1
The Passat, Model Year 2001
Self-Study Programme 251
Service.
2
New Important
Note
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.
Descriptions of modifications always refer to the
predecessor model. A number of the
technologies cited in this Self-Study Programme
have previously been described in other
Self-Study Programmes. To enable you to brush
up your knowledge of specific technologies, we
have enclosed an index at the back of this SSP. It
refers you to the relevant Self-Study Programmes
by keywords such as "T
UMBLE INTAKE PORT".
(In the case of the "tumble intake port" you are
referred to SSP 195 - the SSP in which this
technical feature is described.)
The Self-Study Programme presents the
design and function of new developments.
The contents are not updated!
Please always refer to the relevant Service literature fo r current
inspection, adjustment and repair instructions.
Keywords are always given in SMALL
CAPITALS.
3
At a glance
Concisely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Environmental protection . . . . . . . . . . . . . . . . . . . . . . 10
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
The engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Power transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
The electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4
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
Saloon
● Third-generation immobiliser
● TV tuner
● Anti-vibration measures
(40Hz body)
● Dynamic navigation
New features of the Passat, model year 2001
5
Concisely
● Improved crash concept
● Solar roof
251_103
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.
The rear end has been revised also, including the
rear lights.
6
Concisely
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.
Var ian t
● New locking concept with
radio wave folding key (fob) built into
the driver's door.
7
Concisely
All technical modifications apply to saloon and Variant.
● Distance control
● Comfort-enhanced air conditioning system
● Spare wheel fitted with ready-for-road
tyre
251_104
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.
8
Concisely
Saloon
Dimensions and weights
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 c
w
0.27 cw
Weight (unladen) 1277 kg 1233 kg
2703 mm (2707)
4703 mm (4675)
1746 mm (1740)
1462 mm (1459)
251_016
251_018
The figures quoted in brackets refer to
the predecessor model.
9
Concisely
Vari an t
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 c
w
0.27 cw
Weight (unladen) 1319 kg 1282 kg
2705 mm (2707)
4682 mm (4675)
1746 mm (1740)
1470 mm (1459)
251_054
251_055
251_056
10
Environmental Protection
The water management plan
The water management plan for Wolfsburg plant
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.
To demonstrate our commitment to in-plant
environmental protection throughout all stages
of the vehicle production process through to
delivery of the finished product, we will be
dealing time and again with the topic of
environmental protection in the next Self-Study
Programmes.
Our customer have high expectations of our
products in several respects:
reliability, convenience, quality and, not least,
environmental compatibility. Firstly, the vehicle
itself should pollute the environment as little as
possible. This means raising fuel economy,
reducing pollutant emissions in exhaust gases
and ensuring a high degree of recyclability of
the individual components of a car at the end of
its life cycle. Secondly, our customers also expect
their vehicles to be made in a production facility
that meets stringent environmental protection
standards.
Volkswagen can look back on a long tradition of
protecting the environment. When it built its first and, to date, largest - plant in Wolfsburg,
Volkswagen even then thought about ways of
using the natural resource of water as
economically as possible for example.
Volkswagen currently circulates and reprocesses
more than 95 percent of process water within the
plant.
The amount of fresh potable water which
Volkswagen annually feeds into its circulation
system from external sources accounts for less
than five percent of total volume.
Process water retention tank
1,500,000m
3
Measuring station
to landfill
Process water
treatment
Was t e w a t er
treatment plant
(biological)
Filtration
press
Mittelland
Canal
Drinking water
procurement (from
the Harz mountains)
11
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.
West combined heat and power station
Procurement of drinking water
Filtration sta-
tions
to landfill
Cyclator
Chem. waste
water treatment
plant
To ta l
demineralisation
Canal water cycle
Sewage water
pumping station
Cooling circuits
production
Rainwater
P
r
e
t
r
e
a
t
m
e
n
t
p
l
a
n
t
To ensure that we maintain
high standards in
environmental protection, our
plants are audited and
certified by an independent
expert. Our European plants
were certified according to the
EU eco audit regulations while
our non-European plants were
certified according to the
international
ISO 14001 standard.
251_092
251_091
12
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.
The side and head airbags
The side and head airbags afford excellent side
impact protection. The two side airbags,
integrated in the front seats, have a filling
volume of approximately 12 litres.
The head airbag has a filling volume of
approximately 26 litres and is integrated in the
vehicle headlining, above the doors.
251_082
13
Safety
The complete part number of the airbag control unit, together with the index (colour code) must
be quoted when ordering side impact sensors because these sensors are not labelled with a
parameter index. The part number and the colour index can only be read out, or reproduced,
from the production data (VIN, year of manufacture, list of PR numbers) by using the workshop
tester.
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.
251_069
14
Safety
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.
The upper part of the belt buckles in the new Passat is flexible.
The lower part is rigidly bolted to the bracket.
Rotary belt tensioner
The belt tensioner/belts
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.
251_075
251_066
15
Safety
Child restraint systems
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.
Integrated child safety seats
The Isofix system
The new Passat comes as standard
with an attachment point for the fastening clips
of the I
SOFIX system. Child safety seats integrated
in the rear bench seat are optional.
Belt guide hook
251_010
251_011
16
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.
Roof cross strut
Side member, right
B-pillar, right
17
Body
Vehicle safety and natural body vibration (40 Hz)
have been greatly improved as a result of these
modifications.
Wheel housing, inner
surface (sheet-metal
reinforcements have been
welded in on the left and
right )
B-pillar, left
Side member, left
Side member, top right
Side member, top left
251_041
Tunnel reinforcement
18
The engines
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.
These engines now meet the following standards:
● all petrol engines conform to the EU 4 exhaust
emission standard and
● all diesel engines conform to the EU 3 exhaust
emission standard.
Engines in general
All engines have an electrical throttle control. For
more effective antitheft protection, the engine–
control unit communicates with the immobiliser
control unit via CAN databus (3rd generation
immobiliser).
If a component with a bearing on exhaust
emissions fails while the vehicle is in operation
(e.g. misfiring), the self-diagnosis fault warning
lamp begins to flash. If a component is identified
as being defective while the vehicle is in
operation, the self-diagnosis fault warning lamp
lights up continuously.
In both cases, the engine must be inspected
immediately.
A self-diagnosis fault warning lamp is now
integrated in the dash panel insert in all petrolengined vehicles.
251_044
19
The Engines
The engine is an improved version of the
1.6-litre petrol engine developing 74kW.
The following components were optimised with
regard to friction work and mass for higher fuel
economy:
● the conrods (
TRAPEZOIDAL CONRODS) were opti-
mised for mass
● the piston lands were lowered to reduce pis-
ton mass
●
ALUMINIUM CYLINDER HEAD WITH ROLLER CAM
FOLLOWERS
Specifications
Engine code ALZ
Displacement 1595 cm
3
Type Row
Number of cylinders 4
Number of valves per
cylinder
2
Compression ratio 10.3:1
Bore 81.0 mm
Stroke 77.4 mm
Max. power 75 kW/102 bhp
@ 5600 rpm
Max. torque 148 Nm
@ 3800 rpm
Engine management
system
Simos 4
Fuel grades RON 95 unleaded
petrol
(the Passat also
operates on RON
91 unleaded
petrol, with
reduced engine
power)
1.6-litre 75 kW petrol engine
251_070
251_022
20
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.
● No intermediate shaft
● Oil pump is chain driven
● Piston crown cooling via oil spray jet
● Rod-type ignition coils with integrated output
stage
● P
LANAR PROBE BEFORE CATALYST
● Camshaft timing control - timing chain
adjuster, inlet camshaft only
● The water pump is driven by a toothed belt
Specifications
Engine code AWT
Displacement 1780 cm
3
Type Row
Number of cylinders 4
Number of valves per
cylinder
5
Compression ratio 9.3:1
Bore 81.0 mm
Stroke 86.4 mm
Max. power 110 kW/150 bhp
@ 5700 rpm
Max. torque 210 Nm
@ 1750-4600 rpm
Engine management
system
Bosch Motronic
ME 7.5
Fuel grades RON 95 unleaded
petrol
(the Passat also
operates on RON
91 unleaded
petrol, with
reduced engine
power)
251_071
251_023
21
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).
Specifications
Engine code AZM
Displacement 1984 cm
3
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. torque 172 Nm
@ 3500 rpm
Engine management
system
Simos 3.2
Fuel grades RON 95 unleaded
petrol
(the Passat also
operates on RON
91 unleaded
petrol, with
reduced engine
power)
251_031
251_026
22
The Engines
The following modifications have been made to
this engine:
● 4 valves per cylinder
● R
OLLER CAM FOLLOWER valve gear
● B
UILT-UP CAMSHAFT
● C
AMSHAFT TIMING CONTROL intake and
exhaust camshafts
● Plastic twin-path intake manifold
● E
LECTRIC THROTTLE DRIVE
● "TUMBLE" INTAKE PORT
These modifications provide higher power output
and torque, and hence better driving
performance.
The 2.3-litre 125 kW V-5 petrol
engine with 4 valves per cylinder
Specifications
Engine code AZX
Type VR
Number of cylinders 5
Number of valves per
cylinder
4
Compression ratio 10.75:1
Displacement 2326 cm
3
Bore 81.0 mm
Stroke 90.3 mm
Max. power 125 kW/170 bhp
@ 6200 rpm
Max. torque 225 Nm
@ 3200 rpm
Engine management
system
Bosch Motronic
ME 7.1
Fuel grades RON 98 unleaded
petrol
(the Passat also
operates on RON
95 unleaded
petrol, with
reduced
power output)
251_030
251_027
23
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.
Specifications
Engine code AMX
Type V
Number of cylinders 6
Number of valves per
cylinder
5
Compression ratio 10.6:1
Displacement 2771 cm
3
Bore 82.5 mm
Stroke 86.4 mm
Max. power 142 kW/193 bhp
@ 6000 rpm
Max. torque 280 Nm
@ 3200 rpm
Engine management
system
Bosch Motronic
ME 7.1
Fuel grades RON 98 unleaded
petrol
(the Passat also
operates on RON
95 unleaded
petrol, with
reduced
power output)
251_077
251_029
24
The Engines
1.9-litre 74 kW TDI engine with
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.
Specifications
Engine code AVB
Type In-line engine
Number of cylinders 4
Number of valves per
cylinder
2
Compression ratio 19:1
Displacement 1896 cm
3
Bore 79.5 mm
Stroke 95.5 mm
Max. power 74 kW/100 bhp
4000 rpm
Max. torque 250 Nm
@ 1900 rpm
Engine management
system
BOSCH EDC 15 P
Mixture preparation Direct injection by
pump injection
system
Fuel grades 49 CN diesel,
biodiesel
pump injection system
251_034
251_024
25
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.
Specifications
Engine code AVF
Type In-line engine
Number of cylinders 4
Number of valves per
cylinder
2
Displacement 1896 cm
3
Bore 79.5 mm
Stroke 95.5 mm
Compression ratio 19:1
Max. power 96 kW /130 bhp
4000 rpm
Max. torque 310 Nm
@ 1900 rpm
Engine management
system
BOSCH EDC 15 P
Mixture preparation Direct injection by
pump injection
system
Fuel grades 49 CN diesel,
biodiesel
251_034
251_025
26
The Engines
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 2.5-litre V-6 TDI engine
developing 110 kW
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.
● The 5-hole injector has been replaced by a 6-
hole injector
● Improved
CRANKCASE VENTILATION
Specifications
Engine code AKN
Type V-engine
Number of cylinders 6
Number of valves per
cylinder
4
Displacement 2496 cm
3
Bore 78.3 mm
Stroke 86.4 mm
Compression ratio 19.5 : 1
Max. power 110kW/150 bhp
4000 rpm
Max. torque 310 Nm
@ 1500-3200
rpm
Engine management
system
Bosch EDC 14 M
Mixture preparation Direct injection by
electronically
controlled
distributor
injection pump
Fuel grades 49 CN diesel,
biodiesel
251_078
251_028
27
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.
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.
The 01E manual gearbox will be installed as a
5- or 6-speed manual gearbox in combination
with the turbodiesel engines developing 96 kW
and in the V-6 TDI.
5- and 6-speed manual gearbox 01E
will be installed in the Passat 2001 as a 6-speed
gearbox in combination 4- and 6-cylinder
turbodiesel engines from 96 kW.
The 01E four-wheel drive manual gearbox
(4 Motion)
Power Transmission
251_061
251_052
251_053
251_062
28
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.
The 01N four-speed automatic gearbox is
notable for:
● driver- and situation-dependent
driving programs, fuzzy logic controlled
● a drag-dependent driving program
● a torque converter with
lock-up clutch
The five-speed automatic transmission 01V has:
● a dynamic shift program (DSP)
● Tiptronic
● a torque converter with torque converter lock-
up clutch
The 5-speed automatic gearbox is also
available as a 4 Motion gearbox.
4-speed automatic gearbox 01N
5-speed automatic gearbox 01V
251_065
251_063
29
Power Transmission
Engine/gearbox combinations
1.6-litre ALZ
1.8-litre AWT
2.0-litre AZM
2.3-litre AZX
2.8-litre AMX
1.9-litre AVB
1.9-litre AVF
2.5-litre AKN
012 / 01W
012 / 01W
01 E
01 E
01N
01N
01 V
01 V
01N
01 V
01 V
01 A
01 A
01 A
01 A
01 V
01 V
012 / 01W
012 / 01W
012 / 01W
Front 4 Motion
251_094
30
Running Gear
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.
The rack-and-pinion steering system
The new Passat has
HYDRAULIC POWER STEERING as standard.
The four-link front suspension
Tubular subframe
Bearing bracket
251_072
251_101
31
The torsion beam rear axle
In the TORSION BEAM REAR AXLE, the spring/
damper settings have been adapted to the
modified axle loads.
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. This model has a wheel fitted with a
winter tyre in size 6Jx16 ET40.
Running Gear
Rear axle bearing
Shock absorber
Coil spring
Wheel bearing unit
251_074
251_099
Offset depth 37 mm
Offset depth 45 mm
32
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.
The new Passat still has a Bosch 5.3 anti-lock
braking system with ESP. This system allows the
driver to maintain control over the vehicle at all
times, even in critical driving situations.
● 280 x 22 mm
● 288 x 25 mm
● 312 x 25 mm
● 245 x 16 mm
● 256 x 22 mm
● 269 x 22 mm
Front disc brakes
Bosch 5.3 anti-lock braking system
251_095
251_098
Rear disc brakes
33
Running Gear
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.
For more detailed information, refer to the
separate SSP on the electrical vacuum pump.
The electronic vacuum pump
The electrical vacuum pump makes for reliable
pneumatic brake boosting.
It is activated by the engine control unit as
required.
251_058b
251_058a
34
Running Gear
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.
Insulating bonded rubber bushes provide good
acoustic isolation from the vehicle body.
The flat-type construction of the rear axle
provides a spacious interior.
This type of construction proved successful
in the predecessor model.
Four-wheel drive
The double wishbone rear suspension
Rubber mounting
Suspension strut
Subframe
Upper track control arm
Lower track control arm
Prop shaft
Torsen differential
Gearbox
251_073
251_093
35
Running Gear
Notes
36
The Electrics
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.
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 vehicle electrical system
Automatic gearbox
control unit
(in footwell on right)
Front-end connection
Airbag control unit
(in gearbox tunnel)
RNS-D
radio with dynamic
navigation
Electronics box in the
plenum chamber
- Engine control unit
- Relay station
- Connector station
-Fuses
Connector station in
right A-pillar
37
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
Dash panel insert with
immobiliser control unit
and diagnosis interface
(Gateway)
Window lifter motor
with integrated
door control unit
Convenience control
unit in the footwell left
Connector station
in left A-pillar
Fuse holder dash panel
left
251_003
38
The Electrics
A BI-xenon headlight is available as an optional
extra in place of the standard triaxial ellipsoid
headlight. In this headlight module, a gas
discharge lamp produces both the low and high
beams. The high beam is intensified by a H7
lamp which
also bridges the period until the gas discharge
lamp has reached its full luminous intensity. The
H7 lamp is also used for the flasher function.
Gas discharge lamp (GDL) with
BI-xenon bulb
High beam
(H7 lamp)
Low beam
Indicator
lights
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.
H7 lamp
(additional high
beam)
Indicator lights
Gas discharge headlight
(low beam and high beam)
For trips in countries where vehicles drive on the left-hand side of the road, both these
headlights can be adjusted from asymmetrical low beam to symmetrical low beam.
Please note the information given in the Workshop Manual.
Standard headlights
251_005
251_006
39
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.
Stopping distance 28m
Stopping distance 28m
without xenon headlight
with xenon headlight
Vehicle speeds:
Car: 50 kph
Bicycle: 25 kph
a) represents the time gain
provided by BI-xenon.
In this example,
exactly 1 s is gained.
Without xenon headlights, the driver does not
see the cyclist until much later.
With xenon headlights, the driver sees the cyclist
earlier and still has enough time to reduce speed.
A
251_019
251_021251_020
40
The Electrics
Until now, no single gas discharge headlight has
been capable of producing both low and high
beams. Hence, it was not possible to adjust the
light/dark boundary while driving.
A solenoid-operated mechanical shutter is used
to produce the xenon low and high beams.
This mechanism screens off a portion of the light
generated in the lamp to produce the low beam.
In the high beam setting, the mechanism allows
all of the light generated in the lamp to pass
through.
Lens
Reflector
Solenoid
251_311
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
shutter
ballast
251_006
251_067
Gas discharge headlight
41
The Electrics
Statutory requirements
Where gas discharge headlights are used in a vehicle, the following
auxiliary equipment is required to be installed to avoid dazzling other road users:
● a headlight cleaning system
● automatic headlight range control
251_306
251_307
The shutter screens off part of the
light cone generated.
(light/dark boundary)
The shutter is electromagnetically adjusted to
produce the high beam. The entire light cone
now becomes effective. The H7 lamp is also
switched on.
42
The Electrics
The Passat 2001 with BI-xenon headlights has automatic headlight range control.
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 headlight range control system comprises:
Headlight range control, control unit J431
receives signals from two level sensors (one on
the front axle and one on the rear axle) and the
road speed signal. Having evaluated the signals,
the system activates the control motors in the
headlights and thereby compensates for
variation in vehicle level.
The headlight control motors are configured as
stepping motors. They can perform the full range
of headlight adjustments within approximately 1
second.
The control unit has self-diagnostic capability
and can be addressed with address word 55.
Task
Automatic dynamic headlight range control (LWR)
Function:
Road speed signal
Self-diagnosis
Vehicle "level"
senders
G76
and G78
stepping motor, right
V49
stepping motor, left
V48
Headlight range control,
control unit J431
in the luggage
compartment, left
Term i n a l 15
Term i n a l 31
Terminal 56
Input signal
Output signal Earth
+
251_004
43
The Electrics
The dash panel insert
The dash panel insert is the Group dash panel
insert with blue backlighting and translucent red
dials.
The modified design and chrome-bezeled
instruments stand out. The instruments are now
operated by stepping motors.
The dash panel insert is available in three
versions. They mainly differ with regard to the
display options in the central display.
● Integrated third-generation immobiliser con-
trol unit (see Immobiliser)
● The interface to the CAN databus, i.e. the
dash panel insert, is connected to the drivetrain CAN databus and convenience CAN
databus. The rev counter is activated by signals from the drivetrain CAN bus, for example, and the status of the doors/tailgate can
be displayed in the dash panel insert via the
convenience CAN bus.
● The diagnosis interface (Gateway) in the dash
panel insert is necessary for communication
between the various CAN databuses. Diagnosis data is also transferred via CAN through
this interface to the K-wires (see CAN networking).
Central display
Selector lever range indicator
New functions
251_049
44
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. For vehicles with cruise control system
only.
Exhaust emissions warning lamp
K83
If a fault detrimental to exhaust gas quality occurs in
the vehicle, the fault is saved to fault memory and
the exhaust emissions warning lamp is activated.
The exhaust emissions warning lamp begins to flash
if there is a danger of the catalyst becoming
damaged due to misfiring.
45
The Electrics
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 engine control unit
compares the result returned by the immobiliser
control unit with its own result. This process of
communication takes place along the CAN
databus.
If the results match up, the immobiliser control
unit allows the engine to be started.
Third-generation immobilisation
General notes:
● The keys are marked W3.
● For service personnel, the key adaption
procedure is unchanged. The keys are
electronically locked while being adapted. As
a result, they cannot be used to open any
other vehicle.
● The adaptation procedure in case of
component parts replacement has changed.
CAN databus
251_037
Immobiliser control unit
Engine
control unit
46
The Electrics
Networking of CAN systems
Injection pump
(V-6 TDI)
Gearbox control
unit
Brake control unit
(ABS, ESP,...)
Airbag control
unit
Wheel angle sen-
sor (for ESP)
Radio
(Double DIN
US market)
Multifunctional
steering wheel
Fuel tank sender
(B5-W8 only)
Climatronic
Driver door con-
trol unit
Front passenger
door control unit
Driver's seat
(memory)
Convenience
system control
unit
Door control unit,
rear left
Door control unit,
rear right
DSP
CAN Infotainment on CAN convenience control units (physically the same CAN)
are directly connected to the diagnosis plug.
Control units are direct connected to the diagnosis plug via the Gateway.
Drivetrain CAN bus
Convenience CAN bus
Convenience CAN bus
251_057
Engine
control unit
CAN-Infotainment
47
The Electrics
The Gateway must be informed of the CAN users
by means of the "Encode control units“ function.
The address word for the Gateway control unit
is 19.
All control units from the drive train are connected to
the drivetrain CAN bus (highspeed).
All control units for convenience systems are
connected to the convenience CAN bus and
infotainment CAN bus
(physically one databus = low-speed).
The transmission rates of CAN High-speed and
Low-speed are 500 kBaud and 100 kBaud
respectively, i.e. 500 000 bits or 100 000 bits are
transmitted per second.
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.
48
The Electrics
● 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.
This function can be disabled by the key
switch in the tailgate.
- The radio wave remote control.
1. Basic position
The tailgate can be opened by
means of the lock handle.
2. Service position
In this position, the tailgate cannot
be opened by the lock handle.
3. Mechanical emergency opening
The CAN databus introduced in the convenience
system (Low-speed) of the Passat ’97 has been
modified as follows:
- the transmission rate has been increased to
100 kBaud from 62.5 kBaud.
- Interface to convenience CAN databus and
connection to dash panel insert. This allows
an open door to be represented symbolically
in the dash panel insert, for example .
Convenience system
The key switch in the non-visible part of the
tailgate has three tasks:
The convenience system was modified as follows:
251_038
251_316
251_013
Driver's door switch unit
Tailgate locking concept
Lock handle
Key switch
49
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 tone generator is no longer built into the
memory control unit, rather it is activated via
CAN databus in the dash panel insert.
Seat/mirror position control unit,
driver's side J394
251_086
251_043
251_039
Operator switches for seat adjustment and
Memory
50
The Electrics
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.
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. It converts the high
voltage and low current intensity which the solar
module supplies into a low voltage and high current
intensity since the blower motor requires a very high
starting current.
An electronic circuit in the DC/DC converter
only enables the fresh air blower motor if the
voltage is above a threshold value of 2 V. This
avoids damage to the blower bearings.
Sliding roof/solar roof
Contact switch in
sliding roof F289
+ from blower control
Terminal 15
Solar cell
isolation relay
J309
Earth
Solar cell contact
switch
F288
Solar cells C20
Fresh air blower V2
Solar roof control
unit
J355
When the ignition is off, the contact is in this position.
This allows the fresh air blower to receive its voltage
supply from the solar roof.
251_035b
251_035
251_040
51
The Electrics
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.
Distance control (ADK)
Tone generator
The distance warning system begins to emit
acoustic signals when the vehicle reverses to
within a distance of 1.60 m of an obstacle. The
frequency of the audio signal varies with
decreasing distance to the obstacle. The
intermittent audio signal becomes a continuous
tone when the vehicle reverses to within 20 cm of
the obstacle.
The system is active as soon as the ignition is
turned on and reverse gear is selected.
Continuous tone Intermittent audio signal
with variable frequency
Control unit
Switch reverse
Ultrasound converter
251_051
251_002
52
The Electrics
The radio navigation system
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. 200 km is utilised. If the dynamisation
function is activated by traffic conditions, the
driver is informed of this by the announcement:
„The route is being recalculated on the basis of
traffic information!“
Traffic delays (road closures, traffic jams and
slow-moving traffic) are visualised in the map
and are displayed as text messages.
Glossary
● MFD = multifunctional display
● RDS = Radio Data System
● RNS - High/D = radio navigation with
5“ screen and D for dynamic
navigation
● TMC = Traffic Message Channel
● CAN = CAN bus with proprietary protocol,
incompatible with the
CAN databus protocol to VW' specification
● GPS = Global Positioning System
RNS High/D with tuner
3-line bus
CAN
Antenna
RDS-TMC tuner
control unit
A radio navigation system with dynamic route guidance is also available as two-colour display
(low-end). In this system the RDS-TMC tuner is integrated in the radio navigation system.
251_096
53
The Electrics
In comparison to older systems, which can only
display the position of the vehicle on the planned
route (static route guidance), the new
navigation system also displays information on
traffic conditions and updates the planned route
to a destination in the event of traffic delays
(dynamic route guidance).
To facilitate vehicle navigation, a GPS receiver
and a direction sensor are fitted in the vehicle.
The system determines and displays the exact
location of the vehicle based on acquired data
and a digital map. The route guidance function
permits navigation to pre-entered destination. By
processing digital traffic information broadcast
by radio stations the system can reroute the
vehicle to avoid traffic delays. The driver is only
required to enter his destination. The system
takes care of the rest.
The system constantly collects traffic data, even
when the ignition is off. The system therefore
offers the driver up-to-the-minute traffic
information, which can be retrieved when
needed. Traffic information is provided in text,
graphic or audio form.
Since received traffic data first has to be
converted into voice in the system, traffic
information is available in a range of languages.
The dynamic navigation system is addressed
with the same address word as the standard
navigation system (37) .
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.
Radio navigation with dynamic route guidance
54
The Electrics
Public and private
TMC services for broadcasting general traffic
information are freely available in all European
countries.
These messages relate to road safety and
various traffic delays. Europe's free and public
services are collectively known as the "ALERT
Service“. Other TMC services will not be
provided free of charge.
These services relate to value-added information
or messages intended for special user groups.
Services provided in Europe
European TMC services - public and private are already available. A network providing
European-wide coverage was in place by early
2000. Each service relates to a country in which
it provides either regional or nationwide
coverage. By agreement, all national or
international service providers provide crossborder traffic information for long-distance
drivers.
TMC services
What is a TMC service?
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.
How TMC services work
● Code numbers (TMC Location) have been
assigned to all sections of motorways and
major trunk roads.
● Traffic events (road closure, traffic jam, slow-
moving traffic) have event codes
(TMC Events) corresponding to the extent of
the traffic delay (e.g. length of tailback).
● The navigation computer can refer the
TMC Locations and Events to the maps which
it uses for navigation purposes by means of a
conversion table.
● All data are broadcast nationwide in the
same form.
● As soon as the system receives information on
traffic delays on sections of the planned route,
it reevaluates their viability. If the system
deems recalculating the route necessary, it
may include a detour where required.
55
The Electrics
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 TV tuner is compatible with all current
broadcasting standards such as PAL, NTSC or
Secam. The broadcasting standard used for TV
reception in the country of delivery is preset at
the factory. Teletext is also possible.
Currently available stations are identified
automatically. The system automatically tunes
into the frequency band which provides optimal
reception. When the vehicle leaves a
broadcasting area and enters, for example, an
area with no radio reception or a silent zone, it
enters automute mode.
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 TV is inactive while the vehicle is running.
The TV tuner has a self-diagnosis function
which is activated by address word 57.
Radio navigation system with TV
251_089
56
The Electrics
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 com-
partment on the left
Dynamic navigation with TV tuner
The antenna for the TV tuner is integrated
in the rear window in the saloon and in the
two rear side windows in the Variant.
Antenna for radio and
navigation
TV tuner
RNS
RDS-TMC tuner
Global Positioning System (GPS)
Amplifier
251_059
Antenna for TV
tuner
57
The Electrics
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 radio enters automute
mode while a phone call is being conducted.
The telephone number can be dialled on the
mobile phone. Voice dialling is also possible if
the mobile phone provides this facility.
The mobile phone rest is available in two
versions.
Pre-installed wiring harness for telephone installation
251_009
58
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.
Climatronic control unit
(behind the operating unit)
Signal from temperature sensor
to control unit
Evaporator
Climatronic has an additional new feature:
The Climatronic control unit receives a signal
from the wiper motor. When the wiper motor is
running, blower output and temperature are
raised slightly so as to avoid windscreen fogging.
Windscreen wiper system
59
The Electrics
Compressor
Self-diagnosis
A fault in the temperature sensor is entered in the
control unit's fault memory. The signal from the
sensor can be checked in the self-diagnosis data
block.
251_012
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.
60
Index
A
A
LUMINIUM CYLINDER HEAD WITH ROLLER CAM
FOLLOWER (RSH) - SSP 196
B
B
ELT TENSIONERS/BELTS - SSP 192
B
UILT-UP CAMSHAFT - SSP 243
C
C
AMSHAFT TIMING CONTROL - SSP 246
C
RANKCASE VENTILATION - SSP 241
D
D
OUBLE WISHBONE REAR SUSPENSION - SSP 194
E
E
LECTRIC THROTTLE DRIVE - SSP 210
F
F
IVE- AND SIX-HOLE INJECTORS - SSP 241
F
RONT AIRBAGS - SSP 192
F
RONT AXLE- SSP 167
G
H
H
YDRAULIC POWER STEERING - SSP 191
I
I
NJECTION PRESSURE - SSP 241
I
NJECTOR - SSP 241
I
SOFIX - SSP 192
J
K
K
NOCK SENSORS - SSP 233
L
M
N
O
P
P
LANAR PROBE BEFORE CATALYST - SSP 231
Q
R
R
ACK-AND-PINION STEERING - SSP 191
R
ADIAL-PISTON DISTRIBUTOR INJECTION PUMP -
SSP 241
R
OLLER CAM FOLLOWER VALVE GEAR - SSP 196
Index
61
Index
Index
S
T
T
ORSION BEAM REAR SUSPENSION - SSP 102
T
RAPEZOIDAL CONROD - SSP 209
T
UMBLE INTAKE PORT - SSP 198
T
URBOCHARGER - SSP 190
U
V
V-6 TDI
ENGINE - SSP 183
W
X
Y
Z
62
Notes
63
Notes
64
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.
251
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