Volkswagen Passat '97 User manual

Service.
The Passat ‘97
Construction and operation
191
640.2810.10.00 Technical Status: 09/96
The Presentation
Only for internal use.
© VOLKSWAGEN AG, Wolfsburg
All rights reserved. Subject to modification.
` Printed on chlorine-free
bleached paper.
Self Study Programme
Service Department

2
The most remarkable features of the new
Passat are its:
l High economy
l Dynamic body styling
l High-quality interior equipment designed
with great attention to detail
l Pioneering safety engineering
In this booklet, we would like to provide you
with an initial overview showing how we
justify making these claims.
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Page
The Passat ‘97 04
Environmental Protection and Recycling 08
Body 10
Vehicle Safety 15
Engines and Gearboxes 19
Running Gear 26
Brakes 29
Steering 30
Electrics 31
Extended Systems 36
The Self Study Programme is not a Workshop Manual.
Please refer to the relevant Service Literature for all inspection, adjustment and repair
instructions.
New
Important ! / Note

4
To avoid confusion, concise examples are used
to illustrate the various aspects of this
all-embracing vehicle concept.
You can find detailed information in Self Study
Programme No. 192 Passat ‘97 – The Enginee-
ring.
The Passat ‘97
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Service.
192
Der Passat '97
Die Technik
Konstruktion und Funktion
Selbststudienprogramm
Kundendienst

5
Dimensions and Weights
4675 mm
2707 mm
1740 mm
Track widths
front
rear
1498
1500
mm
mm
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Weights
Unladen weight
Max. permissible weight
appr. 1200
appr. 1805
kg
kg

6
The Platform - an Advantage for Workshops
The term “platform” is frequently used in
publications although its fundamental
meaning is not explained. The result of this is
that people are often unsure of what the term
“platform” implies.
The vehicle consists of a) the platform and b)
the body.
Design and vehicle characteristics dictate what
form the body takes.
In the eyes of the customer, the body characte-
rises the styling of the vehicle as a whole.
The Passat ‘97
The platform
The body
The Passat ‘97
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The advantages for workshops like yourself are:
- More clarity as regards the spare parts situation
- Simplified inventory management
- Fewer different special tools and fixtures
- Easier assembly and repair
Platform
The platform comprises both common parts and system parts.
Common parts
e.g. sliding sunroof, steel rim
Common parts may only be used in platform
vehicles without change.
They do not influence the design of the
vehicle.
System parts
e.g. seat
Some system parts are identical.
They have to be adapted since they are the
interface between the platform and body.
Common part
Frame
Adapted part
Vehicle-specific seat uphol-
stery, seat cover, etc.
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System part

8
Environmental Protection and Recycling
The concept of eco-friendliness was pursued
consistently throughout development of the
new Passat.
We would now like to show you some aspects
of this topic which are also of interest to work-
shops.
Recycling
Not least the recycling requirements present
workshops with problems such as identifying,
presorting and storing materials and waste
operating media.
To achieve this, the following measures were
taken:
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.
Take bumpers for example:
Bumpers were previously manufactured from
composites. What the term “composite”
means is that different materials are combined
with one another in such a way that subse-
quent separation into clean material streams is
no longer possible.
If a plastic is to be recovered for recycling, it
should, if possible, be sorted according to type
for recycling purposes. This means that
different types of plastic, for example, must
not be mixed with one another.
The bumpers on the Passat are recyclable
because they do not contain composites.
.
Collection +
sorting
Recycled plastic
Cleaning +
recycling
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Solvents
Even during production, every effort is made to
keep environmental pollution to a minimum.
To achieve this, the following measures were
taken:
l Full galvanisation means much less
wax and PVC underseal
l Water-dilutable paints including
water-based clear coat
l Stringent requirements for materials ensure
lower emissions in the vehicle interior
Energy + Resources
Raw materials and energy are in limited supply
on the planet Earth.
We must use them sparingly.
To achieve this, the following measures were
taken:
l Less energy consumption during production
through the use of new joining techniques
(e.g. laser welding) and complete assemblies
(e.g. side section of body),
l Full galvanisation and an 11-year warranty
against corrosion perforation ensure high
value retention and conservation of
resources.
Take laser welding for example:
During laser welding, a highly concentrated
light beam with a high energy content is used
instead of a gas flame to join the components.
No additional welding material is required, as
is the case during MIG welding for example.
Laser welded seams are extremely clean and
do not need to be reworked.
Laser welding offers a more favourable energy
balance than conventional welding techniques.
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Body
The following will be of interest to you:
l The Passat in the wind tunnel
l Fully galvanised body
l Greater body rigidity
l Use of high-strength steel parts
l Strategy of using common platform for body
parts
l Ease of repair demonstrated using door
module as example
l Rear collision demonstrated using bumper
as example
The Passat in the Wind Tunnel
As you can see from the streamlines, the body of
the new Passat is very aerodynamic.
No turbulence, which increases aerodynamic
drag, occurs.
The new Passat has a drag coefficient of c
d
=
0.27, making it the best in its class.
Accounting for the projected vehicle area (A) of
2.1 m
2
, aerodynamic drag is (Cd x A) = 0.567 m
2
.
A = 2.1 m
2
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