The Passat W8: Self-Study Programme 261

Service.
Self-Study Programme 261
The Passat W8
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The Passat W8
S261_002
This Self-Study Programme presents the Passat The subject of the W8 engine is described in two
W8. We will only explain the design and function separate Self-Study Programmes:
where the items are totally new. All the changes
described refer to the Passat model year 2001. ● Self-Study Programme No. 248
"The W Engine Concept“
● Self-Study Programme No. 249
"The W8 Engine Management“
NEW Caution
Important
This Self-Study Programme explains the design Please always refer to the relevant Service literature for
and function of new developments. up-to-date inspection, adjustment and repair instructions.
The contents of this book will not be updated.
2
At a glance
In a nutshell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Occupant protection . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Drive units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Vehicle electrical system . . . . . . . . . . . . . . . . . . . . . . . 30
Convenience and safety electronics . . . . . . . . . . . . . .33
Heating and air conditioning system. . . . . . . . . . . . . .44
3
In a nutshell
The Passat W8
The top model of the Passat range is the first car from Volkswagen equipped with an 8-cylinder engine.
The Passat W8 offers luxury class refinement in performance, comfort, safety, quality and equipment.
It will be offered in saloon and estate versions.
Innovations in the Passat W8
● 6-speed manual gearbox or 5-speed automatic with Tiptronic
● Special crash and acoustic measures
● W8 engine 4.0 l/202 kW (275 bhp) 4 valve per cylinder
● Fuel tank 80 l
● Climatronic
● Bi-xenon headlights
● Four-wheel drive 4 Motion
● Exhaust system with 2 chrome tailpipes
● 7.5 J17“ alloy wheels with 225R/45 tyres
4
This high-quality car is based on the Passat launched in model year 2001.
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The W8 engine is a totally new development. The engine power output is transferred to the
One of the technical features is its compact size. road via a 6-speed manual gearbox with
four-wheel drive (4Motion). Optionally there is a
five-speed automatic gearbox with Tiptronic
and 4Motion.
5
In a nutshell
The Estate
All the innovations in the Passat W8 saloon are But whether it is the estate or the saloon, the new
also in the estate. The bodies of both the estate Passat W8 is recognisable from the outside by its
and the saloon have been strengthened to two chrome twin exhausts, the bi-xenon
improve the acoustics and increase crash safety. headlights, additional chrome trims and the
17 inch alloy wheels.
6
Inside, the standard equipment includes head In the extensive list of the Passat W8's optional
airbags front and rear, high-class pillar and extras we have included new luxury leather
headliner trims, chrome and real wood trims, seats, new sports seats, a dynamic navigation
exclusive upholstery, an on-board computer and system with audio, TV unit and Internet access, a
automatic air conditioning. digital sound pack and dark tinted rear windows.
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7
In a nutshell
The Saloon
100 kg S261_073
S261_005
2703 mm
4703 mm
1461 mm
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1746 mm
Size and weight
Length 4703 mm Front track width 1511 mm

Width 1746 mm Rear track width 1510 mm
Height 1461 mm Perm. gross vehicle weight 2220 kg
Wheelbase 2703 mm Kerb weight 1665 kg
Turning circle 11.5 m Permitted roof load 100 kg
Tank capacity 80 l Drag coefficient 0.27 cd
8
The Estate
100 kg S261_073
S261_008
2703 mm
4682 mm
1497 mm
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1746 mm
Size and weight
Length 4682 mm Front track width 1515 mm

Width 1746 mm Rear track width 1510 mm
Height 1497 mm Perm. gross vehicle weight 2290 kg
Wheelbase 2703 mm Kerb weight 1725 kg
Turning circle 11.5 m Permitted roof load 100 kg
Tank capacity 80 l Drag coefficient 0.27 cd
9
Body
Body modifications
To fulfill the claims of greater luxury and safety, We have modified the spare wheel well to attach
the body of the Passat W8 has been the auxiliary fuel tank. On the saloon, the rear
strengthened. By strengthening, we make a bulkhead is welded to the rear backrest. The
distinction between reinforcement to improve the backrest of the rear seat bench is therefore not
acoustics and reinforcement to increase crash foldable.
safety.
Spare-wheel well
Welded rear
bulkhead
The cross strut between the front wheel housings is also enclosed on cars fitted with a V6 engine
(petrol and diesel models).
10
Acoustic measures: Crash reinforcements:
A cross strut is bolted between the front wheel The front footwell is reinforced by an additional
housings. It is fixed to new supports welded to cross-member.
the wheel housings. An additional strut is welded
to the front bulkhead near the front side member.
Cross-member
Support for
cross strut
Cross strut
Reinforcement
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Body modifications
Crash reinforcements:
Acoustic measures
11
Occupant protection
Occupant protection
Occupant protection is ensured by the airbag The Passat W8 has two full size front airbags on
system with two front airbags, sidebags and the driver's and front passenger's sides. They
head airbags, belts and belt tensioners as well as have a filling volume of 64 and 120 litres. The
the child safety restraint system. central airbag control unit is located behind the
central console on the tunnel.
Head airbag
Side airbag
front passenger
Front airbag
driver
Front airbag
front passenger
Front airbag
module
front passenger
Front airbag
module
driver
Side airbag crash sensor Airbag control unit Side airbag crash sensor
front passenger driver
The two side airbags are located in the front The system has 2 lateral acceleration sensors
seats and have a filling volume of 12 litres. The which are located below the front seats as on the
head airbags each have a filling volume of 26 previous model.
litres and are mounted in the vehicle headlining
above the doors.
12
The conventional inertia-reel seat belts are used The rear seats are fitted with Wankel belt
on the front and outer rear seats. tensioners.
Ball-type tensioners are fitted to the front seats. The two types of belt tensioner are triggered by
mechanical/pyrotechnical capsules.
Head airbag
Head airbag
module
Three-point seat belt
Wankel belt tensioner
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Side airbag
module
Ball-type tensioner
Seat with integrated Side airbag

side airbag driver
The top part of the seat belts on the new Passat is flexible.
The bottom part is bolted rigidly to the brackets.
13
Occupant protection
Child safety restraint system
Both the integrated child safety seats and the Isofix system are available on the Passat W8.
Integrated child safety seats
To use the integrated child safety seat, the swab

elements must be raised and engaged. The
correct belt run is corrected by an additional
shoulder belt guide for children measuring 1.3 m
to 1.5 m tall. A belt guide hook on the raised
swab ensures that the belt runs safely across the
child's lap.
Belt guide hook S261_013
The Isofix System
The new Passat W8 is fitted both with a standard

preparation for receiving the ISOFIX system
retaining eyes as well as integrated child safety
seats in the rear seats as an optional extra.
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14
Drive units
The W8 engine in general

The Passat W8 is fitted with one engine, the new
W engine generation, the W8. The W layout is
obtained by joining two V engines at an angle
of 72°. This layout achieves a very compact
8-cylinder engine with very small dimensions.
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S261_071
Compared with other 8-cylinder engines, the W8 Four valves per cylinder, low-friction roller rocker
is very lightweight due to the short size and fingers, chain drive for the four overhead
through the use of aluminium, slim conrods and camshafts with camshaft timing adjuster are
short pistons. some of the noticeable features of this modern
engine.
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For more details, refer to Self-Study Programme No. 248.
15
Drive units
Specifications
Engine code BDN

Displacement 3,999 cm3
Type W engine
Valves per cylinder 4
Compression ratio 10.75±0.25:1
Bore 84.0 mm
Stroke 90.2 mm
Max. output 202 kW / 275 bhp
6000 rpm
Max. torque 370 Nm
2750 rpm
Engine management system Motronic M7.11
Fuel RON 98
(reduced output with RON 95)
Exhaust gas aftertreatment Three-way catalytic converter
with Lambda control
Torque and power output

[Nm] [kW]
The power output of the W8 engine is 202 kW or

500 200 275 bhp at 6000 rpm.
Referred to the displacement, it has a power
output per litre of 50.5 kW or 68.7 bhp.
400 150
The 4.0 l W8 engine develops a maximum
torque of 370 Nm at an engine speed of
2750 rpm.
300 100 Referred to a displacement of 3999 cm3 this
results in a special maximum torque
of 92.5 Nm/l.
200 50
100
2000 4000 6000 rpm
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Torque curve
Output curve
16
The fuel delivery system
The fuel delivery system of the Passat W8 has The two fuel tanks are connected by a connecting
tank capacity of 80 litres. It consists of a 60 litre tube. The additional fuel tank is located under
fuel tank as fitted to the Passat 2001 4Motion the spare-wheel well which is reduced in size for
and an additional tank containing 20 litres. this reason. If the car has a puncture, there is an
emergency wheel available in the reduced
spare-wheel well.
Additional fuel tank 20 l
Connecting tube
Fuel tank 60 l
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17
Drive units
The fuel pumps
The 60-litre fuel tank contains an electrical fuel When the tank is full, fuel is first pumped from
pump and a suction jet pump (entrainment the 60 l tank. When the fuel level in the main
pump). There is another electrical fuel pump in tank drops to 40 litres, the fuel pump in the
the 20-litre additional fuel tank. The different additional fuel tank cuts in and pumps fuel from
heights of the main tank and the additional tank the additional tank to the main tank. When the
require a controlled evacuation of the two tanks. additional fuel tank is empty, the remaining fuel
The engine is always supplied with fuel by the is pumped from the main tank. The suction jet
pump in the 60 l tank. pump (entrainment pump) delivers fuel from the
left chamber in the main tank to the fuel pump.
Fuel pump
Fuel pump
Suction jet pump
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Filler neck
Main fuel
tank 60 l Additional fuel
tank 20 l
Connecting tube S261_020
18
Fuel pump control
The fuel pump in the main fuel tank is controlled When the sender in the main fuel tank signals a
by the engine control unit. The fuel pump in the fuel level of 40 litres, the control unit switches the
additional fuel tank is switched on by the fuel pump in the additional fuel tank on. It pumps fuel
pump control unit. For this reason there are four from the additional fuel tank to the main fuel
fuel level senders in the entire tank and one tank until the sender G293 signals "Additional
sender G293 with a Reed contact. The signals fuel tank empty“. Then the control unit switches
from all the senders are sent to the fuel pump the pump in the additional fuel tank off. This
control unit. prevents the pump from running in an empty
tank as well as noise and additional power
consumption.
Fuel pump
and senders G292 and G293
Fuel pump
and sender G
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Fuel level indicator

sender G237
Suction jet pump

and sender G169
19
Drive units
Function diagram of fuel delivery system
G6
G 293 G 292 G G 237 G 169
J 17
S228
Terminal 30
J 538 S
CAN convenience
G 23
S261_022
G 293 -Fuel level sender, G 6 - fuel pump (pre-supply pump)

additional fuel tank empty J 17 - fuel pump relay
G 292 -fuel level sender, G23 - fuel pump
additional fuel tank J538 - control unit for fuel pumps
G - sender for fuel level indicator S228- fuse in the fuse box
G 237 - sender 3 for fuel level indicator S - fuse in the control unit
G 169 - sender 2 for fuel level indicator
20
The fuel level indicator
Due to the different heights of the fuel tanks, four fuel level senders are required to calculate the
remaining fuel amount correctly. The signals from all the senders are evaluated in the fuel pump control
unit. The resulting signal runs via the CAN convenience bus to the dash panel insert and is used to
control the fuel level indicator. The fuel pump control unit is self-diagnosable by address word 58.
Control unit for fuel pump J538
The fuel pump control unit is located in the spare-wheel well embedded in plastic. It is connected to the
CAN convenience bus. The control unit is therefore connected to the dash panel insert. It has the
following tasks:
● Evaluating signals from the four fuel level senders

● Controlling the fuel level indicators
● Controlling the fuel pump G 23 in the additional fuel tank
● Controlling the tank warning lamp
Fuel pump
control unit J538
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21
Power transmission
Gearbox
The 6-speed manual gearbox 01E, four-wheel drive
The 6-speed manual gearbox 01E from the

Passat 2001 is also fitted to the Passat W8.
As the Passat W8 is supplied with 4Motion
four-wheel drive as standard, a Torsen
differential is integrated in the gearbox to
distribute the engine torque to all four wheels.
The gearbox casing is adapted to fit the W8
engine.
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The 5-speed automatic gearbox 01V
The gearbox was adapted to fit the W8 engine,

i.e. the casing and gear ratios, as well as the
clutches and brakes.
A Torsen differential is also integrated in the
automatic gearbox to distribute the engine
torque to all four wheels.
The five-speed automatic gearbox 01V has:
● a dynamic shift programme (DSP)

● Tiptronic
● a torque converter with torque converter S261_025
lockup clutch
22
The four-wheel drive 4Motion
The main function of the four-wheel drive is to
compensate the drive forces between the front
and rear axles as a factor of positive
engagement.
S261_026
The Torsen differential detects wheel slip in one The Torsen differential permits limited differences in
axle and distributes the drive power to the speed between the front and rear axles and
wheels of an axle with better wheel grip. therefore allows ABS control processes. It operates
automatically and reacts independent of the driver.
The Torsen differential

(Torsen = torque sensing)
Rear axle drive

Differential casing
Front axle drive
Rear axle worm gear
Spur gears
S261_027 Front axle worm gear Worm gears
23
Running gear
The four-link front suspension

The design of the front axle on the Passat W8 is identical to the Passat model year 2001. The following
components have been modified to cope with the higher weight and the resulting axle loads:
● the wheel bearing housing

● the wheel bearings
● the wheel hub, and
● the tubular subframe
Wheel bearing housing
Wheel hub
Tubular subframe
Wheel bearing S261_028
Steering
The steering remains unchanged compared with the Passat 2001:
● steering column adjustable in height and reach

● hydraulic power steering gear
24
The double wishbone rear suspension
The proven double wishbone rear suspension What is new are the wheel bearing housings with
with closed tubular subframe is fitted to the a modified attachment to the track rods.
Passat W8.
Tubular subframe Upper wishbone
Differential
Lower wishbone
S261_029
New wheel bearing housing:
● Wheel bearing housing made of aluminium

● Track rods guided at both ends
● Larger track width
Aluminium
wheel bearing housing
Guided at both ends
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25
Running gear
The brake system

The Passat W8 currently has the most powerful Despite high engine performance, it achieves
brake system of all Volkswagen car models. excellent deceleration rates.
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Rear disc brake
Front disc brake
Hydraulic unit
and control unit
Front disc brake Rear disc brake
Disc diameter x thickness Disc diameter x thickness

● 334 mm x 32 mm ● 269 mm x 22 mm
● 321 mm x 30 mm
S261_032 S261_033
26
The hydraulic unit and ABS control unit
The Passat W8 receives the Bosch 5.7 ABS system with ESP (Electronic Stability Programme) and the
hydraulic brake assistant system (BAS). Special features of the Bosch 5.7 ABS system are:
● The hydraulic unit and the control unit form a single unit
● The ABS two-stage recirculating pump V39 replaces the hydraulic pump for
electronic dynamics control V156.
● The pressure sensor G294 is contained in the hydraulic unit.
Control unit and rear of hydraulic unit
Pressure sensor
G294
S261_034
S261_035
27
Running gear
The ABS two-stage recirculating pump V39
is integrated in the Bosch 5.7 ABS system. While pressure is building up in working
When the ESP intervenes, it supplies the required chamber 1, the piston in working chamber
preliminary pressure in the brake lines. 2 sucks brake fluid in. This creates a suction
The pistons of the two-stage recirculating pump process with every piston stroke.
operate at both sides.
Suction process in working chamber 2 Suction process in working chamber 1
Working chamber 2
Working
chamber 1
TDC BDC TDC BDC S261_040
S261_039
Suction line Connecting line
A suction process takes place with every piston stroke.
S261_041
BDC TDC BDC TDC
As the full suction volume is pumped almost This reduces the pressure in the suction line and
continuously, the maximum suction flow is much prevents cavitation.
smaller than on single-stage recirculating pumps. It ensures rapid pressure build-up, even at
extremely low temperatures.
Cavitation is the formation of vapour bubbles in flowing liquids. The associated pressure surges
could cause material damage.
28
The hydraulic brake assistant system (BAS)
is integrated in the ABS control unit.

Accident research studies have shown that the
Pressure sensor G294
majority of drivers do not press hard enough on
the brakes in critical situations. This means that
pressure build-up is insufficient to reach
maximum vehicle deceleration.
S261_034
Pressure rise in brake system
The pressure sensor G294 detects the pressure

rise in the brake system. The control unit
recognises
an emergency braking action by the rapid rise in
brake pressure within a specific period of time.
Brake pressure [p]
After it detects the emergency situation, it

increases the brake pressure within the ABS
control range. This shortens the stopping distance
and the car comes to a standstill faster.
Time [t] S261_043
ABS control range

Emergency braking
Normal braking
You will find explanations on the design and function of the hydraulic brake assistant system
(BAS) in Self-Study Programme No. 264.
29
Vehicle electrical system
The vehicle electrical system

The electrical system on the Passat W8 has a
similar design as on the Passat model year 2001.
The following pages will describe modifications Airbag control unit
to components and functions compares with the (gearbox tunnel)
Passat model year 2001.
All components not described here are identical
with the Passat 2001.
Connector station
A-pillar, right
Radio with dynamic

navigation RNS-D
Automatic gearbox
control unit
(right footwell)
Electronics box in
plenum chamber
● Engine control unit
● Relay station
● Connector station
● Fuses
Connector front end Central electrics
30
Window lifter motor Control unit for
with integrated parking aid
door control unit (luggage compartment, right)
TV tuner
CD changer
DSP
Window lifter motor

with integrated
door control unit
S261_044
Dash panel insert with

immobiliser
control unit and
diagnostic interface
(gateway)
Connector station Fuse box, dash panel, Convenience control

A-pillar, left left unit in footwell, left
31
Vehicle electrical system
The gas discharge headlight (GDH) with bi-xenon light
The Passat W8 is only fitted with the bi-xenon Due to the gas discharge headlights, all bi-xenon
headlight system. The improved light output of cars are equipped with automatic and dynamic
the system increases active driving safety as the headlight range control (refer to SSP 251).
driver can detect danger earlier.
The bi-xenon headlight module produces the

dipped beam and the main beam from a single
gas discharge lamp.
The main beam is intensified by a H7 lamp. This

lamp also bridges the time until the gas
discharge lamp reaches its full light intensity. The
H7 lamp is also used for the headlight flasher
function.
S261_045
H7 lamp Indicator lights

(additional main beam)
Gas discharge lamp
(dipped and main beams)
When driving in LHD countries, the two headlights can

be changed over from asymmetric to symmetric dipped beam.
Please refer to the information in the Workshop Manual.
The design of a bi-xenon headlight module is described in Self-Study Programme No. 251.
32
Convenience and safety electronics
Passat W8 with Internet access

Networking a vehicle is no longer limited to the The Internet interface is a device which is linked
car's immediate surroundings but goes far to the radio navigation system via the CAN bus.
beyond this. The in-car communications Communication with the Internet (outside world)
equipment now provides access to the world- is by means of a mobile radio aerial (GSM
wide data network, the Internet. antenna) which complies with the present-day
standard.
Internet interface with GSM antenna and connected laptop
S261_046
Internet access allows retrieval of specially processed driver-orientated information over the radio
navigation monitor, e.g. traffic information, trip/route planning, logistics support for hire cars and
breakdown or emergency call systems etc.
If a laptop is connected, the user can surf freely on the Internet and send e-mails.
33
The convenience system

Interior monitor and anti-theft alarm system
The Passat W8 anti-theft alarm system is Two lithium batteries integrated in the horn
equipped with a new function and a new alarm ensure that the horn operates independent of the
horn. The new alarm horn, designated the H12, is car battery. The batteries have a life of approx. 5
mounted in the plenum chamber. It has a to 7 years. If the batteries are discharged or
separate power supply. defective, the horn must be replaced.
Fitting location
Alarm horn H12

S261_047
Function
The horn communicates bidirectionally with the When the car is unlocked by the radio-wave
convenience system control unit J393. After the remote control key, the anti-theft alarm system is
car is locked, the horn is armed via the control deactivated. If the car is opened mechanically
unit. This means the vehicle power supply and via the lock cylinder of the door, the ignition must
the horn signalling line are monitored in addition be turned on within 15 seconds. If this does not
to the other functions of the anti-theft alarm happen, the anti-theft alarm system is activated.
system.
34
Function diagram of signal horn for anti-theft alarm system
J393
30a
H8 H12 F266
S261_048
F266 -contact switch for bonnet, in lock part

H8 -signal horn for anti-theft alarm system
H12 -alarm horn
J393 -central control unit for convenience system
30a -positive terminal
The anti-theft alarm system has self-diagnostic capability. You will find the self-diagnosis in the vehicle
diagnostic testing and information system (VAS 5051) in the guided fault-finding under Body - Body
Repairs and the address word Convenience System. Please always use the latest version of the Workshop
Manual in the electronic Service Information System (ELSA) when fault-finding.
35
The "Delta" radio system

supplements the current radio generation. At first glance the differences to the other units are its larger
size and a redesigned user interface.
Other new features compared to the current radio systems are:
● integrated CD player
● two FM/AM tuners
● improved TIM function (Traffic Information Memory)
● aerial sockets for aerial selection
● compact connectors with central locking
● CAN bus convenience networking
The important new button names and functions are summarised below.
The user interface
Audio CD entry
TIM function
There are two separate adjustable 2 hour timers to
program the time for starting to record radio traffic
information.
Example: The starting time for the trip to work and
back in the evening can be saved separately for 2
hours.
S261_049
36
Rotary/push button for SCAN/TUNE
SCAN
Press in radio mode to search for a station or in CD
MIX button mode to briefly play the start of the track.
In CD mode, tracks are played in random sequence. TUNE
Rotate to tune the FM/AM station manually or to
select the previous/next track in CD mode.
SEEK/TRACK button
SEEK
In radio mode, hit to start station search (SEEK) in AM
band. In FM or TP band, browse through storage
list.
TRACK
Hit briefly to skip forward or backward through CD
tracks. Press longer to start audible fast forward or
fast reverse of a track.
DSP button
Selects the menu for basic tone settings using
Digital Sound Processor (DSP)
37
Radio rear panel
The rear panel of the radio contains the aerial sockets and the central connector.
The aerial sockets
Aerial input for FM/AM signal from control unit

for aerial selection
S261_050
Output to control unit for aerial selection
The aerial sockets

S261_051
To avoid plugging the aerial connectors in the
wrong socket the connector housings have a plug
coding and different colours. This means that a
Aerial wire
connector will only fit in its associated aerial
socket. The connector engages when it is
plugged into the socket. To release the connector, Plug coding
operate the unlocking mechanism on the socket.
Central connector
lock
S261_052
Central connector with central

locking
Connector and locking
clip
The central modular connector groups all the
individual connectors, such as connectors for the
CD changer or loudspeakers. The individual
S261_053
connectors can be plugged separately in the
central connector housing.
Locking and unlocking is by means of a central
locking mechanism.
S261_054
38
Tuner
The radio has two integrated FM/AM tuners. Example:

You are listening to an FM station, e.g. NDR 2,
One of the tuners is only adjusted for receiving which broadcasts supraregional traffic radio
frequencies from FM/AM stations. The other messages. To receive current regional traffic
tuner is used for setting the frequencies to radio messages, select a TP station e.g.
receive TP/FM traffic radio stations. This allows ANTENNE by pressing the TP button. When the
selection of traffic radio messages from a TP selected TP station broadcasts traffic radio
station irrespective of the FM station setting. messages, they will cut into the current
programme of the FM station the driver is
listening to. This also applies when the driver is
listening to an AM/MW station or the radio is in
CD mode.
FM station
TP station S261_074
If the "TP tuner“ is not being used to receive This makes checking the alternative frequencies
TP stations, e.g. TP button OFF, it supports the faster and avoids short-term mute pauses caused
"FM tuner“. It checks the alternative frequencies by checking.
of an FM station setting to find a better reception
frequency.
39
CAN bus networking
To control functions and processes, the radio control unit and the dash panel insert exchange the
following information over the CAN bus.
● NO contact
● Terminal 15
● Road speed signal (GALA)
● Display lighting
● Self-diagnosis processing
● Radio convenience coding
● Control signals from the multifunction steering wheel
● Vehicle identification number
S261_055
For further Information on the subject of the radio system, refer to the following Self-Study
Programmes:
SSP 147 Radio Systems ´94
SSP 199 The Radio Navigation System
SSP 201 The Lupo
For more details on how to operate the radio system, please refer to the related operating
manual.
40
The radio aerial system
FM/AM reception of the radio system on the If reception is poor, the aerial control unit
Passat W8 has been considerably improved. This switches to another aerial with a stronger signal.
was achieved by fitting four independent The aerials are in different locations on the
FM/AM aerials (see SSP 147). saloon and on the estate.
Location of aerials on the saloon
On the saloon, the AM medium wave aerial is Suppressors in the supply wires of the rear
above the rear window heater. The four FM window heater prevent the radio signals received
aerials are integrated in the rear window heater. from flowing via the positive and negative
terminals of the rear window heater.
Outside view onto the rear window in direction of travel
Amplifier 1 Amplifier 4
AM/FM FM aerial
aerial
S261_056
Amplifier 2 Amplifier 3
FM aerial FM aerial
41
Location of aerials on the estate
On the estate, the aerials are located in the rear As on the saloon, each FM aerial is allocated to
side windows. Viewed in the direction of travel an aerial amplifier. Even on the estate, the
there is a combined AM/FM aerial on the left- amplifiers should not be wrongly allocated. As
hand side and two FM aerials on the right-hand the aerials on the estate do not use the rear
side. window heater, no suppressors are required.
Side window, left Side window, right
S261_057
Amplifier 1 Amplifier 2 Amplifier 3 Amplifier 4
AM/FM aerial FM aerial FM aerial FM aerial
The aerial amplifiers
Each FM aerial is allocated to an aerial amplifier.

They are precisely matched to their fitting
location and must not be allocated wrongly.
Depending on country-specific radio
frequencies, a number of antenna amplifier
variants can be fitted.
S261_058
42
Function
The radio signal received from one of the four If the selected signal is too weak for tuner
aerials runs via an aerial switch circuit inside the reception, the aerial switch switches
aerial selector control unit to the tuner. In the automatically to the next of the four aerials.
tuner, the signal quality is checked and the result This process is repeated until an aerial is found
is fed back to the control unit via an aerial output with good reception. Switchover is so fast that the
line. car occupants do not notice it.
Function diagram for aerial system (example: Passat estate)
Side window Side window

left right
AM/ FM 2 FM 3 FM 4
FM 1
Switch
Terminal 30 S261_059
Control unit J515
The control unit for aerial selection J 515
S261_060 is located under the rear shelf on the saloon or

on the rear left wheel housing in the luggage
compartment of the estate. Its function is to
switch over to the aerial with the best reception.
Aerial inputs Output to Input from

tuner tuner
Power supply
This aerial system is currently offered with the "Delta" radio system.
43
Heating, air conditioning system
Heating and air conditioning system

The CLIMAtronic with fully automatic control is offered on the Passat W8.
A combination of the following components forms the main difference with the previous fully automatic
air conditioning system fitted to the Passat:
● Sender for evaporator outlet temperature G263

● Externally regulated compressor with regulating valve N280 and integrated overload protection,
The interaction between these two components in conjunction with the entire CLIMAtronic results in a
needs-orientated temperature control.
It permits a reduction in power consumption and helps to save fuel consumption.
Distribution box and housing for evaporator
S261_061
Evaporator
Front view
Sender for outlet

temperature G 263
S261_062
Rear view
44
The externally regulated compressor
The compressor basically works on the principle of the swash plate.

The technical features of the externally regulated compressor are:
● One-sided swash plate compressor with 7 lifting pistons

● Variable lifting volume to match the refrigerating capacity demand
● Hollow pistons
● Belt pulley drive with no magnetic clutch and integrated overload protection
● External regulating valve N280 to regulate the pressure conditions in the compressor
Belt pulley with

integrated overload protection
Lifting pistons
Regulating valve
Shaped rubber N 280
element
Driven plate
S261_063
Swash plate Terminal for Climatronic

control unit J255
Function
The CLIMAtronic control unit J255 variably The inclined position of the swash plate changes.
controls the regulating valve on the compressor This determines the stroke volume and therefore
N 280. Depending on the parameters, input the refrigeration performance generated.
desired temperature, ambient and interior
temperature, evaporator temperature and The compressor continues to run via the ribbed
refrigerant pressure in refrigerant circuit, the V-belt drive even when the air conditioning
pressure conditions on the intake pressure side is system is off. The delivery volume of the
changed by a control voltage. refrigerant is regulated to under 2%.
45
The overload protection
The V-belt pulley and the driven plate are When the compressor is operational, the two
positively joined by a shaped rubber element. plates rotate in the same ratio to each other.
Compressor in function
Belt pulley
Shaped rubber element
Drive shaft
Compressor
Belt pulley
Driven plate
Shaped rubber
element S261_064
46
If the compressor is damaged internally, it may The projecting shapes on the rubber element
cause the drive shaft to block. The driven plate shear off and the joint between the belt pulley
will also stop. and the driven plate is separated. The belt pulley
This drastically increases the transfer forces continues to rotate unhindered. This prevents any
between the belt pulley and the driven plate. The damage to the ribbed V-belt and excludes
shaped rubber element is pressed by the belt engine damage.
pulley in the direction of rotation onto the
blocked driven plate.
Compressor blocked
Distorted shape Belt pulley
on blocking
Shaped rubber element
Sheared
material
blocked
Drive shaft
Compressor
Belt pulley
Blocked driven plate

Shaped rubber
element
S261_065
Sheared material
47
The evaporator control circuit
When the CLIMAtronic is ON and the driver The components described below form a control
enters the desired temperature, the refrigerant circuit for regulating the desired temperature.
demand is determined and changed by a
number of different influences.
CLIMAtronic control unit J255

The compressor regulating valve N280
The external regulating valve forms an interface

between the suction and high pressure sides of
the compressor. It balances out the pressures
applied.
For example, if the cooling output is increased,

the regulating valve is controlled by the
CLIMAtronic control unit J255.
When the control voltage is applied to the

electromagnet control valve, a plunger in the
control valve moves. The period of the control
voltage applied determines the amount of travel.
The adjustment changes the cross-section of the
opening between the suction and the high
pressure sides in the valve. High pressure rises as
the suction pressure drops. This causes the piston
stroke to reposition the swash plate at a greater
angle.
Compressor regulating
valve N280
48
Outlet temperature sender G263
Influencing parameters:
The outlet temperature sender G263 is located in
● Input of desired temperature
the air duct behind the evaporator. It detects the
● Ambient temperature
vent temperature downstream of the evaporator.
● Interior temperature
● Temperatures downstream of evaporator and air outlets
If fulfills two important tasks:
● Pressure level in refrigerant circuit
● it ensures that the air conditioning system is

switched off at 0°C downstream of the
evaporator.
● together with the externally regulated

Intake air
compressor, the outlet temperature
downstream of the evaporator can now be
regulated between 0°C and approx. 10°C.
Advantage:
It is no longer for the heat exchanger to "reheat"
cold air when the outlet temperatures are
between 0°C and 10°C.
This reduces power consumption and saves fuel.
Cooled air
S261_068
Outlet temperature sender
G263
49
Notes
50
Notes
51
261
For internal use only © VOLKSWAGEN AG, Wolfsburg

All rights reserved. Technical specifications subject to change without notice.
140.2810.80.20 Technical status: 08/01
❀ This paper is produced from

non-chlorine-bleached pulp.

The Passat W8: Self-Study Programme 261

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The Passat W8: Self-Study Programme 261

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Service.

Self-Study Programme 261

Downloaded from www.Manualslib.com manuals search engine

Power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Vehicle electrical system . . . . . . . . . . . . . . . . . . . . . . . 30

Convenience and safety electronics . . . . . . . . . . . . . .33

Heating and air conditioning system. . . . . . . . . . . . . .44

Innovations in the Passat W8

● 6-speed manual gearbox or 5-speed automatic with Tiptronic

● Special crash and acoustic measures

● W8 engine 4.0 l/202 kW (275 bhp) 4 valve per cylinder

● Four-wheel drive 4 Motion

● Exhaust system with 2 chrome tailpipes

● 7.5 J17“ alloy wheels with 225R/45 tyres

Size and weight

Length 4703 mm Front track width 1511 mm

Size and weight

Length 4682 mm Front track width 1515 mm

Three-point seat belt

Wankel belt tensioner

Seat with integrated Side airbag

Child safety restraint system

Integrated child safety seats

To use the integrated child safety seat, the swab

Belt guide hook S261_013

The Isofix System

The new Passat W8 is fitted both with a standard

The W8 engine in general

For more details, refer to Self-Study Programme No. 248.

Engine code BDN

Torque and power output

The power output of the W8 engine is 202 kW or

Additional fuel tank 20 l

The fuel pumps

Suction jet pump

Connecting tube S261_020

Fuel level indicator

Suction jet pump

Function diagram of fuel delivery system

G 293 G 292 G G 237 G 169

G 293 -Fuel level sender, G 6 - fuel pump (pre-supply pump)

Control unit for fuel pump J538

● Evaluating signals from the four fuel level senders

The 6-speed manual gearbox 01E from the

The 5-speed automatic gearbox 01V

The gearbox was adapted to fit the W8 engine,

● a dynamic shift programme (DSP)

The Torsen differential

Rear axle drive

Front axle drive

Rear axle worm gear

S261_027 Front axle worm gear Worm gears

The four-link front suspension

● the wheel bearing housing

Wheel bearing housing

Wheel bearing S261_028

● steering column adjustable in height and reach

Tubular subframe Upper wishbone