New four-wheel drive generation for the Volkswagen Passat saloon and estate

February 6th, 2006
URL: http://www.allcarnews.com/article/volkswagen-passat/vw-passat-4motion/

4MOTION in the Passat
The four-wheel drive system
Haldex coupling provides instant power distribution

The latest generation of the 4MOTION four-wheel drive system is now available in the Passat Electronically controlled Haldex coupling distributes torque between front and rear axles 4MOTION offers more safety, better dynamics, and the ability to tow up to 2 200 kg

4MOTION is the permanent four-wheel drive system from Volkswagen. The name stands for enhanced active safety, more driving pleasure, and a system that redefines limits. In 2006 Volkswagen is bringing the four-wheel drive system to the new Passat in three engine versions. The top model of the Passat range, the 184 kW / 250 PS Passat 3.2 V6 FSI 4MOTION, has what is the most effective form of power distribution as standard. The 4MOTION drivetrain, controlled by an electronic Haldex coupling, is available as option with the Passat 2.0 FSI (110 kW / 150 PS) and the Passat 2.0 TDI (103 kW / 140 PS). The 4MOTION drivetrain may be combined with either body version (saloon or estate) and any of the equipment lines (3.2 V6 FSI 4MOTION available starting with the Comfortline).

Permanent four-wheel drive also enhances the rough terrain handling of the Golf, Sharan, Multivan, Phaeton, and Touareg. Volkswagen has been building Passat’s with four-wheel drive for over two decades; the first model, the Passat estate GT syncro, was launched in 1984. To date over 256,000 Passat drivers worldwide have opted for the four-wheel drive version. Over the last two decades the Volkswagen four-wheel drive system has become established as a superior choice for all drivers who frequently or just occasionally deal with mountainous routes, rough tracks or large towing loads. In general the system is also used by customers in all relevant performance classes who benefit from its improved traction. To suit the all needs, the current Passat 4MOTION is available in a wide power range from 140 PS to 250 PS.

THE LASTEST GENERATION OF 4MOTION: fast, quiet, easy to maintain, and superior to rear-wheel drive

The Passat comes equipped for the first time with a 4MOTION system featuring Haldex coupling. The coupling, which is fitted directly in the rear axle, is considerably more compact and the system works quickly, sensitively, and quietly. As a general rule, four-wheel drive beats rear-wheel drive especially in the wet or on ice and snow. Besides that, even on dry roads 4MOTION improves cornering forces for better active safety. There are known reasons why: 4MOTION's electronically controlled system provides the best possible distribution of force to all four wheels, varying it to suit the road conditions and the levels of grip.

EASY TOWING: Passat 4MOTION makes light work of 2 200 kg

Four-wheel drive also delivers major advantages for towing trailers. The Passat 3.2 V6 FSI 4MOTION, for example pulls, a hefty maximum trailer weight of 2 200 kg on uphill grades of up to 12 percent. Its gross weight rating for the rear axle is 1 220 kg. For the Passat 2.0 TDI 4MOTION a maximum trailer weight of 2 000 kg is allowed on uphill grades of up to 12 percent and 2 200 kg on up to 8 percent grades - in each case 200 kg more than with the front-wheel drive Passat 2.0 TDI.

4MOTION IN DETAIL: An electronically controlled Haldex coupling adjusts power distribution between the front and rear axles

The central element of the 4MOTION system is the latest generation of multi-plate wet coupling (in an oil bath). It is called the Haldex coupling as it was developed together with Swedish systems partner Haldex who have worked with Volkswagen for many years. The Haldex coupling has the major advantage of being electronically controlled. This allows it to work very effectively in conjunction with the anti-lock braking system (ABS), the traction control system (TCS), the electronic differential lock (EDL), and the electronic stability programme (ESP) – all these assistance systems are fitted as standard in the Passat.

The axles are "coupled" by pressure: as soon as differences in the speeds of rotation between the front and rear axles occur, two annular piston pumps within the coupling are activated which build up pressure in the multi-plate coupling, thus "coupling" the two axles to each other. The only go into action when the input and output shafts are no longer turning at the same speed. Only then is it necessary to adjust the torque distribution.

The rear axle always receives at least 10 percent: the transmitted torque can be varied by adjusting the pressure on the coupling plates, thus controlling the flow of power between the front and rear axles. The coupling provides infinitely variable torque adjustment between the front and rear axles. In extreme cases up to 100 percent of the available torque can be transmitted to the rear axle. In the normal case with the vehicle travelling in straight line at a constant speed with no differences in the wheels' grip, 90 percent of the torque produced is transmitted to the front axle and ten percent to the rear axle. The Haldex coupling is driven by a propshaft.

The CAN bus makes it all possible: The coupling's electronic control unit is fed with all relevant drivetrain and engine information via a CAN bus. This includes signals from the wheel sensors, the ABS and ESP, plus information on the accelerator pedal position and engine revs. Based on these data the 4MOTION control unit controls the level and changes in hydraulic pressure acting on the coupling plates. The coupling responds to "commands" from the 4MOTION electronic control unit extremely quickly. The compact coupling also has a very robust design and can transmit a torque of 3 200 newton metres to the rear axle.

4MOTION RUNNING GEAR - Four-link rear suspension connected to the four wheel-drive by a decoupled subframe

The new Passat 4MOTION is a fine example of what modern-day front-wheel or four-wheel drive running gear should offer in terms of comfort and handling properties. The four-link rear suspension (acoustically decoupled from the body by means of a subframe), a McPherson strut front suspension with aluminium components, and electromechanical power steering all add up to the highest level of agility, comfort, and safety. A sports version of the suspension, lowered by 15 millimetres, is available as an optional extra (standard in the Sportline), as is the heavy duty running gear raised by 20 millimetres (with exception of the 3.2 V6 FSI). The Passat 4MOTION 3.2 V6 FSI comes standardly equipped with 17-inch light metal wheels and brakes.

4MOTION TOWING: All Passat’s with a towing attachment come standardly equipped with ESP + trailer stabilisation

To make the running-gear complete, ESP is fitted as standard or ESP + trailer stabilisation for all vehicles fitted with a towing attachment. Aside from the familiar functions which ESP offers, the system also ensures early identification of trailer snaking and counters it by targeted braking and intervention in the engine control system. With the Passat’s trailer stabilisation feature, trailer snaking is detected (via the ESP control unit) through the characteristic vibration brought on in the towing vehicle. False activation of the system is prevented via an extensive verification of all ESP signals. In an actual emergency the ESP slows the trailer by applying the towing vehicle’s brake system to all four wheels and reducing engine torque until the snaking is under control. Since this is an issue of targeted braking, the brake lights are automatically activated, even when the brake pedals are not used.

The 16-inch brakes are uncompromisingly robust (3.2 V6 FSI: 17-inch). The brake discs themselves are fitted with a wiper function. They counter the problem of the thin water film which can form on the disc surface and impair the brake responsiveness in wet weather. The wiper function deals with this by automatically applying the brake pads with very light pressure in five minute intervals and thus drying the discs. The driver, meanwhile, doesn't notice a thing.

4MOTION ENGINES – Two petrol units (FSI) and one turbodiesel (TDI) are available for the four-wheel drive Passat for the initial phase in 2006

4MOTION plus the 110 kW 2.0 FSI – The 2.0 FSI is a four-cylinder petrol engine capable of delivering 110 kW / 150 PS (at 6 000 rpm). At 3 500 rpm it produces its maximum torque of 200 newton metres. In the saloon version the 1 984 cm3 direct injection engine can accelerate the Passat to 100 km/h (62 mph) in 9.9 seconds and reaches a maximum speed of 209 km/h (130 mph). The values for the four-wheel drive estate are 206 km/h (128 mph) and 10.2 seconds. The Passat 2.0 FSI always comes with a manual six-speed gearbox. In the combined driving cycle the saloon consumes an average of 8.7 and the estate 8.9 litres of fuel per 100 kilometres.

4MOTION plus the 184 kW 3.2 V6 FSI – The new top model in the range, the Passat 3.2 V6 FSI, is supplied with 4MOTION and the DSG dual clutch gearbox as standard. At 6 250 rpm the six-cylinder direct injection petrol engine delivers 184 kW / 250 PS. It develops its maximum torque of 320 newton metres at 3 200 rpm. The advantages of direct injection are more output, better fuel economy and lower emissions. An extensive array of new calculations were undertaken to give the V6 FSI optimised stiffness properties, a lower level of component stress, and a lighter weight.

The 3 189 cm3 engine propels the Passat saloon from nought to 100 km/h in just 6.9 seconds, while the estate needs just a tick longer at 7.2 seconds. Both body versions of the Passat can reach well over 240 km/h (149 mph); the saloon hits maximum at 246 km/h (153 mph), the estate at 243 km/h (151 mph). The top Passat models use an average of 9.8 litres (saloon) and 10.0 litres of fuel in the combined cycle.

The DSG in the new Passat 4MOTION has six forward gears and shifts extremely fast with no power interruption. This gearbox – like Volkswagen’s classic Tiptronic – allows manual gear changing using the "plus" and "minus" shift gate.

4MOTION plus the 103 kW 2.0 TDI – A top speed of 204 km/h (127 mph) is possible in the saloon version of the Passat 2.0 TDI 4MOTION, which produces 103 kW / 140 PS at 4.000 rpm, while the estate is capable of 201 km/h (125 mph). The four cylinder engine is supplied in combination with a six-speed gearbox. The 2.0 TDI develops a maximum torque of 320 newton metres between 1 800 and 2 500 rpm and accelerates the saloon to 100 km/h in 10.2 seconds (estate 10.5 seconds). The average fuel economy in the version with optional diesel particulate filter: 6.7 litres and 6.8 litres (estate) per 100 kilometres.

Passat and Passant Estate The Passat range in 2006 Two body variants, four equipment lines, eight engines

Germany's most successful fleet car with a power range of 75 to 184 kW The design shows the largest evolutionary leap since the launch of the series Five star crashworthiness in Euro-NCAP; six airbags and ESP as standard

The current Passat saloon was launched on the first European markets in March 2005; the Passat estate followed in August 2005. Last year the new generation rapidly established itself as the most successful fleet car in Germany. It also went straight to the top of the sales figures to become the highest selling mid-class car.

The story of the bestseller began with the launch of the first generation in 1973. Over the past three decades it has advanced to become an icon of automobile progress "made in Germany". The new Passat has taken the series' rational qualities to a new level of perfection. At the same time the development team have injected a refreshing passion into this Passat with an uncompromising combination of form, function, design, and ergonomics.

VERSIONS / ENGINES – A bestseller in four equipment versions; eight engines with power ranging from 75 kW to 184 kW

The Passat is available in four equipment lines: Trendline, Comfortline, Sportline, and Highline. Each of these lines has a particular standard equipment specification plus a character all its own. Trendline stands for the "youngest" package. The Comfortline does justice to its name with its comfort-centred character, as does the dynamic version, the Sportline. They are followed by the high-end model, the Passat Highline. Moreover, both the saloon and estate can be tailored to personal needs with a Business Package (Germany only) and the range of features from Volkswagen Individual. Even from the entry-level Trendline the Passat has an extensive range of comfort, functional, and safety equipment. This includes two-stage front airbags, side airbags and curtain airbags, ESP, central locking, electromechanical power steering, and the Climatic semi-automatic air conditioning.

The Passat is available in Europe with a choice of eight engines. The FSI petrol engines with homogeneous direct injection are now being fitted in the Passat for the first time. The have power outputs of 85 kW / 115 PS, 110 kW / 150 PS, 147 kW / 200 PS, and 184 kW / 250 PS. The entry-level engine is an economical 1.6 litre four-cylinder engine producing 75 kW / 102 PS. The diesel engine range consists exclusively of advanced TDIs. They have power outputs of 77 kW / 105 PS, 103 kW / 140 PS, and an entirely new engine producing 125 kW / 170 PS. The most powerful TDI has a piezo unit injector high-pressure injection system.

The 140 PS TDI (front-wheel drive optional), 170 PS TDI, and the 3.2 V6 FSI (standard) are available with the automatic dual clutch gearbox (DSG). It has six forward gears and ensures extremely fast gear changes. DSG plus TDI is an ideal combination as it maintains, unlike any system before it, the full fuel economy advantages of a diesel engine with automated gear-changing. The petrol engines with power outputs of 85 kW / 115 PS, 110 kW / 150 PS, and 147 kW / 200 PS are available in their front-wheel drive versions with a high-comfort six-speed automatic gearbox (Tiptronic).

DESIGN / DIMENSIONS - Muscular, avant-garde design; wider, longer, higher – more comfortable

The new Passat design shows what happens when designers interpret a clear, logical, and understandable style in a way that is more muscular, athletic, and passionate than ever before. Blurring class boundaries, the design – together with innovative technologies – catapult the saloon into a more sporting, luxurious dimension with the greatest evolutionary leap since the creation of the series. The sixth Passat is characterised by a muscular and avant-garde design. The VW front end with it chrome shield radiator grille and the defiant headlights, athletic silhouette, and the powerful look at the rear represent the largest design leap since the creation of the series. The Passat's design demonstrates on the outside what is also true of the inside: all new and all different. The Passat saloon is 4.77 metres long, 1.82 metres wide, and 1.47 metres high. The wheelbase is 2.71 metres. Its static torsional rigidity is an indicator of the car's outstanding quality. Its value is 57 (!) percent greater than that of its already very good predecessor and represents the best value in its class. The saloon's boot has grown enormously in volume compared to its predecessor and provides a maximum of 565 litres (+ 90 litres).

INTERIOR - Clear, fresh and intuitive operation with perfection in its details

A glance at the interior of the new Passat reveals a transparent, fresh, and stylish design with a distinct clarity, high-quality materials, and technology focussed on people and not on theoretical capabilities. The aim of this interior design was to create ideal ergonomics and operating comfort. The dominating characteristics of the design are its neatly structured functional elements and the apparently effortless infusion of style.

The interior can be adjusted to suit personal needs and tastes with the four equipment lines, Trendline, Comfortline, Sportline und Highline and four colour worlds ("Black", "Latte macchiato", "Classic Grey", "Pure Beige" / depending on equipment line ) and the Volkswagen Individual range. Depending on the equipment line, the interior can be individualised further with wood (burr walnut, grained poplar, makassar) and aluminium trim. For example, a combination of burr walnut on the instrument panel and aluminium garnish trim for the whole centre console perfectly complements the effortless design of the controls.

SAFETY - Five star crashworthiness in Euro-NCAP; six airbags, ESP, and extensive protective systems as standard

A sensible pairing of highly effective passive safety systems with ever more intelligent active safety components such as ESP and ADR (active cruise control) makes Volkswagen's new Passat one of the safest saloon cars in the world. The essential basis for the best passive safety is and remains high body stiffness. The new Passat has again redefined the standard in its class in this area. In addition to this, the car's restraint systems are the components which make the most noticeable difference to safety. The new Passat is equipped with two-stage front airbags, and side airbags (front) and curtain airbags (front and rear) as standard. Side airbags and belt tensioners are also available for the rear as options. There is no doubt that the Passat, which is an established model on all five continents, conforms to crashworthiness standards anywhere in the world.

WEALTH OF TECHNOLOGY - More safety, more comfort, and more fun with a raft of new systems

Running gear: the four-link rear suspension, which is separated from the body by a noise-reducing subframe, and the McPherson strut front suspension designed with aluminium components (-13.3 kg weight) give the Passat an outstanding level of agility, comfort, and safety. To make the running gear technology complete, the Passat has ESP and all vehicles with a tow bar are equipped with trailer stabilisation as standard.

Brakes with "wipers": all Passat’s have 16-inch brakes with integrated disc wiper function as standard (3.2 V6 FSI: 17-inch). The pads are applied lightly in specific intervals. This wipes away any film of moisture which can form on the discs on wet roads, thus reducing the braking distance.

Electromechanical parking brake: the Passat is the first saloon car in its class to have an electromechanical parking brake as standard. It works at the press of a button. Its electronic control system is linked to other control units via a network. This means it can perform a series of new functions, including dynamic emergency braking, parking brake auto release (for hill starts), and an optional auto-hold function (standard for automatic and DSG versions as well as for vehicles with towing attachment).

Starting and locking system: The Passat's remote control starting and locking functions have been developed as an entirely new system. It has no conventional ignition key. Instead the central locking transmitter slots into a holder to the right of the steering wheel and the driver then presses it to start the engine. The Keyless Entry Start and Exit System (KESSY) is also available as an option.

Adaptive cruise control with reduction of braking distance: bringing another new feature to this segment, the Passat is available with automatic adaptive cruise control. The system, offered with an automatic transmission and DSG, is intuitively operated via a separate lever on the steering column. As soon as the distance to the vehicle in front falls below a defined value, the Passat applies the brakes until the car has slowed to a speed which has been preset via the cruise control system. Once the lane ahead is clear again, the Passat accelerates to the previously selected speed. The system's radar sensor also detects when the car is dangerously closing in on the vehicle in front. The Passat is readied for a braking action, by placing the pads in contact with the discs and activating the brake assist system to maximise the effectives of subsequent emergency braking.

Integrated child seats: the newly designed child seat can be build into the Passat’s rear seat bench either individually or as a pair and offers essential improvements over previous integrated solutions. This is apparent, for example, in the lateral support provided for the child’s head and pelvis. Upon side impact, the lateral head supports minimize the relative movement of head to the chest and in this way offer important additional support to the restraint system. The strain on the child’s sensitive cervical vertebrae is also reduced by up to 60 percent. A patented snap-on mechanism makes it easy to fasten and remove the lateral supports from the brackets on the existing standard head restraints. The function of the rear side airbags remains fully preserved.

When needed, the foldable seat surfaces, the so-called "Booster" can be pulled up with a handle on the front of the seat bench until it clicks into place in the raised position. Folding side supports offer optimal restraint for the child's pelvis and thighs. When the seat is fitted back down into the rear bench, the side supports automatically fold into the horizontal out-of-use position. When not in use, the seat surfaces fit into the rear bench and do not interfere with the seat comfort for adults.

Bluetooth Telephone: the Passat has an optional telephone unit with hands-free capability featuring a Bluetooth interface. The mobile phone has a wireless connection to the vehicle and can stay in the driver's pocket. A permanently installed phone in the car will assume the mobile telephony functions by tapping in to the driver’s SIM card to obtain the data needed. The telephone is operated using either a separate keypad, the multi-function steering wheel or by voice.

Sound systems from Dynaudio and Volkswagen: the 600-Watt high-end sound system from the hifi specialist Dynaudio offers an outstanding audio experience. The 10-channel system equipped with excellent components sets a new standard in this class. A 250-Watt Volkswagen sound system is also available as an alternative. Both systems are available in combination with the navigation systems RNS MFD2-DVD and the radio system RCD 500.

Draught-free Climatronic: the two-zone automatic air conditioning system, standard in the Passat Highline and otherwise available as optional equipment, provides draught-free ventilation at the touch of a button, just as in the Phaeton. New power supply: business travellers will welcome the ability to recharge a laptop via a 230 Volt power supply.

Bi-xenon headlights with bend lighting: for this model, substantial improvements have been made to all headlight systems, most notably to the high-beam settings. Moreover, the adaptive bi-xenon headlights now light up the road even better. The integrated dynamic bend lighting follows the course of the road with a maximum swivel angle of 15 degrees and thus ensures the best-possible illumination at all times. An additional static cornering light makes the system complete: thanks to its lighting angle of around 35 degrees off centre, it offers a considerable advantage to the driver when turning off at intersections and junctions.

Tyre pressure monitoring system: this system of sensors alerts the driver to any loss of pressure in a tyre. New tyres with run-flat features: the self-supporting tyres (SST) on the “Monza” alloys feature reinforced sidewalls and enable continued safe travel even if tyre pressure is low or the tyre is completely deflated. A warning light indicates the loss of pressure. The Passat 3.2 V6 FSI 4MOTION comes standardly equipped with the tyre pressure monitoring system.