Volkswagen Passat (2011) Self Study Program

Service Training

Self-study Programme 488

The Passat 2011

The Passat 2011

In its seventh generation, the new Passat has been perfected in terms of comfort, quality and safety attributes as
well as in the range of driver assistance systems offered.

Straight lines, clearly structured surfaces and dynamic proportions distinguish the design of the new generation
saloon and estate.

New experiences in comfort are achieved by the rear seat system that can be released from the luggage
compartment, a trailer hitch that folds out at the press of a button, noise insulating laminated safety glass for the
windscreen and front side windows and 2nd generation park assist steering system.

Highly efficient and eco-friendly TSI engines, TDI CR lightweight engines, a natural gas powered engine and an
engine of the newest generation that can be powered with up to 85% ethanol in the vehicle.

Engine downsizing, the start-stop system and regenerative braking facilitate a significant saving in fuel
consumption during operation.

The Front Assist system with automatic City Emergency Brake (braking function) and the Fatigue Detection System
are new and progressive functions in the area of safety.

With its high level of quality, the new Passat generation bridges a gap to the next highest vehicle category.

S488_045

S488_043

The self-study programme portrays the
design and function of new
developments.
The contents will not be updated.

For current testing, adjustment and repair
instructions, refer to the relevant service literature.

Caution

Note

2

Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Occupant protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Driver assist systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Convenience electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Radio, navigation and telephone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Heating and air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

3

Introduction

The Passat 2011

The overview indicates important series production and optional equipment features of the new Passat. The range
of options depends on the equipment lines: Trendline, Comfortline and Highline. Deviations may be possible
depending on the country.

● Bi-xenon headlights with dynamic light assist and

LED day driving lights, optional

● LED tail lights

● Main beam assist for halogen headlights,

optional

● Windscreen with acoustic laminated glass

● Heated windscreen, optional

● Front side windows with acoustic laminated glass,

optional

● Sliding/tilting electric solar roof, optional*

S488_007

● Luggage compartment lid with automatic

opening*

● Dual clutch gearbox with freewheel function,

optional

● Adaptive chassis control DCC, optional

* Only saloon

● Adaptive cruise control ACC

● Front Assist with City Emergency Brake

● 2nd generation park assist steering, optional

● Fatigue Detection System

4

● "Premium" cellphone preparation, optional

● Air conditioning system

● Keyless access inc. start button, optional

● Panoramic sliding roof, optional**

● Electromechanical parking brake

● Electric opening and closing rear lid, optional**

S488_009

● Head restraints adjustable in X-direction

● Rear seat backrest with remote release

● Climate control seat with massage function,

optional

** Only estate

● Trailer hitch with folding feature and electric

release

● Luggage compartment management, optional**

● Convenient opening of luggage compartment

cover**

5

Introduction

Technical d ata

Exterior dimensions and weights

The details for the Passat saloon 2011 and the estate 2011 are based on a vehicle without driver, with standard
equipment, 1.4l 90 kW TSI engine and 205/55 R16 tyres.

S488_029

Exterior dimensions

Passat saloon 2006 2011

Length 4765mm 4769mm

Width 1820mm 1820mm

Height 1472mm 1470 mm

Wheelbase 2710mm 2712mm

Track width at front 1552mm 1552mm

Track width at rear 1551mm 1551mm

Turning circle 11.4m 11.4m

1552mm

1820mm

2712mm 1116mm941mm

4769 mm

1470mm

1551mm

Weights/further details

Passat saloon 2006 2011

Gross vehicle weight 1950kg 1990kg

Kerb weight 1391kg 1365kg

Max. trailer load, braked 1300kg 1400kg

Max. roof load 100kg 100kg

Tank capacity 70litres 70litres

Drag coefficient 0.295c

d

0.291c

d

6

2712mm 1118mm941 mm

4771mm

S488_031

1552mm

1820mm

Exterior dimensions

Passat estate 2006 2011

Length 4774mm 4771 mm

Width 1820mm 1820 mm

Height (with roof rails) 1516mm 1516mm

Wheelbase 2710mm 2712mm

Track width at front 1552mm 1552mm

Track width at rear 1551mm 1551 mm

1516mm

1551mm

Weights/further details

Passat estate 2006 2011

Gross vehicle weight 1950kg 2070kg

Kerb weight 1391 kg 1402kg

Max. trailer load, braked 1300kg 1400 kg

Max. roof load 100kg 100kg

Tank capacity 70 litres 70 litres

Drag coefficient 0.304c

0.298c

d

d

7

Introduction

Interior dimensions and volumes

S488_033

565litres

m

m

2

2

0

1

1797mm

1766mm

859mm

mm

1

6

9

729mm 332mm

S488_037

1014mm

Interior dimensions and volumes

Passat saloon

Luggage compartment volume 565litres 565litres

Height of rear lid 1756mm 1766mm

Height of load sill 729mm 729mm

Cargo area height 332mm 332mm

Width of cargo area/wheel
housing

2006 2011

1014mm 1014mm

Passat saloon

Interior length 1797 mm 1797mm

Interior length 2nd seat row 859mm 859mm

Front headroom 1022mm 1022mm

Headroom 2nd seat row 961mm 961mm

Knee room 2nd seat row 91mm 76mm

2006 2011

8

m

8m

1

0

1

0mm

8

9

S488_035

603litres

S488_039

859mm

1797mm

2027mm

624mm 719mm

1003mm

Interior dimensions and volumes

Passat estate

Luggage compartment volume 603litres 603litres

Height of rear lid 2058mm 2027mm

Height of load sill 624mm 624mm

Cargo area height 719mm 719mm

Width of cargo area at wheel
housing

2006 2011

1000mm 1003 mm

Passat estate

Interior length

Interior length 2nd seat row 859mm 859mm

Front headroom 1018mm 1018mm

Headroom 2nd seat row 980mm 980mm

Knee room 2nd seat row 91mm 76mm

2006 2011

1797mm 1797 mm

9

Body

Body structure

The main aim during development of the body was to increase the body strength whilst, at the same time, reducing
weight. The bodies of the new Passat saloon and Passat estate are the same as the tried and tested 2006 model
series and have been further improved.

Scope of modifications to Passat saloon

● Bonnet

● Rear lid

● Wings

● Outer skin of doors

● Side panel

● A-pillar and door frame

● Rear panel

10

S488_032

Key

Carried over

New

Scope of modifications to Passat estate

● Bonnet

● Rear lid

● Wings

● Doors

● Roof

● Side panel

● A-pillar and door frame

● D-pillar

● Rear panel

S488_030

11

Body

Windscreen with acoustic laminated glass

The windscreen in the Passat 2011 features acoustic laminated glass as standard. Furthermore, the windows in the
front doors are also available as an option with acoustic laminated glass. The use of acoustic PVB in the door
windows makes it possible to achieve a noise reduction of approx. 2-4 dB in the interior. Furthermore, a heated
windscreen can be ordered for the first time in the Passat in conjunction with heat reflective glass.

Windscreen with acoustic laminated glass Conventional windscreen

Outer glass

(2.1mm)

Inner glass

(1. 6mm)

Door window (TSG) with acoustic glass Standard door window (safety glass)

Outer glass

1.6mm)

Inner glass

(1. 6mm)

S488_036

S488_044

PVB film
(0.33mm)

Acoustic PVB film
(0.1mm)

PVB film
(0.33mm)

PVB film
(0.33mm)

Acoustic PVB film
(0.1mm)

PVB film
(0.33mm)

PVB film

(0.76mm)

Safety glass

(3.85mm)

S488_041

Outer glass
(2.1mm)

Inner glass
(1.6mm)

S488_034

S488_038

12

Compared with conventional door windows, there is a change to the software in the door control unit
on vehicles with acoustic door windows, and the window retainer in the door is also different. This
must be taken account of in the event of retroinstallation and repairs.

The luggage compartment

In the Passat estate, the following special features should be noted:

● the additional partition

● the sliding cargo floor

Sliding cargo floor

● Variable stowage space

● Different locking positions possible

● Removable cargo floor

● Withstands up to 100kg

S488_047

Cargo floor Remote release

Remote release of
rear seat backrest

The new remote release of the rear seat backrest
makes release possible from the luggage
compartment. The function is a standard feature from
the Trendline equipment level.

Cargo floor position

In the saloon and estate model, the rear bench seat
has a 60/40 split folding backrest.

13

Body

Halogen headlights

On this headlight module, the dipped beam and main beam are designed as separate H7 headlights. The side light
is integrated into the dipped beam headlight.

Dynamic light assist is not available for this module. As an option, the main beam assist function is available in
conjunction with halogen headlights.

Dipped beam, H7 (55W) Main beam, H7 (55W)

Turn s i gnal ( 2 4W)

Side light (5W)

S488_013

14

S488_064

Light module in bumper

In conjunction with H7 headlights, the cornering, fog
and day driving lights feature two separate bulbs.

Day driving light (21W) Fog and cornering light

(H8, 35W)

Xenon headlights with LED

On this headlight unit, the dipped beam and main beam are integrated into the xenon module (D3S 35W). It
features LED daytime running lights and side light. Fifteen individual LEDs are located around the xenon module.
The amount of power drawn by the day driving lights is reduced to approx. 30watts compared with approx. 140 to
180watts on daytime headlights with dipped beam activated.

The xenon headlight always comes with the dynamic cornering light. Dynamic light assist (DLA) is available as an
option. Main beam assist cannot be combined with the xenon headlight.

Turn s ig n al ( 2 4W )

Dipped beam and main beam,

xenon (D3S 35W)

Daytime runing light and side light
(15 LEDs with total 30W)

S488_011

S488_064

Light module in bumper

In conjunction with xenon headlights, the cornering
and fog lights feature two separate bulbs.

Fog light (35W)Cornering light (35W)

15

Body

Tail l ights

The tail lights of the Passat 2011 have a two part design. Only the outer lights are secured by a central bolt.

Tail light Reflector (in trim)

Brake light

Turn s i g nal

(21W)

Tail light

Reflector (in lens) Reversing light

LED tail lights

Access to the securing screws is on the left and right above the covers in the luggage compartment side panels.

Reflector

(in lens)

(16 W)

Tail and brake light

S488_050

Rear fog light
(LED 2.2W)

Reflector (in lens)

16

Turn signal (21W)

Reversing light

(16 W)

S488_048

Rear fog light
(3xLED; 3W total)

Interior equipment

Head restraints with X­adjustment

Once the release mechanism has been activated, the
head restraints in the Passat can be adjusted at the
base to be further away from or closer to the neck.
This helps to achieve an optimal position of the head
restraint, which, in addition to comfort, also enhances
safety.

Stowage facilities

Front

There are many multifunctional stowage compartments in he Passat. A centre armrest, which opens to reveal a
compartment, is an option in both the saloon and the estate.

Release

S488_052

Glove compartmentStorage under AC controls

Door compartment

S488_068

Small glove compartment by

steering wheel

Storage in centre console

with drink/can holder

Storage in centre armrest with cellphone

charging cradle and compartment beneath

17

Body

In rear

Stowage pockets on

back of front seatsRear door compartment

in centre armrest

S488_066

Drink/can holderStorage compartment

12 volt connection

18

Occupant protection

Safety equipment

The new Passat is equipped as standard with six airbags: Driver and front passenger airbag, side airbags at front
and curtain airbags for front and rear passengers. As an option, two side airbags are available for the rear seats.
The crash sensors ensure that all airbags trigger safely.

Curtain airbag

The curtain airbag of the Passat 2011 ensures the
safety of occupants in all seat rows in the head and
shoulder area.

Side crash sensor

Front doors

Side crash sensor

C-pillar

Side crash sensors

The side crash sensors in the bottom area of the front
doors are designed as pressure sensors. Lateral
acceleration sensors to detect side impact are located
in the C-pillar.

S488_015

19

Engines

Engine/gearbox combinations

Petrol engine

Diesel engine

6-speed
manual gearbox
MQ200-6F
0AJ

6-speed
manual gearbox
MQ250-6F
02S

1.4l 90kW
TSI engine

with turbocharger

R+S R R R

1.4l 110kW
TSI engine

with dual charging

1.4l 118kW
TSI engine

with dual charging

1.8l 118kW
TSI engine

with 4-valve

technology

6-speed
manual gearbox
MQ350-6F
02Q

6-speed
dual clutch gearbox
DQ250-6F
02E

7-speed
dual clutch gearbox
DQ200-7F
0AM

R = with regenerative braking; S = with start-stop system (optional equipment)

20

2.0l 155kW
TSI engine

with 4-valve

technology and

turbocharger

R R R+S R+S R+S

3.6l 220kW
FSI engine

with 4-valve

technology

1.6l 77kW

TDI CR engine

2.0l 103kW

TDI CR engine

2.0l 125kW

TDI CR engine

DQ250-6A DQ250-6F/A

F = front-wheel drive; A = four-wheel drive

MQ350-6F/A

21

Engines

1.4l 90kW TSI engine with turbocharger

This engine has found application in other vehicle
models and was carried over.

Technical features

● Homogeneous mode (lambda 1)

● Turbocharger with wastegate

● Dual circuit cooling system

● Air-to-liquid charge air cooling

● Regulated duo-centric oil pump

● Demand-based fuel system

● High pressure fuel pump with integrated pressure

limiting valve

S488_201

Technical data Torque and power diagram

Engine code CAXA

Type 4-cylinder in-line engine

Displacement 1390 cm

Bore 76.5mm

Stroke 75.6mm

Valves per cylinder 4

Compression ratio 10:1

Maximum output 90kW at

Maximum torque 200Nm at

Engine management Bosch Motronic MED 17.5.5

Fuel Super unleaded RON 95

Exhaust gas treatment 3-way catalytic converter,

Emissions standard EU5

3

5000 rpm

1500 to 4000 rpm

broadband lambda probe
upstream and regular
lambda probe downstream of
catalytic converter

Further information on this engine can be
found in self-study programme
no. 405 "The 1.4l 90kW TSI engine with
turbocharger".

250

225

200

175

150

125

100

Tor q u e [ Nm ]

75

50

25

0

1000 3000 5000

Engine speed [rpm]

100

90

80

70

60

50

40

30

20

10

0

7000

S488_200

Output [kW]

22

1.4l 110kW TSI engine with dual charging (EcoFuel)

This engine is practically the same as the EcoFuel
engine of the Passat 2010. Items changed are the
electronic gas pressure regulator and gas inlet valves.
Their function has remained the same, however.

Technical features

● One engine control unit for natural gas and petrol

operation

● Homogeneous mode (Lambda 1) in both operating

modes

● Turbocharger with wastegate

● Mechanical supercharger that can be activated

separately

● Mechanical pressure reduction stage discontinued

on electronic gas pressure regulator

● Optimised gas inlet valves, thereby making engine

start possible from -10 °C in natural gas mode

Further information on this engine can be
found in self-study programme no. 359
"The 1.4l TSI engine with dual charging" and
no. 425 "EcoFuel natural gas power with 1.4l
110kW TSI engine".

S488_231

Technical data Torque and power diagram

Engine code CDGA

Type 4-cylinder in-line engine

Displacement 1390cm

Bore 76.5mm

Stroke 75.6 mm

Valves per cylinder 4

Compression ratio 10:1

Maximum output 110kW at 5500 rpm

Maximum torque 220 Nm at

Engine management Bosch Motronic MED 17.1

Fuel Natural gas H (high)

Exhaust gas
treatment

Emissions standard EU5

3

1500 rpm to 4500 rpm

Natural gas L (low) with
reduced range
Super unleaded RON 95

Main catalytic converter,
lambda control

260

240

220

200

180

160

140

Tor q ue [ N m ]

120

100

80

60

1000 3000 5000

Engine speed [rpm]

7000

120

110

100

90

80

70

60

Output [kW]

50

40

30

20

S488_216

23

Engines

1.4l 118kW TSI engine with dual charging (MultiFuel)

This engine was first used as a bioethanol
version. First introduced in Sweden and Finland.

Technical features

● Bioethanol compatible up to 85%

● Fuel quality sender for detection of bioethanol

content in fuel

● Electric engine preheater in cooling system

● Cylinder head of 1.4l 110 kW TSI EcoFuel engine

● Homogeneous mode (lambda 1)

● Turbocharger with wastegate

● Mechanical supercharger that can be activated

separately

● High pressure fuel pump with a specially coated

pump piston that reduces friction and wear

Further information on this engine
can be found in self-study programme
no. 359 "The 1.4l TSI engine with dual
charging".

S488_203

Technical data Torque and power diagram

Engine code CKMA

Type 4-cylinder in-line engine

Displacement 1390 cm³

Bore 76.5mm

Stroke 75.6mm

Valves per cylinder 4

Compression ratio 10:1

Maximum output 118kW at 5800 rpm

Maximum torque 240Nm at

Engine management Bosch Motronic MED 17.1

Fuel Super unleaded RON 95

Exhaust gas treatment 3-way catalytic converter,

Emissions standard EU5

2000 to 4500 rpm

Ethanol can be mixed up to
85% (E85) in all conditions

broadband lambda probe
upstream and regular
lambda probe downstream of
catalytic converter

280

260

240

220

200

180

160

Tor q ue [ N m ]

140

120

100

80

1000 3000 5000

Engine speed [rpm]

120

110

100

90

80

70

60

50

40

30

20

7000

S488_202

Output [kW]

24

1.8l 118kW TSI engine with 4-valve technology

The 1.8l TSI engine designated EA888 is a technically
optimised further development of the familiar 4­cylinder EA113 engine series. Tried and tested engine
components have been consistently further
developed. The engine also finds application in the
Golf GTI.

Technical features

● Improved pedestrian impact protection

● Significant improvement in comfort and acoustics

● Balancer shaft system with two shafts, offset in

height and each with three bearings

● Reduced repair complexity thanks to modified

housing of oil filter module

● Base engine configured for a very broad

performance range

● The turbocharger pressure unit can be exchanged

and adjusted.

Further information on this engine can be
found in self-study programme no. 401
"The 1.8l 118 kW TFSI engine with timing
chain".

Technical data Torque and power diagram

Engine code CDAA

Type 4-cylinder in-line engine

Displacement 1799 cm

Bore 82.5mm

Stroke 84.1mm

Valves per cylinder 4

Compression ratio 9.8:1

Maximum output 118kW at

Maximum torque 250Nm at

Engine management Bosch Motronic MED 17.5.2

Fuel Super unleaded RON 95

Exhaust gas treatment Upstream catalytic converter

Emissions standard EU5

3

4500 to 6200 rpm

1500 to 4500 rpm

(Normal unleaded RON 91
with marginally reduced
performance)

in proximity of engine with
upstream broadband probe,
main catalytic converter with
downstream regular lambda
probe

280

260

240

220

200

180

160

Tor q u e [ Nm ]

140

120

100

80

1000 3000

Engine speed [rpm]

5000

S488_227

120

110

100

90

80

70

60

50

40

30

20

7000

S488_226

Output [kW]

25

Engines

2.0l 155kW TSI engine with 4-valve technology and
turbocharger

The 2.0l TSI engine also belongs to the in-line 4­cylinder EA888 engine series. It has the same design
as the 1.8l TSI engine, but with an increased capacity.

Technical features

● The higher displacement is achieved by modified

pistons, conrods and crankshaft.

● The turbocharger pressure unit CANNOT be

exchanged and adjusted.

S488_229

Technical data

Engine code CCZB

Type 4-cylinder in-line engine

Displacement 1984 cm

Bore 82.5mm

Stroke 92.8mm

Valves per cylinder 4

Compression ratio 9.6:1

Maximum output 155kW at

Maximum torque 280Nm at

Engine management Bosch Motronic MED 17.5.2

Fuel Super unleaded RON 95

Exhaust gas treatment Upstream catalytic converter

Emissions standard EU5

3

5300 to 6200 rpm

1700 to 5200 rpm

(Normal unleaded RON 91
with marginally reduced
performance)

in proximity of engine with
upstream broadband probe,
main catalytic converter with
downstream regular lambda
probe

Further information on this engine can be
found in self-study programme
no. 401 "The 1.8l 118 kW TFSI engine with
timing chain".

Torque and power diagram

340

320

300

280

260

240

220

Tor q ue [ N m ]

200

180

160

140

1000 3000 5000

Engine speed [rpm]

200

180

160

140

120

100

80

60

40

20

0

7000

S488_228

Output [kW]

26

3.6l 220kW FSI engine with 4-valve technology

The 3.6l 220kW FSI engine with 4-valve technology is
a constituent of the VR engine series. Numerous
consumption-optimising measures have been
performed on the engine.

Technical features

● Oil pump output reduced and oil pressure lowered

to 3.6 bar

● Non-engaged chain tensioner

● 89° opening temperature of coolant

thermostat

● One-part oil pump chain sprocket

● Exhaust camshaft adjuster with 32°

setting range

● Vibration damper secured with 7 bolts

Further information on this engine can be
found in self-study programme
no. 360 "The 3.2l and 3.6l FSI engine"

S488_233

Engine code BWS

Type 6-cylinder in-line engine

Displacement 3597 cm

Bore 89mm

Stroke 96.4mm

Valves per cylinder 4

Compression ratio 11.4:1

Maximum output 220kW at 6600 rpm

Maximum torque 350Nm at

Engine management Bosch Motronic MED 17.1

Fuel Highest grade unleaded

Exhaust gas treatment Three-way catalytic converter

Emissions standard EU5

3

2400 to 5300 rpm

with RON 98
(Super unleaded RON 95 with
marginally reduced
performance)

with lambda control

Torque and power diagramTechnical data

400

380

360

340

320

300

280

Tor q ue [ N m ]

260

240

220

200

1000 3000

Engine speed [rpm]

5000

240

220

200

180

160

140

120

100

80

60

40

7000

S488_230

Output [kW]

27

Engines

New features of 3.6l 220kW FSI engine

To reduce fuel consumption and the emission of CO2, several consumption optimising features were performed on
the engine. In addition, further innovative developments were implemented in the design of the engine.

Duo-centric oil pump

The entire oil circuit of the engine was improved and the output of the oil pump consequently reduced. In doing so,
it was possible to lower the opening oil pressure from 5.7bar to 3.6bar.

Gasket

Seal

1st half of housing

Bearing bush

Radial shaft seal

Vibration damper

To ensure secure attachment, the vibration damper is
secured with 7 bolts, as on the Passat R36
(previously one centre bolt).

2nd half of housing

Outer rotor

Drive shaft

S488_026

Inner rotor

Spring

Control plunger

Plug

28

Bolt attachment

Vibration damper

S488_234

Chain tensioner

The lower chain tensioner has been optimised in terms of leaks and works without engagement at a lower oil flow
rate (originally 0.86l/min, now 0.04l/min). Without a locking mechanism it was possible to reduce the chain forces.
The spring serves to pretension the chain during cold starting. The ram serves purely to fill the void in the hollow
control plunger and thereby facilitates faster response from the chain tensioner when oil pressure is building up.

Chain tensioner module

Guide rail

S488_038

Housing

Control plunger

The choke bore must not be punched
through or cleaned using any kind of tool.

Ram

Choke bore

S488_036

Pretensioning
spring

Marking for primary

chain drive

S488_060

Chain sprocket

The oil pump chain sprocket has a one-piece design
to prevent incorrect fitment.

Marking for
camshaft timing
chain drive

29

Engines

Camshaft adjuster

The exhaust camshaft adjuster only works in a 32°
range of crankshaft adjustment. At idle, less exhaust
gas flows back into the inlet port, which means
residual gas compression no longer occurs.
Engine running is thus smoother and consumption at
idling speed is reduced by about 3-5%

Range of adjustment

32°

Camshaft adjuster

S488_028

Camshaft adjuster cover

Located between the camshaft adjuster cover and the
cylinder head is a seal.
The seal optimises oil supply to the camshaft adjuster,
which in turn raises its adjustment speed.

Cover for

camshaft adjuster

S488_239

Seal

30

1.6l 77kW TDI CR engine

The 1.6l TDI CR engine, already tried and tested in the
Polo 2010, was further developed for use in the Passat

2011.

Technical features

● Common rail injection system with piezo injectors.

● EGR module with exhaust gas recirculation valve

and exhaust gas recirculation cooler.

● Plastic intake manifold without swirl plate

adjustment

● Spur gear drive for camshafts without

tooth backlash compensation

● Fuel high pressure pump without sprocket

for pressurisation pump

S488_205

The design and function of the

1.6l TDI CR engine is described in self-study
programme no. 442 "The 1.6l 77kW TDI
engine with common rail injection system".

Technical data

Engine code CAYC

Type 4-cylinder in-line engine

Displacement 1598cm

Bore 79.5mm

Stroke 80.5mm

Valves per cylinder 4

Compression ratio 16.5:1

Maximum output 77kW at 4400 rpm

Maximum torque 250Nm at 1500-2500 rpm

Engine management Simos PCR2.1

Fuel Diesel complying with DIN

Exhaust gas
treatment

Emissions standard EU5

3

EN590

Exhaust gas recirculation,
oxidising catalytic converter
and diesel particulate filter

Torque and power diagram

280

260

240

220

200

180

160

Tor q ue [ N m ]

140

120

100

0

1000 3000 5000

Engine speed [rpm]

100

90

80

70

60

50

40

30

20

10

10

S488_204

Output [kW]

31

Engines

2.0l 103/125kW TDI CR engine

Second generation 2.0l TDI CR engines are used in
the Passat 2011. These engines are a further
development of the 2.0l TDI CR engine from the 1st
generation, tried and tested in many Volkswagen
models since 2007. The engine is offered with two
performance levels.

S488_207

Features of 2nd generation 2.0l TDI CR engine

Common rail fuel injection system with solenoid valve
controlled injectors

Cylinder head as on 1.6 l TDI CR engine with portion of

channel for recirculated gas running through cylinder
head

Exhaust gas recirculation module as on 1.6l TDI CR
engine with EGR valve and exhaust gas recirculation
cooler.

S488_206

S488_211

S488_209

32

Plastic intake manifold without swirl plate adjustment

S488_213

Technical data Torque and power diagram

Output 103kW 125kW

Engine code CFFB CFGB

Type 4-cylinder in-line engine

Displacement 19 68 cm

Bore 8 1mm

Stroke 95 .5mm

Valves per cylinder 4

Compression ratio 16.0:1

Maximum output 103kW at

4200 rpm

Maximum torque 320Nm at

1750 to

2500 rpm

Engine management Bosch EDC 17 (common rail

injection system)

Fuel Diesel complying with DIN

EN 590

Exhaust gas treatment Exhaust gas recirculation,

oxidising catalytic

converter,

diesel particulate filter

Emissions standard EU5

3

125kW at

4200 rpm

350Nm at

1750 to

2500 rpm

Nm

360

340

320

300

280

260

240

220

200

180

160

1000 2000 3000

Output [kW] - 125kW
Tor q u e [ N m ] - 1 2 5 kW

Output [kW] - 103kW
Tor q u e [ Nm] - 1 03 kW

kW

120

110

100

90

80

70

60

50

40

30

20

4000 5000

rpm

S488_208

● Detailed information about the 2.0l TDI CR engine can be found in self-study programme no. 403

"The 2.0l TDI engine with common rail injection system".

● The design and function of the 1.6l TDI CR engine is described in self-study programme no. 442

"The 1.6l TDI engine with common rail injection system".

● Further information about the solenoid valve controlled injectors can be found in

self-study programme no. 445 "The Sharan 2011".

● In combination with the 2.0l 103 kW TDI CR engine, the Passat 2011 can also be equipped with the

"Selective Catalytic Reduction" (SCR) exhaust gas treatment system as a Blue TDI version.
The SCR system serves as a means of reducing nitrogen oxide emissions and is described in detail in
self-study programme no. 424 "The exhaust gas treatment system: Selective catalytic reduction".

33

Engines

Fuel system for TDI engines

The overview shown represents the fuel system of the 2.0l TDI engine.

1 - Fuel system pressurisation pump G6

The fuel pump builds up pressure in the fuel supply
line.

2 - Fuel filter

The fuel filter keeps impurities in the diesel fuel away
from the components of the injection system. The high
precision components, for example, the high pressure
pump and the injectors, can be damaged or their
function impaired by even the most minute particles of
dirt.

8

3

5

3 - Fuel temperature sender G81

The fuel temperature sender measures the current fuel
temperature.

4 - High pressure pump

The high pressure pump generates the
fuel high pressure required for injection.

5 - Fuel metering valve N290

The fuel metering valve regulates the quantity of fuel
needed to generate the high pressure as required.

4

2

34

6

6 - Fuel pressure regulating valve N276

7

The fuel pressure regulating valve sets the
fuel pressure in the high pressure range.

7 - High pressure accumulator (rail)

The high pressure accumulator keeps the fuel
required for injection under high pressure for all

9

cylinders.

8 - Fuel pressure sender G247

10 10

1

Colour coding/key

High pressure

Supply pressure

Return pressure from injectors

10

10

The fuel pressure sender determines the current
fuel pressure in the high pressure range.

9 - Pressure retention valve

The pressure retention valve ensures that pressure
remains constant in the return flow to the injectors.
In this way fluctuations in pressure are avoided,
thereby making precise control of the injectors
possible.

10 - Injectors N30, N31, N32, N33

S488_220

The injectors inject fuel into the combustion chambers.

Return pressure

35

Engines

Fuel system pressurisation pump G6

In the fuel system of the 1.6l TDI CR engine and the 2.0l TDI CR engines, the fuel system pressurisation pump
generates the fuel pressure required for the low pressure system in the fuel tank.
As a consequence, the gear-type pump used in the high pressure pump of the previous model in the fuel system of
the 1.6l TDI CR engine is no longer required. Likewise, the electric pressurisation pump in the supply line of the low
pressure fuel system of the 2.0 l TDI CR engine has been discontinued.

The fuel system pressurisation pump in the Passat 2011 is an electrically driven internal gear pump. It is located in
the fuel delivery unit GX1. In the fuel pressurisation system for diesel engines, the pump generates a pressure of
approx. 6bar. This ensures that the high pressure pump is supplied with sufficient fuel in all operating conditions.
A valve in the high pressure pump reduces the fuel pressure generated by the fuel system pressurisation pump in
the fuel supply line to approx. 5 bar. This maintains a constant level of pressure in the fuel supply line.
The fuel pump is activated by the engine control unit via a relay when the engine is started.

Design of fuel delivery unit GX1

Fuel line for

auxiliary heater

Fuel supply

Fuel return

Electrical connection

Fuel system
pressurisation pump G6

S488_215

36

Effects in event of failure

The engine will not run if the fuel system pressurisation pump fails.

Power transmission

Dual clutch gearbox with freewheel function

Steady consumption

Speed [km/h]

Distance [m]

Dual clutch gearbox without freewheel function
Dual clutch gearbox with freewheel function

The 6-speed dual clutch gearbox 02E and the 7-speed dual clutch gearbox 0AM can be ordered for the the new
Passat with a freewheel function.

Overrun cut-off

Overrun cut-offCoasting

S488_240

The role of the freewheel function is to isolate the engine from the gearbox at overrun. This is made possible by
opening the dual clutch. The engine turns at idling speed and the vehicle coasts without any engine braking effect.
With the freewheel function and by driving with foresight, fuel can be saved.

The freewheel function is only possible with the selector lever in the "D" position. If the selector lever is in the "S"
position or in the tiptronic gate, or if the driver presses the brake, the freewheel function is suppressed.
Not until the engine is placed under load again is the freewheel function reactivated.

On dual clutch gearboxes with freewheel
function, the gear shift points with the
selector lever in "S" are only marginally
higher than those in the "D" position.

37

Power transmission

Overview of gearboxes

Manual gearbox

Gearbox type Technical features Further

information

6-speed
manual gearbox
MQ200-6F 0AJ

6-speed
manual gearbox

MQ250-6F 02S

● Further development of 0AG gearbox

● Adapted for 1.4l 90 kW TSI engine, gap between pinion shaft

and differential increased, sheet metal bearing support replaced
by cast metal bearing support for higher torque, teeth ground

● Final drive uprated

● Without speedometer sender

● CO

● Torque capacity up to 200Nm

● Further development from 0A4

● Longer shafts with additional bearings, additional gear pair,

-optimised gear ratios

2

new longer housing lid made from aluminium

● Without speedometer sender

● CO

● Torque capacity up to 250Nm

-optimised gear ratios

2

SSP 237
SSP 306

SSP 99

SSP 306

38

6-speed
manual gearbox
MQ350-6F 02Q

● Further development of 02M gearbox

● Changes to selector shaft, selector forks with stops in housing,

modified bearings

● Without speedometer sender

● Torque capacity up to 350Nm

SSP 205
SSP 306

Dual clutch gearbox

Gearbox type Technical features Further

information

6-speed

dual clutch gearbox

DQ250-6F DSG 02E

7-speed

dual clutch gearbox

DQ200-7F 0AM

The 6-speed dual clutch gearbox 02E is equipped with a hydraulic
dual clutch. It combines the high level of efficiency as well as
sturdiness and sportiness of a manual gearbox with the high level of
comfort of an automatic gearbox during gear changes.

The 7-speed dual clutch gearbox 0AM is a further development of the
6-speed dual clutch gearbox 02E.
Unlike the 02E, it works with a dry-plate dual clutch and separate oil
circuits for the gearbox and mechatronics.
Another difference to the 02E is that the electric oil pump for the
hydraulics is only actuated by the control unit when required.
Actuation occurs once hydraulic pressure in the mechatronics drops
below a certain value, necessitating an increase in pressure again in
order to assure operability of the mechatronics.

SSP 308

SSP 390

39

Running gear

Overview

The Passat 2011 offers the highest level of driving comfort thanks to its running gear configuration. The running
gear is based in essence on the tried and tested running gear of the Passat 2006. Sporty and standard running
gear versions are available, as well as adaptive chassis control DCC.

● Extended EDL (XDS)

● Lightweight McPherson strut

front suspension

● Parallel axis power steering (APA)

● ESP/ABS TRW 450M

● Tyre pressure monitoring

TPM with auto location

● Further details about the power steering system can be found in self-study programme

no. 399 "The electromechanical steering with parallel axis drive".

● For further details about the adaptive chassis control, see self-study programme no. 406

"The adaptive chassis control DCC".

● Adaptive chassis control DCC,

optional

40

● AUTO HOLD function

● Electromechanical parking brake

● Four-link rear suspension

S488_027

● Auto leveling on rear axle,

optional

● Fatigue Detection System (FDS)

● ContiSeal tyres from 17" rims

● Further details about the self-leveling system can be found in

self-study programme no. 357 "The Nivomat".

● Further details about the parking brake can be found in

self-study programme no. 346 "The electromechanical parking brake".

41

Running gear

Extended EDL (XDS)

The Volkswagen Passat 2011 is equipped with the ESP extension XDS on vehicles with diesel engines from 125kW
and on vehicles with petrol engines from 220kW. XDS keeps the wheel on the inside of the corner within the slip
limit during fast cornering. Up to a defined torque level, XDS decelerates the wheel on the inside of the corner, thus
enabling any increase in torque at the vertex to be offset against the wheel on the outside of the corner. This
feature only works if the vehicle is accelerated in the corner and sufficient torque is available. The effect is greater
in tight bends in 2nd or 3rdgear and at higher road speeds than in bends with larger radii.

With XDS

● Better traction

● Greater agility

● Follows line of drive better due to less steering

angle requirement

● Reduced tendency to understeer

● Greater speed out of corners possible

XDS already finds application in the Golf 6
GTI/GTD and Polo 5 GTI.

Key:

Key:

with XDS

with XDS

without XDS

without XDS

S488_074

Without XDS

● Torque at wheels cannot be increased

● TCS/EDL/engine torque intervention

42

Tyre pressure monitoring TPM with auto location

A new, direct measuring tyre pressure monitoring system is employed in the Passat. As before, the system uses
sensors in the tyre that report the inflation pressure to the control unit in the vehicle. With the "auto location"
feature, the system is capable of clearly identifying and displaying any tyre affected by pressure loss. Furthermore,
there is an option of displaying the inflation pressures of all tyres in the dash panel display.

The "intelligent aerial" is a combination of TPM auto location control unit and central reception aerial. It is
connected to the onboard supply via the extended CAN. Term.15, the speed signal and the reversing signal serve
as input parameters. The "intelligent aerial" can be found on the outside of the body in the rear (vicinity of spare
wheel well) in a place where reception is favourable.

S488_078

S488_080

Vehicle status

TPM auto location control unit
with central reception aerial

Key:

Reception with high level (rear)

Once the vehicle is in motion, the electronics in each
wheel start sending data telegrams. Some of the
information these data telegrams contain is as
follows:

● ID (identification)

● Pressure

● Temperature

● Direction of rotation

Dash panel insert with

controls

Example of display in

dash panel insert

Wheel electronics with detection

of rotational direction

Reception with low level (front)

With the direction of rotation data, it is possible even
after a short time of driving for each set of electronics
to be allocated to the individual wheels. In line with
this, the front and rear are identified by a level
assessment (which is why the reception aerial is
positioned on the rear bumper). This makes it possible
to clearly identify the location of every set of wheel
electronics.

43

Driver assist systems

Fatigue Detection System (FDS)

Driver fatigue is detected by monitoring the steering behaviour. The system meets the following criteria:

● Driver alert when fatigue is detected

● Fatigue monitoring only on motorways, dual carriageways and wide A roads

● Does not become operable until above 65km/h

● No imminent warning in event of microsleep

Function and display

The system stores a reference map in the gateway control unit based on the steering behaviour during the first 15
minutes of driving. A comparison of the driver's current steering response with this reference map is carried out and
evaluated. An alert is issued no earlier than 15 minutes of continual driving.

Displays in dash panel insert (example of German versions)

"Lowline"

The function analyses the driver's behaviour while driving the vehicle and detects driver fatigue from certain
patterns. The function cannot detect fatigue among all drivers as not all drivers demonstrate the same typical
steering behaviour.

If the behaviour falls into the fatigue category, the driver is alerted for 5 seconds by a message in the dash panel
and a gong. If the driver fails to take a break within the next 15 minutes, the message and gong are repeated. No
further message is given once it has been repeated. When the ignition is switched off, the reference map is cleared.

S488_136

"Highline"

S488_138

S488_076

"Premium"

44

Adaptive Cruise Control (ACC)

Adaptive Cruise Control (ACC) regulates the speed and the distance of the vehicle in relation to the traffic ahead at
a value predetermined by the driver. In all situations, the driver remains master of the situation in as far as the
system can be switched off or the intervention can be interrupted at any time by pressing the brake or accelerator
pedal.

The Front Assist feature integrated in the ACC helps as an "alert co-driver" to avoid any collision with moving traffic
– remaining alert even when the ACC is switched off.

The new City Emergency Brake function also reacts to parked vehicles at speeds below 30 km/h. In the event of
danger, it initiates a brake manoeuvre and can thereby help to avoid an imminent collision or reduce the amount
of damage caused as a result.

Terminology for driver assist systems

Name

ACC
(Adaptive Cruise
Control)

Front Assist Front Scan

Formerly
known as

ADC Maintains specific distance in relation to vehicle travelling ahead and adapts speed

City Emergency
Brake

Brake interventions avoid accidents only in
exceptional circumstances.

N/A

Function

Short description of function

dynamically to traffic flow.

Conditions vehicle, alerts driver to hazardous situations and improves
driving dynamics during overtaking manoeuvres. Reacts to moving vehicles
only at speeds greater than 30km/h.

Co-function of front assist. Automatically brakes the vehicle prior to a
collision. Reacts to moving and stationary vehicles at speeds less than
30km/h.

If the road ahead is clear, ACC moderately accelerates the vehicle up
to the desired (set) speed. If a vehicle travelling ahead in the same
lane is moving more slowly, the system brakes so that the vehicle
ahead can be followed comfortably.

S488_090

45

Driver assist systems

Optimised lane change function

When the turn signal is activated, the system detects an intention to overtake and improves the dynamics while
taking safe distances into account.

Veering out

If, with the ACC active, the Passat approaches a
vehicle travelling ahead, all that is required is for the
turn signal to be activated and the Passat will
accelerate up to the set speed when veering out. In
this way, the vehicle can be overtaken comfortably.
ACC helps to maintain the safe distance
automatically.

Veering in

If the driver activates the turn signal after the vehicle
has been overtaken, the road speed is reduced back
to the value set in the ACC.

Example (80km/h set)

1) Appr oaching a slower
vehicle. Speed adapted to
target.

2) Driver indicates and veers out:
system accelerates automatically
to 80 km/h.

S488_122

3) Driv er indicates.

4) Driver veers in: automatic follow-on
with ACC set to 80km/h.

Go Trigger

In combination with a DSG gearbox, the vehicle can
be brought to a halt when following traffic (follow to
stop). A safe distance is taken into account in this case.

Vehicle brought to halt

within safe distance

S488_124

As soon as the vehicle travelling ahead gains distance
and the driver briefly presses the accelerator, the ACC
takes up its control function again immediately (Go
Trigger).

Go Trigger

S488_126 S488_128

46

Front Assist

General description

Front Assist aids as an "alert co-driver" in certain situations to avoid collisions with traffic - even with the ACC
switched off. The new Front Assist is now capable of considerably more. In a manner of speaking it is an "alert co­driver with its own brake pedal". Even before the situation reaches a critical point, measures are taken unbeknown
to the driver. The aim of Front Assist is to minimise the stopping distance in critical situations.

Interplay of ACC and Front Assist

The ACC and Front Assist functions are housed in one control unit, although they are two separate components.
Front Assist works independently of the ACC status. It also remains active when the driver switches off the ACC.
Decisive for the functional readiness of Front Assist is the display of the status LEDs.

S488_082

Caution!

Front Assist does not intervene until just before a collision!
Interventions avoid accidents only in exceptional circumstances.

LED green: Front Assist switched on and ready to intervene.

LED yellow: Front Assist switched on but function sometimes impaired -

e.g. blocked sensor, overheated brakes, etc.

LED off: Front Assist switched off or malfunction.

47

Driver assist systems

Overview of Front Assist co-functions

1. Vehicle conditioning

Vehicle conditioning works in a speed range of 5km/h to 210km/h. The vehicle is prepared for the driver to
perform an emergency stop:

● Prefill function (brake pads against brake discs).

● Hydraulic brake assist (HBA) trigger threshold adapted to highest sensitivity.

2. Driver alert

The driver alert is issued in a speed range from 30km/h to 210km/h. The driver is alerted in two stages:

● Preliminary warning: Warning sound and warning symbol in multifunction display.

● Main warning: Warning jolt.

3. Active brake interventions

Active brake interventions take place in a speed range from 5km/h to 210km/h. There are two types of operation:

● Target braking (braking pressure imparted by driver is boosted).

● Automatic partial braking (APB) in cases where the driver fails to react.

In a speed range from 5km/h to 30km/h, automatic partial braking is also referred to as
the "City Emergency Brake" function.

City Emergency Brake

48

In a speed range from 5km/h to 30km/h, automatic partial braking carries the name "City Emergency Brake". The
main difference compared with braking at speeds above 30km/h is that the city brake also reacts to stationary
vehicles. Furthermore, in the event of an immediate risk of collision there is no warning jolt, nor is the vehicle

2

decelerated (APB pilot stage). If a collision cannot be avoided, the vehicle is decelerated at a rate of 6.0m/s

.

Overview of Front Assist and City Emergency Brake

The following graph shows the sequence if a risk of collision is detected and the driver shows no reaction.

Risk of collision:

Marginal Raised

S488_084

HBA

sensitive

Warning jolt APB pilot stage APB main stage

HBA = Hydraulic Brake Assist; APB = Automatic Partial Braking

Marginal

Front Assist

Speed of obstacle greater
than 30km/h

risk of collision

Optical and acoustic warning
signal,
HBA changeover,
braking system prefilled

Raised
risk of collision

Warning jolt and APB pilot
stage
(Brake deceleration 1m/s

2

Highest

Highest
risk of collision

APB main stage
(Brake deceleration 3.5m/s

)

Collision

2

)

City Emergency Brake

Speed of obstacle less than
30km/h

If the driver intervenes by braking every time there is a risk of collision, the system supports him/her by
boosting the brake pressure. In doing so, the system attempts to keep any potential accident damage as
minimal as possible.

HBA changeover,
braking system prefilled

-APB main stage
(Brake deceleration 6.0m/s

2

)

49

Driver assist systems

Park assist steering 2.0

The new park assist steering 2.0 represents a marked improvement over the previous park assist steering 1.0 and
also park assist steering 1.5. With this new semi-automatic parking system, parking in bays perpendicular to the
road is made possible and parking in even tighter parking spaces parallel to the road (kerb-side parking) has been
made much easier. It is now possible, for example, to

- park fully or partly on kerbs,

- park between trees and other obstacles and

- park on bends.

It is still possible to drive out of kerb-side parking spaces with this system and the process of entering or exiting can
be done in several stages. As the first parking system of its kind, park assist steering 2.0 includes active braking
support.

Further information about this new parking system can be found in
self-study programme no. 494 "Park assist steering 2.0".

S488_092

50

Overview

The Passat 2011 is equipped with state-of-the-art technology.

Electrical system

● KESSY with separate ignition

and engine start button

● Dynamic light assist,

optional

● 2nd generation park assist

steering, optional

S488_051

● Main beam assist

● Lane departure warning

with steering intervention

● Multifunction camera,

optional

● Control unit for terminal and

engine start control J942

● Heated windscreen, optional

51

Electrical system

System overview

The lane departure warning system, previously used in the Phaeton and Touareg, is now utilised in the Passat 2011.
Also finding application in the VW brand are the new light assist systems 'dynamic light assist' (DLA) and 'main
beam assist'. The following diagram shows the largest possible network, with the Passat fully equipped.

Key

Powertrain CAN data bus

Convenience CAN data bus

Infotainment CAN data bus

Extended CAN data bus

LIN data bus

J364

J772

R78

J412

J525

R/J503

T16

CAN data bus line

LIN data bus line

Private bus

d - CAN diagnosis

k - CAN dash insert

* - or (not both)

J764

J453

R215

J245

J394

Y

J810

J301 G397

J393/J362

J527

J255

J519

J345

J386

J387

d

J533

k

J285

J400

J926

J927

52

J605

J501

J500

J623

J234

E313

J250

CX1

J367

J428

J502

J540

J104

J743

J791/J446*

J492

J844

R242

J745

J668J667

S488_010

Key

CX1 - Alternator
E313 - Selector lever
G397- Rain and light sensor
J104 - ABS control unit
J234 - Airbag control unit
J245 - Sliding sunroof control unit
J250- Electronically controlled damping control unit
J255 - Climatronic control unit
J285 - Control unit in dash panel insert
J301 - Air conditioning system control unit
J345 - Trailer detector control unit
J362 - Immobilizer control unit
J364 - Auxiliary heater control unit
J367 - Battery monitor control unit
J386 - Driver door control unit
J387 - Front passenger door control unit
J393 - Convenience system central control unit
J394 - Roof roller blind control unit
J400- Wiper motor control unit
J412 - Mobile telephone operating electronics control unit
J428- Control unit for adaptive cruise control
J446 - Parking aid control unit
J453 - Multifunction steering wheel control unit
J492- Four-wheel drive control unit
J500- Power steering control unit
J501 - Multifunction unit control unit
J502- Tyre pressure monitor control unit
J503- Control unit with display for radio and

navigation system
J519 - Onboard supply control unit
J525 - Digital sound package control unit
J527 - Steering column electronics control unit
J533 - Data bus diagnosis interface (gateway)
J540- Control unit for electromechanical parking brake
J605- Rear lid control unit
J623 - Engine control unit
J667 - Power output module for left headlight
J668 - Power output module for right headlight
J743 - Mechatronic unit for direct shift gearbox
J745 - Cornering light and headlight range control unit
J764 - Electronic steering column lock control unit
J772 - Reversing camera system control unit
J791 - Control unit for park assist steering
J810 - Driver seat adjustment control unit
J844 - Main beam assist control unit

(except with R242 and J745)
J926 - Rear door control unit, driver side
J927 - Rear door control unit, front passenger side
R78 - TV tuner
R215 - Interface for external multimedia devices
R242- Front camera for driver assist systems

(except with J844)
T16 - 16-pin connector
Y - Analogue clock

53

Electrical system

The control unit for terminal and engine start control

For the first time, a terminal control unit finds application in the new Passat. It serves on one hand to actuate the
terminals in advance as a link between the onboard supply control unit and the control elements of the electronic
ignition lock. On the other hand, it serves to emulate the terminals for the newly added ignition starter button (ISB).
The terminal control unit is only installed in conjunction with KESSY.

The terminal control unit can be found in a separate
housing holder above the pedal bracket in the driver's
footwell. The terminal control unit has a discrete
connection to the onboard supply control unit. The
control unit is permanently coded for automatic start
(pin coding). For the Passat, provision has been made
for two functions: with and without start/stop system.

Diagnosis

If the terminal control unit should fail while the vehicle is in motion, terminal 15 will continue to be supplied as an
emergency running measure until engine speed is zero. Thereafter, ignition is switched off and emergency running
is activated both on the hardware and software side (internal terminal CU measure). This means that the terminal

request from the electronic ignition lock is enabled, thereby allowing the vehicle to be operated through this switch.
The ISB will no longer work and its light is switched off as with all other implausible ignition starter button problems.

The engine control unit interrogates the existing potential for plausibility just before the terminal 50 request from
the terminal control unit via the diagnosis wire (terminal 50 R for "read back") for starter actuation. In the event of
implausibility, the engine ECU ceases its attempt to start the engine. The onboard supply control unit (OSCU)
receives this information at the same time.

Both input pins of the ISB must have the same signal so that the operational request from the ISB is accepted by the
terminal control unit. Inputs open means ISB not pressed; inputs to earth means ISB pressed. In addition to the
information (no fault present; all conditions met for starting), diagnoses are also transported via the path "fault
information" from terminal CU to OSCU (2 of 3 status lines currently in use). There are currently two possible fault
messages: "Control unit faulty" and "ISB faulty".

S488_132

54

Function

The driver can control the vehicle functions at the same time from the electric ignition lock or/and from the ignition
starter button. Terminals S, 15 and 50 from the electric ignition lock are just passed through in the terminal CU.
Terminals S and 15 are generated electronically by the terminal CU due to the request from the ISB. These carry a
steady signal upon active request. The term. 50 request during automatic start represents a 200ms square wave
impulse from the terminal CU to the engine control unit, irrespective of how long the ISB is pressed.

If the engine control unit has information about the framework conditions, such as the PN signal on automatic
vehicles (selector lever in P or N position) and the brake signal, the engine control unit actuates both its starter
relays (SST1, SST2). On vehicles with manual gearbox, the clutch actuation signal (interlock) serves as a condition
for input.

Functional diagram

B B

ESL

As
Cs

S

EIL

ISB

Key

A-terminal 15
As - terminal 15s
B-terminal 30
C-terminal 50
Cs - terminal 50s
P-terminal P

P

Coding

J527

J942

terminal

CU

SMLS

Ks
Ka

ST

50_SMLS

C

PN/interlock

J519

OSCU

CAN

Te rm . 75

CAN

J623

ECU

Kc

● PN (automatic gearbox), interlock

(manual gearbox)

● Neutral gear sensor (NGS)*

● Brake signal (BLS, BTS)

S-terminal S
Ks - terminal CU_S (request from J942)
Ka - terminal CU_15 (request from J942)
Kc - terminal CU_50 (request from J942)
ST - Status lines with fault and status information
SST - Start control
* - On vehicles with start/stop system

A

SST1

SST2

Te rm . 50 R

S488_134

B

A

C

55

Convenience electronics

Dynamic light assist (DLA)

A new generation of dynamic light assist is used in the Passat 2011 in combination with xenon headlights. It works in
the same way as the headlights on the Touareg, though differs in its technical makeup due to different
manufacturers. The headlight installed in the Passat features a rotating shutter with four shield profiles. In addition,
there is a shutter range with variable light shield (masked permanent main beam).

Headlight

S488_094

Networking

D3S

Power electronics

Reflector

Masking area (DLA)

Lens

Shutter with shields

J533

56

J519

J527

Key

J519 - Onboard supply control unit
J527 - Steering column electronics control unit
J533 - Data bus diagnosis interface (gateway)
J285 - Control unit in dash panel insert
J667 - Power output module for left headlight

J745

R242

J285

J668 - Power output module for right headlight
J745 - Cornering light and headlight

range control unit

R242- Front camera for driver assist systems

J667

J668

S488_042

Shield positions

Main road light, motorway light, urban light and touring mode

These light cone patterns (from a vehicle for right-hand traffic) are made possible by three different shield profiles
on one shutter. Depending on the speed of the vehicle or menu setting, the shutter toggles between the positions for
main road, motorway, urban (not including xenon headlight function with masked permanent main beam) and
touring mode. In touring mode, there is no main road (dipped beam), motorway and dynamic cornering light. The
following light cone patterns are projected against a wall from a distance of approx. 10m (full illumination):

Main road light
(up to 110km/h)

Motorway light
(from 110km/h)

Left light cone raised

Urban light (10-45km/h)
Touring mode (static)

S488_096

Maximum dipping of light cone

Main beam and masking position

The masking range on the shutter is used in conjunction with a gradual transition to main beam for dynamic light

assist. If the system does not detect any vehicles in the dazzle range of the light cone, the shutter is turned to the
non-dipped position. The light cone is therefore unmasked. If a vehicle travelling ahead approaches the light cone,
the large shield on the shutter is turned into the light cone dynamically. In this way, only the light that could dazzle
oncoming traffic or the vehicle travelling ahead is "dipped". The remaining field of light on the left-hand side is
swiveled away from oncoming traffic to the left and "dipped" to the maximum range available for the main road
setting. The DLA becomes active from 60km/h and remains this way even if the vehicle is slowed down to 55km/h.

Main beam (unmasked position) Dynamic range* Maximum "dipped" range*

*Left headlight (mirror image on right headlight)Light cones overlap

S488_098

57

Radio, navigation and telephone

The radios

Technical d a t a

Display Monochrome, 122 x 36 pixels

Touch sensitive (touchscreen)
AM, FM, TP and RDS reception (basic tuner) ●

AM, FM, TP and RDS reception (diversity tuner)

Integrated DAB tuner (digital radio)

Integrated disc drive CD

Integrated SD/SDHC memory card reader

Media support CD and MP3 audio data

Audio input interface (AUX-IN) Can be retrofitted
Telephone interface for hands-free device ● (Mono-channel only)

Interface for connecting a reversing camera

Loudspeaker output stages 4x20 watt output
(2 or 4 loudspeakers can be connected)

Control of external CD changer ● (No MP, WMA3)

Control of external amplifier

Connection of external media devices (USB, mini USB, iPod)
Speed-dependent volume adjustment ●

Brightness of display light can be regulated
independently of interior light in vehicle

Self-diagnosis and loudspeaker diagnosis ●
Service test mode ●

Optical parking system (OPS)

Air conditioning information

For further information, see self-study programme no. 404

RCD 210

●

●

58

* Discontinued from model year 2012
** DAB version shown
*** EU version without DAB shown

RCD 310** RCD 510***

Monochrome, 302 x 45 pixels 6.5", 400 x 240 pixels

●

●●

Depending on equipment Depending on equipment

CD CD (6-disc changer)

●

CD, MP3 and

WMA audio files

●●

●●

●●

●●

●●

●●

●●

CD, MP3 and

WMA audio files

Depending on equipment

● (No MP3, WMA)*

●●

●●

●●

●●

no. 417 no. 423

59

Radio, navigation and telephone

The radio-navigation systems

Technical d a t a

Display 5", 400 x 240 pixels
Touch sensitive (touchscreen) ●

AM, FM, TP and RDS reception (diversity tuner) ●

Integrated DAB tuner (digital radio) Optional

Integrated disc drive CD
Integrated SD/SDHC memory card reader ●

Media support CD, MP3 and

Audio input interface (AUX-IN) External and front
Telephone preparation support ●/+Bluetooth internal
Interface for connecting a reversing camera ●
Loudspeaker output stages 4x20 watt output ●
Control of external CD changer ●
Control of external amplifier ●
Connection of external media devices (USB, mini USB, iPod) ●

Can be combined with TV-tuner
Speed-dependent volume adjustment ●

Brightness of display light can be regulated
independently of interior light in vehicle

Self-diagnosis and loudspeaker diagnosis ●
Service test mode ●
Optical parking system (OPS) ●
Air conditioning information ●

Navigation function with map,
integrated driving symbols and voice

Integrated storage media Flash memory***

Navigation data Internal memory

Navigation data update via SD card**
Traffic sign display ●

For further information, see self-study programme no. 493

RNS 315

WMA audio files

●

●

(6GB/4GB NAR)

60

* The hard-disc is partitioned: 20GB are available for media data,

10GB are reserved for navigational data.

** The purchased SD card can be used for any navigation unit, though it is only coupled to the specific device once

updated and can only be used with this device.

*** Can only be used for navigational data.

RNS 510

6.5", 800 x 480 pixels

●

●

DVD

●

CD, MP3, WMA audio,

DVD formats

External

●

●

●

●

●

●

●

●

●

●

●

●

●

Hard-disc 30GB*

Hard-disc*

DVD

●

no. 423

61

Radio, navigation and telephone

The aerial concept

Passat saloon

On the saloon, all of the aerials are integrated in the rear window. The entire heating wire structure is part of the
FM and TV signal aerial system. The signals are separated electronically according to TV1, TV2 and FM1, FM2.

The GSM/UMTS and GPS aerials are designed as separate modules and are clipped onto the rear window. The
aerial connections all run via the aerial module, which has the corresponding impedance transformer. Depending
on the signals required, the aerial module has three mechanical configurations and nine versions (part numbers).
The diagram shows the maximum equipment.

Auxiliary

heater

S488_118

GSM/UMTS

Modules

FM2 /T V2

AM

K

D

GPS

GCA IB

TV tuner

DAB

K

B

H

G

I

A

Aerial module

FM1/ T V1

62

Left Right

Further information on this aerial concept can be found in self-study programme
no. 342 "Radio systems 2006".

Passat estate

On the estate model, the radio aerials and the aerials for radio remote control (RRC) of the auxiliary heater are
integrated in both rear side windows. In addition to this, it features a roof aerial for GPS and/or GSM/UMTS.
Depending on the signals required, the impedance transformer is available in different versions. The diagram
shows the maximum equipment.

Auxiliary

heater

S488_116

K

GA CIB

GSM/UMTS,
GPS

D

Impedance

transformer

AM/FM1/TV1 D AB FM2/TV2

FM1/ T V1

Left

Key:

B

I

A

C

D

G/H

K

FM1 /AM

FM2 ( Diver sity)

DAB

GPS

GSM/UMTS

TV

Auxiliary heater

RRC

auxiliary heater

AM

TV tuner

DAB

FM2/ TV2

Right

63

Radio, navigation and telephone

Universal cellphone preparation (UHV)

High (9ZB)

On the UHV High system, the cellphone is connected exclusively via Bluetooth. In this case, only the voice data is
transferred between the microphone, the control unit for cellphone operating electronics (J412) and the
loudspeaker system of the vehicle. Communication with the GMS/UMTS network is via the cellphone aerial. This
UHV features the following functions:

Internal functions:

● Hands-free profile (HFP 1.5)

● BT audio streaming (A2DP 1.2) and control

Microphone in

roof unit

Convenience control
dash panel insert
(MFD+)

CAN**

J412

Control unit for

cellphone operating electronics

External functions:

● Convenience radio/sat nav operation

● Multifunction display (MFD)

● Multifunction steering wheel, optional

● 3 button module in roof unit

GSM/
UMTS*

P

D

2

A

P,

F

H

3 button
module

64

Multifunction steering

wheel, optional

** Always stands for signal transfer via

CAN data bus, irrespective of bus designation and
interconnected gateway.

Loudspeaker

S488_110

RCD/RNS

* Depending on cellphone/SIM card

High "baseplate" (9ZA)

Compared with the UHV High (9ZB), this UHV features a baseplate. This serves to mount the telephone-specific
charging cradle via which connection to the roof aerial takes place. When the cellphone is connected to the vehicle
via the charging cradle, any radio communication (GSM/UMTS) from the vehicle is processed via the roof aerial.
This UHV also features the following functions:

Internal functions:

● Hands-free profile (HFP 1.5)

● BT audio streaming (A2DP 1.2) and

control (AVRCP 1.3)

● Voice-controlled operation (G2P/TTS)

● SMS speaking

Charging cradle with

aerial connection

to roof aerial

GSM/

UMTS*

Convenience control
dash panel insert
(MFD+)

CAN**

HFP, A2DP

External functions:

● Convenience radio/sat nav operation

● Multifunction display (MFD)

● Multifunction steering wheel, optional

● 3 button module in roof unit

● Baseplate for mounting special

phone holder

● External aerial connection via phone

holder

Microphone in
roof unit

J412

3 button
module

Multifunction steering

wheel, optional

** Always stands for signal transfer via

CAN data bus, irrespective of bus designation and
interconnected gateway.

Loudspeaker

S488_112

RCD/RNS

* Depending on cellphone/SIM card

65

Radio, navigation and telephone

Premium (9ZU)

The UHV Premium distinguishes itself from the UHV High "baseplate" by the internal GSM/UMTS module. A
connection between the cellphone and the vehicle is not made (charger cradle optional) as the internal UHV
module has access to the telephone data via Bluetooth by way of the Sim Access Profile (SAP). In this way, any
radio communications (apart from Bluetooth) outside the vehicle are processed via the integrated GSM/UMTS
module and the roof aerial. This UHV also features the following functions:

Internal functions:

● Hands-free profile (HFP 1.5)

● BT audio streaming (A2DP 1.2) and

control (AVRCP)

● Voice-controlled operation (G2P/TTS)

● Sim Access Profile (SAP 1.0)

● SMS reading, writing and speaking

GSM/

UMTS

External functions:

● Convenience radio/sat nav operation

● Multifunction display (MFD) with Highline or

● Multifunction steering wheel

● 3-button module in roof unit

● Charger cradle

● External aerial connection via control unit

Convenience control
dash panel insert
(Highline/Premium)

CAN**

Premium line dash panel insert

P

,

P

D

A

2

S

A

,

P

F

H

Microphone in
roof unit

66

Roof aerial

Multifunction

steering wheel

** Always stands for signal transfer via

CAN data bus, irrespective of bus designation and
interconnected gateway.

GSM/UMTS module

Internal

3 button

module

Loudspeaker

S488_114

RCD/RNS

Internal RNS315 (9ZI)

The internal UHV of the RNS315 operates without additional external UHV control units. The cellphone is
connected exclusively via Bluetooth. Only the voice data and command instructions are transferred in this case.
GSM communication with the network provider is via the aerial in the cellphone. This UHV features the following
functions:

Internal functions:

● Hands-free profile (HFP 1.5)

● BT audio streaming (A2DP 1.2) and control

Microphone in

roof unit

External functions:

● Convenience radio/sat nav operation

● Multifunction steering wheel, optional

Convenience control dash
panel insert
(MFD+)

CAN**

GSM/
UMTS*

P

D

2

A

,

P

F

H

Loudspeaker

Multifunction

steering wheel,

optional

** Always stands for signal transfer via

CAN data bus, irrespective of bus designation and
interconnected gateway.

S488_120

RNS315

* Depending on cellphone/SIM card

67

Heating and air conditioning

Air conditioning

Rear window heater button Instant heat button

AC button

Rotary switch for

temperature control

for auxiliary coolant heater

Air circulation button

Rotary switch for
air distribution

S488_059

Operation

The air conditioning system features manual controls.

Depending on the equipment, there are different
control and display units. The illustration above shows
the maximum equipment. Depending on the
equipment, an instant heat button for the coolant
supplementary heater or a button for activation of the
windscreen heater may be installed.

The control elements are equipped with LEDs for
visual feedback. They indicate whether a function is
active or at what output stage a function is operating.

Front left seat

heating button

Rotary switch for

fresh air blower

Unlike the familiar Climatic system, the interior
temperature sensor and the temperature sensors at
the air vents have been discontinued. Therefore, no
provision is made on the AC system for a fixed
temperature selection in °C. Instead, the interior
temperature is regulated manually using the rotary
temperature control switch. This rotary switch can be
adjusted without increments between HI and LO.
Adjustment of the temperature flap on the AC unit is
still performed by servomotors with feedback
potentiometers.

Supplementary heater and PTC heater are not
deactivated when the AC unit is switched off.

Front right seat
heating button

68

2-zone Climatronic

The 2-zone Climatronic features an AC unit with two temperature flaps that can be adjusted independently of each
other. In this way, the interior temperature on the driver side and front passenger side can be selected separately.

Head vent Torso vent

Defrost

Left temperature

rotary control

Front left seat

heating button

Auto high/low

Windscreen heater

OFF

Unvented interior

sensor

S488_003

Rocker switch

for fresh air blower

Footwell vent

Air recirc./
auto air recirc.

Heated rear window

Right temperature
rotary control

Front right seat
heating button

AC ON/OFF

Instant heat button

2-zone
synchronisation

Operating and display unit

Depending on the set values and the environmental
conditions, such as the outside temperature, the
temperature, air quantity and also air distribution are
regulated automatically by the Climatronic system.
Manual operation of the Climatronic system is still
possible.

LEDs in the individual function buttons give feedback
regarding the current settings of the selected
functions. This information can be displayed as a
popup in the radio and radio-navigation unit as well.

Supplementary heater and PTC heater are not
deactivated when the AC unit is switched off.

69

Heating and air conditioning

Thermo Top fleece auxiliary coolant heater

On vehicles with diesel engines, the new ThermoTopfleece from WEBASTO is used as an auxiliary coolant heater
and as a supplementary heater. The difference to ThermoTopV is that the new heater is equipped with a fleece
burner. There are no changes in operation, fitting location or functions.

On petrol engine vehicles, ThermoTopV with venturi burner will continue to be installed until further notice.

Temperature sensor

Overheating sensor

Metal fleece

Heat exchanger

Exhaust gas outlet

Coolant inlet and outlet

Combustion
air blower

Control unit

Electrical connection

Combustion air inlet

Fuel inlet

S488_049

70

Notes

71

488

© VOLKSWAGEN AG, Wolfsburg
All rights and rights to make technical alterations reserved.

000.2812.48.20 Technical status 12.2010

Volkswagen AG
After Sales Qualification
Service Training VSQ-1
Brieffach 1995
D-38436 Wolfsburg

❀ This paper was manufactured from pulp that was bleached without the use of chlorine.