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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