Volkswagen Passat '97 Bedienungsanleitung

Service.

The Passat ‘97

Construction and operation

191

640.2810.10.00 Technical Status: 09/96

The Presentation

Only for internal use.

Printed on chlorine-free

bleached paper.

Self Study Programme

Service Department

The most remarkable features of the new

Passat are its:

High economy

Dynamic body styling

High-quality interior equipment designed

with great attention to detail

Pioneering safety engineering

In this booklet, we would like to provide you

with an initial overview showing how we

justify making these claims.

191/01

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

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

191/86

191/73

Service.

192

Der Passat '97

Die Technik

Konstruktion und Funktion

Selbststudienprogramm

Kundendienst

Dimensions and Weights

4675 mm

2707 mm

1740 mm

Track widths

front

rear

1498

1500

191/71

Weights

Unladen weight

Max. permissible weight

appr. 1200

appr. 1805

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

191/44

191/76

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.

191/90

System part

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:

Identiﬁcation of plastic part materials

Fewer composite materials

Reduction in ﬁne sealing through the use of

laser welding

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

191/67

Solvents

Even during production, every effort is made to

keep environmental pollution to a minimum.

To achieve this, the following measures were

taken:

Full galvanisation means much less

wax and PVC underseal

Water-dilutable paints including

water-based clear coat

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:

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),

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.

191/03

Body

The following will be of interest to you:

The Passat in the wind tunnel

Fully galvanised body

Greater body rigidity

Use of high-strength steel parts

Strategy of using common platform for body

parts

Ease of repair demonstrated using door

module as example

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

0.27, making it the best in its class.

Accounting for the projected vehicle area (A) of

2.1 m

, aerodynamic drag is (Cd x A) = 0.567 m

A = 2.1 m

191/02

191/72

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