Volkswagen PASSAT - YEAR 2001 User manual

1
The Passat, Model Year 2001
Self-Study Programme 251
Service.

2
New Important
Note
The Passat, Model Year 2001
This Self-Study Programme summarises the
design features of the Passat 2001. It provides
you with information about the various engines
and gearboxes, the front and rear axle
configurations, the electronics and the
modifications to the convenience system. The
design and function of the various components
and modules will not be explained in depth in
this SSP.
Descriptions of modifications always refer to the
predecessor model. A number of the
technologies cited in this Self-Study Programme
have previously been described in other
Self-Study Programmes. To enable you to brush
up your knowledge of specific technologies, we
have enclosed an index at the back of this SSP. It
refers you to the relevant Self-Study Programmes
by keywords such as "TUMBLE INTAKE PORT".
(In the case of the "tumble intake port" you are
referred to SSP 195 - the SSP in which this
technical feature is described.)
The Self-Study Programme presents the
design and function of new developments.
The contents are not updated!
Please always refer to the relevant Service literature for current
inspection, adjustment and repair instructions.
Keywords are always given in SMALL
CAPITALS.

3
At a glance
Concisely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Environmental protection . . . . . . . . . . . . . . . . . . . . . . 10
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
The engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
The electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

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Brief description of vehicle
The Passat 2001 is based on the highly successful
predecessor model. In revising the vehicle,
Volkswagen's designers retained the
characteristic basic shape of the saloon, with its
distinctive dome roof.
The front end of the Passat has been redesigned,
and particularly the bonnet, the wings and the
radiator grille. The bumpers now have full-length
rubbing strips.
Concisely
Saloon
●Third-generation immobiliser
●TV tuner
●Anti-vibration measures
(40Hz body)
●Dynamic navigation
New features of the Passat, model year 2001

5
Concisely
●Improved crash concept
●Solar roof
251_103
The headlights have clear lenses and the
indicator lights are built into the headlights.
BI-xenon headlights with dynamic headlight
range control are also available.
The rear end has been revised also, including the
rear lights.

6
Concisely
The Variant has been revised, too. In addition to
the new front-end design, which is identical in the
Variant and saloon, the rear end and the rear
lights have been redesigned in the Variant.
Variant
●New locking concept with
radio wave folding key (fob) built into
the driver's door.

7
Concisely
All technical modifications apply to saloon and Variant.
●Distance control
●Comfort-enhanced air conditioning system
●Spare wheel fitted with ready-for-road
tyre
251_104
The Passat has a new locking concept. All models
come with radio wave folding keys. There is no lock
cylinder on the front passenger's door and the
tailgate is separately released.

8
Concisely
Saloon
Dimensions and weights
Model MY 2001 MY 1997
Length 4703 mm 4675 mm
Width 1746 mm 1740 mm
Height 1462 mm 1459 mm
Wheelbase 2703 mm 2707 mm
Turning circle 11.4 m 11.4 m
Tank capacity 62 l 62 l
Drag coefficient 0.27 cw0.27 cw
Weight (unladen) 1277 kg 1233 kg
2703 mm (2707)
4703 mm (4675)
1746 mm (1740)
1462 mm (1459)
251_016
251_018
The figures quoted in brackets refer to
the predecessor model.

9
Concisely
Variant
Dimensions and weights
Model MY 2001 MY 1997
Length 4682 mm 4675 mm
Width 1746 mm 1740 mm
Height 1470 mm 1459 mm
Wheelbase 2705 mm 2707 mm
Turning circle 11.4 m 11.4 m
Tank capacity 62 l 62 l
Drag coefficient 0.27 cw0.27 cw
Weight (unladen) 1319 kg 1282 kg
2705 mm (2707)
4682 mm (4675)
1746 mm (1740)
1470 mm (1459)
251_054
251_055
251_056

10
Environmental Protection
The water management plan
The water management plan for Wolfsburg plant
Environmental protection is a matter of
fundamental importance. Each and everyone of
us should strive to protect the environment
wherever possible, day by day. You are required
to think pro-environmentally when you repair
and service vehicles. And we must do likewise in
vehicle manufacture.
To demonstrate our commitment to in-plant
environmental protection throughout all stages
of the vehicle production process through to
delivery of the finished product, we will be
dealing time and again with the topic of
environmental protection in the next Self-Study
Programmes.
Our customer have high expectations of our
products in several respects:
reliability, convenience, quality and, not least,
environmental compatibility. Firstly, the vehicle
itself should pollute the environment as little as
possible. This means raising fuel economy,
reducing pollutant emissions in exhaust gases
and ensuring a high degree of recyclability of
the individual components of a car at the end of
its life cycle. Secondly, our customers also expect
their vehicles to be made in a production facility
that meets stringent environmental protection
standards.
Volkswagen can look back on a long tradition of
protecting the environment. When it built its first -
and, to date, largest - plant in Wolfsburg,
Volkswagen even then thought about ways of
using the natural resource of water as
economically as possible for example.
Volkswagen currently circulates and reprocesses
more than 95 percent of process water within the
plant.
The amount of fresh potable water which
Volkswagen annually feeds into its circulation
system from external sources accounts for less
than five percent of total volume.
Process water retention tank
1,500,000m3
Measuring station
to landfill
Process water
treatment
Was t e w a te r
treatment plant
(biological)
Filtration
press
Mittelland
Canal
Drinking water
procurement (from
the Harz mountains)

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Environmental Protection
The Emden plant
The Emden plant, where
the majority of Passat
models are built, was the
first automobile
manufacturing plant in
Europe to be certified (in
September 1995). The plant
was re-audited and re-
certified in September 1998.
West combined heat and power station
Procurement of drinking water
Filtration sta-
tions
to landfill
Cyclator
Chem. waste
water treatment
plant
Tota l
demineralisa-
tion
Canal water cycle
Sewage water
pumping station
Cooling circuits
production
Rainwater
Pretreatmentplant
To ensure that we maintain
high standards in
environmental protection, our
plants are audited and
certified by an independent
expert. Our European plants
were certified according to the
EU eco audit regulations while
our non-European plants were
certified according to the
international
ISO 14001 standard.
251_092
251_091

12
Safety
Occupant protection
The front airbags
Full-size airbags are fitted in the Passat 2001 on
the driver's and front passenger's sides. As in the
predecessor model, the airbags have filling
volumes of approximately 64 and 120 litres
respectively.
The central airbag control unit is located behind
the central console, above the tunnel.
The side and head airbags
The side and head airbags afford excellent side
impact protection. The two side airbags,
integrated in the front seats, have a filling
volume of approximately 12 litres.
The head airbag has a filling volume of
approximately 26 litres and is integrated in the
vehicle headlining, above the doors.
251_082

13
Safety
The complete part number of the airbag control unit, together with the index (colour code) must
be quoted when ordering side impact sensors because these sensors are not labelled with a
parameter index. The part number and the colour index can only be read out, or reproduced,
from the production data (VIN, year of manufacture, list of PR numbers) by using the workshop
tester.
As before, the system has two lateral
acceleration sensors, located beneath the seats.
The lateral acceleration sensors are
programmed with a vehicle-specific parameter
when they are replaced.
Where repair or replacement of defective parts
is needed, it is important to specify the correct
SP-number.
251_069

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Safety
Belts and BELT TENSIONERS round off the restraint
system. Standard belt tensioner systems are used
in the outer seat positions, front and rear.
These systems deploy mechanically and
pyrotechnically.
The upper part of the belt buckles in the new Passat is flexible.
The lower part is rigidly bolted to the bracket.
Rotary belt tensioner
The belt tensioner/belts
Ball-type tensioner
Ball-type tensioners are used in the front seating
positions. In comparison with the predecessor
model, they are rotated through 180°.
The rear seating positions have rotary belt
tensioners.
251_075
251_066

15
Safety
Child restraint systems
To make use of the integrated child safety seats,
the elements of the seat cushion have to be
raised and locked in place. An additional
shoulder belt guide corrects the belt position for
children with a height from 1.3m - 1.5m. A belt
guide hook on the booster cushion ensures an
ideal belt position around the child's pelvis.
Integrated child safety seats
The Isofix system
The new Passat comes as standard
with an attachment point for the fastening clips
of the ISOFIX system. Child safety seats integrated
in the rear bench seat are optional.
Belt guide hook
251_010
251_011

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Body
Body reinforcements
The body of the Passat 2001 was reinforced in the zones described below.
In other words, the body panels have been thickened and the spot welds
have been supplemented with laser-welded seams.
Roof cross strut
Side member, right
B-pillar, right

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Body
Vehicle safety and natural body vibration (40 Hz)
have been greatly improved as a result of these
modifications.
Wheel housing, inner
surface (sheet-metal
reinforcements have been
welded in on the left and
right )
B-pillar, left
Side member, left
Side member, top right
Side member, top left
251_041
Tunnel reinforcement

18
The engines
On the following pages, you will find
descriptions of the engines to be used in the new
Passat. They include specifications, torque and
performance curves, as well as details of
technical features and engine modifications.
In developing all engines, special emphasis was
put on raising fuel economy and reducing
exhaust emissions.
These engines now meet the following standards:
●all petrol engines conform to the EU 4 exhaust
emission standard and
●all diesel engines conform to the EU 3 exhaust
emission standard.
Engines in general
All engines have an electrical throttle control. For
more effective antitheft protection, the engine–
control unit communicates with the immobiliser
control unit via CAN databus (3rd generation
immobiliser).
If a component with a bearing on exhaust
emissions fails while the vehicle is in operation
(e.g. misfiring), the self-diagnosis fault warning
lamp begins to flash. If a component is identified
as being defective while the vehicle is in
operation, the self-diagnosis fault warning lamp
lights up continuously.
In both cases, the engine must be inspected
immediately.
A self-diagnosis fault warning lamp is now
integrated in the dash panel insert in all petrol-
engined vehicles.
251_044

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The Engines
The engine is an improved version of the
1.6-litre petrol engine developing 74kW.
The following components were optimised with
regard to friction work and mass for higher fuel
economy:
●the conrods (TRAPEZOIDAL CONRODS) were opti-
mised for mass
●the piston lands were lowered to reduce pis-
ton mass
●ALUMINIUM CYLINDER HEAD WITH ROLLER CAM
FOLLOWERS
Specifications
Engine code ALZ
Displacement 1595 cm3
Type Row
Number of cylinders 4
Number of valves per
cylinder
2
Compression ratio 10.3:1
Bore 81.0 mm
Stroke 77.4 mm
Max. power 75 kW/102 bhp
@ 5600 rpm
Max. torque 148 Nm
@ 3800 rpm
Engine management
system
Simos 4
Fuel grades RON 95 unleaded
petrol
(the Passat also
operates on RON
91 unleaded
petrol, with
reduced engine
power)
1.6-litre 75 kW petrol engine
251_070
251_022

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The Engines
1.8-litre 110 kW petrol engine with 5 valves per cylinder and
turbocharger
The engine was adopted from the predecessor
model and adapted to meet the applicable
exhaust emissions regulations, as outlined below.
●No intermediate shaft
●Oil pump is chain driven
●Piston crown cooling via oil spray jet
●Rod-type ignition coils with integrated output
stage
●PLANAR PROBE BEFORE CATALYST
●Camshaft timing control - timing chain
adjuster, inlet camshaft only
●The water pump is driven by a toothed belt
Specifications
Engine code AWT
Displacement 1780 cm3
Type Row
Number of cylinders 4
Number of valves per
cylinder
5
Compression ratio 9.3:1
Bore 81.0 mm
Stroke 86.4 mm
Max. power 110 kW/150 bhp
@ 5700 rpm
Max. torque 210 Nm
@ 1750-4600 rpm
Engine management
system
Bosch Motronic
ME 7.5
Fuel grades RON 95 unleaded
petrol
(the Passat also
operates on RON
91 unleaded
petrol, with
reduced engine
power)
251_071
251_023