Professional Documents
Culture Documents
191
Service Department
191/01
The most remarkable features of the new In this booklet, we would like to provide you
Passat are its: with an initial overview showing how we
l High economy justify making these claims.
l Dynamic body styling
l High-quality interior equipment designed
with great attention to detail
l Pioneering safety engineering
2
Page
Body 10
Vehicle Safety 15
Running Gear 26
Brakes 29
Steering 30
Electrics 31
Extended Systems 36
3
The Passat ‘97
To avoid confusion, concise examples are used You can find detailed information in Self Study
to illustrate the various aspects of this Programme No. 192 Passat ‘97 – The Enginee-
all-embracing vehicle concept. ring.
192
ice.
Serv
a t '97
P ass
Der h nik
Tec
Die
n
ktio
Fun
und
tion
struk
Kon
ienp
rog
ram
m
191/86
st stud
Selb
st
dien
den
Kun
191/73
4
Dimensions and Weights
2707 mm
4675 mm
191/71
1740 mm
5
The Passat ‘97
The term “platform” is frequently used in The vehicle consists of a) the platform and b)
publications although its fundamental the body.
meaning is not explained. The result of this is
that people are often unsure of what the term Design and vehicle characteristics dictate what
“platform” implies. form the body takes.
In the eyes of the customer, the body characte-
rises the styling of the vehicle as a whole.
The body
The platform
191/76
191/44
6
Platform
Common parts may only be used in platform Some system parts are identical.
vehicles without change. They have to be adapted since they are the
They do not influence the design of the interface between the platform and body.
vehicle.
System part
191/90
7
Environmental Protection and Recycling
Recycling
Not least the recycling requirements present To achieve this, the following measures were
workshops with problems such as identifying, taken:
presorting and storing materials and waste
operating media. l Identification of plastic part materials
l Fewer composite materials
l Reduction in fine sealing through the use of
laser welding
l No parts containing CFCs are used.
8
Solvents
Even during production, every effort is made to To achieve this, the following measures were
keep environmental pollution to a minimum. taken:
191/03
9
Body
l The Passat in the wind tunnel l Strategy of using common platform for body
l Fully galvanised body parts
l Greater body rigidity l Ease of repair demonstrated using door
l Use of high-strength steel parts module as example
l Rear collision demonstrated using bumper
as example
191/72
A = 2.1 m2
191/02
10
Fully-galvanised Body
For the first time, the Passat has a fully galva- Surface patterns, which are also visible after
nised body which comes with an 11-year anti- painting, emerge during the hot-dip
corrosion perforation warranty. galvanisation process.
That is why the outer skin of the body is
The drawing below shows you the parts which electrolytically galvanised to produce a
are hot-dip galvanised and those which are smooth finish.
electrolytically galvanised.
Hot-dip galvanised
11
Body
12
High-strength Panels The Rear Bumpers
High-strength panels are used to produce a
body with greater stability and strength and
therefore to provide more safety for the
vehicle occupants.
They also substantially reduce the weight of
the body-in-white.
191/61
191/46
13
Body
Body Platform
The floorpan assembly, side members and
luggage compartment floor assembly were
adopted from the Audi A4 as a platform.
+86
mm
l The Passat already complies with the new l Inside door panels with pelvis paddings
European standard for crashworthiness
Safety body
Steering column
191/75
15
Vehicle Safety
Crashworthiness
The new Passat offers the driver and front pas-
senger more safety, particularly during a side
impact.
191/06
Overlap
16
Airbag Systems
In addition to the driver and front passenger The driver and front passenger airbags, which
airbags, the Passat is equipped with side air- have filling volumes of roughly 65 ltr. and 120
bags as standard. ltr. respectively, conform to the new internatio-
nal-standard airbag sizes.
Depending on the side and angle of impact, The volume of the standard side airbag is
only the airbags in the immediate vicinity of roughly 12 litres.
the danger zone are inflated.
60°
60° 60°
191/04
17
Vehicle Safety
191/17
18
Engines and Gearboxes
In addition to the six tried and tested engines listed below, the new
VR5 unit will also be mounted in the Passat.
191/85
191/77
19
Engines and Gearboxes
191/31
191/32
20
2.3-ltr. VR5 Engine AGZ
The new VR5 engine has a displacement of 2.3
litres. It is derived from the VR6 engine and is
designed for in-line or transverse mounting.
Power output is 110 kW.
191/53
The engineering of the VR5 engine is explained in a separate Self Study Programme.
21
Engines and Gearboxes
191/28
22
Range of Engines and Gearboxes
1.6-ltr.
012/01W 74kW 01N
1.8-ltr. 5V
92kW
1.8-ltr. 5V
turbo 01V
110kW
2.3-ltr.
VR5
110kW
1.9-ltr.
TDI
66kW
1.9-ltr.
TDI
81kW
2.8-ltr.
01V
01A V6 5V
Syncro
142kW
191/64
23
Engines and Gearboxes
191/34
191/35
24
4-speed Automatic Gearbox 01N
191/36
191/78
25
Running Gear
Tripoid joint
191/37
26
The Torsion Beam Rear Suspension
Advantages of torsion beam rear suspension:
Single-tube damper
Coil spring
191/55
27
Running Gear
191/54
28
Brakes
191/16 191/14
The front disc brakes are This disc brake is vented and The Passat has rear
vented. larger in size. disc brakes.
The smaller disc diameter is The brake caliper is made of
based on a smaller vehicle aluminium.
mass and lower power output
29
Steering
The Passat is equipped with power steering. A damper element located above the double
universal joint prevents vibrations and noise
The steering column can be adjusted manually from being transmitted to the body.
50 mm fore and aft and 28 mm for height. A clamped connection links the steering
column to the power steering gear.
The steering column is attached to the body by
a mounting pedestal with sliding guide.
Clamped connection
Damper element
You can find additional information on the steering in Self Study Programme SSP 167.
30
Electrics
31
Electrics
191/79
Auto Check System with
multi-function display
32
Fuel gauge
In previous systems, the fuel gauge tended to The new fuel gauge eliminates this drawback.
fluctuate, e.g. when cornering. To counteract
this, damping of the fuel gauge was increased If the ignition is switched off and fuel tank
using electronic devices. capacity increases by four litres or more, the
However, the drawback of this was that the new
fuel gauge took longer to display the correct fuel level is recalculated and displayed straight
fuel level after refueling. after the ignition is restarted.
191/51
33
Electrics
Gas discharge headlights, which are integrated On acount of the greater danger of dazzling
into the headlights, are available for the Passat oncoming traffic, vehicles with gas discharge
as an option. headlights are equipped with dynamic head-
However, the use of gas discharge technology light range control.
is limited to the dipped beam headlight Consequently, the switch for the manual head-
because it takes up to three seconds to achieve light range control is not required.
maximum luminous intensity. Therefore, H4
halogen lights will continue to be installed for
the main beam headlight.
Electronic Headlight Range Control
Advantage of gas discharge headlights:
- Greater luminous efficiency than
This function gathers its information on body
conventional headlights tilt angle relative to the vehicle axes from two
- Better brightness distribution by virtue of a sensors located inside the front and rear wheel
lens housings on the left-hand side of vehicle.
- Fog light is no longer necessary
H4 halogen headlights
1 Lux
1 Lux
34
Fan Jet Nozzle
Installation from
below
Mode of operation
For the sake of simplicity, the mode of opera- A nozzle insert for producing the pendulum jet
tion can be compared to that of a garden hose is integrated in the spray nozzle. It ensures a
when it is swung from side to side. fan jet.
Moving the garden hose quickly produces a
fan jet. A heated version of the spray nozzle is also
available.
Fan-type jet
with an opening angle
of 45° - 50°
191/81
35
Extended Systems
Various systems cater for ride comfort and Extended Central Locking System
ease of operation in the new Passat.
The extended central locking system is based on
The following features will be of interest to a decentralised system concept.
you: It has a central control unit and a separate door
control unit with a control panel for every door.
l Extended central locking system
– Decentralised system concept Self-diagnosis:
l Heater/air-conditioning Diagnosis is initiated using the address word “46”.
– Innovations in the air-conditioning
l Navigation + communications
– Preparation for mobile cellular phone
191/62
36
Functions of the Extended Central Locking System
Central locking of
doors, with Safe mode
Diagnosis
Address word „46”
fi
191/45
37
Extended Systems
The heater
Unlike predecessor models, the new heater is
constructed in one piece. The heater, which is controlled at the air intake
The air distributing housing and the air duct side, permits fresh-air and air-recirculation
with shutoff flap are combined in a single modes. A main shutoff flap is therefore no longer
component. required.
Fresh-air/air-recirculation flap
191/27
191/48
Central flap
- By virtue of the stepped form of the central flap, the central air vent is closed in
defrost mode.
- An electric-motor-operated fresh-air/air-recirculation flap is integrated.
- In defrost mode, the air recycle function is switched off.
38
Pleasant air-conditioning for comfort and safety in the Passat.
The CLIMAtronic
Temperature sensor
CLIM
Atro
nic
AUT
O
ECO
N
191/47
39
Extended Systems
The Air-conditioning
Fresh-air/air-recirculation flap Back pressure flap
191/42
Fresh-air blower
Central flap
40
Navigation
The navigation system enables the driver to The system comprises the following elements:
reach his (her) destination easily and safely.
It replaces the road map and enhances - The navigation computer with integrated
road safety. CD-ROM drive
- The control unit with control and
This system employs a map stored on a loudspeaker
CD-ROM. The driver can select his (her) - The display integrated in the dash panel
destination on this map. insert
Directions for the driver are then given on the
- The earth magnetic field sensor
display in the dash panel insert and via the
- ABS wheel speed sensor
loudspeaker built into the control unit.
- The sensor for the global positioning
satellite system (GPS)
- The GPS satellite network
Navigation computer
Operating unit
191/66
ABS-control unit
41
Extended Systems
191/49
191/83
42
ABS wheel speed sensor
191/84
191/87
GPS sensor
Base of aerial
GPS stands for Global Positioning System, a
global navigation system.
The sensor is integrated in the roof aerial.
The navigation computer uses the data
supplied by the GPS sensor as a correction
factor or when relocating the vehicle if the
191/88 computer loses track of the current position
(e.g. during rail transport).
Connector
GPS sensor
However, this particular navigation system is not yet able to make allowance
for traffic lights, one-way roads, building sites, traffic jams, etc.
43
Extended Systems
Diagnositic
connection 191/68
With the cellular phone provision, only mobile phones with a VDA-standard connection
can be operated.
44
Notes
45
Notes
46
47
Service. 192
Service Department
The Passat ‘97
SSP 192/107
Having provided you with an initial overview The subjects of the VR5 engine, convenience
of the new Passat in the Self Study Programme electronics and navigation system are so wide-
entitled “The Passat ‘97 – The Presentation”, ranging that it would be beyond the scope of
we now want to describe in detail how the this Self Study Programme.
car’s various components are designed and We will therefore deal with them separately.
how they function.
2
Page
Introduction 04
Vehicle Safety 06
Gearbox 38
Drive Shafts 40
Running Gear 43
ABS/EDL 48
Electrics 55
Air-conditioning 60
3
Introduction
Overview of topics
Engines
Gearbox
You will be given information regarding We will explain how length compensation
the gas discharge headlights. works in the triple roller drive shafts.
4
ABS/EDL
Running gear
The latest developments and the special fea- We will describe the gradual action of the
tures of the CLIMAtronic will be described. side airbag and the belt tensioner with
belt force limiter.
5
Vehicle Safety
SSP 192/047
6
Effect of the restraint systems during minor accidents
During minor accidents, the body only partially belt tensioners restrain the car’s occupants in
absorbs the impact energy of components their seats.
such as bumpers and impact absorbers. The belt force limiter reduces the risk of the
belt causing injury.
The seat belts provide adequate protection; the In this case, the airbags are not triggered.
SSP 192/048
7
Vehicle safety
During serious accidents, the car body absorbs In addition to the protection afforded by the
the impact energy. The passenger compart- seat belts, the restraint systems protect the
ment remains by and large intact and the front passengers from more serious injuries in
airbags are triggered. the upper body and head areas.
The car’s central locking system is opened.
Airbags are
triggered. Central locking system is opened.
SSP 192/049
8
Side airbag
The new side airbag system is integrated in the In terms of its appearance, the new airbag
driver’s and front passenger’s seats. control unit has a different connector
housing code to the previous model.
The side airbag is described as a thorax airbag.
It mainly protects the thorax, and with it the
lungs and pelvis, from lateral bruising.
Side airbag
(illustrated as triggered)
Connection
When carrying out work on the airbag systems, always follow the instructions given in
the Workshop Manuals.
9
Vehicle safety
The side airbags are integrated in the front While expanding, the gas cools and mixes with
seat backrests. the hot gas of the pyrotechnical charge. The
The folded airbag and gas generator are temperature of the gas mixture is therefore so
accommodated inside the plastic housing. low that there is no risk of burning.
When the side airbag is triggered, the gas The side airbag has a capacity of approx. 12
cartridges in the gas generator are opened litres.
and the pyrotechnical charge ignites. The
highly pressurised gas contained inside
the cartridge expands instantaneously,
inflating the airbag.
Housing
Gas generator
SSP 192/005
Air bag with gas cartridge and
pyrotechnical charge
10
A two-stage crash recognition system is used to ensure reliable side airbag activation.
SSP 192/119
11
Vehicle safety
In parallel to the crash sensors, sensors in the There is an additional energy storage device in the
airbag control unit evaluate the severity of the airbag control unit for igniting the side airbags. If
crash. The relevant side airbag is not triggered the power supply fails during an accident, this
until these sensors have also rcognised that an energy storage device has sufficient energy to
accident has occurred and a crash sensor power the control unit and, if necessary, to ignite
sends an airbag trigger request. the airbags.
The system status of the side airbags can be The self-diagnosis is started using address word
displayed via the self-diagnosis. The airbag “15”.
control unit also indicates when a fault may
possibly have occurred in the crash sensors or
the side airbags via the airbag warning lamp.
SSP 192/120
12
Belt tensioner
The pyrotechnical belt tensioner combines The mode of operation of the belt tensioner is
with the force limiter and the seat belt very different to that of its predecessors.
recognition device in a single unit. It is only
triggered if the mechanical seat belt fastened
recognition system recognises an unreeled There are two belt tensioner variants:
belt.
Its compact design makes for much easier l A ball-driven belt tensioner, used on the
replacement. front seats.
l Belt tensioners operating according to
When an impact occurs, the belt tensioners the same principle as the Wankel
reel in the belt and thus take up any slack engine, used on the rear seats.
(clearance between belt and body).
Ball retainer
Gearwheel
SSP 192/126
13
Vehicle safety
Propellant charge
Belt
Feed tube
SSP 192/124
Gearwheel
SSP 192/125
Ball retainer
14
Rear belt tensioner
Belt
SSP 192/066
15
Vehicle safety
Wankel rotor
Firing pin
Propellant charge
SSP 192/010
SSP 192/011
SSP 192/012
16
Belt force limiter
Functional description of belt force limiter
If, due to acceleration, the tensile force of the It is limited by the belt reeling device torsion
belt is so high that bruising or internal injuries shaft. The torsion shaft operates in much the
can occur, the tensile force of the belt must be same way as a spring. Depending on its tensile
limited to a tolerable level. force, the belt “gives”.
Both types of belt tensioner use the same
system
Belt
SSP 192/065
The torsion shaft is con- The torsion shaft runs through the
nected to the reeling belt reeling device.
device on this side.
17
Test your knowledge
a) 8 litres,
b) 12 litres or
c) 15 litres.
3. The side airbag crash sensors respond to the application of ................................. force.
18
5. The rear belt tensioner
c) is ball-activated.
d)
a)
e)
b)
f)
c)
SSP 192/126
19
1.8-ltr. 5V Engine ADR
On the following page, we will show you the new technical features of the 1.8-ltr. 5V engine,
1.8-ltr. 5V turbo, 2.8-ltr. V6 and TDI engines.
The 1.8-ltr. 5V engine has a twin path intake Long intake path
manifold.
The twin path intake manifold is designed so A long intake path permite optimum charging
that it is possible to switch between long and of the cylinder, and consequently high torque,
short intake paths. in the low speed range.
SSP 192/085
Vacuum unit
20
The engine control unit sends a signal to the
Engine control unit J220 intake manifold pressure change valve.
It uses the vacuum unit to change over the
intake manifold. Power is supplied via the fuel
pump relay.
Vacuum unit
SSP 192/127
Electric circuit
30 30
Components 15 15
X X
J17 Fuel pump relay 31 31
J220 Motronic control unit
J17
N156 Intake manifold pressure
change valve
S Fuse
N156
64 4 3
J220
2
IN OUT
SSP 192/106
21
1.8-ltr. 5V Turbo Engine AEB
The 1.8-ltr. 5V turbo engine is equipped with the Motronic M 3.8.2 engine management system.
System overview
Sensors Actuators
Intake manifold
Engine control unit Output stage
temperature sender
J220 N122
G72
Knock sensors
G61 + G66
Ignition coils
N, N128, N158, N163
Hall sender
G40
Throttle valve con-
trol unit J338
Engine speed
sender G28
Activated charcoal
Coolant tempera-
filter system sole-
ture sender G62
noid valve N80
Altitude sender
F96
Charge pressure limi-
Throttle valve con- tation solenoid valve
trol valve J338 N75
Diagnostic connec-
Immobiliser control unit tion
J362
SSP 192/074
22
Function diagram 1.8-ltr. 5V turbo engine AEB
N Ignition coil
N30 Injection valve, cylinder 1
N31 Injection valve, cylinder 2
N32 Injection valve, cylinder 3
N33 Injection valve, cylinder 4
N75 Charge pressure limitation solenoid valve
N80 Activated charcoal system solenoid valve
N122 Output stage
N128 Ignition coil 2
N158 Ignition coil 3
N163 Ignition coil 4
Colour code
S Fuse
Input signal
Output signal
Positive
Negative
23
30
15
X
31
J17
N
S
IN OUT
15 64 65 58 80 73 4 3 1
50 50 50
50 50 50 50 50 50 50 50
J220
50 50 50
27 25 26 12 13 2 68 60 56 63 53 54 67
24
30
15
X
31
N122
77 78 70 5 6 7 8 18 20 22 23 49 19
50 50 50
50 50 50 50 50
59 69 75 11 74 76 62 61
F96
G40
SSP 192/076
25
2.8-ltr. V6 Engine ACK
It provides high torque when driving in low gears High output is needed at high speeds. To
at low speeds, thus improving fuel economy and achieve both, the cylinder must be well-filled
reducing exhaust emissions. in all speed ranges.
Injection valve
closes early
At low speeds, the piston moves so slowly that
the gas mixture in the intake manifold follows
the movement of the piston.
The inlet valve must be closed early so that the
fuel-air mixture is not forced back into the
intake manifold.
SSP 192/130
Injection valve
At high speeds, the flow rate inside the intake closes late
manifold is so high that the mixture can continue
to flow into the cylinder although the piston is
moving back up.
The inlet valve is closed when the fuel-air mixture
can no longer enter the cylinder.
SSP 192/131
26
The principle of variable valve timing:
The exhaust camshaft is driven by the With variable valve timing, the opening times
crankshaft by means of a toothed belt. of the inlet valves are adjusted depending on
The inlet camshaft is driven by the exhaust engine speed. The drive chain therefore turns
camshaft by means of a chain. the inlet camshaft.
Torque position
27
2.8-ltr. V6 Engine ACK
Exhaust camshaft
28
Variable valve timing in the V6 engine
SSP 192/129
Idling
SSP 192/103
Torque position
SSP 192/104
Performance position
SSP 192/103
29
2.8-ltr. V6 Engine ACK
The 2.8-ltr. V6 engine is equipped with variable valve timing and is controlled by the
Motronic M 3.8.2 engine control unit.
Sensors
Fuel pump G6
with fuel pump relay
Lambda probes I+II J17
G39 + G108
Injectors
Sensor for intake N30, N31, N32,
manifold tempera- Engine control unit N33, N83, N84
ture G72 J220
Throttle valve con-
Knock sensors trol unit J338
G61 + G66
Intake manifold
Engine speed pressure change
sender G28 solenoid valve
N156
Activated charcoal
Hall sender
filter system sole-
G40
noid valve N80
Hall sender II
G163
Bank1, variable valve
timing N205
Coolant tempera-
ture sender G62
Diagnostic connec-
Immobiliser control unit tion
J362
SSP 192/073
30
Function diagram of 2.8-ltr. 6V Engine ACK
N Ignition coil
N30 Injection valve, cylinder 1
N31 Injection valve, cylinder 2
N32 Injection valve, cylinder 3
N33 Injection valve, cylinder 4
N83 Injection valve, cylinder 5
N84 Injection valve, cylinder 6
N75 Charge pressure limitation solenoid
valve
N80 Activated charcoal system solenoid
valve
N152 Ignition transformer
N156 Twin path intake manifold valve
N205 Camshaft adjustment valve I
N208 Camshaft adjustment valve II Colour code
31
30
15
X
31
J17
S S S
N80 N156 N205 N208 N84 N83 N33 N32 N31 N30
15 64 55 79 72 65 58 80 73 4 3
50 50 50 50 50 50 50 50 50 50 50 50 50
50 50 50 50 50 50 50 50 50
25 26 39 40 44 11 76 68 60
32
30
15
X
31
G70
N152
12 13 70 71 78 5 6 7 8 18 20 22 23 45 49
50
50 50 50 50 50
3 56 53 54 67 66 59 69 75 62 74 14 2 19
IN OUT
SSP 192/075
33
1.9-ltr. TDI Engine AFN
A radiator fan run-on facility controlled by the The run-on time is determined by the engine
engine management system is being used in control unit via a characteristic map. Allowance
the 1.9-ltr. 81kW TDI engine for the first time. is also made for the coolant temperature and
The advantage of this is that the radiator fan engine load during the final minutes of car
run-on time is variable and can consequently operation before the engine is turned off.
be adapted to the previous operating
conditions and load conditions of the engine.
The radiator fan run-on relay J397 is designated as blower relay J323 in the self-diagno-
sis.
30 30
15 15
Electric circuit X X
31 31
Components
J397
N39 Series resistor for
coolant fan
S Fuse N39
3
V7 Coolant fan
V7
J248
SSP 192/086
34
Test your knowledge
a) b)
so that the fuel-air mixture is not forced back into the intake manifold.
35
Gearbox
Magnesium
The strength of a material depends on its The housing is therefore ribbed more intensively
density, among other things. Low density goes and the wall thickness has been increased. As a
hand in hand with low strength. This loss of result, the magnesium housing actually weighs
strength has to be compensated for somehow. 27% less than the aluminium housing.
Bolt insertion depth has also been increased.
H2O
Al Fe Pb Cu Au
Magnesium
SSP 192/096
37
Gearbox
Magnesium
SSP 192/097
Corrosion
Water
SSP 192/061
Special coating
A special coating is applied to all add-on parts which come into direct contact with
magnesium. Please follow the instructions given in the Workshop Manual.
38
Test your knowledge
1. What is the insertion depth for magnesium compared to that for iron?
2. Assign the metals of gold, iron, magnesium, copper, aluminium and lead to the following
drawing.
a) b) c) d) e)
f)
39
Drive shafts
The triple roller CV joint reduces the transmis- Triple roller joints are principally used in diesel
sion of vibrations and noise from the engine/ and automatic cars.
gearbox unit to the body. This is necessary due to the high vibrations
which occur in diesel engines and the preten-
sioning forces which occur in automatic drive
trains.
SSP 192/056
Design
Race
SSP 192/071
Tripod star
Roller
Housing
Drive shaft
40
Function
Race
Triple roller joint pin
Drive shaft
This movement is compensated by the triple
roller joints, whereby the tripod star, together
with the rollers, slide within their races.
SSP 192/042
Roller
SSP 192/043
41
drive shafts
SSP 192/044
SSP 192/045
The drive shaft is moved away from the
gearbox by the rebound action of the wheels.
At the same time, the rollers are displaced in
only one plane within their races, thereby
reducing friction and noise transmission
to the body.
SSP 192/046
42
Running Gear
The following pages describe the design modifications to the axles of the Passat ‘97 as presented
to you in Self Study Programme SSP 191.
SSP 192/100
43
Running Gear
Shear centre
SSP 192/134
44
Hub/wheel bearing unit
The newly developed wheel bearing generation The advantages of the new wheel bearing
is used on the rear axle of front-wheel-drive generation are as follows:
vehicles. The twin-tracked ball bearing has a
stationary outer race which is bolted to the rear l Minimal wear due to improved sealing.
axle mounting plate. l The rotor is protected by the inserted
speed sensor and cannot be damaged by
The bearing inner race serves as the carrier for external influences.
the brake disc and wheel. This design eliminates l The wheel bearing does not have to be
the need for an axle pivot.
adjusted any longer because the bearing
The ABS speed sensor is inserted into the wheel
preload is predetermined by its design.
bearing and secured with a clip to prevent it
from falling out.
Speed sensor
Inner race
SSP 192/057
45
Running Gear
The newly developed double wishbone rear The subframe is connected to the body by four
axle allows the same through-loading width as large bonded rubber mountings.
the torsion beam rear axle. It has an enclosed
subframe to which the transverse links are
attached.
Lowerwishbonek
SSP 192/099
46
Test your knowledge
1. How is the high transverse rigidity of the torsion beam rear axle achieved?
a)
b)
a) Minimal wear,
c) It is self-adjusting,
is
achieved.
47
ABS/EDL
The anti-lock braking system is a 4-channel system. This means that two valves are assigned to
each wheel (inlet and outlet valves).
The hydraulic unit and the ABS control unit are combined in a single module and can only be
renewed as one unit.
System overview
ABS recirculating
pump V39
Brake light
Braking system
switch
warning lamp
F
SSP 192/062
48
ABS/EDL hydraulic unit
Connection for:
Hydraulic block
49
ABS/EDL
In this case, redundant stands for a computer This third computer is known as the watchdog.
concept with several backups. If it detects a fault, it stores the fault message
In the control unit there are two computers in a read-only memory and can be read out
which work with the same program during the self-diagnosis. The fault is indicated
independently and check one another. by the ABS warning lamp.
The two computers are, in turn, monitored by
a third computer which assumes the task of
controlling the solenoid valve relays.
50
ABS speed sensor
Signal utilisation
SSP 192/057
51
ABS/EDL
Function diagram 30
15
X
Components 31
52
30
15
X
31
J104
5 4 9 8 7 6 19 23 24 13 21 10 14 11
SSP 192/087
53
Test your knowledge
1. How do you distinguish the ABS/EDL hydraulic unit from an ABS hydraulic unit?
2. Where is the rotor for the speed sensor of the torsion beam rear axle located?
a) e)
b)
f)
c)
g)
d)
h)
k)
54
Electrics
In the case of gas discharge lamps, light is components due to the composition of the gas
generated by an electric arc between two in the lamp tube.
electrodes in a pea-sized gas-filled glass tube. This is the external distinguishing feature of
gas discharge technology.
The lamp emits light with high green and blue The advantages of this new headlight genera-
tion over conventional lamp technology are as
follows:
Electrode
Electric arc
Glass tubewith
gas filling
Electrode
SSP 192/121
l Up to three times higher luminous efficiency, l The special design of the reflector, aperture
same power consumption. and lens provides a much longer range
A 35W gas discharge lamp is sufficient to and a wider near-field scatter zone. This
provide twice the illumination of a 55W lamp. illuminates the roadside better, thus
l The useful life of approx. 2500 hours is several reducing driver eye fatigue.
times that of the halogen lamp. l Fog lights are not needed due to the
wide near-field beam.
55
Electrics
SSP 192/122
SSP 192/078
Electrical connection Headlight range control actuator
56
Automatic headlight range control
To prevent dazzling oncoming traffic, the gas The control unit for automatic headlight range
discharge headlights have to be equipped with control determines the car’s load condition by
an automatic headlight range control. two sensors located on the front and rear axles
on the left of the car. It continuously adjusts
the headlight via the actuator to ensure that
the road is always illuminated optimally.
Manual adjustment is no longer provided.
SSP 192/051
Sensor Sensor
SSP 192/052
57
Electrics
Emergency operation:
Self-diagnosis:
SSP 192/102
The high voltage applied to the gas discharge lamps can endanger life.
When carrying out repairs, the headlight must always be disconnected from the power
supply.
58
Test your knowledge
59
Air-conditioning
Refrigerant circuit
The refrigerant in the evaporator absorbs heat The refrigerant is circulated in a closed circuit.
and dissipates it into the ambient air to cool The refrigerant circuit contains the
the passenger compartment. refrigerant R134a.
Compressor
Evaporator Condenser
SSP 192/029
Restrictor
60
CLIMAtronic
The operating and display unit is combined The dash panel insert temperature sensor and
with the CLIMAtronic control unit as a single the temperature sensor fan are integrated in
module. the control unit.
The installation location of the temperature For right-hand drive cars, the temperature
sensor in the CLIMAtronic control unit is sensor is installed on the right. Using this
different in left- and right-hand drive cars. layout, drinks in the can holder have less effect
In left-hand drive vehicles, the temperature on the temperature sensor.
sensor is located behind the cover grille on the
left.
61
Air-conditioning
System overview
Sensors
Sunshine penetration
photosensor G107
CLIM
Atro
nic
AUTO
Sender
for footwell air outlet tempera-
ture
G192
Sender
for central air outlet temperature
G191
Air-conditioning
pressure switch
F129
Additional signals
62
Actuators
Control unit
for CLIMAtronic J255 Footwell/defrost flap actuator
V85
with potentiometer
AUT
O
Additional signals
Diagnostic connection SSP 192/030
63
Air-conditioning
SSP 192/024
SSP 192/028
Ventilation mode
Recirculated air
SSP 192/027
Colour code
Ventilation flap
Recirculated air Fresh/air recirculation flap
Drive disc
64
Fresh air
SSP 192/022
Above a speed of 160 kph, the ventilation flap
is closed. A small amount of fresh air trickles
into the passenger compartment through a
narrow opening in the ventilation flap.
SSP 192/026
Recirculated air
Fresh air
Air recirculation mode
SSP 192/025
Recirculated air
An air-conditioner without a ventilation
flap is installed in right-hand drive
vehicles.
65
Air-conditioning
Central flap
To
footwell
and
DEFROST
Central flap
air outlets At low outside temperatures and when the
engine is cold, the central flap is fully closed.
This prevents ice-cold air from being blown
into the passenger compartment.
SSP 192/002
SSP 192/003
To central
air outlets
SSP 192/004
66
Fresh air blower V2
SSP 192/038
Air-conditioner Blower control unit
J126
67
Air-conditioning
How it works:
SSP 192/034
68
Diagonal sunlight penetration
Electric circuit
The temperature of the air streaming into the vehicle is now measured by two separate
temperature sensors.
SSP 192/033
NTC resistor
Signal utilisation
In the event of signal failure, the control unit Open circuit/short circuit to positive.
calculates a substitute value on the basis of the Short circuit to earth.
outside temperature.
70
Test your knowledge
a) The ventilation flap and the fresh/air recirculation flap are activated by a common electric
motor drive.
b) In the air recirculation mode, the ventilation flap is in its upper limit position and
the fresh/air recirculation flap is in its lower limit position.
c) The central flap controls the air flow to the central, side, footwell and
DEFROST air outlets.
d) The new shape of the central flap makes it possible to fully close the central
and side air outlets.
c)
a)
b)
71
72
Solutions:
Page 18/19
Re. 1.
Driver airbag, Front passenger airbag, Side airbags, Front + rear belt tensioners, Belt force limiter
Re. 2.
b)
Re. 3.
side
Re. 4.
Its purpose is to reduce the tensile force of the belt to an acceptable level so that persons wearing a seatbelt are not injured by the belt
during an accident.
Re. 5.
a)
Re. 6.
a) Tripping device, b) Ball retainer, c) Gear, d) Belt , e) Propellant charge,
f) Feed tube containing balls
Page 35
Re. 1.
a) Torque position, b) Performance position
Re. 2.
a) slowly, b) intake manifold , c) be closed early, d) high,
e) can continue to control the cylinder, f) closed late
Page 39
Re. 1.
c)
Re. 2.
a) Aluminium, b) Iron, c) Lead, d) Copper, e) Gold, f) Magnesium
Page 47
Re. 1.
a) The rear axle mountings are attached on the far outer side.
b) The anti-roll bar is in front of the axis of rotation.
Re. 2.
downward
Re. 3.
a), b), c)
Re. 4.
a) within, b) a low load floor and large through-loading width
Page 54
Re. 1.
a)
Re. 2.
Er is inserted into the wheel bearing and secured by a clip.
Re. 3.
a) ABS/EDL control unit, b) Front speed sensor, c) Rear speed sensor, d) Brake light switch
e) ABS recirculating pump, f) Hydraulic unit with solenoid valves, g) ABS warning lamp,
h) Brake warning light system, k) Diagnostic connection
Page 59
Re. 1.
a) Electric arc, b) Electrodes
Re. 2.
c)
Re. 3.
Headlight housing, Ballast, Headlight range control actuator
Re. 4.
c)
Page 71
Re. 1.
a), c), d)
Re. 2.
The photosensor controls the air-conditioning temperature control when sunlight impinges directly incident on the car’s occupants. A
filter and an optical element deflect the sunlight onto a photodiode. The photodiode is a light-sensitive semiconductor element. The
stronger the sunlight directly incident, the higher the current which can flow through the diode.
Re. 3.
a) Filter, b) Photodiode, c) Optical element
Notes
73
Notes
74
Notes
75