Volkswagen Passat 2012 Manual

Service Training
Self Study Program 890113
The all new 2012 Passat

Volkswagen Group of America, Inc.
Volkswagen Academy
Printed in U.S.A.
Printed 05/2011
Course Number 890113
©2011 Volkswagen Group 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 Group of America, Inc., its
affiliated 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 modified 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 Group 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.

iii
Contents
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.
Note Important!
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Occupant Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Running Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Radio, Navigation and Telephone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Heating and Air Conditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Knowledge Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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1
Introduction
S488_045
This SSP portrays the design and function of new technologies and its contents will
not be updated. For current information and repair instructions, refer to the relevant
service literature.
The 2012 Passat
The seventh generation Passat has made improvements in design, comfort, quality, efficiency and safety
attributes.
Its straight lines, clearly structured surfaces and dynamic proportions distinguish the design of the new
generation sedan.
Highly efficient gasoline and diesel engines supply ample power and fuel efficiency.
With its high level of quality, the new Passat is another advancement for Volkswagen.
The Passat images in this Self-Study Program (SSP) were provided by German media
during early production. North American vehicles may differ slightly.

2
Introduction
S488_029
Technical Data
Exterior Dimensions and Weights
Passat 2006 2012
Length 188.2 in 191.6 in
Width 71.7 in 72.2 in
Height 58 in 58.5 in
Wheelbase 106.7 in 110.4 in
Track width at front 61.1 in 62.1 in
Track width at rear 61.1 in 61.0 in
Turning circle 35.8 ft 36.4 ft
Passat 2006 2012
Gross vehicle weight 4719 lb 4387 lb
Curb weight 3577 lb 3165 - 3446 lb
Maximum roof load 220 lb 220 lb
Tank capacity 18.5 gal 18.5 gal
Drag coefficient 0.295cd 0.291cd
Exterior dimensions Weights/further details
36.4in 110.4 in
191.6 in
44.8in
62.1 in
72.2 in
61.0 in

3
Introduction
S488_033
Interior Dimensions and Volumes
Passat 2006 2012
Luggage compartment volume 14.2 ft315.9ft3
Height off rear lid (open) 69.1 in 69.5 in
Height off load sill 28.7 in 28.7 in
Cargo area height 13.0 in 13.0 in
Interior dimensions and volumes
Passat 2006 2012
Interior length 70.7 in 70.7 in
Interior length 2nd seat row 37.7 in 39.1 in
Front headroom 38.4 in 38.3 in
Headroom 2nd seat row 37.8 in 37.8 in
S488_037
39.1 in
70.7 in
38.3 in
37.8 in
15.9 ft3
39.9in
28.7 in 13.0 in
69.5 in

4
Body
S488_032
Body Structure
The primary focus of body development increased body strength while reducing weight. This Passat is a
completely new develoment when compared to the previous Passat.
Modifications to Passat Sedan
• Hood
• Rear lid
• Wings
• Door skin
• Side panel
• A-pillar and door frame
• Rear panel
Up to 220 MPa pressure resistance
Up to 420 MPa pressure resistance
Over 1000 MPa pressure resistance
1 Megapascal (MPa) = 145 Pounds per Square Inch (PSI)

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6
Body
On this headlight module, the low beam and high beam are designed as separate H7 headlights. The side light is
integrated into the low beam headlight.
S488_064
S488_013
Light Module in Bumper
The cornering, fog and day driving lights have two
separate bulbs.
Fog and Cornering Light
(H8, 35W)
Day Driving Light (21W)
Turn Signal (24W)
Side Light (5W)
Low Beam, H7 (55W)
High Beam, H7 (55W)
Halogen Headlights

7
Body
S488_050
Tail Lights
The tail lights of the 2012 Passat have a two-part design. One segment is attached to the rear fender and the
other is attached to the trunk lid.
Reflector (in lens)
Turn Signal
(21W)
Brake Light
Tail Light Reflector (in trim) Reverse Light

8
Body
S488_068
S488_052
Interior Equipment
Head Restraints with Adjustment
The head restraint distance to the head can be
adjusted using a release mechanism for maximum
comfort and safety.
Front Storage Compartments
Release
Door Compartment
Glove Compartment
Storage Under AC Controls
Storage in Center Armrest
Storage in Center Console
with Beverage/Can Holder
Small Glove Compartment by
Steering Wheel

9
Body
S488_066
Rear Storage Compartments
Storage Pockets on
Back of Front Seats
Rear Door Compartment
Beverage/Can
Holder 12 volt Connection
Storage Compartment
in Center Armrest

10
Occupant Protection
Safety Equipment
The new Passat has six standard airbags as well as pyrotechnic
seat belts:
• Driver and front passenger airbag
• Side airbags at front
• Curtain airbags for front and rear passengers
• Front inner and outer seat belt pyrotechnic igniters
• Rear outboard seat pyrotechnic igniters
Side Crash Sensors
The side crash sensors in the bottom area of the
front doors are designed as pressure sensors.
Lateral acceleration sensors that detect side impact
are located in the C-pillar.

11
Engines
2.5L Engine
The 2.5L engine was first used in the 2005 Jetta. It
has been optimized for the 2012 Passat
Technical Features:
• Variable oil pump for the lowering of the fuel
consumption
• Exhaust manifold redesigned to reduce weight
• Spark plugs switched to Bosch from NGK
S468_021
S468_020
Engine
Configuration
Inline 5-Cylinder
Displacement 2480 cm3 (151 in3)
Bore 82.5 mm (3.25 in)
Stroke 92.8 mm (3.7 in)
Valves per Cylinder 4
Compression 9.5:1
Maximum Power 170 hp (125kW) at 5,700 rpm
Maximum Torque 177 lb/ft (240 Nm) at 4,250 rpm
Engine
Management
Bosch Motronic ME 17.5
Fuel Requirement Regular Unleaded
Emission Rating PZEV
185
220
150
110
75
35
0
1000 2000 3000 4000 5000 6000 7000
35
70
100
135
170
200

12
Engines
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3.6L FSI Engine with 4-Valve Technology
The 3.6L FSI engine with 4-valves per cylinder is based on the VR engine series. Many efficiency technologies
are used on this engine.
Technical features
• Oil pump output reduced and oil pressure lowered to 3.6 bar
• Non-engaged chain tensioner
• 89° opening temperature of coolant thermostat
• One-part oil pump chain sprocket
• Exhaust camshaft adjuster with 32° setting range
• Vibration damper secured with 7 bolts
Additional information on this engine is
available in SSP 823603, the 3.2L and
3.6L Engines.
Engine Code BWS
Type 6-cylinder in-line engine
Displacement 219.5 in3(3597 cm3)
Bore 3.5 in (89 mm)
Stroke 3.8 in (96.4 mm)
Valves Per Cylinder 4
Compression Ratio 11.4:1
Maximum Output 295 hp (220kW) at 6600
rpm
Maximum Torque 258 lb/ft(350Nm) at
2400 to 5300 rpm
Engine Management Bosch Motronic MED 17.1
Fuel Premium unleaded
Exhaust Gas Treatment Three-way catalytic
converter with lambda
control
Emissions Standard ULEV 2
Technical data Torque and power diagram
Torque
Engine Speed [rpm]
Output
S488_230
1000 3000 5000 7000
295
280
265
250
235
220
205
190
175
160
150
320
295
270
240
215
185
160
135
110
80
55

13
Engines
New Features of 3.6L FSI Engine
Several areas of this engine were improved to reduce fuel consumption and CO2emissions.
Duo-Centric Oil Pump
The entire oil circuit of the engine was improved, allowing for the reduction of oil pump output from 5.7 bar to
3.6 bar.
S488_026
Vibration Damper
The vibration damper is secured with seven bolts
instead of a single center bolt.
Plug
Control Plunger
Spring
Inner Rotor
Drive Shaft
Radial Shaft Seal
Bearing Bush
1st Half of Housing
Outer Rotor
2nd Half of Housing
Seal Gasket
S488_234
Bolts
Vibration Damper

14
Engines
S488_236
S488_238
S488_060
Do not punch through or clean the bore
with any kind of tool.
Chain Sprocket
The oil pump chain sprocket has a one-piece design
to prevent incorrect installation.
Chain Tensioner
The lower chain tensioner has been redesigned to work without engagement at a lower oil flow rate (originally
0.86l/min, now 0.04l/min). Removing the locking mechanism made it possible to reduce the chain forces. The
spring serves to pretension the chain during cold starting. The ram fills the void in the hollow control plunger and
gives a faster response from the chain tensioner when oil pressure is building.
Chain tensioner module
Guide Rail
Marking for Primary
Chain Drive
Marking for
Camshaft Timing
Chain Drive
Control Plunger Ram
Pretensioning
Spring
Choke Bore
Housing

15
Engines
Range of Adjustment
32°
Camshaft Adjuster
S488_028
Camshaft Adjuster
The exhaust camshaft adjuster allows for a 32° range
of crankshaft adjustment. At idle, less exhaust gas
flows back into the inlet port, eliminating residual gas
compression. This makes the engine run smoother
and reduces consumption at idling speed by 3-5%.
S488_239
Seal
Cover for
Camshaft Adjuster
Camshaft Adjuster Cover
A seal is now located between the camshaft adjuster
cover and the cylinder head seal.
This seal optimizes oil supply to the camshaft
adjuster, allowing for a faster adjustment speed.

16
Engines
2.0L TDI CR Engine
The second generation 2.0l TDI CR engine is used in
the 2012 Passat. This engines is revised from the first
generation.
2nd Generation 2.0lTDI CR Engine Features
Exhaust gas recirculation module with Exhaust Gas
Recirculation (EGR) valve and EGR cooler.
Common rail fuel injection system with solenoid
valve controlled injectors has high injection pressures
and can deliver multiple injections per stroke.
Cylinder head has a channel that allows for
recirculated gas running through cylinder head.
Plastic intake manifold without swirl plate
adjustment.
S488_213
S488_209
S488_211
S488_206
S488_207