Volkswagen Self Study Program 861803 – Tiguan Haldex All-Wheel Drive SSP-861803-Tiguan-Haldex-All-Wheel-Drive

Service Training

Self Study Program 861803

Tiguan Haldex All-Wheel Drive

Volkswagen of America, Inc.
Volkswagen Academy
Printed in U.S.A.
Printed 1/2008
Course Number 861803

©2008 Volkswagen of America, Inc.

All rights reserved. All information contained in this manual is
based on the latest information available at the time of printing
and is subject to the copyright and other intellectual property
rights of Volkswagen of America, Inc., its affi liated companies
and its licensors. All rights are reserved to make changes at
any time without notice. No part of this document may be
reproduced, stored in a retrieval system, or transmitted in any
form or by any means, electronic, mechanical, photocopying,
recording or otherwise, nor may these materials be modifi ed
or reposted to other sites without the prior expressed written
permission of the publisher.

All requests for permission to copy and redistribute
information should be referred to Volkswagen of America,
Inc.

Always check Technical Bulletins and the latest electronic
repair information for information that may supersede any
information included in this booklet.

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

Contents

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

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Drivetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

All-Wheel Drive Clutch Details . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Knowledge Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Note

Important!

This Self-Study Program provides information
regarding the design and function of new
models.
This Self-Study Program is not a Repair Manual.

This information will not be updated.

For maintenance and repair procedures,
always refer to the latest electronic
service information.

iii

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Introduction

Introduction

Volkswagen has used a Haldex clutch for the
4MOTION all-wheel drive since 1998. A new
generation of the all-wheel drive clutch is now used
by Volkswagen for the fi rst time in the Tiguan.

The new all-wheel drive clutch is controlled
electronically. It allows torque to be transmitted to
the drive wheels that have traction regardless of

slip at other wheels. The distribution of the drive
forces to the axles is variable and depends on the
driving conditions. The new all-wheel drive clutch in
4MOTION responds rapidly to any driving situation
and maintains the best possible traction at all times.

S414_002

1

Overview

History

Overview

In 1998, 4MOTION drive replaced synchro all-wheel
drive at Volkswagen. While the synchro all-wheel
drive used a visco clutch, an all-wheel clutch by
Haldex was used for the fi rst time in the 4MOTION
drive.

With this hydraulic multiplate clutch, the all-wheel
drive could be controlled electronically. Apart from
slip control, the control module also allowed handling
dynamic driving conditions such as curves, speed,
and overrun, or load operation.

Function of Haldex Clutches

The fi rst two generations of the Haldex clutch use
a rotational speed difference between the front and
rear axles to operate. A pump effect is generated
using a cam plate, rollers, and two reciprocating
pistons working in parallel. This creates oil pressure
that compresses the multiplate clutch through
a working piston. The drive torque transferred
determines the amount of pressure applied.

The pressure on the multiplate disks of the clutch is
regulated through:

First Generation Haldex Clutch

S414_003

Generation II Haldex Clutch from Model Year 2004

Suction valves

•

Pressure valves

•

Electronic control valve

•

Control module

•

2

S414_004

Haldex Generation IV
All-Wheel Drive Clutch

Overview

The power transfer through the multiplate pack of
the generation IV all-wheel drive clutch is nearly
identical to the previous Haldex models. Generating
the pressure with an electric pump is a new feature.
The torque to be transferred is determined by All
Wheel Drive Control Module J492 through the
selection of Haldex Clutch Control Valve N373. Speed
differences between the front and rear axles are no
longer a prerequisite for activating the all-wheel drive
clutch.

Technical Features

Electro-hydraulically controlled multiplate clutch

•

Integrated in the rear axle drive

•

Simplifi ed hydraulic circuit

•

Optimized demand-controlled pump selection

•

Advantages

Clutch selection independent from the driving

•
situation

Rapid torque build-up

•

Permanent rear wheel drive capacity

•

Unrestricted compatibility with the slip control

•
systems (e.g. ESP, ABS)

S414_005

3

Drivetrain

Drivetrain

4MOTION Drivetrain System

The front wheels are conventionally driven by the
front axle differential. At the same time, the torque is
transferred to the propeller shaft by this differential
through the angle transmission.

Depending on the degree of engagement of the all­wheel drive clutch, a torque that matches the driving
situation is transmitted to the rear axle drive.

Engine

Transmission

Angle Transmission Propeller Shaft

All-Wheel Drive Clutch

Front Axle Differential

Rear Axle Drive

Rear Axle Differential

S414_007

4

Angle Transmission

The angle transmission increases the torque to the
propeller shaft by a factor of 1.6. The diameter of the
shaft can be smaller for this reason, since it transfers
a smaller torque. In the rear axle drive, the torque is
reduced again by the same factor of 1.6.

Drivetrain

Output to

Right Wheel

Power Flow

The force is transferred from the spur gear to
the propeller shaft by the differential cage of the

differential, the hollow shaft with crown wheel, and
the pinion.

Output to
Left Wheel

From

Transmission

Drive from Transmission

and Output to Left Wheel

Differential Cage

Output to

Propeller Shaft

S414_008

Hollow Shaft

Output to
Right Wheel

Spur Gear Pinion

Crown Wheel

Output to

Propeller Shaft

S414_009

5

Drivetrain

Propeller Shaft

The propeller shaft has two parts. They are linked
by a center joint. Flexible disk joints are used to
make the connection to the transfer case and the
all-wheel drive clutch. A rotational vibration absorber
is permanently attached to the rear fl exible disk joint
and cannot be serviced separately. It reduces the
transfer of engine vibrations through the rear axle
differential to the body.

Flexible
Disk Joint

Center Joint

Flexible Disk Joint
with Rotational
Vibration Absorber

Direction of Travel

Rear Flexible Disk Joint

The rear axle transmission and the propeller shaft
are balanced during production. For this reason the
drivetrain does not require balancing in the vehicle.

Rotational
Vibration
Absorber

No Balancing
Required

S414_010

Center Joint

The center joint is press-fi tted and cannot be
separated. This results in a compact and light design
and the roll bellows is better protected.

Roll Bellows

S414_011

S414_012

6

Rear Axle Drive

The all-wheel drive clutch is integrated in the rear
axle drive.

Rear Axle Drive Pinion

All-Wheel Drive Clutch
Multiplate Pack

Drivetrain

Crown Wheel

Drive Shaft

Rear Axle Differential

All-Wheel Drive
Clutch Oil Reservoir

All Wheel Drive
Control Module J492

S414_013

7

Drivetrain

Function of the All-Wheel
Drive Clutch

The all-wheel drive clutch between front and rear
axle drives controls the drive torque to the rear axle.
Depending on the degree of engagement, the all­wheel drive clutch directs the required drive torque
to the rear axle.

All-Wheel Drive Clutch Components

Accumulator

Oil Filter

Haldex Clutch
Pump V181

Haldex Clutch

Oil Circuit Components

Multiplate Clutch

Control Valve N373

Multiplate Pack

All Wheel Drive
Control Module J492

S 414_014

Haldex Clutch
Control Valve N373

All Wheel Drive
Control Module J492

Accumulator

Haldex Clutch
Pump V181

S414_064

8

All-Wheel Drive Clutch Details

All-Wheel Drive Clutch Details

Overview

The individual all-wheel drive clutch component
groups are shown here to provide a better
understanding of how they work.

Spring Plate

Mechanical Assembly

Needle
Bearing

Electro-Hydraulic Assembly and All Wheel Drive
Control Module J492

All Wheel
Drive Control
Module J492

Needle Bearing

Thrust Plates

Working Pistons

Drive Hub

Multiplate Pack

Clutch Cage

S414_015

Haldex Clutch
Control Valve N373

Haldex Clutch Pump V181

Accumulator

Oil Filter

S414_040

9

All-Wheel Drive Clutch Details

Mechanical Assembly

The following sub-groups belong to the mechanical
assembly:

Multiplate clutch

•

Working piston

•

Spring plate

•

The entire assembly creates the frictional connection
between front and rear axles. The multiplate pack
is compressed when pressure is applied to the
working piston. Depending on the contact pressure,
a different torque (up to 1770 lbs-ft or 2400 Nm) can
be transferred.

Multiplate Clutch

The multiplate clutch consists of the drive hub, the
multiplate pack and the clutch cage.

Drive Hub

The drive hub is driven by the propeller shaft via the
fl ange.

Multiplate Pack

The multiplate pack consists of friction plates and
steel plates, with one thrust plate in the front and
one in the rear.

The friction plates have internal teeth that engage the
drive hub. The steel plates engage the clutch cage
with external teeth. The number of plates depends
on the vehicle type.

Steel Plate

Friction
Plate

Thrust
Plate

10

Drive Hub

S414_041

From
Propeller
Shaft

S414_051

S414_042

Thrust Plate

Multiplate Pack

S414_052

All-Wheel Drive Clutch Details

Clutch Cage

The clutch cage is connected with the pinion of the
rear axle by a spline, and transfers the drive torque to
the rear axle.

Working Piston

The working piston is a cylindrical piston.

Function

When actuating the clutch, the pressure of the
working piston is transferred to the multiplate pack
via a needle bearing. The working piston does not

turn. The multiplate pack, on the other hand, rotates
at drive speed.

Rear Axle Pinion

Clutch Cage

S414_053

Splines

S414_043

Needle
Bearing

S414_054

Spring Plate

The spring plate is located on the oil pressure side of
the working piston.

Function

It creates a preload which pushes the working piston
in place. This removes the play from the multiplate
pack and the needle bearings.

Spring Plate

S414_044

Oil Pressure Side

S414_045

Working Piston

S414_055

11

All-Wheel Drive Clutch Details

Electro-Hydraulic Assembly

The electro-hydraulic assembly consists of the
Haldex Clutch Pump V181, the oil fi lter, the
accumulator, and the Haldex Clutch Control Valve
N373.

Haldex Clutch Pump V181

The Haldex Clutch Pump V181 is a reciprocating
piston pump and is installed in the lower section
of the all-wheel drive clutch. It generates the oil
pressure. The accumulator in the oil circuit is fi lled
regularly. It is requested by the All Wheel Drive
Control Module J492 depending on the demand.

S414_046

Compressed Oil

Is Discharged

Function

The bores of the cylinder housing each contain a
piston with a locating pin and a return spring. With
the help of an angular ball bearing, the piston and
locating pin are moved in stroke fashion when the
cylinder housing turns so that oil is drawn in at the
bottom and is discharged compressed at the top
after 180 degrees of rotation.

Effects of Failure

When the Haldex Clutch Pump V181 fails, oil
pressure cannot be generated. Torque is no longer
transferred to the rear axle.

Oil Filter

The oil fi lter is a no-maintenance fl eece fi lter. A check
valve is integrated in the oil fi lter housing which
prevents the oil pressure to the Haldex Clutch Pump
V181 from dropping.

Oil Is

Drawn In

From Oil
Reservoir

Cylinder
Housing

Ball
Bearing

Piston

Locating Pin

Return Spring

To Accumulator

S414_022

12

All-Wheel Drive Clutch Details

Accumulator

The compact design of the accumulator includes
three parallel acting springs and is positioned on top
of the clutch. It adjusts the oil pressure using spring
force and keeps it at 435 psi (30 bar).

System without Pressure:

The springs of the accumulator are relieved.

System with Working Pressure:

The pressure chamber is fi lled by the pump. The
pressure piston is pushed back and the spring is
under tension.

Return to Oil Reservoir

Return Channel

Pressure Piston

Return to Oil ReservoirReturn to Oil Reservoir

From Pump to Valve

S414_016

Pressure
Chamber

If the oil pressure exceeds 435 psi (30 bar), the
return channels become accessible, the pressure in
the direction of the oil reservoir is reduced, and oil
returns to the reservoir.

Return

to

Oil Reservoir

Return Channel

S414_017

Pressure
Chamber

Return Channel

S414_018

13

All-Wheel Drive Clutch Details

Haldex Clutch Control Valve N373

Task

The Haldex Clutch Control Valve N373 controls the
working pressure that is passed on to the working
pistons. Pressure increases in proportion to the
electric current applied to the solenoid. Pressure is
precisely defi ned for each current value.

Spring

Solenoid Coil

Needle

To Oil Reservoir

Bore

To Working Piston

Regulating Chamber

From Accumulator

Control Piston

14

Magnet Core

Electrical Connector

S414_019

All-Wheel Drive Clutch Details

Function

The Haldex Clutch Pump V181 and the accumulator
have built a pressure of 435 psi (30 bar). (1)

Applying an electrical current to the solenoid coil
generates a magnetic force the amount of which
depends on the current applied. This moves the
control piston up, opens the fl ow, and the working
pressure is generated. (2)

When the desired working pressure has been
reached, the balance of force described below
is established so that the fl ow is closed and the
working pressure maintained. (3)

The working pressure is applied to the working
piston and in the control piston regulating chamber.
The pressure in the regulating chamber works in the
same direction as the return force of the spring and
supports it as counteracting force to the magnetic
force. A balance of force is achieved.

1

Oil Pressure

435 psi (30 bar)

Spring Force

Compression
Force

2

Working

Pressure

Generated

3

Flow Closed,

Working

Pressure

Maintained

S414_020

When the full current is applied, the intake on the
bottom remains open and the entire oil pressure

generated by Haldex Clutch Pump V181 is used as
working pressure.

If the clutch has to be opened, no more current will
be applied to the solenoid coil, the control piston
returns to its original position, and the pressure is
relieved by routing oil to the oil reservoir.

Effects of Failure

If the Haldex Clutch Control Valve N373 fails, the all­wheel function is no longer available.

Magnetic Force

Regulating
Chamber

S414_021

Working Pressure
Routed to Oil Reservoir

S414_023

15

All-Wheel Drive Clutch Details

All Wheel Drive Control Module
J492

Task

All Wheel Drive Control Module J492 regulates the
pump operating times and Haldex Clutch Control
Valve N373. The amount of pressure is solely
determined by the valve position. A temperature
sensor is located on the printed circuit board of
All Wheel Drive Control Module J492 where its
measured values indicate the oil temperature.

All Wheel Drive Control Module J492 is integrated
in the CAN data bus drive. This allows precise
control of the system with only one sensor. Based
on data on the driving situation, the All Wheel
Drive Control Module J492 determines the desired
pressure so that the amount of all-wheel drive
clutch engagement and transfer are adjusted to the
situation.

In case of ESP or ABS intervention, ABS Control
Module J104 determines the amount of all-wheel
drive clutch engagement via All Wheel Drive Control
Module J492.

Effects of Failure

Because Haldex Clutch Control Valve N373 can no
longer be selected, no more working pressure is
generated. The clutch is disengaged and the rear axle
is no longer driven.

16

All Wheel Drive
Control Module J492

S414_024

Controls

Oil Circuit

The electro-hydraulic components build up the oil
pressure, controlling the contact pressure on the
multiplate clutch.

Controls

Multiplate Clutch

Working Piston

Oil Reservoir

Spring Plate

Accumulator

Haldex Clutch
Control Valve N373

Oil Filter

Strainer

Return

All Wheel
Drive Control
Module J492

Haldex Clutch
Pump V181

System Without Pressure

The illustration shows the system in the
depressurized state. As long as the engine is off
and only the ignition is turned on, All Wheel Drive
Control Module J492 is selected but no pressure is
generated.

The Haldex Clutch Control Valve N373 is opened
without current.

Because a small amount of pressure is
applied through the spring plate, a speed
of 31 mph (50 km/h) and a distance of
31 miles (50 km) may not be exceeded
when towing with one axle raised.

S414_027

A Pressureless System Is Needed in These Situations

Towing

Roll Dynamometer

S414_031S414_030

17

Controls

Pressure Buildup at Engine Start

When the engine is started, Haldex Clutch Pump
V181 is activated. Haldex Clutch Pump V181 is
selected as soon as an engine speed of 400 rpm is
reached. It delivers oil via the fi lter to the accumulator
until a pressure of 435 psi (30 bar) is reached in the
oil circuit. Haldex Clutch Control Valve N373 is closed
by All Wheel Drive Control Module J492 so that the
working pressure is passed on to the working piston
and the multiplate pack is compressed.

Starting

When starting to drive and when accelerating, the
entire rear axle drive torque is immediately available.

Driving

In each driving situation, the pressure between
pump and valve is kept constant at 435 psi (30 bar)

Working Piston

through the accumulator. The working pressure is
solely controlled through Haldex Clutch Control Valve
N373, which can adjust the contact pressure on the
working piston according to the demand.

This working pressure may lie between 0%, such as
when braking, and 100%, as when accelerating.

Controlled Working Pressure

Oil Pressure

0 – 435 psi (0 – 30 bar)

S414_029

Haldex Clutch
Control Valve N373

Multiplate Clutch

18

Oil Reservoir

Oil Pressure 0 – 435 psi (0 – 30 bar)

Spring Plate

Accumulator

Oil Pressure
435 psi (30 bar)

Oil Filter

Strainer

Return

All Wheel
Drive Control
Module J492

Haldex Clutch
Pump V181

S414_028

Driving Scenarios

Starting or Accelerating

A high drive torque is required at the rear axle. The
valve closes completely and the contact pressure can
reach its maximum.

Drive Torque at the Rear Axle

100%

Controls

Control Range

Fast Driving

Only a low torque is required at the rear axle. The
contact pressure is controlled according to demand
(control range).

Braking

No torque is transferred to the rear axle when
braking. The valve is opened and the pressure on the
working piston is reduced. The clutch is disengaged.

Stopping

The clutch is disengaged as long as the vehicle is
being braked. When the vehicle is stopped, the pre­control uses the signal from the accelerator position.
When starting to drive, the pressure is built up again
and full torque capacity is available.

Parking Maneuvers

Only a low torque is transferred during parking
maneuvers. The drivetrain is not under tension. The
clutch is controlled according to demand (control
range).

0%

100%

0%

100%

0%

100%

0%

100%

0%

Starting/Accelerating

Control Range

Fast Driving

Braking

Stopping

Control Range

Parking Maneuvers

S414_056

S414_057

S414_058

S414_059

S414_057

SS414_032

S414_033

S414_049

S414_034

S414_035

19

Controls

Critical Driving Situations

Driving on Slippery Roads

The working pressure is controlled according to
demand.

Signals come from ABS Control Module J104, which
detects slippage through the speed sensors and
calculates the required traction.

ESP or ABS Intervention

When a wheel slip control system is activated, the
amount of clutch engagement is controlled indirectly
through the ABS Control Module J104. For example,
the clutch may be disengaged entirely for an ABS
intervention while it can be engaged for an ESP
intervention.

Starting with Slip (On Ice or Snow)

The all-wheel clutch is engaged when both wheels

of the front axle spin. The rear axle takes on all of the
drive force.

Drive Torque at the Rear Axle

100%

0%

Driving on Slippery Roads
ESP or ABS Intervention

S414_060

Control Range

S414_036

If only one wheel of the front axle spins, the
Electronic Differential Lock (EDL) becomes active.
The spinning wheel is braked and the drive force of
the other wheel is increased. At the same time the
all-wheel drive clutch is engaged and a large portion
of the drive force is transferred to the rear axle.

20

S414_038S414_065

S414_062

System Overview

Controls

Sensors

Engine Speed
(RPM) Sensor G28

Throttle Position (TP)
Sensor G79

ABS Wheel Speed
SensorS G44-G47

Brake Light Switch F

Engine Control
Module (ECM) J623

Drive CAN Data Bus

ABS Control
Module J104

All Wheel
Drive Control
Module J492

Actuators

Haldex Clutch
Control Valve N373

Haldex Clutch
Pump V181

Electro-Mechanical Parking
Brake Control Module J540

Data Bus On Board
Diagnostic Interface J533

Steering Angle Sensor G85

A sensor cluster is integrated
in Electro-Mechanical Parking
Brake Control Module J540. It
contains the sensors for lateral
acceleration, longitudinal
acceleration, and yaw rate.

S414_026

21

Controls

Functional Diagram

30

S

J540

J104

J623

G85

N373

31

G85 Steering Angle Sensor
J104 ABS Control Module
J492 All Wheel Drive Control Module
J540 Electro-Mechanical Parking Brake Control Module
J623 Engine Control Module
N373 Haldex Clutch Control Valve
S Fuse
V181 Haldex Clutch Pump

J492

V181

Color Coding

Positive
Ground
CAN Data Bus Line

22

S414_047

Service

Testing Individual Components

Service

Individual component tests can be called through
function and component selections in Guided Fault
Finding.

All Wheel Drive Control Module J492 Self­Diagnostics

All Wheel Drive Control Module J492 has the

address word 22 for self-diagnostics.

Guided Fault Finding
Function/Component selection

Select function or component

+ Chassis

+ All-wheel drive with Haldex clutch (4th generation)

+ 01 - Systems capable of self-diagnostics

+ Electrical components

G79 - Throttle Position Sensor

J492 - All Wheel Drive Control Module

N373 - Haldex Clutch Control Valve

V181 - Haldex Clutch Pump

Mode Enter Print

VOLKSWAGEN

S414_069

The all-wheel drive clutch can be
replaced separately.

Elaborate adjustment activities after
replacement are no longer necessary
because the pinion is part of the rear axle
transmission and is not replaced.

High-performance oil was developed
especially for the requirements of the
generation VI all-wheel drive clutch.

23

Notes

24

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

The Knowledge Assessment may or may not be required for Certifi cation.

For Assistance, please call:

Knowledge Assessment

You can fi nd this Knowledge Assessment at:

www.vwwebsource.com

Volkswagen Academy

Certification Program Headquarters

Or, E-Mail:

1 – 877 – 791 – 4838

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

25

Volkswagen of America, Inc.
3800 Hamlin Road
Auburn Hill, MI 48326
Printed in the U.S.A.
January 2008