynew. All the changes described refer to thePassat model year 2002.

The design and function of the W8 engineis described in detail in two separate Self-Study Programs:

• The W Engine Concept,Course Number 821203.

• Passat W8 Engine Management,Motronic ME 7.1.1, CourseNumber 843103.

SSP261/002

Introduction

2

The top model of the Passat range is thefirst car from Volkswagen equipped with an8-cylinder engine. The Passat W8 offersluxury class refinement in performance,comfort, safety, quality and equipment.

It will be offered in sedan and wagonversions.

Innovations in the Passat W8

• Six-speed manual transmission, or five-speed automatic transmission withTiptronic function.

• Special body design refinements toenhance crash protection and acoustics.

• The new W8 engine.— 244 cu in (3999 cm3).— 270 bhp (201 kW) @ 6,000 rpm.— 273 lbs-ft (370 Nm) of torque @

2,500 rpm.— Four valves per cylinder.

Horsepower specificationwas not final at the time ofprinting. Please seewww.vwwebsource.comfor the latest specifications.

• Larger fuel tank with a capacity of 21.1gallons (80 liters).

• Climatronic air conditioning system.• Bi-xenon headlights.• 4MOTION all-wheel drive.• Dual exhaust system with two chrome

tailpipes on each side.• 7J x 16 alloy wheels.• P205/55 R16H all-season tires.

The sedan

Introduction

3

This high-quality car is based on thePassat launched in North America inmodel year 2001.

SSP261/003

The W8 engine is a totally newdevelopment. One of the most importanttechnical features of the W8 engine is itscompact size.

The engine power output is transferredto the road through a five-speed automatictransmission with Tiptronic and 4MOTION. Asix-speed manual transmission will beavailable at a later date.

For a description of all theavailable options, please seewww.vwwebsource.com forthe latest information.

Introduction

4

All the innovations in the Passat W8 sedanare also available in the wagon body style.The bodies of both the wagon and thesedan have been strengthened to improvetheir acoustics and increase crash safety.

Whether it is the wagon or the sedan, thenew Passat W8 is distinguishable fromother Passat models on the outside by:

• Dual exhaust with two chrome tailpipeson each side.

• Bi-xenon headlights.• Additional chrome body trim.• 7J x 16 alloy wheels.• P205/55 R16H all-season tires.

The wagon

Introduction

5

S261/004

Inside both body styles, the standardequipment includes:

• Side airbags in the front seats.• Head airbags front and rear.• Upgraded pillar and headliner trims.

• Chrome and real wood interior trim.• Exclusive upholstery.• On-board computer.• Multi-function trip computer.The extensive list of Passat W8 optionsincludes:

• New luxury leather seats.• New sport seats.• A digital sound pack.• Dark tinted rear windows.

6

Sedan Specifications

• Front track width

59.49 inches (1511 mm)

• Rear track width

59.45 inches (1510 mm)

• Permitted gross vehicle weight

4,894 pounds (2220 kg)

• Curb weight

3,671 pounds (1665 kg)

• Permitted roof load

220 pounds (100 kg)

• Drag coefficient

0.27 CD

• Length

185.16 inches (4703 mm)

• Width

68.74 inches (1746 mm)

• Height

57.52 inches (1461 mm)

• Wheelbase

106.42 inches (2703 mm)

• Turning circle

37.7 feet (11.5 m)

• Fuel tank capacity21.1 gallons (80 liters)

Introduction

SSP261/007

57.5

2 in

(146

1 m

m)

SSP261/006

68.74 in (1746 mm)

SSP261/005

185.16 in (4703 mm)

106.42 in (2703 mm)

SSP261/73220 lbs (100 kg)

7

Wagon Specifications

• Front track width

59.49 inches (1511 mm)

• Rear track width

59.45 inches (1510 mm)

• Permitted gross vehicle weight

5,049 pounds (2290 kg)

• Curb weight

3,803 pounds (1725 kg)

• Permitted roof load

220 pounds (100 kg)

• Drag coefficient

0.27 CD

• Length

184.33 inches (4682 mm)

• Width

68.74 inches (1746 mm)

• Height

58.94 inches (1497 mm)

• Wheelbase

106.42 inches (2703 mm)

• Turning circle

37.7 feet (11.5 m)

• Fuel tank capacity

21.1 gallons (80 liters)

Introduction

SSP261/010

68.74 in (1746 mm)

SSP261/009

58.9

4 in

(149

7 m

m)

SSP261/008

184.33 in (4682 mm)

106.42 in (2703 mm)

SSP261/73220 lbs (100 kg)

Engine

8

The W8 Engine

The Passat W8 comes with one engine,the W8.

The new generation W engine seriesincorporates design features of the V andVR engines. As with the V engines, thecylinders are arranged in two banks. In theW8 engine, these banks of cylinders arealigned at a V-angle of 72 degrees inrelation to one another. As in the VRengines, the cylinders within each bankmaintain a V-angle of 15 degrees.

This layout achieves a very compacteight-cylinder engine with relatively smalldimensions. When the W8 engine isviewed from the front, the cylinderarrangement looks like a double-V. Putthe two Vs together, and you get a W.Hence the designation “W engine.”

Compared with other eight-cylinderengines, the W8 is relatively lightweightdue to its size and through the use ofaluminum alloy castings, slim connectingrods, and short pistons.

Four valves per cylinder, low-friction rollerrocker fingers, and chain drive for thefour overhead camshafts with camshafttiming adjusters are also features of thismodern engine.

For more detailed informationabout the design and functionof W engines, please refer toThe W Engine Concept, CourseNumber 821203.

SSP248/104

SSP248/001

SSP248/002

72°

15° 15°

SSP248/101

Engine

9

W8 Engine Specifications

SSP248/017

• Displacement

244 cu in (3999 cm3)

• Bore

3.307 in (84.0 mm)

• Stroke

3.550 in (90.168 mm)

• Number of cylinders

8

• Number of cylinder heads

2

• Offset

± 0.492 in (12.5 mm)

• Bank offset

0.512 in (13 mm)

• V-angle of cylinder heads

between banks

72 degrees

• V-angle of cylinders in a bank

15 degrees

• Number of valves

4 per cylinder

• Crankshaft journal offset

218 degrees

• Firing order

1-5-4-8-6-3-7-2

Engine

10

• Fuel type recommendation

Premium unleaded gasoline (91 AKI)

• Engine management system

Bosch Motronic ME 7.1.1

• Installation position

In-line

• Allocated transmissions

5HP19 4MOTION,C90 6-speed 4MOTION

• Dimensions

16.5 in (420 mm) long28.0 in (710 mm) wide26.9 in (683 mm) high

• Weight

Approximately 425 lbs (193 kg)

• Maximum power output

Approximately 270 bhp(201 kW) @ 6,000 rpm

• Maximum torque

Approximately 273 lbs-ft(370 Nm) @ 2,500 rpm

Horsepower and torquespecifications were not final atthe time of printing. Please seewww.vwwebsource.com for thelatest specifications.

SSP248/018

Torque and Power Output

Speed (rpm)

2000 4000 6000

hp kW

268 200

201 150

134 100

67 50

lbs-ft Nm

369 500

295 400

221 300

148 200

74 100

SSP248/021

To

rqu

e

Ou

tpu

t

Fuel Supply

11

Fuel Delivery System

Fuel Tanks

The Passat W8 has a combined fuel tankcapacity of approximately 21.1 gallons(80 liters). The fuel delivery system includesthe 15.85-gallon (60-liter) fuel tank as usedon the Passat 2002 4MOTION and anauxiliary tank with a capacity of 5.28 gallons(20 liters).

5.28-gal (20-L)Auxiliary Fuel Tank

SSP261/018

15.85-gal (60-L)Main Fuel Tank

Connecting Tube

The two fuel tanks are connected by atube. The auxiliary fuel tank is located underthe spare-wheel well which has beenreduced in size to accommodate the tank.There is still enough room to store atemporary spare in the reducedspare-wheel well in the event of a flat tire.

12

Fuel Supply

Fuel Pumps

The 15.85-gallon (60-liter) main fuel tankcontains an electric Fuel Pump G6 and asuction jet pump (entrainment pump).There is also an electric Transfer Fuel PumpG23 in the 5.28-gallon (20-liter) auxiliary fueltank. The different heights of the main tankand the auxiliary tank require a controlledevacuation of the two tanks. The engine isalways supplied with fuel by the pump inthe main tank.

Transfer Fuel Pump G23

SSP261/020Connecting Tube

5.28-gal (20-L)Auxiliary Fuel Tank

15.85-gal (60-L)Main Fuel Tank

Filler Neck

SSP261/019

Suction Jet Pump

Fuel Pump G6

When both tanks are full, fuel is firstpumped from the main tank. When thefuel level in the main tank drops to10.57 gallons (40 liters), the fuel pump inthe auxiliary fuel tank is activated andpumps fuel from the auxiliary tank to themain tank. When the auxiliary fuel tank isempty, the remaining fuel is pumped fromthe main tank. The suction jet pump(entrainment pump) delivers fuel from theleft chamber of the main tank to the FuelPump G6 located in the right chamber.

13

Fuel Supply

Fuel Level Sensors

There are four fuel level sensors thatprovide information about fuel levels in thevarious parts of the two tanks. Thisinformation is necessary to controlevacuation of the tanks and to calculate theamount of fuel remaining in the combinedtanks:• Sender for Fuel Gauge G• Fuel Level Sensor 2 G169• Fuel Supply Sensor 3 G237• Auxiliary Tank Fuel Level Sensor G292There is also a separate reed-contactsensor that provides a signal when theauxiliary tank is empty:• Auxiliary Tank Fuel Level Empty

Sensor G293The signals from all these sensorsare sent to the Fuel PumpControl Module J538for evaluation.

Fuel Pump G6 andSender for Fuel Gauge G

SSP261/021

Suction Jet Pump andFuel Level Sensor 2 G169

Fuel Supply Sensor 3 G237

Transfer Fuel Pump G23,Auxiliary Tank Fuel Level Sensor G292,and Auxiliary Tank Fuel LevelEmpty Sensor G293

Fuel Pump Control

The Fuel Pump G6 in the main fuel tank iscontrolled by the Motronic Engine ControlModule J220. The Transfer Fuel Pump G23in the auxiliary fuel tank is controlled by theFuel Pump Control Module J538.When the Fuel Level Sensor 2 G169 signalsa fuel level of 10.57 gallons (40 liters) in themain fuel tank, the Fuel Pump ControlModule J538 turns on the Transfer FuelPump G23 in the auxiliary fuel tank.The Transfer Fuel Pump G23 pumps fuelfrom the auxiliary fuel tank to the main fueltank until the Auxiliary Tank Fuel LevelEmpty Sensor G293 signals “auxiliary fueltank empty.” Then the Fuel Pump ControlModule J538 turns off the Transfer FuelPump G23. This prevents the pump fromrunning in an empty tank, and reducesnoise and power consumption.

14

Fuel Supply

Fuel Level Indicator

Because of the differences in the shape,size, and placement of the fuel tanks,signals from four of the fuel level sensorsare required to calculate the remaining fuelamount correctly:

• Sender for Fuel Gauge G• Fuel Level Sensor 2 G169• Fuel Supply Sensor 3 G237• Auxiliary Tank Fuel Level Sensor G292

The signals from these four sensors areevaluated in the Fuel Pump Control ModuleJ538 to calculate the combined amount offuel in the tanks. The resulting signal runsvia the convenience CAN data bus to theinstrument cluster and is used to controlthe fuel level indicator reading.

Fuel Pump Control Module J538

The Fuel Pump Control Module J538 islocated in the spare-wheel well, embeddedin plastic. It is connected to its inputsensors and to the Control Module with

Indicator Unit in Instrument Panel InsertJ285 through the convenience CAN databus. It has the following tasks:

• Evaluates signals from the five fuel levelsensors:— Sender for Fuel Gauge G— Fuel Level Sensor 2 G169— Fuel Supply Sensor 3 G237— Auxiliary Tank Fuel Level

Sensor G292— Auxiliary Tank Fuel Level Empty

Sensor G293• Controls the fuel level indicator in the

Control Module with Indicator Unit inInstrument Panel Insert J285

• Controls the Transfer Fuel Pump G23 inthe auxiliary fuel tank

• Controls the Low Fuel Level WarningLight K105

Address Word 58

The Fuel Pump Control Module J538self-diagnosis can be accessed usingAddress Word 58.

Fuel PumpControl ModuleJ538

SSP261/023

15

Fuel Supply

Fuel Delivery System

Functional Diagram

Components

G Sender for Fuel GaugeG6 Fuel PumpG23 Transfer Fuel PumpG169 Fuel Level Sensor 2G237 Fuel Supply Sensor 3G292 Auxiliary Tank Fuel Level SensorG293 Auxiliary Tank Fuel Level Empty Sensor

G293

SSP261/022

G23

ConvenienceCAN Data Bus

SJ538

Terminal 30

S228J17

G6

G169G237GG292

J17 Fuel Pump RelayJ538 Fuel Pump Control Module

S Fuse (in Fuel Pump Control Module J538)S228 Fuse in Fuse Holder

Control Module with Indicator Unitin Instrument Panel Insert J285

16

Transmissions

Six-Speed

Manual Transmission 01Ewith 4MOTION All-Wheel Drive

The six-speed manual transmission 01Eused on the 2002 Passat is also used onthe Passat W8. Since the Passat W8 issupplied with 4MOTION all-wheel drive asstandard equipment, a torsen differential isintegrated in the transmission to properlydistribute the engine torque to all fourwheels. The transmission casing is adaptedto fit the W8 engine.

Five-SpeedAutomatic Transmission 01V

with 4MOTION All-Wheel Drive

The five-speed automatic transmission 01Vis adapted to fit the W8 engine, includingmodifications to the casing and gear ratios,as well as the clutches and brakes. Atorsen differential is also integrated into theautomatic transmission to distribute theengine torque to all four wheels for4MOTION all-wheel drive.

The five-speed automatic transmission 01Valso has:

• Dynamic shift program (DSP).

• Tiptronic function.

• Torque converter with a lockup clutch.

SSP261/024

SSP261/025

17

Final Drive

4MOTION All-Wheel Drive

The 4MOTION all-wheel drive system isdesigned to distribute the drive forcesbetween the front and rear axles tomaintain positive engagement at thewheels with traction.

The Torsen differential detects wheel slipin one axle and distributes the drive powerto the wheels of an axle with betterwheel grip.

”Torsen” is acombined form of“torque sensing.”

SSP261/026

The Torsen Differential

SSP261/027

Front Axle Worm Gear

Worm Gears

Spur Gears

Rear Axle Worm Gear

Rear Axle DriveFront Axle Drive

Differential Case

The Torsen differential permits limiteddifferences in speed between the front andrear axles to allow for ABS controlprocesses. It operates automatically andreacts independent of driver input.

18

Running Gear

Tubular Subframe

SSP261/028

Four-Link Front Suspension

The design of the front axle on the PassatW8 is nearly identical to the Passat modelyear 2002. The following components havebeen modified to cope with the higherweight and the resulting axle loads:

• Wheel bearing housing.

• Wheel bearings.

• Wheel hub.

• Tubular subframe.

Wheel Hub

Wheel Bearing Housing

Wheel Bearing

Steering

The steering on the Passat W8 is the sameas on the Passat 2002:

• Steering column is adjustable in heightand reach.

• Hydraulic power steering gear.

19

Running Gear

Double-Wishbone Rear Suspension

The proven double-wishbone rearsuspension with closed tubular subframe isinstalled on the Passat W8.

What is new are the wheel bearinghousings with modified attachments to thetrack rods.

New wheel bearing housing:

• Wheel bearing housing madeof aluminum.

• Track rods guided at both ends.

• Larger track width.

Tubular Subframe

Guided atBoth Ends

SSP261/030

AluminumWheelBearingHousing

SSP261/029

Lower Wishbone

Upper Wishbone

Differential

20

Running Gear

Brake System

The Passat W8 currently has the mostpowerful brake system of all Volkswagencar models. It achieves excellentdeceleration rates.

Front Disc Brake

Disc diameter x thickness:

• 321 mm x 30 mm

Rear Disc Brake

Disc diameter x thickness:

• 269 mm x 22 mm

Hydraulic Unitand Control Unit

SSP261/031

SSP261/033

SSP261/032

Rear Disc Brake

Front Disc Brake

21

Running Gear

Hydraulic Modulator

The Passat W8 has the Bosch 5.7 ABSsystem with Electronic StabilizationProgram (ESP) and the hydraulic BrakeAssist system. Special features of theBosch 5.7 ABS system include:

• The hydraulic unit and the control unitform a single hydraulic modulator unit.

• The two-stage ABS Return Flow PumpV39 replaces the Hydraulic Pump forTraction Control V156.

• The Brake Booster Pressure SensorG294 is installed in the hydraulic unit.

Hydraulic Modulator

Brake BoosterPressureSensor G294

SSP261/034

SSP261/035

22

Running Gear

Two-Stage ABS Return Flow Pump V39

The two-stage ABS Return Flow Pump V39is integrated in the Bosch 5.7 ABS system.When the ESP intervenes, ABS ReturnFlow Pump V39 supplies the requiredpreliminary pressure in the brake lines.

The piston of the two-stage ABS ReturnFlow Pump V39 is stepped and has adouble-acting function within twoworking chambers.

Suction is effected in two stages; brakefluid is drawn through the suction lineduring each stroke of the piston, inboth directions.

Since the entire suction volume is suppliedalmost continuously, the maximum suctionflow rate is significantly lower than insingle-stage pumps. This diminishes thesuction pressure and prevents cavitation. Aquick pressure buildup is ensured, even atextremely low temperatures.

“Cavitation” refers to both theformation of a partial vacuumin a liquid by rapidly movingcomponents like a pump rotoror piston, and the resultingpitting damage to componentsthat the collapse of such avacuum can cause.

Suction process in working chamber 2.

Suction process in working chamber 1.

SSP261/041

SSP261/040

BDC TDC BDC TDC

A suction process takes place

with every piston stroke.

SSP261/039

WorkingChamber 1

WorkingChamber 2

Connecting LineSuction Line

BDCTDC

TDC BDC

23

Running Gear

Brake Assist

Brake Assist is integrated in the ABScontrol unit. Accident research studies haveshown that the majority of drivers do notpress hard enough on the brakes in criticalsituations. This means that pressurebuild-up is insufficient to reach maximumvehicle deceleration.

The Brake Booster Pressure Sensor G294detects the pressure rise in the brakesystem. The control unit recognizes anemergency braking action by the rapid risein brake pressure within a specific period oftime. After it detects the emergencysituation, the control unit increases thebrake pressure automatically to a levelexceeding the locking limit, within theABS control range. This enables maximumdeceleration and shortens the vehiclestopping distance.

Brake BoosterPressure Sensor G294

Pressure rise in brake system.

SSP261/034

SSP261/043

ABS Control Range

Emergency Braking

Normal Braking

Time

Bra

ke P

ress

ure

24

Body

Body Modifications

To fulfill the mandate for greater luxury andsafety, the body of the Passat W8 has beenstrengthened. There is a distinctionbetween reinforcements made to improvethe body acoustics and reinforcementsmade to increase crash safety.

We have also modified the spare-wheelwell to accommodate the auxiliary fueltank. On the sedan, the rear bulkhead iswelded to the rear backrest. The backrestof the rear seat bench is not foldable.

The cross strut between thefront wheel housings is alsoused on Passat 2002 modelswith V6 engines.

Spare-Wheel Well

Body Modifications

Crash Reinforcements

Acoustic Measures

Welded RearBulkhead

25

Body

Acoustic Measures

A cross strut is bolted between the frontwheel housings. It is fixed to new supportswelded to the wheel housings. Anadditional strut is welded to the frontbulkhead near the front side member.

Crash Reinforcements

The front footwell is reinforced by anadditional crossmember.

SSP261/011

Reinforcement

Cross Strut

Support for Cross Strut

Crossmember

26

Occupant Protection

Airbags and Seat Belts

Occupant protection is ensured by theairbag system with driver and passengerfront airbags, side airbags and Side CurtainProtection, and three-point seat belts andbelt tensioners.

The Passat W8 has two full-sizefront airbags:

• Driver’s side front airbag filling volume is2.26 cubic feet (64 liters).

• Passenger’s side front airbag fillingvolume is 4.24 cubic feet (120 liters).

The Airbag Control Module J234 is locatedbehind the central console on the tunnel.

Igniter for Side Airbag,Passenger Side N200

The two side airbags are located in thefront seats and have a filling volume of0.42 cubic feet (12 liters). Each Side CurtainProtection curtain has a filling volume of0.92 cubic feet (26 liters) and is mounted inthe vehicle headlining above the doors.

The system has two lateral accelerationsensors which are located below the frontseats as on the Passat 2002 model:

• Crash Sensor for Side Airbag, Driver’sSide G179

• Crash Sensor for Side Airbag, PassengerSide G180

Crash Sensorfor Side Airbag,Driver’s Side G179

Airbag ControlModule J234

Crash Sensorfor Side Airbag,Passenger Side G180

Driver’s SideAirbag Igniter N95

Passenger’s SideAirbag Igniter 1 N131

Front Airbag,Front Passenger

Side Airbag,Front Passenger

Side CurtainProtection

Front Airbag, Driver

27

Occupant Protection

Conventional inertia-reel seat belts are usedon the front and outer rear seats.

Ball-type tensioners are used on the frontseat belts.

The rear seat belts are equipped with rotarybelt tensioners.

SSP261/012Side Airbag, Driver

Seat with IntegratedSide Airbag

Ball-Type Tensioner

Igniter for Side Airbag,Driver’s Side N199

Rotary Belt Tensioner

Three-Point Seat Belt

Left Rear Side AirbagCrash Sensor G256

Side CurtainProtection

Right Rear Side AirbagCrash Sensor G257

These two types of belt tensioner are bothtriggered by combination mechanical andpyrotechnical capsules.

The upper part of thebelt buckle is flexible.The lower part is rigidlybolted to the bracket.

Air Conditioning System

28

Heating and


The Climatronic air conditioning systemwith fully automatic control is offered onthe Passat W8.

The incorporation of the followingcomponents into the system is the maindifference from the previous fully automaticair conditioning system used on the Passat:

• Evaporator Vent TemperatureSensor G263.

• Externally regulated compressor withA/C Compressor Regulator Valve N280and integrated overload protection.

Distribution Box and Housing

for Evaporator

SSP261/061

Rear View

Evaporator VentTemperatureSensor G263

Evaporator

SSP261/062

Front View

The interaction between thesecomponents in conjunction with the otherelements of the Climatronic system resultsin a needs-orientated temperature controlwhich reduces power consumption andfuel consumption.

29


Externally ControlledA/C Compressor

The compressor basically works on theprinciple of the swash plate.

The technical features of the externallycontrolled compressor are:

• One-sided swash-plate compressor withseven lifting pistons.

• Variable lifting volume to match therefrigerating capacity demand.

• Hollow pistons.

• Belt pulley drive with integrated overloadprotection and no magnetic clutch.

• A/C Compressor Regulator Valve N280to regulate the pressure conditions inthe compressor.

Function

The Climatronic Control Module J255variably controls the A/C CompressorRegulator Valve N280. Depending on theparameters, desired temperature input,ambient and interior temperature,evaporator temperature, and refrigerantpressure in the refrigerant circuit, thepressure conditions on the intake pressureside are changed by a control voltage.

The angle of the swash plate changes.This determines the stroke volume andthe resulting refrigeration performancegenerated.

When the air conditioning system isoff the delivery volume of the refrigerant isregulated to under 2%, but the compressorcontinues to run via the ribbed-belt drive.

Belt Pulleywith IntegratedOverloadProtection

SSP261/063

Terminal for ClimatronicControl Module J255

A/C CompressorRegulator Valve N280

LiftingPiston

SwashPlate

DrivenPlate

ShapedRubberElement

30


Overload Protection

The ribbed-belt pulley and the drivenplate are positively joined by a shapedrubber element.

When the compressor is operatingnormally, the two plates rotate in the sameratio to each other.

Compressor Functioning

SSP261/064Shaped Rubber Element

Compressor Drive Shaft

Belt Pulley

Driven Plate

Belt Pulley

Shaped Rubber Element

31


Compressor Locked

If the compressor is damaged internally,it may cause the drive shaft to lock.The driven plate will also stop.

This drastically increases the transferforces between the belt pulley and thedriven plate. The shaped rubber elementis pressed by the belt pulley in the directionof rotation onto the locked driven plate.

SSP261/065Sheared Material


Compressor Drive Shaft

Belt PulleyDistorted Shapeon Locking

Locked Driven Plate

Belt Pulley

Locked

Sheared Material


The projecting shapes on the rubberelement shear off and the joint betweenthe belt pulley and the driven plate isseparated. The belt pulley continues torotate unhindered. This prevents damageto the ribbed belt, and allows the engineto continue to operate without damage.

Evaporator Control Circuit

When the Climatronic air conditioningsystem is on and the driver enters thedesired temperature, the refrigerantdemand is determined by a number ofdifferent influences.

The components described below form acontrol circuit for regulating the desiredtemperature.

A/C Compressor Regulator Valve N280

The external A/C Compressor RegulatorValve N280 forms an interface betweenthe suction and high-pressure sidesof the compressor. It balances out thepressures applied.

The A/C Compressor Regulator Valve N280is controlled by the Climatronic ControlModule J255. For example, if the driverwants to increase cooling output:

• When the control voltage is applied tothe electromagnetic A/C CompressorRegulator Valve N280, a plunger in thevalve moves. The period of time that thecontrol voltage is applied determines theamount of plunger travel.

• The adjustment changes the cross-section of the opening between thesuction and the high-pressure sides inthe valve.

• Pressure on the high-pressure side risesas the suction pressure drops. Thiscauses the piston stroke to reposition theswash plate at a greater angle.


Climatronic Control Module J255

A/C CompressorRegulator Valve N280

32


Intake Air

Influencing Parameters:

• Input of desired temperature.

• Ambient temperature.• Interior temperature.

• Temperatures downstream of evaporator andair outlets.

• Pressure level in refrigerant circuit.

SSP261/068

Evaporator VentTemperatureSensor G263

Cooled Air

33

Evaporator Vent

Temperature Sensor G263

The Evaporator Vent Temperature SensorG263 is located in the air duct behind theevaporator. It detects the vent temperaturedownstream of the evaporator. It fulfills twoimportant tasks:

• It ensures that the air conditioningsystem is turned off at a temperatureof 32°F (0°C) downstream ofthe evaporator.

• Together with the externally regulatedcompressor, the outlet temperaturedownstream of the evaporator can nowbe regulated between 32°F (0°C) andapproximately 50°F (10°C).

Advantage:

It is no longer necessary to use theheat exchanger to “reheat” cold air whenthe outlet temperatures are between32°F (0°C) and 50°F (10°C).

This reduces power consumption andsaves fuel.

Electrical System

Vehicle Electrical System

The electrical system on the Passat W8 hasa similar design to that used on the 2002Passat. The following pages describemodifications to components and functionsthat differ from the 2002 Passat. All othercomponents and functions not describedhere are the same as those used on the2002 Passat.

Central Junction BlockFront-End WiringHarness ConnectorLocation

Electronics Box (Engine Compartment)• Motronic Engine Control Module J220• Relays• Wiring Harness Connectors• Fuses

TransmissionControl Module(TCM) J217

Wiring Harness ConnectorLocation (Right A-pillar)

34

Airbag Control Module J234(Transmission Tunnel)

Electrical System

Wiring HarnessConnector Location(Left A-pillar)

SSP261/044

35

Motor 2 for Window Lifter,Right Front V172 with Integrated DoorControl Module, Passenger Side J387; andMotor 2 for Window Lifter, Right Rear V174with Integrated Door Control Module,Rear, Right J388 (Doors)

Motor 2 for Window Lifter,Left Front V171 with Integrated DoorControl Module, Driver Side J386;and Motor 2 for Window Lifter,Left Rear V173 with IntegratedDoor Control Module, Rear,Left J389 (Doors)

Control Module with Indicator Unitin Instrument Panel J285 withControl Module for Anti-TheftImmobilizer J362 and Data BusOn-Board Diagnostic Interface J533

Central Control Modulefor Comfort System J393(Left Footwell)

Fuse Panel(Left Side ofInstrument Panel)

Electrical System

Bi-Xenon Headlights

The Passat W8 is only equipped with thebi-xenon headlight system. The improvedlight output of the system increases activedriving safety because the driver can detectdanger earlier.The bi-xenon headlight module producesboth the low beam and the high beamfrom a single High-Intensity Gas-DischargeLamp L13.The high beam is intensified by a normalH7 lamp. This lamp also bridges the timeuntil the High-Intensity Gas-DischargeLamp L13 reaches its full light intensity.The H7 lamp is also used for the headlightflasher function.

Both headlamps can be switchedfrom asymmetrical tosymmetrical low beam fortraveling in countries wheredriving is on the left side of theroad. All vehicles with bi-xenonheadlights are equipped withautomatic and dynamic headlightrange control. Please refer to theinformation in the Repair Manual.

High IntensityGas-DischargeLamp L13 (Lowand High Beams)

36

SSP261/045

Left High BeamLamp L125 (Normal H7Lamp – AdditionalHigh Beam)

Left Front TurnSignal Light M5

Electrical System

37

More Light Means More Safety

The improved luminous efficiency of thebi-xenon headlight system provides greaterdriving safety, because hazards can now berecognized sooner.

The wider range and increased brightnessof the light beam enable the driver torecognize hazards and reduce speed earlier.If the driver reacts in time, he will be ableto stop the vehicle ahead of the hazard andavoid a collision.

Sto

ppin

g D

ista

nce

92 f

t (2

8 m

)

Without Bi-Xenon Headlights

Vehicle speeds:

Car: 31 mph(50 km/h)

Bicycle: 15.5 mph(25 km/h)

Distance A representsthe time gain providedby bi-xenon headlights.In this example, exactly1 second is gained.

Without bi-xenon headlights, thedriver does not see the cyclist untilmuch later.

With bi-xenon headlights, the driversees the cyclist earlier and still hasenough time to reduce speed.

With Bi-Xenon Headlights

A

SSP251-019

SSP251-021

Sto

ppin

g D

ista

nce

92 f

t (2

8 m

)

SSP251-020

Bi-Xenon Headlight Module Design

The headlight modules consist of thefollowing components:

• Ballast Unit for Gas-DischargeHeadlight, Left J426; or Ballast Unitfor Gas-Discharge Headlight, Right J427

• Left Headlight Beam Adjusting MotorV48 or Right Headlight Beam AdjustingMotor V49.

• Left High Beam Lamp L125 or Right HighBeam Lamp L126 (normal H7 lamps).

• High-Intensity Gas-Discharge Lamp L13.• Housing with laminated clear glass lens.

Electrical System

38

SSP261/045

Ballast Unit for Gas-DischargeHeadlight, Left J426

SSP251/067

High IntensityGas-DischargeLamp L13

LensReflector

ElectromagnetSSP251/311

MechanicalShutter

Electrical System

39

Functional Principles

Low beam

When the bi-xenon headlights are set tolow beam, an electro-magnetically actuatedmechanical shutter is moved into positionin front of the reflector, to block out part ofthe light cone.

High beam

When the bi-xenon headlights are set tohigh beam, the entire light cone reflectedfrom each High-Intensity Gas-DischargeLamp L13 is effective. In addition, the LeftHigh Beam Lamp L125 and Right HighBeam Lamp L126 (normal H7 lamps) areturned on.

Additional Equipment

On vehicles equipped with gas-dischargeheadlights, the following equipment isrequired to avoid dazzling other drivers.

• Headlight cleaning system

• Automatic headlight range control

SSP251/306

SSP251/307

Electrical System

40

The Passat W8 with bi-xenon headlightshas automatic headlight range control.The task of the automatic headlight rangecontrol is to adjust the headlights tocompensate for variation in ride height as afunction of payload. The automaticheadlight range control also compensatesfor variation in headlight range caused bydynamic effects under braking andacceleration.

Function

Headlight Range Control Module J431receives signals from the two level sensors(one on the front axle and one on the

Terminal 15

Terminal 31

Terminal 56

Left Rear LevelControl SystemSensor G76

Left Front LevelControl SystemSensor G78

Road Speed Signal

Self-Diagnosis

Right HeadlightBeam AdjustingMotor V49

Left HeadlightBeam AdjustingMotor V48

SSP251/004

Input Signal

Output Signal

Positive

Ground

Headlight RangeControl Module J431

Automatic Dynamic

Headlight Range Control

Overview

rear axle) and the road speed signal. Havingevaluated the signals, the system activatesthe control motors in the headlights tocompensate for variation in vehicle level.The Right Headlight Beam Adjusting MotorV49 and Left Headlight Beam AdjustingMotor V48 are configured as steppingmotors. They can perform the full range ofheadlight adjustments within approximatelyone second.Address Word 55

The Headlight Range Control Module J431has self-diagnostic capability and can beaccessed with Address Word 55.

Electrical System

41

Instrument Cluster

The instrument cluster has bluebacklighting and translucent red dials.The modified design and chrome-bezeledinstruments stand out. The instruments arenow operated by stepping motors.The instrument cluster is available in threeversions. They mainly differ with regard tothe display options in the driver informationsystem (DIS) display.

New Functions

• Integrated third-generation ControlModule for Anti-Theft Immobilizer J362.

• The Control Module with Indicator Unit inInstrument Panel J285 interface to theCAN data bus is connected to thedrivetrain CAN data bus and convenienceCAN data bus. The tachometer isactivated by signals from the drivetrainCAN data bus, for example, and thestatus of the doors/tailgate can be shownon the DIS display via the convenienceCAN data bus.

• The Data Bus On-Board DiagnosticInterface J533 in the Control Modulewith Indicator Unit in Instrument PanelJ285 is necessary for communicationbetween the various CAN data buses.Diagnosis data is also transferred viaCAN data bus through this interface tothe K-wires.

Selector LeverRange Indicator

DIS Display

SSP251/049

New Warning Lamps

noitangiseD lobmyS noitcnuF

961KpmaLrotacidnIkcoLtfihS ehT.ekarbehtsserpedotrevirdehtsdnimeRsnoissimsnartcitamotuanokcolrevelrotceles

.yawsihtnidesaelersi

611KdekcolnUdiLraeRrofthgiLgninraW321KtfeL,tnorFrooDnepOrofthgiLrotacidnI421KthgiR,tnorFrooDnepOrofthgiLrotacidnI

521KtfeL,raeRrooDnepOrofthgiLrotacidnI621KthgiR,raeRrooDnepOrofthgiLrotacidnI

721KknurTnepOrofthgiLrotacidnI

.etagliatroknurt,sroodneposetacidnIsiht,yalpsidlanitcnufitlumahtiwselcihevnI

.lobmysasadeussisigninraw

13KthgiLrotacidnIlortnoCesiurC metsyslortnocesiurcehtnehwnosemoC.nodenrutsi)SSC(

.ylnometsyslortnocesiurchtiwselcihevroF

38K)LIM(pmaLrotacidnInoitcnuflaM ytilauqsagtsuahxeotlatnemirtedtluafafIotdevassitluafeht,elcihevehtnisrucco

.detavitcasipmalsihtdnayromemtluaf

regnadasierehtfihsalfotsnigebpmalehTdegamadgnimocebretrevnoccitylatacehtfo

.gnirifsimoteud

Electrical System

42

Electrical System

43

Comfort/Convenience System

Interior Monitor and

Anti-Theft Alarm System

(Delayed Availability)

The Passat W8 anti-theft alarm systemis equipped with a new function and anew Alarm Horn H12 that is mounted inthe plenum chamber. It has a separatepower supply.

Two lithium batteries integrated in theAlarm Horn H12 ensure that it operatesindependent of the car battery. Thebatteries have a life of approximatelyfive to seven years.

If the batteries are dischargedor defective, the horn mustbe replaced.

Function

The Alarm Horn H12 communicatesbidirectionally with the Central ControlModule for Comfort System J393. After thecar is locked, the Alarm Horn H12 is armedby the Central Control Module for ComfortSystem J393. This means that the vehiclepower supply and the horn signaling lineare monitored in addition to the otherfunctions of the anti-theft alarm system.

When the car is unlocked by the radioremote key control, the anti-theft alarmsystem is deactivated. If the car is openedmechanically using the door lock cylinder,the ignition must be turned on within15 seconds or the anti-theft alarm systemwill be activated.

Alarm Horn H12

SSP261/047

Electrical System

44

Functional Diagram for

Anti-Theft System Alarm Horns

J393

SSP261/048

F266H12H8

Components

F266 Front Hood Switch

H8 Alarm Horn

H12 Alarm Horn (with self-containedbackup battery)

J393 Central Control Module forComfort System

30a Positive Terminal

30a

Electrical System

45

Self-diagnosis address word

Convenience System

The anti-theft alarm system hasself-diagnostic capability. You will find theself-diagnosis in the Vehicle Diagnosis,Test and Information System VAS 5051, inthe guided diagnosis under Body -Body Repairs and the address word“Convenience System.” Please always usethe latest version of the Repair Manual inthe Electronic Service Information System(ESIS) when performing diagnosis.

46

Electrical System

Entertainment

and Communications

Premium VI Radio

Features

• Integrated CD player.

• Optional CD changer.

• Cassette tape player.

• Two FM/AM tuners.

79600001

• Antenna sockets for antenna selection.

• Central connector module withpositive locking.

• Convenience CAN data bus.

47

Electrical System

Functions

ON/OFF turns system power on or offwhen pressed.

VOLUME adjusts the sound levelwhen rotated.

FM 1/2 selects the FM band or switches tothe second set of presets.

AM 1/2 selects the AM band or switchesto the second set of presets.

CD selects CD mode. The player loadsindividual CDs through the slot at the top.To switch to the optional CD changer, tapthe CD button while in the CD mode.Tapping the button again will returnoperation to the internal CD.

EJECT next to the CD slot ejects theinstalled CD when pressed.

MIX plays CD selections in randomsequence. If the optional CD changer is inoperation when this button is pressed, thesystem will randomly shuffle among 65 to80 percent of the selections on one discbefore shuffling to the next disc to reduceCD changes and allow the user to enjoymore music.

“CD HOT” will display when vehicleinterior temperatures are too hot for properCD operation and the CD function will notbe available until the temperature drops.

TAPE A/B activates the tape player when atape is in place. Pressing this switchanother time will switch between the Aside and the B side. If no tape is presentthere is an audible beep and “NO TAPE”is displayed.

EJECT next to the cassette tape slot ejectsthe installed tape when pressed.

Dolby® symbol button next to the cassettetape slot turns the Dolby® noise reductionsystem on or off when pressed in tapemode.

SCAN by pressing the knob while in radiomode to search for a station or in CD ortape mode to briefly play the beginning ofeach track.

TUNE by rotating the knob to change theFM/AM station manually or to select theprevious or next track in CD mode.

“Up” symbol selects SEEK up for radio,next TRACK for CD, or fast-forward fortape mode.

SEEK the next radio station while in radiomode by pressing this button to startstation search (SEEK) in AM band. In FMband this function will browse through thestorage list.

TRACK changes are effected by pressingthis button briefly while in CD mode to skipforward or backward through CD tracks.Press it longer to start audible fast forwardor fast reverse of a track.

“Down” symbol selects SEEK downfor radio, previous TRACK for CD, orfast-rewind for tape mode.

AS (Auto Store) will automatically selectthe six strongest radio signals in theimmediate area when pressed in the AM orFM mode. This will not erase the previouslyestablished presets, which can be retrievedby briefly pressing either the TAPE, CD,AM, or FM function button.

BASS, MIDDLE, and TREBLE range tonecontrol and adjustment of side-to-sideBALANCE, and front-to-rear FADE aremade by rotating their respectivefunction buttons.

48

Electrical System

Radio rear panel

The rear panel of the radio contains theantenna connector sockets and the centralconnector socket.

Antenna Input forFM/AM Signalfrom AntennaSelection ControlModule J515

Radio Output toAntenna SelectionControl Module J515

CentralConnectorSocket

79600002

49

Electrical System

Antenna Wire

LockingClip

SSP261/054

SSP261/052Locking Tab

PlugCoding

CentralConnectorModule

Antenna connection

The antenna connectors and the sockets onthe back of the radio are different colorsand have different plug codingconfigurations. Each connector will only fitin its associated socket to prevent improperconnection.

The connectors have locking tabs thatengage when they are plugged into thesockets. To disconnect an antennaconnector, disengage the locking tab.

Central connector module

The central connector module groupsall the individual electrical and audioconnectors for power supply, theCD changer, and speakers into a singlehousing to provide a quick and secureconnection. Individual connectors can alsobe plugged into the central connectorhousing separately.

The entire central connector module is heldin place with a locking clip. To disconnectthe module, unlock the clip and pull outthe module.

50

Electrical System

Convenience CAN data bus networking

To control functions and processes, theradio and the Control Module with IndicatorUnit in Instrument Panel Insert J285exchange the following information overthe convenience CAN data bus.

• No contact• Terminal 15• Road speed signal• Display lighting• Self-diagnosis processing• Radio convenience coding• Control signals from the multifunction

steering wheel• Vehicle identification number

79600003

Control Module with Indicator Unitin Instrument Panel Insert J285

ConvenienceCAN Data Bus

Radio

51

Electrical System

Radio Antenna System

AM/FM reception of the radio system onthe Passat W8 has been considerablyimproved. This was achieved by using fourseparate AM/FM antennas.

If reception is poor, the Antenna SelectionControl Module J515 switches to anotherantenna with a stronger signal. Theantennas are in different locations on thesedan and on the wagon.

Outside View of the Rear Window

in Direction of Travel

SSP261/056

To Antenna Amplifier 4R113 for FM Antenna



To Antenna Amplifier R24for AM/FM Antenna

Location of Antennas on the Sedan

On the sedan, the AM antenna is above therear window heater.

The four FM antennas are integrated withthe rear window heater. Suppressors in thesupply wires of the rear window heaterprevent the radio signals received fromflowing through the positive and negativeterminals of the rear window heater.

Output from each antenna is allocated to aspecific antenna amplifier.

Electrical System

52

Left Side Window

SSP261/057



Rear WindowAntenna 4 R133


Right Side Window


To Antenna Amplifier R24for AM/FM Antenna



Location of Antennas on the Wagon

On the wagon, the antennas are located inthe rear side windows. Viewed in thedirection of travel there is a combined AM/FM antenna and an FM antenna on the left-hand side and two more FM antennas onthe right-hand side.

As on the sedan, output from each antennais allocated to a specific antenna amplifier.Because its antennas do not use the rearwindow heater, no suppressors arerequired on the wagon.

Electrical System

53

Antenna Amplifiers

On both the wagon and the sedan, eachantenna is allocated to an antenna amplifier:

• Antenna Amplifier R24for AM/FM Antenna

• Antenna Amplifier 2 R111for FM Antenna



Antenna amplifiers are preciselymatched to their installationlocation and must be connectedto the proper antennas orreception will be poor.

Depending on country-specificradio frequencies, a number ofantenna amplifier variants can beinstalled at each location.

SSP261/058

54

Electrical System

AntennaInputs

SSP261/060

Inputfrom Tuner

PowerSupply

Outputto Tuner

Antenna Selection Control Module J515

The Antenna Selection Control ModuleJ515 is located under the rear shelf on thesedan and on the rear left wheel housing inthe luggage compartment of the wagon. Itsfunction is to switch over to the antennawith the best reception.

Function

The radio signal received from one of thefour antennas and amplifiers runs throughan antenna switch circuit in the AntennaSelection Control Module J515 and out tothe tuner. In the tuner, the signal quality ischecked and the result is fed back to theAntenna Selection Control Module J515through an antenna output line.

If the selected signal is too weak for tunerreception, the antenna switch in theAntenna Selection Control Module J515switches automatically to the next of thefour antennas. This process is repeateduntil an antenna is found with goodreception. Switchover is so fast that thevehicle occupants do not notice it.

Antenna Amplifier 2 R111 for

FM Antenna Right SideWindow

AntennaAmplifier R24

for AM/FMAntenna

AntennaAmplifier 3

R112 for FMAntenna

AntennaAmplifier 4R113 for

FM Antenna

55

Functional Diagram for

Antenna System(Passat Wagon Shown, Sedan Similar)

Electrical System

Left SideWindow

SSP261/059

Antenna SelectionControl Module J515





Antenna Switch

Right SideWindow

Terminal 30

Notes

56

Knowledge Assessment

57

An on-line Knowledge Assessment (exam) is available for this Self-Study Program.

This Knowledge Assessment may or may not be required for Certification. You can find thisKnowledge Assessment under the Certification tab at:

www.vwwebsource.com

For assistance please call:

Certification Program Headquarters

1-877-CU4-CERT (1-877-284-2378)

(8:00 a.m. to 8:00 p.m. EST)

Or email: [email protected]

Documents

February 2002 3800 Hamlin Road Volkswagen of America, Inc