Passat 2011

Service Training
Self-study Programme 488
The Passat 2011

The Passat 2011
In its seventh generation, the new Passat has been perfected in terms of comfort, quality and safety attributes as
well as in the range of driver assistance systems offered.
Straight lines, clearly structured surfaces and dynamic proportions distinguish the design of the new generation
saloon and estate.
New experiences in comfort are achieved by the rear seat system that can be released from the luggage
compartment, a trailer hitch that folds out at the press of a button, noise insulating laminated safety glass for the
windscreen and front side windows and 2nd generation park assist steering system.
Highly efficient and eco-friendly TSI engines, TDI CR lightweight engines, a natural gas powered engine and an
engine of the newest generation that can be powered with up to 85% ethanol in the vehicle.
Engine downsizing, the start-stop system and regenerative braking facilitate a significant saving in fuel
consumption during operation.
The Front Assist system with automatic City Emergency Brake (braking function) and the Fatigue Detection System
are new and progressive functions in the area of safety.
With its high level of quality, the new Passat generation bridges a gap to the next highest vehicle category.
S488_043
S488_045
The self-study programme portrays the For current testing, adjustment and repair
design and function of new instructions, refer to the relevant service literature.
Caution
developments.
The contents will not be updated. Note
2
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Occupant protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Driver assist systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Convenience electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Radio, navigation and telephone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Heating and air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3
Introduction
The Passat 2011

The overview indicates important series production and optional equipment features of the new Passat. The range
of options depends on the equipment lines: Trendline, Comfortline and Highline. Deviations may be possible
depending on the country.
● Bi-xenon headlights with dynamic light assist and ● Windscreen with acoustic laminated glass
LED day driving lights, optional ● Heated windscreen, optional
● LED tail lights ● Front side windows with acoustic laminated glass,
● Main beam assist for halogen headlights, optional
optional ● Sliding/tilting electric solar roof, optional*
S488_007
● Luggage compartment lid with automatic ● Adaptive cruise control ACC

opening* ● Front Assist with City Emergency Brake
● Dual clutch gearbox with freewheel function, ● 2nd generation park assist steering, optional
optional ● Fatigue Detection System
● Adaptive chassis control DCC, optional
* Only saloon
4
● "Premium" cellphone preparation, optional ● Panoramic sliding roof, optional**
● Air conditioning system ● Electromechanical parking brake
● Keyless access inc. start button, optional ● Electric opening and closing rear lid, optional**
S488_009
● Head restraints adjustable in X-direction ● Trailer hitch with folding feature and electric
● Rear seat backrest with remote release release
● Climate control seat with massage function, ● Luggage compartment management, optional**
optional ● Convenient opening of luggage compartment
cover**
** Only estate
5
Introduction
Technical data
Exterior dimensions and weights
The details for the Passat saloon 2011 and the estate 2011 are based on a vehicle without driver, with standard
equipment, 1.4l 90kW TSI engine and 205/55 R16 tyres.
S488_029
941mm 2712mm 1116mm
4769mm
1470mm
1552mm 1551mm
1820mm
Exterior dimensions Weights/further details
Passat saloon 2006 2011 Passat saloon 2006 2011

Length 4765mm 4769mm Gross vehicle weight 1950kg 1990kg
Width 1820mm 1820mm Kerb weight 1391kg 1365kg
Height 1472mm 1470mm Max. trailer load, braked 1300kg 1400kg
Wheelbase 2710mm 2712mm Max. roof load 100kg 100kg
Track width at front 1552mm 1552mm Tank capacity 70litres 70litres
Track width at rear 1551mm 1551mm Drag coefficient 0.295cd 0.291cd
Turning circle 11.4m 11.4m
6
S488_031
941mm 2712mm 1118mm
4771mm
1516mm
1552mm 1551mm
1820mm
Exterior dimensions Weights/further details
Passat estate 2006 2011 Passat estate 2006 2011

Length 4774mm 4771mm Gross vehicle weight 1950kg 2070kg
Width 1820mm 1820 mm Kerb weight 1391kg 1402kg
Height (with roof rails) 1516mm 1516mm Max. trailer load, braked 1300kg 1400kg
Wheelbase 2710mm 2712mm Max. roof load 100kg 100kg
Track width at front 1552mm 1552mm Tank capacity 70 litres 70 litres
Track width at rear 1551mm 1551mm Drag coefficient 0.304cd 0.298cd
7
Introduction
Interior dimensions and volumes
961 mm
mm
1022
S488_033 859mm
1797mm
332mm
1766mm
565litres
729mm
S488_037 1014mm
Passat saloon 2006 2011 Passat saloon 2006 2011

Luggage compartment volume 565litres 565litres Interior length 1797mm 1797mm
Height of rear lid 1756mm 1766mm Interior length 2nd seat row 859mm 859mm
Height of load sill 729mm 729mm Front headroom 1022mm 1022mm
Cargo area height 332mm 332mm Headroom 2nd seat row 961mm 961mm
Width of cargo area/wheel 1014mm 1014mm Knee room 2nd seat row 91mm 76mm
housing
8
m
m
980 m
1018 m
S488_035 859mm
1797mm
719mm
2027mm
603litres
624mm
S488_039 1003mm
Passat estate 2006 2011 Passat estate 2006 2011

Luggage compartment volume 603litres 603litres Interior length 1797mm 1797mm
Height of rear lid 2058mm 2027mm Interior length 2nd seat row 859mm 859mm
Height of load sill 624mm 624mm Front headroom 1018mm 1018mm
Cargo area height 719mm 719mm Headroom 2nd seat row 980mm 980mm
Width of cargo area at wheel 1000mm 1003mm Knee room 2nd seat row 91mm 76mm
housing
9
Body
Body structure
The main aim during development of the body was to increase the body strength whilst, at the same time, reducing
weight. The bodies of the new Passat saloon and Passat estate are the same as the tried and tested 2006 model
series and have been further improved.
Scope of modifications to Passat saloon

● Bonnet ● Side panel
● Rear lid ● A-pillar and door frame
● Wings ● Rear panel
● Outer skin of doors
S488_032
Key
Carried over
New
10
Scope of modifications to Passat estate
● Bonnet ● Roof
● Rear lid ● Side panel
● Wings ● A-pillar and door frame
● Doors ● D-pillar
● Rear panel
S488_030
11
Body
Windscreen with acoustic laminated glass

The windscreen in the Passat 2011 features acoustic laminated glass as standard. Furthermore, the windows in the
front doors are also available as an option with acoustic laminated glass. The use of acoustic PVB in the door
windows makes it possible to achieve a noise reduction of approx. 2-4 dB in the interior. Furthermore, a heated
windscreen can be ordered for the first time in the Passat in conjunction with heat reflective glass.
S488_041
Windscreen with acoustic laminated glass Conventional windscreen

PVB film
Outer glass (0.33mm) Outer glass
(2.1mm) (2.1mm)
Acoustic PVB film PVB film
Inner glass (0.1mm) (0.76mm) Inner glass
(1.6mm) PVB film (1.6mm)
S488_036 (0.33mm) S488_034
Door window (TSG) with acoustic glass Standard door window (safety glass)
PVB film
Outer glass (0.33mm)
1.6mm)
Acoustic PVB film Safety glass
Inner glass (0.1mm) (3.85mm)
(1.6mm) PVB film
S488_044 (0.33mm) S488_038
Compared with conventional door windows, there is a change to the software in the door control unit
on vehicles with acoustic door windows, and the window retainer in the door is also different. This
must be taken account of in the event of retroinstallation and repairs.
12
The luggage compartment
In the Passat estate, the following special features should be noted:
● the additional partition

● the sliding cargo floor
S488_047
Cargo floor Remote release
Sliding cargo floor Remote release of

rear seat backrest
● Variable stowage space
● Different locking positions possible The new remote release of the rear seat backrest
● Removable cargo floor makes release possible from the luggage
● Withstands up to 100kg compartment. The function is a standard feature from
the Trendline equipment level.
Cargo floor position
In the saloon and estate model, the rear bench seat

has a 60/40 split folding backrest.
13
Body
Halogen headlights
On this headlight module, the dipped beam and main beam are designed as separate H7 headlights. The side light
is integrated into the dipped beam headlight.
Dynamic light assist is not available for this module. As an option, the main beam assist function is available in
conjunction with halogen headlights.
Dipped beam, H7 (55W) Main beam, H7 (55W)
Side light (5W)
Turn signal (24W)
S488_013
S488_064
Light module in bumper Day driving light (21W) Fog and cornering light
(H8, 35W)
In conjunction with H7 headlights, the cornering, fog
and day driving lights feature two separate bulbs.
14
Xenon headlights with LED
On this headlight unit, the dipped beam and main beam are integrated into the xenon module (D3S 35W). It
features LED daytime running lights and side light. Fifteen individual LEDs are located around the xenon module.
The amount of power drawn by the day driving lights is reduced to approx. 30watts compared with approx. 140 to
180watts on daytime headlights with dipped beam activated.
The xenon headlight always comes with the dynamic cornering light. Dynamic light assist (DLA) is available as an
option. Main beam assist cannot be combined with the xenon headlight.
Dipped beam and main beam, Daytime runing light and side light
Turn signal (24W) xenon (D3S 35W) (15 LEDs with total 30W)
S488_011
S488_064
Light module in bumper

Cornering light (35W) Fog light (35W)
In conjunction with xenon headlights, the cornering

and fog lights feature two separate bulbs.
15
Body
Tail lights
The tail lights of the Passat 2011 have a two part design. Only the outer lights are secured by a central bolt.
Tail light Reflector (in trim)

Brake light Tail light
Turn signal
(21W)
S488_050
Reflector (in lens) Reversing light Rear fog light

(16W) (LED 2.2W)
LED tail lights

Access to the securing screws is on the left and right above the covers in the luggage compartment side panels.
Tail and brake light Reflector (in lens)
Reflector
(in lens)
S488_048
Turn signal (21W) Reversing light Rear fog light

(16W) (3xLED; 3W total)
16
Interior equipment
Head restraints with X-
adjustment
Once the release mechanism has been activated, the
head restraints in the Passat can be adjusted at the
base to be further away from or closer to the neck.
This helps to achieve an optimal position of the head
restraint, which, in addition to comfort, also enhances
Release
safety.
S488_052
Stowage facilities
Front
There are many multifunctional stowage compartments in he Passat. A centre armrest, which opens to reveal a
compartment, is an option in both the saloon and the estate.
Storage under AC controls Glove compartment Door compartment

S488_068
Small glove compartment by Storage in centre console Storage in centre armrest with cellphone
steering wheel with drink/can holder charging cradle and compartment beneath
17
Body
In rear
Stowage pockets on
Rear door compartment back of front seats
S488_066
Storage compartment Drink/can holder 12 volt connection

in centre armrest
18
Occupant protection
Safety equipment
The new Passat is equipped as standard with six airbags: Driver and front passenger airbag, side airbags at front
and curtain airbags for front and rear passengers. As an option, two side airbags are available for the rear seats.
The crash sensors ensure that all airbags trigger safely.
Curtain airbag
The curtain airbag of the Passat 2011 ensures the
safety of occupants in all seat rows in the head and
shoulder area.
S488_015
Side crash sensor

Front doors
Side crash sensor

C-pillar
Side crash sensors

The side crash sensors in the bottom area of the front
doors are designed as pressure sensors. Lateral
acceleration sensors to detect side impact are located
in the C-pillar.
19
Engines
Engine/gearbox combinations
1.4l 90kW 1.4l 110kW 1.4l 118kW 1.8l 118kW

Petrol engine
TSI engine TSI engine TSI engine TSI engine
with turbocharger with dual charging with dual charging with 4-valve
technology
Diesel engine
R+S R R R
6-speed
manual gearbox
MQ200-6F
0AJ
6-speed
manual gearbox
MQ250-6F
02S
6-speed
manual gearbox
MQ350-6F
02Q
6-speed
dual clutch gearbox
DQ250-6F
02E
7-speed
dual clutch gearbox
DQ200-7F
0AM
R = with regenerative braking; S = with start-stop system (optional equipment)
20
2.0l 155kW 3.6l 220kW 1.6l 77kW 2.0l 103kW 2.0l 125kW
TSI engine FSI engine TDI CR engine TDI CR engine TDI CR engine
with 4-valve with 4-valve
technology and technology
turbocharger
R R R+S R+S R+S
MQ350-6F/A
DQ250-6A DQ250-6F/A
F = front-wheel drive; A = four-wheel drive
21
Engines
1.4l 90kW TSI engine with turbocharger
This engine has found application in other vehicle

models and was carried over.
Technical features
● Homogeneous mode (lambda 1)

● Turbocharger with wastegate
● Dual circuit cooling system
● Air-to-liquid charge air cooling
● Regulated duo-centric oil pump
● Demand-based fuel system
● High pressure fuel pump with integrated pressure S488_201
limiting valve
Further information on this engine can be

found in self-study programme
no. 405 "The 1.4l 90kW TSI engine with
turbocharger".
Technical data Torque and power diagram
250 100
Engine code CAXA
Type 4-cylinder in-line engine 225 90
Displacement 1390cm3
200 80
Bore 76.5mm
Stroke 75.6mm 175 70
Valves per cylinder 4 150 60
Torque [ Nm]
Output [kW]
Compression ratio 10:1

125 50
Maximum output 90kW at
5000 rpm 100 40
Maximum torque 200Nm at
1500 to 4000 rpm 75 30
Engine management Bosch Motronic MED 17.5.5 50 20
Fuel Super unleaded RON 95
25 10
Exhaust gas treatment 3-way catalytic converter,
broadband lambda probe 0 0
upstream and regular 1000 3000 5000 7000
lambda probe downstream of Engine speed [rpm]
catalytic converter S488_200
Emissions standard EU5
22
1.4l 110kW TSI engine with dual charging (EcoFuel)
This engine is practically the same as the EcoFuel

engine of the Passat 2010. Items changed are the
electronic gas pressure regulator and gas inlet valves.
Their function has remained the same, however.
Technical features
● One engine control unit for natural gas and petrol

operation
● Homogeneous mode (Lambda 1) in both operating
modes
● Mechanical supercharger that can be activated
separately S488_231
● Mechanical pressure reduction stage discontinued
on electronic gas pressure regulator Further information on this engine can be
● Optimised gas inlet valves, thereby making engine found in self-study programme no. 359
start possible from -10 °C in natural gas mode "The 1.4l TSI engine with dual charging" and
no. 425 "EcoFuel natural gas power with 1.4l
110kW TSI engine".
Engine code CDGA

260 120
Type 4-cylinder in-line engine
Displacement 1390cm3 240 110
Bore 76.5mm 100
220
Stroke 75.6mm
Compression ratio 10:1 180 80
Torque [ Nm]
Output [kW]
Maximum output 110kW at 5500 rpm

160 70
1500 rpm to 4500 rpm 140 60
Engine management Bosch Motronic MED 17.1
120 50
Fuel Natural gas H (high)
Natural gas L (low) with 100 40
reduced range
Super unleaded RON 95 80 30
Exhaust gas Main catalytic converter,
60 20
treatment lambda control
1000 3000 5000 7000
Emissions standard EU5 Engine speed [rpm]
S488_216
23
Engines
1.4l 118kW TSI engine with dual charging (MultiFuel)
This engine was first used as a bioethanol

version. First introduced in Sweden and Finland.
Technical features
● Bioethanol compatible up to 85%

● Fuel quality sender for detection of bioethanol
content in fuel
● Electric engine preheater in cooling system
● Cylinder head of 1.4l 110kW TSI EcoFuel engine
● Homogeneous mode (lambda 1)
S488_203
● Mechanical supercharger that can be activated
separately
● High pressure fuel pump with a specially coated Further information on this engine
pump piston that reduces friction and wear can be found in self-study programme
no. 359 "The 1.4l TSI engine with dual
charging".
280 120
Engine code CKMA
Displacement 1390cm³ 240 100
Bore 76.5mm
Torque [ Nm]
Output [kW]
Compression ratio 10:1

180 70
Maximum torque 240Nm at 160 60
2000 to 4500 rpm
140 50
Fuel Super unleaded RON 95 120 40
Ethanol can be mixed up to
85% (E85) in all conditions 100 30
Exhaust gas treatment 3-way catalytic converter, 80 20
broadband lambda probe 1000 3000 5000 7000
upstream and regular
Engine speed [rpm]
lambda probe downstream of S488_202
catalytic converter
24
1.8l 118kW TSI engine with 4-valve technology
The 1.8l TSI engine designated EA888 is a technically
optimised further development of the familiar 4-
cylinder EA113 engine series. Tried and tested engine
components have been consistently further
developed. The engine also finds application in the
Golf GTI.
Technical features
● Improved pedestrian impact protection

S488_227
● Significant improvement in comfort and acoustics
● Balancer shaft system with two shafts, offset in
height and each with three bearings
● Reduced repair complexity thanks to modified
housing of oil filter module
● Base engine configured for a very broad
performance range Further information on this engine can be
● The turbocharger pressure unit can be exchanged found in self-study programme no. 401
and adjusted. "The 1.8l 118kW TFSI engine with timing
chain".
280 120
Engine code CDAA
Displacement 1799cm3 100
240
Bore 82.5mm
Torque [ Nm]
Output [kW]
Compression ratio 9.8:1

180 70
4500 to 6200 rpm 160 60
1500 to 4500 rpm 140 50
(Normal unleaded RON 91 100 30
with marginally reduced
80 20
performance) 5000 7000
1000 3000
Exhaust gas treatment Upstream catalytic converter Engine speed [rpm]
in proximity of engine with S488_226
upstream broadband probe,
main catalytic converter with
downstream regular lambda
probe
25
Engines
2.0l 155kW TSI engine with 4-valve technology and

turbocharger
The 2.0l TSI engine also belongs to the in-line 4-
cylinder EA888 engine series. It has the same design
as the 1.8l TSI engine, but with an increased capacity.
Technical features
● The higher displacement is achieved by modified

pistons, conrods and crankshaft.
● The turbocharger pressure unit CANNOT be
exchanged and adjusted.
S488_229

no. 401 "The 1.8l 118kW TFSI engine with
timing chain".
340 200
Engine code CCZB
Bore 82.5mm
280 140
Stroke 92.8mm
Torque [ Nm]
Output [kW]

240 100
5300 to 6200 rpm 220 80
1700 to 5200 rpm 200 60
(Normal unleaded RON 91 160 20
with marginally reduced 140 0
performance) 1000 3000 5000 7000
Exhaust gas treatment Upstream catalytic converter Engine speed [rpm]
in proximity of engine with S488_228
upstream broadband probe,
main catalytic converter with
downstream regular lambda
probe
26
3.6l 220kW FSI engine with 4-valve technology
The 3.6l 220kW FSI engine with 4-valve technology is
a constituent of the VR engine series. Numerous
consumption-optimising measures have been
performed on the 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 S488_233
● One-part oil pump chain sprocket
● Exhaust camshaft adjuster with 32°
setting range
● Vibration damper secured with 7 bolts

no. 360 "The 3.2l and 3.6l FSI engine"
400 240
Engine code BWS
Bore 89mm
340 180
Stroke 96.4mm
Torque [ Nm]
Output [kW]

300 140
Maximum torque 350Nm at 280 120
2400 to 5300 rpm
260 100
Fuel Highest grade unleaded 240 80
with RON 98
(Super unleaded RON 95with 220 60
marginally reduced 200 40
performance) 1000 3000 5000 7000
Exhaust gas treatment Three-way catalytic converter Engine speed [rpm]
with lambda control S488_230
27
Engines
New features of 3.6l 220kW FSI engine

To reduce fuel consumption and the emission of CO2, several consumption optimising features were performed on
the engine. In addition, further innovative developments were implemented in the design of the engine.
Duo-centric oil pump
The entire oil circuit of the engine was improved and the output of the oil pump consequently reduced. In doing so,
it was possible to lower the opening oil pressure from 5.7bar to 3.6bar.
Gasket
Seal
2nd half of housing
Outer rotor S488_026
1st half of housing
Bearing bush
Inner rotor
Radial shaft seal
Spring
Control plunger
Drive shaft Plug
Vibration damper
To ensure secure attachment, the vibration damper is

secured with 7 bolts, as on the Passat R36
(previously one centre bolt).
Bolt attachment
Vibration damper
S488_234
28
Chain tensioner
The lower chain tensioner has been optimised in terms of leaks and works without engagement at a lower oil flow
rate (originally 0.86l/min, now 0.04l/min). Without a locking mechanism it was possible to reduce the chain forces.
The spring serves to pretension the chain during cold starting. The ram serves purely to fill the void in the hollow
control plunger and thereby facilitates faster response from the chain tensioner when oil pressure is building up.
Chain tensioner module
Housing Choke bore
Guide rail S488_036
Control plunger Ram Pretensioning

spring
The choke bore must not be punched

S488_038 through or cleaned using any kind of tool.
Chain sprocket
Marking for primary
chain drive The oil pump chain sprocket has a one-piece design
to prevent incorrect fitment.
Marking for
S488_060 camshaft timing
chain drive
29
Engines
Camshaft adjuster
Range of adjustment
The exhaust camshaft adjuster only works in a 32° 32°
range of crankshaft adjustment. At idle, less exhaust
gas flows back into the inlet port, which means
residual gas compression no longer occurs.
Engine running is thus smoother and consumption at
idling speed is reduced by about 3-5%
Camshaft adjuster
S488_028
Camshaft adjuster cover
Located between the camshaft adjuster cover and the

cylinder head is a seal.
The seal optimises oil supply to the camshaft adjuster,
which in turn raises its adjustment speed.
Cover for
S488_239
camshaft adjuster
Seal
30
1.6l 77kW TDI CR engine
The 1.6l TDI CR engine, already tried and tested in the
Polo 2010, was further developed for use in the Passat
2011.
Technical features
● Common rail injection system with piezo injectors.

● EGR module with exhaust gas recirculation valve
and exhaust gas recirculation cooler.
● Plastic intake manifold without swirl plate
adjustment
● Spur gear drive for camshafts without
tooth backlash compensation S488_205
● Fuel high pressure pump without sprocket
for pressurisation pump
The design and function of the

1.6l TDI CR engine is described in self-study
programme no. 442 "The 1.6l 77kW TDI
engine with common rail injection system".
Engine code CAYC 280 100

Displacement 1598cm3
240 80
Bore 79.5mm
Valves per cylinder 4
200 60
Torque [ Nm]
Output [kW]

Maximum output 77kW at 4400 rpm 180 50
Maximum torque 250Nm at 1500-2500 rpm 160 40
Engine management Simos PCR2.1
140 30
Fuel Diesel complying with DIN
EN590 120 20
Exhaust gas Exhaust gas recirculation,
treatment oxidising catalytic converter 100 10
and diesel particulate filter
0 10
Emissions standard EU5 S488_204
1000 3000 5000
Engine speed [rpm]
31
Engines
2.0l 103/125kW TDI CR engine
Second generation 2.0l TDI CR engines are used in

the Passat 2011. These engines are a further
development of the 2.0l TDI CR engine from the 1st
generation, tried and tested in many Volkswagen
models since 2007. The engine is offered with two
performance levels.
S488_207
Features of 2nd generation 2.0l TDI CR engine
Common rail fuel injection system with solenoid valve

controlled injectors
S488_206
Cylinder head as on 1.6l TDI CR engine with portion of

channel for recirculated gas running through cylinder
head
S488_211
Exhaust gas recirculation module as on 1.6l TDI CR

engine with EGR valve and exhaust gas recirculation
cooler.
S488_209
Plastic intake manifold without swirl plate adjustment
S488_213
32
Nm kW
Output 103kW 125kW
Engine code CFFB CFGB 360 120
Type 4-cylinder in-line engine
340 110
Displacement 19 68cm3
Bore 8 1mm 320 100
Stroke 95 .5mm
300 90
Valves per cylinder 4
Compression ratio 16.0:1 280 80
Maximum output 103kW at 125kW at 260 70
4200 rpm 4200 rpm
Maximum torque 320Nm at 350Nm at 240 60
1750 to 1750 to
220 50
2500 rpm 2500 rpm
Engine management Bosch EDC 17 (common rail 200 40
injection system)
Fuel Diesel complying with DIN 180 30
EN 590 20
160
Exhaust gas treatment Exhaust gas recirculation, 1000 2000 3000 4000 5000
oxidising catalytic rpm
converter, S488_208
diesel particulate filter
Output [kW] - 125kW
Torque [Nm] - 1 25kW
Output [kW] - 103kW
Torque [ Nm] - 1 03kW
● Detailed information about the 2.0l TDI CR engine can be found in self-study programme no. 403
"The 2.0l TDI engine with common rail injection system".
● The design and function of the 1.6l TDI CR engine is described in self-study programme no. 442
"The 1.6l TDI engine with common rail injection system".
● Further information about the solenoid valve controlled injectors can be found in
self-study programme no. 445 "The Sharan 2011".
● In combination with the 2.0l 103kW TDI CR engine, the Passat 2011 can also be equipped with the
"Selective Catalytic Reduction" (SCR) exhaust gas treatment system as a Blue TDI version.
The SCR system serves as a means of reducing nitrogen oxide emissions and is described in detail in
self-study programme no. 424 "The exhaust gas treatment system: Selective catalytic reduction".
33
Engines
Fuel system for TDI engines

The overview shown represents the fuel system of the 2.0l TDI engine.
1 - Fuel system pressurisation pump G6

8
The fuel pump builds up pressure in the fuel supply
line.
2 - Fuel filter
The fuel filter keeps impurities in the diesel fuel away

from the components of the injection system. The high
precision components, for example, the high pressure
pump and the injectors, can be damaged or their 3 5
function impaired by even the most minute particles of
dirt.
3 - Fuel temperature sender G81
4
The fuel temperature sender measures the current fuel
temperature.
4 - High pressure pump
The high pressure pump generates the

fuel high pressure required for injection.
2
5 - Fuel metering valve N290
The fuel metering valve regulates the quantity of fuel

needed to generate the high pressure as required.
34
6 - Fuel pressure regulating valve N276
6
7
The fuel pressure regulating valve sets the
fuel pressure in the high pressure range.
7 - High pressure accumulator (rail)
The high pressure accumulator keeps the fuel

required for injection under high pressure for all
9 cylinders.
8 - Fuel pressure sender G247

10 10 10 10
The fuel pressure sender determines the current
fuel pressure in the high pressure range.
9 - Pressure retention valve
The pressure retention valve ensures that pressure

remains constant in the return flow to the injectors.
In this way fluctuations in pressure are avoided,
thereby making precise control of the injectors
possible.
10 - Injectors N30, N31, N32, N33

S488_220
1 The injectors inject fuel into the combustion chambers.
Colour coding/key
High pressure
Supply pressure
Return pressure from injectors
Return pressure
35
Engines
Fuel system pressurisation pump G6
In the fuel system of the 1.6l TDI CR engine and the 2.0l TDI CR engines, the fuel system pressurisation pump
generates the fuel pressure required for the low pressure system in the fuel tank.
As a consequence, the gear-type pump used in the high pressure pump of the previous model in the fuel system of
the 1.6l TDI CR engine is no longer required. Likewise, the electric pressurisation pump in the supply line of the low
pressure fuel system of the 2.0 l TDI CR engine has been discontinued.
The fuel system pressurisation pump in the Passat 2011 is an electrically driven internal gear pump. It is located in
the fuel delivery unit GX1. In the fuel pressurisation system for diesel engines, the pump generates a pressure of
approx. 6bar. This ensures that the high pressure pump is supplied with sufficient fuel in all operating conditions.
A valve in the high pressure pump reduces the fuel pressure generated by the fuel system pressurisation pump in
the fuel supply line to approx. 5 bar. This maintains a constant level of pressure in the fuel supply line.
The fuel pump is activated by the engine control unit via a relay when the engine is started.
Design of fuel delivery unit GX1
Fuel line for

auxiliary heater
Fuel supply
Fuel return
Electrical connection
Fuel system
pressurisation pump G6
S488_215
Effects in event of failure
The engine will not run if the fuel system pressurisation pump fails.
36
Power transmission
Dual clutch gearbox with freewheel function
Steady consumption Overrun cut-off

Speed [km/h]
Coasting Overrun cut-off
Distance [m] S488_240
Dual clutch gearbox without freewheel function

Dual clutch gearbox with freewheel function
The 6-speed dual clutch gearbox 02E and the 7-speed dual clutch gearbox 0AM can be ordered for the the new
Passat with a freewheel function.
The role of the freewheel function is to isolate the engine from the gearbox at overrun. This is made possible by
opening the dual clutch. The engine turns at idling speed and the vehicle coasts without any engine braking effect.
With the freewheel function and by driving with foresight, fuel can be saved.
The freewheel function is only possible with the selector lever in the "D" position. If the selector lever is in the "S"
position or in the tiptronic gate, or if the driver presses the brake, the freewheel function is suppressed.
Not until the engine is placed under load again is the freewheel function reactivated.
On dual clutch gearboxes with freewheel

function, the gear shift points with the
selector lever in "S" are only marginally
higher than those in the "D" position.
37
Power transmission
Overview of gearboxes
Manual gearbox
Gearbox type Technical features Further

information
6-speed ● Further development of 0AG gearbox SSP 237
manual gearbox ● Adapted for 1.4l 90kW TSI engine, gap between pinion shaft SSP 306
MQ200-6F 0AJ and differential increased, sheet metal bearing support replaced
by cast metal bearing support for higher torque, teeth ground
● Final drive uprated
● Without speedometer sender
● CO2-optimised gear ratios
● Torque capacity up to 200Nm
6-speed ● Further development from 0A4 SSP 99

manual gearbox ● Longer shafts with additional bearings, additional gear pair, SSP 306
MQ250-6F 02S new longer housing lid made from aluminium
● CO2-optimised gear ratios
6-speed ● Further development of 02M gearbox SSP 205

manual gearbox ● Changes to selector shaft, selector forks with stops in housing, SSP 306
MQ350-6F 02Q modified bearings
38
Dual clutch gearbox
Gearbox type Technical features Further

information
6-speed The 6-speed dual clutch gearbox 02E is equipped with a hydraulic SSP 308
dual clutch gearbox dual clutch. It combines the high level of efficiency as well as
DQ250-6F DSG 02E sturdiness and sportiness of a manual gearbox with the high level of
comfort of an automatic gearbox during gear changes.
7-speed The 7-speed dual clutch gearbox 0AM is a further development of the SSP 390
dual clutch gearbox 6-speed dual clutch gearbox 02E.
DQ200-7F 0AM Unlike the 02E, it works with a dry-plate dual clutch and separate oil
circuits for the gearbox and mechatronics.
Another difference to the 02E is that the electric oil pump for the
hydraulics is only actuated by the control unit when required.
Actuation occurs once hydraulic pressure in the mechatronics drops
below a certain value, necessitating an increase in pressure again in
order to assure operability of the mechatronics.
39
Running gear
Overview
The Passat 2011 offers the highest level of driving comfort thanks to its running gear configuration. The running
gear is based in essence on the tried and tested running gear of the Passat 2006. Sporty and standard running
gear versions are available, as well as adaptive chassis control DCC.
● Extended EDL (XDS)
● Lightweight McPherson strut

front suspension
● Parallel axis power steering (APA)
● ESP/ABS TRW 450M
● Tyre pressure monitoring

TPM with auto location
● Adaptive chassis control DCC,

optional
● Further details about the power steering system can be found in self-study programme
no. 399 "The electromechanical steering with parallel axis drive".
● For further details about the adaptive chassis control, see self-study programme no. 406
"The adaptive chassis control DCC".
40
● AUTO HOLD function
● Electromechanical parking brake
● Four-link rear suspension
S488_027
● Auto leveling on rear axle,
optional
● Fatigue Detection System (FDS)
● ContiSeal tyres from 17" rims
● Further details about the self-leveling system can be found in

self-study programme no. 357 "The Nivomat".
● Further details about the parking brake can be found in
self-study programme no. 346 "The electromechanical parking brake".
41
Running gear
Extended EDL (XDS)

The Volkswagen Passat 2011 is equipped with the ESP extension XDS on vehicles with diesel engines from 125kW
and on vehicles with petrol engines from 220kW. XDS keeps the wheel on the inside of the corner within the slip
limit during fast cornering. Up to a defined torque level, XDS decelerates the wheel on the inside of the corner, thus
enabling any increase in torque at the vertex to be offset against the wheel on the outside of the corner. This
feature only works if the vehicle is accelerated in the corner and sufficient torque is available. The effect is greater
in tight bends in 2nd or 3rdgear and at higher road speeds than in bends with larger radii.
Key:
with XDS
without XDS
S488_074
With XDS Without XDS
● Better traction ● Torque at wheels cannot be increased

● Greater agility ● TCS/EDL/engine torque intervention
● Follows line of drive better due to less steering
angle requirement
● Reduced tendency to understeer
● Greater speed out of corners possible
XDS already finds application in the Golf 6

GTI/GTD and Polo 5 GTI.
42
Tyre pressure monitoring TPM with auto location
A new, direct measuring tyre pressure monitoring system is employed in the Passat. As before, the system uses
sensors in the tyre that report the inflation pressure to the control unit in the vehicle. With the "auto location"
feature, the system is capable of clearly identifying and displaying any tyre affected by pressure loss. Furthermore,
there is an option of displaying the inflation pressures of all tyres in the dash panel display.
The "intelligent aerial" is a combination of TPM auto location control unit and central reception aerial. It is
connected to the onboard supply via the extended CAN. Term.15, the speed signal and the reversing signal serve
as input parameters. The "intelligent aerial" can be found on the outside of the body in the rear (vicinity of spare
wheel well) in a place where reception is favourable.
S488_078
S488_080 Vehicle status
Example of display in
dash panel insert
TPM auto location control unit Dash panel insert with Wheel electronics with detection
with central reception aerial controls of rotational direction
Key:
Reception with high level (rear) Reception with low level (front)
Once the vehicle is in motion, the electronics in each With the direction of rotation data, it is possible even
wheel start sending data telegrams. Some of the after a short time of driving for each set of electronics
information these data telegrams contain is as to be allocated to the individual wheels. In line with
follows: this, the front and rear are identified by a level
assessment (which is why the reception aerial is
● ID (identification) positioned on the rear bumper). This makes it possible
● Pressure to clearly identify the location of every set of wheel
● Temperature electronics.
● Direction of rotation
43
Driver assist systems
Fatigue Detection System (FDS)

Driver fatigue is detected by monitoring the steering behaviour. The system meets the following criteria:
● Driver alert when fatigue is detected

● Fatigue monitoring only on motorways, dual carriageways and wide A roads
● Does not become operable until above 65km/h
● No imminent warning in event of microsleep
Function and display

The system stores a reference map in the gateway control unit based on the steering behaviour during the first 15
minutes of driving. A comparison of the driver's current steering response with this reference map is carried out and
evaluated. An alert is issued no earlier than 15 minutes of continual driving.
Displays in dash panel insert (example of German versions)
S488_138
S488_136 S488_076
"Lowline" "Highline" "Premium"
The function analyses the driver's behaviour while driving the vehicle and detects driver fatigue from certain
patterns. The function cannot detect fatigue among all drivers as not all drivers demonstrate the same typical
steering behaviour.
If the behaviour falls into the fatigue category, the driver is alerted for 5 seconds by a message in the dash panel
and a gong. If the driver fails to take a break within the next 15 minutes, the message and gong are repeated. No
further message is given once it has been repeated. When the ignition is switched off, the reference map is cleared.
44
Adaptive Cruise Control (ACC)
Adaptive Cruise Control (ACC) regulates the speed and the distance of the vehicle in relation to the traffic ahead at
a value predetermined by the driver. In all situations, the driver remains master of the situation in as far as the
system can be switched off or the intervention can be interrupted at any time by pressing the brake or accelerator
pedal.
The Front Assist feature integrated in the ACC helps as an "alert co-driver" to avoid any collision with moving traffic
– remaining alert even when the ACC is switched off.
The new City Emergency Brake function also reacts to parked vehicles at speeds below 30km/h. In the event of
danger, it initiates a brake manoeuvre and can thereby help to avoid an imminent collision or reduce the amount
of damage caused as a result.
Terminology for driver assist systems
Name Formerly Short description of function

known as
ACC ADC Maintains specific distance in relation to vehicle travelling ahead and adapts speed
(Adaptive Cruise dynamically to traffic flow.
Control)
Front Assist Front Scan Conditions vehicle, alerts driver to hazardous situations and improves
driving dynamics during overtaking manoeuvres. Reacts to moving vehicles
only at speeds greater than 30km/h.
City Emergency N/A Co-function of front assist. Automatically brakes the vehicle prior to a
Brake collision. Reacts to moving and stationary vehicles at speeds less than
30km/h.
Brake interventions avoid accidents only in

exceptional circumstances.
Function
If the road ahead is clear, ACC moderately accelerates the vehicle up
to the desired (set) speed. If a vehicle travelling ahead in the same
lane is moving more slowly, the system brakes so that the vehicle
ahead can be followed comfortably.
S488_090
45
Optimised lane change function

When the turn signal is activated, the system detects an intention to overtake and improves the dynamics while
taking safe distances into account.
Veering out Example (80km/h set)
If, with the ACC active, the Passat approaches a

1) Appr oaching a slower
vehicle travelling ahead, all that is required is for the vehicle. Speed adapted to
turn signal to be activated and the Passat will target.
accelerate up to the set speed when veering out. In
this way, the vehicle can be overtaken comfortably.
ACC helps to maintain the safe distance 2) Driver indicates and veers out:
automatically. system accelerates automatically
to 80km/h.
S488_122
Veering in
If the driver activates the turn signal after the vehicle

has been overtaken, the road speed is reduced back 3) Driv er indicates.
to the value set in the ACC.
4) Driver veers in: automatic follow-on

with ACC set to 80km/h.
S488_124
Go Trigger
In combination with a DSG gearbox, the vehicle can As soon as the vehicle travelling ahead gains distance
be brought to a halt when following traffic (follow to and the driver briefly presses the accelerator, the ACC
stop). A safe distance is taken into account in this case. takes up its control function again immediately (Go
Trigger).
Vehicle brought to halt

within safe distance Go Trigger
S488_126 S488_128
46
Front Assist
General description
Front Assist aids as an "alert co-driver" in certain situations to avoid collisions with traffic - even with the ACC
switched off. The new Front Assist is now capable of considerably more. In a manner of speaking it is an "alert co-
driver with its own brake pedal". Even before the situation reaches a critical point, measures are taken unbeknown
to the driver. The aim of Front Assist is to minimise the stopping distance in critical situations.
Interplay of ACC and Front Assist

The ACC and Front Assist functions are housed in one control unit, although they are two separate components.
Front Assist works independently of the ACC status. It also remains active when the driver switches off the ACC.
Decisive for the functional readiness of Front Assist is the display of the status LEDs.
LED green: Front Assist switched on and ready to intervene.
LED yellow: Front Assist switched on but function sometimes impaired -

e.g. blocked sensor, overheated brakes, etc.
LED off: Front Assist switched off or malfunction.
S488_082
Caution!
Front Assist does not intervene until just before a collision!

Interventions avoid accidents only in exceptional circumstances.
47
Overview of Front Assist co-functions

1. Vehicle conditioning
Vehicle conditioning works in a speed range of 5km/h to 210km/h. The vehicle is prepared for the driver to
perform an emergency stop:
● Prefill function (brake pads against brake discs).

● Hydraulic brake assist (HBA) trigger threshold adapted to highest sensitivity.
2. Driver alert
The driver alert is issued in a speed range from 30km/h to 210km/h. The driver is alerted in two stages:
● Preliminary warning: Warning sound and warning symbol in multifunction display.

● Main warning: Warning jolt.
3. Active brake interventions
Active brake interventions take place in a speed range from 5km/h to 210km/h. There are two types of operation:
● Target braking (braking pressure imparted by driver is boosted).

● Automatic partial braking (APB) in cases where the driver fails to react.
In a speed range from 5km/h to 30km/h, automatic partial braking is also referred to as
the "City Emergency Brake" function.
City Emergency Brake

In a speed range from 5km/h to 30km/h, automatic partial braking carries the name "City Emergency Brake". The
main difference compared with braking at speeds above 30km/h is that the city brake also reacts to stationary
vehicles. Furthermore, in the event of an immediate risk of collision there is no warning jolt, nor is the vehicle
decelerated (APB pilot stage). If a collision cannot be avoided, the vehicle is decelerated at a rate of 6.0m/s2.
48
Overview of Front Assist and City Emergency Brake
The following graph shows the sequence if a risk of collision is detected and the driver shows no reaction.
Risk of collision: Collision

Marginal Raised Highest
S488_084 HBA Warning jolt APB pilot stage APB main stage
sensitive
HBA = Hydraulic Brake Assist; APB = Automatic Partial Braking
Marginal Raised Highest

risk of collision risk of collision risk of collision
Optical and acoustic warning Warning jolt and APB pilot APB main stage
Front Assist signal, stage (Brake deceleration 3.5m/s2)
Speed of obstacle greater HBA changeover, (Brake deceleration 1m/s2)
than 30km/h braking system prefilled
HBA changeover, - APB ain stage m

City Emergency Brake braking system prefilled (Brake deceleration 6.0m/s2)
Speed of obstacle less than
30km/h
If the driver intervenes by braking every time there is a risk of collision, the system supports him/her by
boosting the brake pressure. In doing so, the system attempts to keep any potential accident damage as
minimal as possible.
49
Park assist steering 2.0

The new park assist steering 2.0 represents a marked improvement over the previous park assist steering 1.0 and
also park assist steering 1.5. With this new semi-automatic parking system, parking in bays perpendicular to the
road is made possible and parking in even tighter parking spaces parallel to the road (kerb-side parking) has been
made much easier. It is now possible, for example, to
- park fully or partly on kerbs,

- park between trees and other obstacles and
- park on bends.
S488_092
It is still possible to drive out of kerb-side parking spaces with this system and the process of entering or exiting can
be done in several stages. As the first parking system of its kind, park assist steering 2.0 includes active braking
support.
Further information about this new parking system can be found in

self-study programme no. 494 "Park assist steering 2.0".
50
Electrical system
Overview
The Passat 2011 is equipped with state-of-the-art technology.
S488_051
● KESSY with separate ignition ● Main beam assist ● Multifunction camera,

and engine start button optional
● Dynamic light assist, ● Lane departure warning ● Control unit for terminal and
optional with steering intervention engine start control J942
● 2nd generation park assist ● Heated windscreen, optional

steering, optional
51
Electrical system
System overview
The lane departure warning system, previously used in the Phaeton and Touareg, is now utilised in the Passat 2011.
Also finding application in the VW brand are the new light assist systems 'dynamic light assist' (DLA) and 'main
beam assist'. The following diagram shows the largest possible network, with the Passat fully equipped.
Key
Powertrain CAN data bus
Convenience CAN data bus J364 J412
Infotainment CAN data bus T16

J772 J525
Extended CAN data bus
LIN data bus R78 R/J503
d
CAN data bus line R215
LIN data bus line
Private bus
d - CAN diagnosis J245
k - CAN dash insert
* - or (not both) J394 J533
J810 J285
J301 J519 G397
J764 J393/J362 J345 J400
J453 J527 J386 J926
J255 J387 J927
J605 J501
52
Key
CX1 - Alternator
E313 - Selector lever
G397- Rain and light sensor
J104 - ABS control unit
J234 - Airbag control unit
J245 - Sliding sunroof control unit
J250- Electronically controlled damping control unit
J255 - Climatronic control unit
J285 - Control unit in dash panel insert
J301 - Air conditioning system control unit
J540
J345 - Trailer detector control unit
J362 - Immobilizer control unit
J364 - Auxiliary heater control unit
J367 - Battery monitor control unit
J500 J104 J386 - Driver door control unit
J387 - Front passenger door control unit
J393 - Convenience system central control unit
J623 J743
J394 - Roof roller blind control unit
J400- Wiper motor control unit
J234 J791/J446* J412 - Mobile telephone operating electronics control unit
J428 - Control unit for adaptive cruise control
J446 - Parking aid control unit
E313 J492 J453 - Multifunction steering wheel control unit
J492 - Four-wheel drive control unit
J250 J844 J500- Power steering control unit
J501 - Multifunction unit control unit
J502- Tyre pressure monitor control unit
J503 - Control unit with display for radio and
navigation system
J519 - Onboard supply control unit
CX1 J525 - Digital sound package control unit
J527 - Steering column electronics control unit
J367 J533 - Data bus diagnosis interface (gateway)
J540 - Control unit for electromechanical parking brake
J605 - Rear lid control unit
J623 - Engine control unit
J667 - Power output module for left headlight
J668 - Power output module for right headlight
J743 - Mechatronic unit for direct shift gearbox
J745 - Cornering light and headlight range control unit
J764 - Electronic steering column lock control unit
J772 - Reversing camera system control unit
J791 - Control unit for park assist steering
J428 R242 J810 - Driver seat adjustment control unit
J844 - Main beam assist control unit
(except with R242 and J745)
J502 J745 J926 - Rear door control unit, driver side
J927 - Rear door control unit, front passenger side
R78 - TV tuner
R215 - Interface for external multimedia devices
R242- Front camera for driver assist systems
J667 J668 (except with J844)
T16 - 16-pin connector
S488_010 Y - Analogue clock
53
Electrical system
The control unit for terminal and engine start control
For the first time, a terminal control unit finds application in the new Passat. It serves on one hand to actuate the
terminals in advance as a link between the onboard supply control unit and the control elements of the electronic
ignition lock. On the other hand, it serves to emulate the terminals for the newly added ignition starter button (ISB).
The terminal control unit is only installed in conjunction with KESSY.
The terminal control unit can be found in a separate

housing holder above the pedal bracket in the driver's
footwell. The terminal control unit has a discrete
connection to the onboard supply control unit. The
control unit is permanently coded for automatic start
(pin coding). For the Passat, provision has been made
for two functions: with and without start/stop system.
S488_132
Diagnosis
If the terminal control unit should fail while the vehicle is in motion, terminal 15 will continue to be supplied as an
emergency running measure until engine speed is zero. Thereafter, ignition is switched off and emergency running
is activated both on the hardware and software side (internal terminal CU measure). This means that the terminal
request from the electronic ignition lock is enabled, thereby allowing the vehicle to be operated through this switch.
The ISB will no longer work and its light is switched off as with all other implausible ignition starter button problems.
The engine control unit interrogates the existing potential for plausibility just before the terminal 50 request from
the terminal control unit via the diagnosis wire (terminal 50 R for "read back") for starter actuation. In the event of
implausibility, the engine ECU ceases its attempt to start the engine. The onboard supply control unit (OSCU)
receives this information at the same time.
Both input pins of the ISB must have the same signal so that the operational request from the ISB is accepted by the
terminal control unit. Inputs open means ISB not pressed; inputs to earth means ISB pressed. In addition to the
information (no fault present; all conditions met for starting), diagnoses are also transported via the path "fault
information" from terminal CU to OSCU (2 of 3 status lines currently in use). There are currently two possible fault
messages: "Control unit faulty" and "ISB faulty".
54
Function
The driver can control the vehicle functions at the same time from the electric ignition lock or/and from the ignition
starter button. Terminals S, 15 and 50 from the electric ignition lock are just passed through in the terminal CU.
Terminals S and 15 are generated electronically by the terminal CU due to the request from the ISB. These carry a
steady signal upon active request. The term. 50 request during automatic start represents a 200ms square wave
impulse from the terminal CU to the engine control unit, irrespective of how long the ISB is pressed.
If the engine control unit has information about the framework conditions, such as the PN signal on automatic
vehicles (selector lever in P or N position) and the brake signal, the engine control unit actuates both its starter
relays (SST1, SST2). On vehicles with manual gearbox, the clutch actuation signal (interlock) serves as a condition
for input.
Functional diagram
S488_134
SMLS CAN
J527 B
ESL
B B 50_SMLS
Term.75
PN/interlock
As A
Cs
J519
Ks A
S Ka
OSCU
C
P
EIL J942
terminal
ST
CU CAN
J623
ECU SST1
Kc SST2
ISB
Term.50R C
Coding
● PN (automatic gearbox), interlock
(manual gearbox)
● Neutral gear sensor (NGS)*
● Brake signal (BLS, BTS)
Key
A - terminal 5 1 S - terminal S
As - terminal 15s Ks - terminal CU_S (request from J942)
B - terminal 0 3 Ka - terminal CU_15 (request from J942)
C - terminal 0 5 Kc - terminal CU_50 (request from J942)
Cs - terminal 50s ST - Status lines with fault and status information
P - terminal P SST - Start control
* - On vehicles with start/stop system
55
Convenience electronics
Dynamic light assist (DLA)

A new generation of dynamic light assist is used in the Passat 2011 in combination with xenon headlights. It works in
the same way as the headlights on the Touareg, though differs in its technical makeup due to different
manufacturers. The headlight installed in the Passat features a rotating shutter with four shield profiles. In addition,
there is a shutter range with variable light shield (masked permanent main beam).
Headlight
D3S Power electronics
Reflector
Masking area (DLA)
S488_094 Lens
Shutter with shields
Networking
J533
J519 J745 J667
J527 R242 J668
S488_042
J285
Key
J519 - Onboard supply control unit J668 - Power output module for right headlight
J527 - Steering column electronics control unit J745 - Cornering light and headlight
J533 - Data bus diagnosis interface (gateway) range control unit
J285 - Control unit in dash panel insert R242- Front camera for driver assist systems
J667 - Power output module for left headlight
56
Shield positions
Main road light, motorway light, urban light and touring mode
These light cone patterns (from a vehicle for right-hand traffic) are made possible by three different shield profiles
on one shutter. Depending on the speed of the vehicle or menu setting, the shutter toggles between the positions for
main road, motorway, urban (not including xenon headlight function with masked permanent main beam) and
touring mode. In touring mode, there is no main road (dipped beam), motorway and dynamic cornering light. The
following light cone patterns are projected against a wall from a distance of approx. 10m (full illumination):
Main road light Motorway light Urban light (10-45km/h)

(up to 110km/h) (from 110km/h) Touring mode (static)
S488_096
Left light cone raised Maximum dipping of light cone
Main beam and masking position
The masking range on the shutter is used in conjunction with a gradual transition to main beam for dynamic light
assist. If the system does not detect any vehicles in the dazzle range of the light cone, the shutter is turned to the
non-dipped position. The light cone is therefore unmasked. If a vehicle travelling ahead approaches the light cone,
the large shield on the shutter is turned into the light cone dynamically. In this way, only the light that could dazzle
oncoming traffic or the vehicle travelling ahead is "dipped". The remaining field of light on the left-hand side is
swiveled away from oncoming traffic to the left and "dipped" to the maximum range available for the main road
setting. The DLA becomes active from 60km/h and remains this way even if the vehicle is slowed down to 55km/h.
Main beam (unmasked position) Dynamic range* Maximum "dipped" range*
S488_098
Light cones overlap *Left headlight (mirror image on right headlight)
57
Radio, navigation and telephone
The radios
Technical data RCD 210

Display Monochrome, 122 x 36 pixels
Touch sensitive (touchscreen)
AM, FM, TP and RDS reception (basic tuner) ●
AM, FM, TP and RDS reception (diversity tuner)
Integrated DAB tuner (digital radio)

Integrated disc drive CD
Integrated SD/SDHC memory card reader
Media support CD and MP3 audio data
Audio input interface (AUX-IN) Can be retrofitted

Telephone interface for hands-free device ● (Mono-channel only)
Interface for connecting a reversing camera
Loudspeaker output stages 4x20watt output ●
(2 or 4 loudspeakers can be connected)
Control of external CD changer ● (No MP, WMA3)
Control of external amplifier
Connection of external media devices (USB, mini USB, iPod)
Speed-dependent volume adjustment ●
Brightness of display light can be regulated ●
independently of interior light in vehicle
Self-diagnosis and loudspeaker diagnosis ●
Service test mode ●
Optical parking system (OPS)
Air conditioning information
For further information, see self-study programme no. 404
* Discontinued from model year 2012

** DAB version shown
*** EU version without DAB shown
58
RCD 310** RCD 510***
Monochrome, 302 x 45 pixels 6.5", 400 x 240 pixels
●
● ●
Depending on equipment Depending on equipment

CD CD (6-disc changer)
●
CD, MP3 and CD, MP3 and
WMA audio files WMA audio files
● ●
● ●
Depending on equipment
● ●
● (No MP3, WMA)*

● ●
● ●
● ●
● ●
● ●
● ●
● ●
● ●
no. 417 no. 423
59
The radio-navigation systems
Technical data RNS 315

Display 5", 400 x 240 pixels
Touch sensitive (touchscreen) ●
AM, FM, TP and RDS reception (diversity tuner) ●

Integrated DAB tuner (digital radio) Optional
Integrated disc drive CD
Integrated SD/SDHC memory card reader ●
Media support CD, MP3 and
WMA audio files
Audio input interface (AUX-IN) External and front
Telephone preparation support ●/+Bluetooth internal
Interface for connecting a reversing camera ●
Loudspeaker output stages 4x20watt output ●
Control of external CD changer ●
Control of external amplifier ●
Connection of external media devices (USB, mini USB, iPod) ●
Can be combined with TV-tuner
Speed-dependent volume adjustment ●
Brightness of display light can be regulated ●
independently of interior light in vehicle
Self-diagnosis and loudspeaker diagnosis ●
Service test mode ●
Optical parking system (OPS) ●
Air conditioning information ●
Navigation function with map, ●
integrated driving symbols and voice
Integrated storage media Flash memory***
(6GB/4GB NAR)
Navigation data Internal memory
Navigation data update via SD card**
Traffic sign display ●
For further information, see self-study programme no. 493
* The hard-disc is partitioned: 20GB are available for media data,

10GB are reserved for navigational data.
** The purchased SD card can be used for any navigation unit, though it is only coupled to the specific device once
updated and can only be used with this device.
*** Can only be used for navigational data.
60
RNS 510
6.5", 800 x 480 pixels
●
DVD
●
CD, MP3, WMA audio,
DVD formats
External
●
●
●
●
●
●
●
●
●
●
●
●
●
Hard-disc 30GB*
Hard-disc*
DVD
●
no. 423
61
The aerial concept

Passat saloon
On the saloon, all of the aerials are integrated in the rear window. The entire heating wire structure is part of the
FM and TV signal aerial system. The signals are separated electronically according to TV1, TV2 and FM1, FM2.
The GSM/UMTS and GPS aerials are designed as separate modules and are clipped onto the rear window. The
aerial connections all run via the aerial module, which has the corresponding impedance transformer. Depending
on the signals required, the aerial module has three mechanical configurations and nine versions (part numbers).
The diagram shows the maximum equipment.
Auxiliary
heater
S488_118
K
D
C A I G B
GSM/UMTS TV tuner
B K Aerial module
G H
A I
Modules
FM2/TV2 GPS FM1/TV1
AM DAB
Left Right
Further information on this aerial concept can be found in self-study programme

no. 342 "Radio systems 2006".
62
Passat estate
On the estate model, the radio aerials and the aerials for radio remote control (RRC) of the auxiliary heater are
integrated in both rear side windows. In addition to this, it features a roof aerial for GPS and/or GSM/UMTS.
Depending on the signals required, the impedance transformer is available in different versions. The diagram
shows the maximum equipment.
Auxiliary
heater
S488_116
GSM/UMTS,
GPS
D
K
B G A I C
TV tuner
Impedance
transformer
AM/FM1/TV1 D RRC AB FM2/TV2

auxiliary heater
FM1/TV1 FM2/TV2
Left AM DAB Right
Key:
B FM1/AM
I FM2 (Diversity)
A DAB
C GPS
D GSM/UMTS
G/H TV
K Auxiliary heater
63
Universal cellphone preparation (UHV)

High (9ZB)
On the UHV High system, the cellphone is connected exclusively via Bluetooth. In this case, only the voice data is
transferred between the microphone, the control unit for cellphone operating electronics (J412) and the
loudspeaker system of the vehicle. Communication with the GMS/UMTS network is via the cellphone aerial. This
UHV features the following functions:
Internal functions: External functions:
● Hands-free profile (HFP 1.5) ● Convenience radio/sat nav operation

● BT audio streaming (A2DP 1.2) and control ● Multifunction display (MFD)
● Multifunction steering wheel, optional
● 3 button module in roof unit
Convenience control GSM/

dash panel insert UMTS*
(MFD+)
P
2D
CAN** P,A
F
H
Microphone in J412
roof unit Control unit for 3 button
cellphone operating electronics module
Multifunction steering
wheel, optional Loudspeaker
S488_110
RCD/RNS
** Always stands for signal transfer via * Depending on cellphone/SIM card

CAN data bus, irrespective of bus designation and
interconnected gateway.
64
High "baseplate" (9ZA)
Compared with the UHV High (9ZB), this UHV features a baseplate. This serves to mount the telephone-specific
charging cradle via which connection to the roof aerial takes place. When the cellphone is connected to the vehicle
via the charging cradle, any radio communication (GSM/UMTS) from the vehicle is processed via the roof aerial.
This UHV also features the following functions:

● BT audio streaming (A2DP 1.2) and ● Multifunction display (MFD)
control (AVRCP 1.3) ● Multifunction steering wheel, optional
● Voice-controlled operation (G2P/TTS) ● 3 button module in roof unit
● SMS speaking ● Baseplate for mounting special
phone holder
● External aerial connection via phone
holder
Convenience control
dash panel insert
(MFD+)
Microphone in
CAN** roof unit
Charging cradle with J412

aerial connection
HFP, A2DP
to roof aerial
GSM/
UMTS* 3 button
module
Multifunction steering
wheel, optional Loudspeaker
S488_112
RCD/RNS
65
Premium (9ZU)
The UHV Premium distinguishes itself from the UHV High "baseplate" by the internal GSM/UMTS module. A
connection between the cellphone and the vehicle is not made (charger cradle optional) as the internal UHV
module has access to the telephone data via Bluetooth by way of the Sim Access Profile (SAP). In this way, any
radio communications (apart from Bluetooth) outside the vehicle are processed via the integrated GSM/UMTS
module and the roof aerial. This UHV also features the following functions:

● BT audio streaming (A2DP 1.2) and ● Multifunction display (MFD) with Highline or
control (AVRCP) Premium line dash panel insert
● Voice-controlled operation (G2P/TTS) ● Multifunction steering wheel
● Sim Access Profile (SAP 1.0) ● 3-button module in roof unit
● SMS reading, writing and speaking ● Charger cradle
● External aerial connection via control unit
Convenience control
dash panel insert
(Highline/Premium)
P
,A ,
Microphone in
FP SAP
2D
CAN** roof unit

GSM/
H
UMTS
Internal 3 button
Roof aerial GSM/UMTS module module
Multifunction
steering wheel
Loudspeaker
S488_114
RCD/RNS
** Always stands for signal transfer via
66
Internal RNS315 (9ZI)
The internal UHV of the RNS315 operates without additional external UHV control units. The cellphone is
connected exclusively via Bluetooth. Only the voice data and command instructions are transferred in this case.
GSM communication with the network provider is via the aerial in the cellphone. This UHV features the following
functions:

● BT audio streaming (A2DP 1.2) and control ● Multifunction steering wheel, optional
Convenience control dash GSM/

panel insert UMTS*
(MFD+)
P
2D
,P A
H F
CAN**
Microphone in
roof unit Loudspeaker
S488_120
Multifunction RNS315
steering wheel,
optional

67
Heating and air conditioning
Air conditioning
Rear window heater button Instant heat button

for auxiliary coolant heater
AC button
Air circulation button
Rotary switch for Rotary switch for
temperature control air distribution
S488_059
Front left seat Rotary switch for Front right seat

heating button fresh air blower heating button
Operation
The air conditioning system features manual controls. Unlike the familiar Climatic system, the interior
Depending on the equipment, there are different temperature sensor and the temperature sensors at
control and display units. The illustration above shows the air vents have been discontinued. Therefore, no
the maximum equipment. Depending on the provision is made on the AC system for a fixed
equipment, an instant heat button for the coolant temperature selection in °C. Instead, the interior
supplementary heater or a button for activation of the temperature is regulated manually using the rotary
windscreen heater may be installed. temperature control switch. This rotary switch can be
adjusted without increments between HI and LO.
The control elements are equipped with LEDs for Adjustment of the temperature flap on the AC unit is
visual feedback. They indicate whether a function is still performed by servomotors with feedback
active or at what output stage a function is operating. potentiometers.
Supplementary heater and PTC heater are not

deactivated when the AC unit is switched off.
68
2-zone Climatronic
The 2-zone Climatronic features an AC unit with two temperature flaps that can be adjusted independently of each
other. In this way, the interior temperature on the driver side and front passenger side can be selected separately.
Unvented interior Air recirc./

Head vent Torso vent sensor Footwell vent auto air recirc.
Defrost Heated rear window
Left temperature Right temperature

rotary control rotary control
Front left seat Front right seat

heating button heating button
S488_003
Auto high/low AC ON/OFF
Windscreen heater Instant heat button
Rocker switch 2-zone

OFF
for fresh air blower synchronisation
Operating and display unit

Depending on the set values and the environmental LEDs in the individual function buttons give feedback
conditions, such as the outside temperature, the regarding the current settings of the selected
temperature, air quantity and also air distribution are functions. This information can be displayed as a
regulated automatically by the Climatronic system. popup in the radio and radio-navigation unit as well.
Manual operation of the Climatronic system is still
possible. Supplementary heater and PTC heater are not
deactivated when the AC unit is switched off.
69
Heating and air conditioning
Thermo Top fleece auxiliary coolant heater

On vehicles with diesel engines, the new ThermoTopfleece from WEBASTO is used as an auxiliary coolant heater
and as a supplementary heater. The difference to ThermoTopV is that the new heater is equipped with a fleece
burner. There are no changes in operation, fitting location or functions.
On petrol engine vehicles, ThermoTopV with venturi burner will continue to be installed until further notice.
Coolant inlet and outlet

Temperature sensor
Overheating sensor
Combustion
air blower
Metal fleece
Control unit
Heat exchanger
Electrical connection
Combustion air inlet
Exhaust gas outlet

Fuel inlet
S488_049
70
Notes
71
488
© VOLKSWAGEN AG, Wolfsburg

All rights and rights to make technical alterations reserved.
000.2812.48.20 Technical status 12.2010
Volkswagen AG
After Sales Qualification
Service Training VSQ-1
Brieffach 1995
D-38436 Wolfsburg
❀ This paper was manufactured from pulp that was bleached without the use of chlorine.

Passat 2011

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Service Training

Self-study Programme 488

The Passat 2011

Power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Driver assist systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Convenience electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Radio, navigation and telephone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Heating and air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

The Passat 2011

● Luggage compartment lid with automatic ● Adaptive cruise control ACC

941mm 2712mm 1116mm

Exterior dimensions Weights/further details

Passat saloon 2006 2011 Passat saloon 2006 2011

941mm 2712mm 1118mm

Exterior dimensions Weights/further details

Passat estate 2006 2011 Passat estate 2006 2011

Interior dimensions and volumes

Interior dimensions and volumes

Passat saloon 2006 2011 Passat saloon 2006 2011

Interior dimensions and volumes

Passat estate 2006 2011 Passat estate 2006 2011

Scope of modifications to Passat saloon

Windscreen with acoustic laminated glass

Windscreen with acoustic laminated glass Conventional windscreen

● the additional partition

Cargo floor Remote release

Sliding cargo floor Remote release of

Cargo floor position

In the saloon and estate model, the rear bench seat

Dipped beam, H7 (55W) Main beam, H7 (55W)

Side light (5W)

Turn signal (24W)

Light module in bumper

In conjunction with xenon headlights, the cornering

Tail light Reflector (in trim)

Reflector (in lens) Reversing light Rear fog light

LED tail lights

Tail and brake light Reflector (in lens)

Turn signal (21W) Reversing light Rear fog light

Storage under AC controls Glove compartment Door compartment

Storage compartment Drink/can holder 12 volt connection

Side crash sensor

Side crash sensor

Side crash sensors

1.4l 90kW 1.4l 110kW 1.4l 118kW 1.8l 118kW

R = with regenerative braking; S = with start-stop system (optional equipment)

R R R+S R+S R+S

F = front-wheel drive; A = four-wheel drive

1.4l 90kW TSI engine with turbocharger

This engine has found application in other vehicle

● Homogeneous mode (lambda 1)

Further information on this engine can be

Technical data Torque and power diagram

Compression ratio 10:1

This engine is practically the same as the EcoFuel

● One engine control unit for natural gas and petrol

Technical data Torque and power diagram

Engine code CDGA

Maximum output 110kW at 5500 rpm

1.4l 118kW TSI engine with dual charging (MultiFuel)

This engine was first used as a bioethanol

● Bioethanol compatible up to 85%

Technical data Torque and power diagram