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Sumario

Crash test
Dimenciones

3/5 Puerta S.WAGON PICK- UP


Cotas y pesos
A – Batalla 2468 2468 2599
B - Distancia delantera (ejes) 1388 1388 1388
C – Distancia trasera (ejes) 1384 1384 1384
D – Largo 3883 4131 4463
E - Ancho 1628 1628 1640
Ancho con espejos 1902 1902 1903
F – Altura (descargado) 1415 1455 1483
G – Altura libre con carga maxima
120 117 154
Ergonomia y estilo
Ergonomia y estilo
Ergonomia y estilo

Parati

Parati

Parati
Tecnologia y
Seguridad

Codigos Sistemas
01 Inyeccion
03 electronica
Frenos ABS 5.3
15 Air-bag
17 Tableros de instrumento
25 Inmobilizado
r
Tecnologia y
Seguridad

Codigos Sistemas
01 Inyeccion
03 electronica
Frenos ABS 5.3
15 Air-bag
17 Tableros de instrumento
25 Inmobilizado
r
Motor EA 827

Dados Tecnicos
Cilindrada (cm3) 1596

Identificacion del motor UNF

Potencia max. (cv / KW - rpm) 92 / 68 - 5500

Par max. (kgfm - rpm) 13,9 - 3000


Motor EA 827
Motor EA 827
Motor EA 827
Motor EA 827
Motor EA 827
Motor EA 827
Motor EA 827
Motor EA 827
Motor EA 827
Motor EA 827
Componentes del Sistema
Unidad
Sensores del Motor Actuadores
J382
(Sensor Convinado)
Transmisor de presión
(G71) e Temperatura del
aire de admisión Bobina de encendido
(G42) (N152)
Transmisor Hall (G40)
Valvulas inyectoras
N30, N31, N32, N33
Sonda Lambda (G39)
Rele (J17)
Sensor de Bomba de
picado combustible(G6)
(G61) Conector Válvula para purga de aire
Sensor de de del depósito (N80)
temperatura (G62) diagnostico

Sensor da posicion Corretor de ralenti


de la
mariposa(G69)
Linia 30
Rele de plena potencia
A/C Señal A/C
Sensor Hall

720° (2 vueltas del motor)

PMS 1° Cil. PMS 3° Cil PMS 4° Cil PMS 2° Cil

72° 66° 6° APMS

Marca OT (Primero ciliindro PMS)


Esquema Electrico
Motor EA 827
Puesta a punto
Motor EA 827

Specifications
Cilindrada (cm3) 999

Identificacion del motor AZN


Potencia max. (cv / KW - rpm) 57,0 / 42,0 - 5200

Par motor (kgfm / Nm - rpm) 8,6 / 84,0 - 3500


Motor EA 111
Caracteristicas
el colector de admisión en material
plástico

la culata con carcasa de los árboles de levas

la impulsión de las válvulas a través de balancines de


rodillo

el bloque motor en fundición a presión de


aluminio

la bomba de aceite duocentric

el colector de escape

Magneti
la gestión del motor Magneti MarelliMarelli
4LV
4SV
Motor EA 111

Culata

la carcasa del árbol de


levas y la culata hacen
un par
Motor EA 111
Sistema RSH

Balancin
es de
rodillos

Outlet
Intake
Motor EA 111
Sistema RSH
Motor EA 111
Sistema RSH
Motor EA 111
Sistema RSH
Motor EA 111
Sistema RSH
Motor EA 111
Sistema RSH
Motor EA 111
El Colector de Admisión en Material Plástico
Motor EA 111
Bomba de Aceite Duocentric
Motor EA 111
Bomba de Aceite Duocentric
Motor EA 111
Inyector de Aceite
Motor EA 111

Bielas
Corte Craqueo
Motor EA 111

Bielas

Canal de lubrificación
Motor EA 111
Brida de estanqueidad con retén de PTFE
Motor EA 111
G 28 Unidad del motor
J 448
G6
J 17
G 40

G 187 N 30... N 33
G 188

G 62 N 152

G 71
G 42
G 185
G 39

G 61 Unidad de
Z 19
Inmobilizador
G 36 J 362

F / F 47 N 80

G 79
K 132
G 185
Motor EA 111

El transmisor del número de revoluciones del motor


G28
Motor EA 111
Distribución estática de alta tensión

Transformador de encendido
Circuito eléctrico
Motor EA 111
Transmisor Hall G40
Motor EA 111
Transmisor Hall G40
Motor EA 111
Transmisor Hall G40
Motor EA 111
Transmisor Hall G40
Motor EA 111
Sensor Hall

720° (2 vueltas del motor)

TDC 1ro Cil. TDC 3ro Cil TDC 4to Cil TDC 2do Cil

72° 66° 6° BTDC

Distribuidor montado en OT (primeiro cilindro em


PMS)
Emisiones – Proconve Fase III

Gases de escape Fase II Fase III


Monóxido de Carbono 12g / km 2g / km
(CO)
Hidrocarburos (HC) 1,2g / km 0,3g / km

Óxidos nitricos (NOx) 1,4g / km 0,6g / km


Porcentage de CO 2,5% 0,5%
en velocidad media
Porcentage de CO 400PPM 250PPM
en velocidad media
Motor EA 111
Sincronismo
punto de
referenci
a

Protecion
plastica de
referencia

P.M.S. (2V)
referencia

Punto
correcto de la Dente
correa chanfrado de
dentada referecia de
cuando los la polea
dos punteros
esten juntos
Electric Diagram
Electronic Power Control
Electronic Power Control
System Description
Electronic Power Control
Control Process
Electronic Power Control
U
EC

A
S C
E T
N U
S A
O T
R O
S R
S
Electronic Power Control
Monitoring Function
Electronic Power Control
Accelerator Pedal Module

Sliding contact path

Sender
Electronic Power Control
Throttle Valve Control Unit J 338
Electronic Power Control
Function

G188

G187
Electronic Power Control

Brake Light Switch (F) and Brake Pedal Switch (F 47)


Electronic Power Control
Clutch Pedal Switch F 36
Electronic Power Control
Fault Indicator Lamp
Clutch System

Clutch locking position


Gear Box
Gear box 013
1st speed gear

Gear Box 3rd speed gear Rear speed


5th speed gear
Rear speed
gear

Main axle

2nd speed gear


Pinion axle 4th speed
gear
Gear Box
Gear
Synchronizing
Intermediate ring
ring Synchronizing
Gear sleeve

Internal Intermediate
ring ring

Internal Synchronizing Synchronizing body


ring ring
Speed Transmission
Adjust of ring gear and pinion assembly
Brakes System

Servo-brake load ratio


Generation III

1 : 4,5
Brakes System
Brakes System
Springs

F (N)

Deflection

Rate = N/mm Linear Progressiv Super


e Progressiv
e

Service Training
Comfort Front Suspension

Current Suspension Comfort Suspension Strut


Strut
Not Centered “S” Type Springs

7 coils - lower 5 coils - higher


distance distance
between coils between coils
Auxiliary Spring - Rear Suspension

Current Comfort
Comfort Suspension Strut

Support
plates

Steering
arms
Current Comfort
GOL 1.0 Steering Trapezium

Steering rods

Steering arm

Steering arm

Steering gear Current system


Comfort
system
Steering System
Atom
Electrons
Protons

Nucleus
Neutron
s
Electrical Current
Customers

Free electrons Conductor

Negativ Positive
e pole pole

BATTERY
Wiring Diagram

(+)

Resistor

Switch

Lamp

(-)
Relay
Relay - Wiring
diagram
86 (-) 30 (+)

Command line
85

Working line
87 30
Comman
d
86
coil

85 (+) 87

Command Working
current current
85 (+) Positive on 30 (+) Permanent
positive
86 ( - ) Negative 87 Consumer supply
Electrical Measurement Instruments
Reading and Interpreting Wiring Diagrams

Line 30
Line 31 Line 15

Fuse 10A
Fuse 20A (Line 15)
(Line 30)
Electrical Cooling
central system Fuse 30A
relay (line 30)
Wiring (1)

Coolant
temperatur
e sensor

Coolant
temperatur
e indicator
Beam Switch Connection

High / low
beam switch

Circuit Number
Harnesses

Injection harness Doors harness Cover harness

Front Panel Rear harness


harness harness
Electrical
central
Harnesses

Injection harness Doors harness

Front Panel
harness harness Rear harness
Electrical
central
Electrical Central Connectors

Pos. Color Harnes


s
A Orange Pane
l
B Black Fron
t
C1 Gray Pane
Lock after l
fitting C2 Blue Pane
connectors l
C3 Red Pane
l
C4 Brown Pane
l
D White Rear
E1 Yellow Fron
t
E2 Green Fron
t
Ignition and Start Switches

Steering Lines Circuits


Key position
wheel supplied supplied

Locked

Ignition
Unlocked 15 and X and
accessorie
s

Ignition
Unlocked 15 and 50 and start
Combined Switches

wiper
Wiper - speed
Wiper - speed

Momentary
activating
53a
56b
56a

53b
49a

53a
PR

31
30

56

53
30
50

15
PL

timing
Wiper
H
X
R

T
S
P

P
L
Momentar

J
y light

Off
signal

2
1
O J Automatic
L O R II I wiper
Lights
r/
commutin wipe
g OH o n
Fr eane
t r
High and O cl
low beams Rea
clea rw
neriper /
71

Stop
Key introduced
Key removed Ignitio
n
Star
t
Electrical Distribution Central

Double contacts
Relays

Insula-
tors
Power Suppor Metalli
supply t pins Plastic
Fuses c bars bearings

Locking
rule Faste- Power
ning supply
Location of Fuses

Electrical central
1 AVP Electronic Management System
Wiring Diagram
Front view
Fuses positioning

S13 - Main power, 1 AVP control


unit (Management System)
(15A), lambda probe
S14 - Fuel pump, Canister
valve, cylinder injection
valves (15A)

Note:
S13 and S14 represent fuses
13 and 14 respectively, in the
electric central.
Relays

1st speed
cooling motor relay
2nd speed
cooling motor relay
Wiring Diagram

Relays positioning
Top view
R7 X contact relief relay (black)
Auxiliary Support

POS. Relay no. Name Color

4 325 911 261.1 A/C load cut-off Blue

5 377 906 383 Fuel pump Blac


k
Dash Panel Insert
Dash Panel Insert

Temperature Indicator
Dash Panel Insert

Fuel Indicator
Dash Panel Insert

Speed Limit Monitor - SLM


Dash Panel Insert
L15
Left/Right turn
signal

Dash Panel Insert


Fuel sensor
Air-bag
Ground L31
Coolant
Engine temperatura
oil pressure
Tachometer
Battery load L61
Defroster
Immobilizer
ABS
Lighting Level
Open door Line K of VAG
Coolant level Temperature
Positive L30 Oil
Tail light L58 pressure
km/h
Speedometer RPM
High beam L56a
Headlight L56
Dash Panel Insert
Diagnostic Connector
Warming Lights

C
Alarm System
Alarm system (TOP
model)
Alarm System

Remote Control

Separate remote control Activated/Deactivate


and key d
and Car finder
Pushing the
locking clips
Unlocked
luggage
compartment

Batteries
Lamp does not
light up
Alarm System

Remoto Control Programming


Alarm System

Synchronism
Alarm System
Electric Circuit Diagram ( TOP Alarm)
Immobilizer system

Immobilizer Control Unit

Engine Control Unit


Immobilizer system

Immobilizer Components
Immobilizer Control Unit

Coil/Antenna

Engine Control Unit

Diagnosis Connector

Key
Immobilizer system

Immobilizer Function

Engine Control Unit

Key with Transponder Immobilizer Control Unit


Immobilizer system

Secret Code Request

Recipient = VWB.SBC.IMOCOD or
imocod@volkswagen.com.br
Title = Secret code – 07 digits
Code type = Immobilizer
Immobilizer unit = VWZ9ZOV7000658
Identification number
Secret code Service manage´s name = Mr. José Gomes
Immobilizer system

Immobilizers Types

Fixed Code

Rotative
Code

Cryptography Code
News
Body Stiffness
Cut off Points
Front Bumper and Its Fastenings
Hood

Section C-C
Current

Section C-C
New
Hood’s Detail

Current New
Doors
Windows
Roof

Detail R3 Detail T3
News
Rear Bumper
Front Bumper and Its Fastenings
Windows
Windshield Wiper
Front Seat Adjusting
Current
New

Strength
Refrigeration Cicle

Discharge Suction

C Expansion
Compresso valve
O r
O H
Flow
L
E
A A
I Heat
T
R
Condenser Evaporator
Cool
air
Filter
Refrigerant Circuit

Expansion valve

Dryer
filter

Condenser

Evaporator
Variable Compressor

Piston Floating disc

Intake/Impeler valve
Driving shaft
Floating disc
Piston
High Refrigeration

Folded spring 2
Folded spring 1

Regulator valve
Pressure inside
the chamber

Pressure inside
Dimensioned tube the chamber

High pressure
Low pressure

Spring 1 Spring 2
Low Refrigeration

Folded spring 2
Folded spring 1

Regulator valve
Pressure inside
the chamber

Pressure inside
Dimensioned tube the chamber

High pressure
Low pressure

Spring 1 Spring 2
Expansion Valve
Outlet (to compressor) Inlet (from filter)

Sphere

Inlet (from Outlet (to


Temperatur evaporator) evaporator
e sensor )
Expansion Valve

Low presure Low presure


outlet (to intlet (from
compressor) evaporator)

High presure High presure


intlet (from outtlet (to
filter) evaporator)
Evaporator
Plate A Plate B 1
Brazing

2
Tubes
2 3
Working Cycle

Thermostat
Off O
Closed
n
Opened Temp. °C
0,3 1,5 3 5

Pressure switch Compresor Line


Electro-fan (2nd speed)

On On
Off Off
180 220 PSI 28 32 370 455 PSI
Dryer Filter for HFC 134a
Inlet Outlet

Drying element
Spring Loaded
A/C Components Wiring Diagram
Line 30 Line X Line 30 Line 30

Fuse 4 Fuse24 Fuse 10 Fuse 14


40A 26A 25A Electrical 15A
E1/1 C3/3 A/3 L 30 central L 30 A /4

86 30 86 30 1 4 86 30 A/C 86 30 Full
relay power
85 87 85 87 2 3 85 87 85 87 relay
1st speed
relay Pressur
e switch
2nd speed
relay

Thermos- Motor
tat 5 control
35 unit

1 2 A/C compressor
7 A/C
Air housing
electro-fan 2
Radiator
thermal Button
switch 4 leds
Resistor L58 1
1st speed 3
resistor
1 2 3 4 6
Speed switch
5 Recirc
Recirculation
servo-motor
Airbag system

Driver Side

Airbag

Cover
Passenger Side

Gas Generator

Gas Generator

Cover

Types of Gas Generator Airbag


Airbag system
AIRBAG components

Contact
Gas Generator
Unit
(Driver side)
Piezo electric
sensor

Control Unit Gas Generator


(Passenger side)

Electromechanic
sensor

Diagnosis
Connector
Fault Lamp
Indicator
Airbag system

AIRBAG control unit


Airbag system

The range of AIRBAG


trigger
+ 30°

Center

+ 30°
Airbag system
Car
AIRBAG triggered
Time in thousandth
of sec.

Driver Passanger
Airbag system

Airbag does not trigger when.....

EXTREME MANEUVER MINOR FRONT COLISION CAPSIZE

LATERAL COLISION REAR COLISION