Volkswagen Passat 1997 Service Manual
Service.
The Passat ‘97
Construction and 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.
Self Study Programme
Service Department
2
The most remarkable features of the new
Passat are its:
l
High 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 initial overview showing how we
justify making these claims.
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3
Page
The Passat ‘97 04
Environmental Protection and Recycling 08
Body 10
Vehicle 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 Literature for all inspection, adjustment and repair
instructions.
New
Important ! / Note
4
To avoid confusion, concise examples are used
to illustrate the various aspects of this
all-embracing vehicle concept.
You can find detailed information in Self Study
Programme No. 192 Passat ‘97 – The Engineering.
The Passat ‘97
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Service.
192
Der Passat '97
Die Technik
Konstruktion und Funktion
Selbststudienprogramm
Kundendienst
5
Dimensions and Weights
4675 mm
2707 mm
1740 mm
Track widths
front
rear
1498
1500
mm
mm
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Weights
Unladen weight
Max. permissible weight
appr. 1200
appr. 1805
kg
kg
6
The Platform - an Advantage for Workshops
The term “platform” is frequently used in
publications although its fundamental
meaning is not explained. The result 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.
In the eyes of the customer, the body characterises the styling of the vehicle as a whole.
The Passat ‘97
The platform
The body
The Passat ‘97
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The advantages for workshops like yourself are:
- More clarity as regards the spare parts situation
- Simplified inventory management
- Fewer different special tools and fixtures
- Easier assembly and repair
Platform
The platform comprises 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.
System parts
e.g. seat
Some system parts are identical.
They have to be adapted since they are the
interface between the platform and body.
Common part
Frame
Adapted part
Vehicle-specific seat upholstery, seat cover, etc.
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System part
8
Environmental Protection and Recycling
The concept of eco-friendliness was pursued
consistently throughout development of the
new Passat.
We would now like to show you some aspects
of this topic which are also of interest to workshops.
Recycling
Not least the recycling requirements present
workshops with problems such as identifying,
presorting and storing materials and waste
operating media.
To achieve this, the following measures were
taken:
l
Identification of plastic part materials
l
Fewer composite materials
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 “composite”
means is that different materials are combined
with one another in such a way that subsequent separation into clean material streams is
no longer possible.
If a plastic is to be recovered for recycling, it
should, if possible, be sorted according to type
for recycling purposes. This means that
different types of plastic, for example, must
not be mixed with one another.
The bumpers on the Passat are recyclable
because they do not contain composites.
.
Collection +
sorting
Recycled plastic
Cleaning +
recycling
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9
Solvents
Even during production, every effort is made to
keep environmental pollution to a minimum.
To achieve this, the following measures were
taken:
l
Full galvanisation means much less
wax and PVC underseal
l
Water-dilutable paints including
water-based clear coat
l
Stringent requirements for materials ensure
lower emissions in the vehicle interior
Energy + Resources
Raw materials and energy are in limited supply
on the planet Earth.
We must use them sparingly.
To achieve this, the following measures were
taken:
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
against corrosion perforation ensure high
value retention and conservation of
resources.
Take laser welding for example:
During laser welding, a highly concentrated
light beam with a high energy content is used
instead of a gas flame to join the components.
No additional welding material is required, as
is the case during MIG welding for example.
Laser welded seams are extremely clean and
do not need to be reworked.
Laser welding offers a more favourable energy
balance than conventional welding techniques.
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Body
The following will be of interest to you:
l
The Passat in the wind tunnel
l
Fully galvanised body
l
Greater body rigidity
l
Use of high-strength steel parts
l
Strategy of using common platform for body
parts
l
Ease of repair demonstrated 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 turbulence, which increases aerodynamic
drag, occurs.
The new Passat has a drag coefficient of c
d
=
0.27, making it the best in its class.
Accounting for the projected vehicle area (A) of
2.1 m
2
, aerodynamic drag is (Cd x A) = 0.567 m
2
.
A = 2.1 m
2
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Fully-galvanised Body
For the first time, the Passat has a fully galvanised body which comes with an 11-year anticorrosion perforation warranty.
The drawing 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 process.
That is why the outer skin of the body is
electrolytically galvanised to produce a
smooth finish.
Electrolytically galvanised
Hot-dip galvanised
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Body
Stability and Structure
The Passat leads its class 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 rigidity and leakproofing
while minimising noise levels.
13
The Rear Bumpers
Repairing damage to the rear bumpers
previously involved expensive repair and
welding work, even after minor accidents.
The bumpers on the Passat ‘97 have the
capacity to absorb so much energy during a
low-speed rear collision that only plastic parts
have to be replaced.
Time-consuming welding work is no longer
necessary.
High-strength Panels
High-strength 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-white.
As you can see, the high-strength steel components in the front section of the vehicle
create a cage-type structure to protect the
vehicle occupants.
The wings are also manufactured from highstrength steel.
Advantages:
- Less weight
- Greater resistance to buckling
- Higher strength
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High-strength panels
Adhesive joints
Laser-welded
Mash seam welded
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Body
Body Platform
The floorpan assembly, 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.
+
8
6
m
m
+86 mm
New parts in Passat ‘97
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15
Vehicle Safety
As you will no doubt already know, we make a
distinction between active and passive safety.
Active safety
Braking systems
Steering
Running gear
Airbag systems
Restraint systems
Inside door panels and side
trims with 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
European standard for crashworthiness
l Door module with enclosed subframe
l Driver, front passenger and side airbags
as standard
l New seat belt tensioner with force limiter
l Inside door panels with pelvis paddings
Passive safety
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Vehicle Safety
Crashworthiness
The new Passat offers the driver and front passenger more safety, particularly during a side
impact.
The inside door panel, which is fitted complete
with built-in door fittings, is bolted to the door.
To protect the occupants, the inside door panel
has an enclosed surface to prevent intrusion of
the built-in door fittings into 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
absorbed, distributed and converted.
Pelvis and rib paddings give the vehicle
occupants added protection.
The size of the overlap between the door and
the sill, columns and side section has been
increased.
Deformation strength is increased due to the
larger contact surface.
Side impact beam
Pelvis paddings
Inside door panel
Overlap
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Rib paddings
16
Airbag Systems
In addition to the driver and front passenger
airbags, the Passat is equipped with side airbags as standard.
Depending on the side and angle of impact,
only the airbags in the immediate vicinity of
the danger zone are inflated.
Therefore, an uninflated airbag on the side
facing away from the accident need not
necessarily be defective.
The driver and front passenger airbags, which
have filling volumes of roughly 65 ltr. and 120
ltr. respectively, conform to the new international-standard airbag sizes.
The volume of the standard side airbag is
roughly 12 litres.
Side impact,
right-hand side
Head-on collision
Side impact,
left-hand side
60°
60°
60°
Detected by:
crash sensor
located beneath the
left-hand seat and a
safety sensor
integrated in the airbag
control unit
Detected by:
crash sensor and a
safety sensor
integrated in the airbag
control unit
Detected by:
crash sensor
located beneath the
right-hand seat and a
safety sensor
integrated in the airbag
control unit
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Vehicle Safety
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Seat belt tensioner
Belt force limiter
The Seat Belt Tensioner
The pyrotechnical seat belt tensioner, together
with the “belt fastened” sensor and belt force
limiter, are combined in a single assembly.
This compact design greatly simplifies replacement.
The “belt fastened” sensor prevents the seat
belt tensioner from being activated when the
seat belt is not worn.
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Engines and Gearboxes
In addition to the six tried and tested engines listed below, the new
VR5 unit will also be mounted in the Passat.
1.6-ltr. Engine AHL
Displacement 1595 cc
Compression ratio 10.3 : 1
Max. torque 140 Nm at 3800 rpm
Max. power output 74 kW at 5300 rpm
Engine management Simos 2
Fuel 95 RON unleaded premium
This engine is also used in the 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 5800 rpm
Engine management Motronic M 3.8.2
Fuel 95 RON unleaded premium
This engine is also used in the Audi A6.
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Engines and Gearboxes
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1.8-ltr. 5V Turbo Engine AEB
Displacement 1781cc
Compression ratio 9.3 : 1
Max. torque 210 Nm
at 1750-4600 rpm
Max. power output 110 kW at 5700 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 3200 rpm
Max. power output 142 kW at 6000 rpm
Engine management Motronic M 3.8.2
Fuel 98 RON unleaded premium
This engine is also used in the Audi A6.
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2.3-ltr. VR5 Engine AGZ
The new VR5 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 separate Self Study Programme.
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Engines and Gearboxes
1.9-ltr. TDI Engine AHU
Displacement 1896 cc
Compression ratio 19.5 : 1
Max. torque 202 Nm at 1900 rpm
Max. power output 66 kW at 4000 rpm
Fuel 45 CN diesel
Mixture preparation Direct injection with
electronically 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 preparation Direct injection with
electronically controlled
distributor injection
pump
This engine features a variable-rate
turbocharger. You will find further
information on this engine in
Self Study Programme SSP190.
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Range of Engines and Gearboxes
Manual gearbox Engines Automatic gearbox
1.6-ltr.
012/01W
74kW
01N
1.8-ltr. 5V
92kW
1.8-ltr. 5V
turbo
01V
110kW
2.3-ltr.
VR5
110kW
01A
1.9-ltr.
TDI
66kW
1.9-ltr.
TDI
81kW
2.8-ltr.
V6 5V
142kW
01V
Syncro
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Engines and Gearboxes
5-speed Manual Gearbox 012/01W
The 012/01W 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 for
four-wheel drive vehicles as used in the
Audi A4.
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4-speed Automatic Gearbox 01N
The 01N is also installed in the Audi A6, for
example.
You can find 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
standard.
You can find detailed information on this
gearbox in Self Study Programme No. 180.
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Running Gear
In addition to the four-link front suspension,
we will show you on the following pages the
newly developed torsion beam rear suspension 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 four-wheel drive vehicles.
In the case of vehicles with tripoid joints, these
joints can be repaired.
Tripoid joint
26
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The Torsion Beam Rear Suspension
Single-tube damper
Coil spring
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Advantages 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 of axle beam
- Self-aligning twin-grooved oblique ball
bearings act as wheel bearings
27
Running Gear
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The 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 differential.
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Brakes
The Passat is equipped with the Bosch 5.3 antilock braking system as standard.
Two different sizes of brake disc are available
for the front axle. The rear suspensions also
have disc brakes as standard.
Disc brakes, front Disc brakes, rear
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
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282.5 x 25 mm brake disc
This disc brake is vented and
larger in size.
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Rear brake caliper
The Passat has rear
disc brakes.
The brake caliper is made of
aluminium.
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Steering
Height and Reach Adjustment of Steering Column
The Passat is equipped with power steering.
The steering column can be adjusted manually
50 mm fore and aft and 28 mm for height.
The steering column is attached to the body 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 steering
column to the power steering gear.
Mounting pedestal with
sliding guide
Damper element
Double universal joint
Clamped connection
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You can find additional information on the steering in Self Study Programme SSP 167.
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