Volkswagen Phaeton 2003 User manual

Self-Study Program

Course Number 891303

The Phaeton

Volkswagen of America, Inc.

Service Training

Printed in U.S.A.

Printed 08/2003

Course Number 891303

in this manual is based on the latest

information available at the time of printing

and is subject to the copyright and other

intellectual property rights of Volkswagen of

America, Inc., its affiliated companies and its

licensors. All rights are reserved to make

changes at any time without notice. No part

of this document may be reproduced,

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mechanical, photocopying, recording or

otherwise, nor may these materials be

modified or reposted to other sites without

the prior expressed written permission of

the publisher.

All requests for permission to copy and

redistribute information should be referred

to Volkswagen of America, Inc.

Always check Technical Bulletins and the

Volkswagen Worldwide Repair Information

System for information that may supersede

any information included in this booklet.

Trademarks: All brand names and product

names used in this manual are trade names,

service marks, trademarks, or registered

trademarks; and are the property of their

respective owners.

i

Table of Contents

The Self-Study Program provides you with information

regarding designs and functions.

The Self-Study Program is not a Repair Manual.

For maintenance and repair work, always refer to the

current technical literature.

Important/Note!

New !

Introduction ................................................................................................... 1

Volkswagen’s Flagship, The Phaeton Name,

Phaeton’s Place in Automotive History, The Transparent Factory,

Phaeton Technical Innovations, Specifications, Aerodynamics

Engines......................................................................................................... 10

The 4.2-Liter V8-5V Gasoline Engine,

The 6.0-Liter W12 Gasoline Engine

Fuel Supply .................................................................................................. 14

Fuel Delivery System

Transmissions.............................................................................................. 15

Automatic Transmissions

Running Gear............................................................................................... 26

Phaeton Chassis Overview

Body ............................................................................................................. 28

Body Structure, Body Attachments, Sound Silencers, Glass,

Power-Assisted Luggage Compartment Lid, Sunroof

Occupant Protection ................................................................................... 38

Overview, Airbag Systems, Seat Belt Systems,

Active Headrest System

Seats............................................................................................................. 44

Front Seats, Rear Seats

Air Conditioning System ............................................................................ 49

Four-Zone Climatronic, Air Distribution in the Vehicle,

System Overview

Electrical System......................................................................................... 54

Convenience Electronics, Adaptive Cruise Control,

Headlights, Fog Lights, Rear Lights, Battery, Phaeton Battery

Systems, Emergency Starting, Using the Front Information Display

Control Head J523 for Component Service, Infotainment System

Service.......................................................................................................... 74

Special Tools

Knowledge Assessment ............................................................................. 77

Introduction

1

Volkswagen’s Flagship

The introduction of the Volkswagen

Phaeton is the result of developments in

the international market for luxury cars.

Product quality alone is no longer sufficient

to guarantee success in highly-developed

markets. The prestige and value of the

brand are also decisive in influencing

purchasing decisions.

The increasing importance of customer

brand awareness spurred Volkswagen’s

entry into the luxury-class vehicle

market segment.

With the launch of the Phaeton, we are

introducing a product that both meets the

technical requirements demanded by our

customers, and also satisfies the value and

prestige demands being made on the

Volkswagen brand.

There are separate Self-Study

Programs on the following topics:

• The W Engine Concept

(821203)

• The Phaeton W12 Engine

Management System (892303)

• The Phaeton Heating and

Air Conditioning System

(894303)

• The Phaeton On-Board Power

Supply (895303)

• The Phaeton Convenience and

Safety Electronics (896303)

• The Phaeton Infotainment

System (897303)

• The Phaeton Air Suspension

(899303)

• The Phaeton Adaptive Cruise

Control (898303)

• The Phaeton Chassis (893303)

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Introduction

2

The Phaeton Name

The name Phaeton (or Phaethon) originally

derives from Greek mythology. Phaeton

(the “incandescent”) was the son of the

sun god Helios, who was the owner of the

sun chariot.

Derived from this, the word “phaeton” also

refers to the four-wheeled horse-drawn

walking coaches that became popular in the

18th century.

These phaetons are open owner-driver

carriages, featuring a trestle seat for two

persons with or without a canopy top.

Behind the trestle seat there is a seat for

one or two passengers facing forward.

Even now, these phaetons are driven

at special events. Original examples

have become extremely coveted

collectors’ items.

At the onset of the 20th century, the

term “phaeton” was applied to touring

carriages with a fabric canopy and without

side windows.

The Phonetics of Phaeton

How is it pronounced?

Phaeton is pronounced as follows:

fay - ton

The ending is spoken with an unvoiced

“N,” comparable to the pronunciation of

the words Futon or Flacon.

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Introduction

3

Phaeton’s Place in Automotive History

Since 1910, August Horch endowed some

of his models with the “Phaeton” suffix.

Some examples include the 1931 Horch

18/90 hp 450 Phaeton and the 1911 Horch

12/28 hp Phaeton, as well as the 1937

Horch 853A Parade Phaeton only three of

which were built, and the last remaining

model of which recently sold for $334,000.

The choice of the name “Phaeton” for

the Volkswagen flagship links this vehicle

to the tradition of employing superior

quality-control requirements in the

production phase to provide the ultimate

in exclusivity for each future owner

of a Phaeton.

Horch 18/90 hp 450 Phaeton, 1931-32

Horch 853A Parade Phaeton, 1937

Horch 12/28 hp Phaeton, 1910-11

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4

Introduction

The Transparent Factory

Concept

Not only has the advent of the exclusive

Phaeton led to the building of an

impressive production line in Dresden,

it has also engendered a polished and

precisely-functioning logistics concept.

The transparent factory represents a

significant milestone for Volkswagen’s

customer-oriented manufacturing

and delivery.

In addition to these outstanding technical

production details, purchasers of this

high-quality luxury-class automobile can

expect a perfectly-arranged vehicle transfer

with all of the pageantry suitable to such

a special event.

Production Line

Contrary to the popular opinion that

automobile manufacture is irrevocably

linked with dirt and oil, the vision of

manufacturing evident in Dresden depicts

production in an almost noble light.

The core of the manufacturing process

features overlapping conveyor belts floored

with fine wood parquet. The result is a

production line with an atmosphere like that

otherwise only seen in elite luxury sports

car plants.

5

Introduction

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Logistics

An automated system guides baskets

containing the individual components used

for the assembly of each vehicle through

the factory. Each basket accompanies its

corresponding vehicle throughout the

assembly stage. This reduces wasted

motion during assembly.

The chassis for a specific vehicle, including

the engine, transmission and exhaust

system, and the corresponding body are

simultaneously assembled on different

floors. These major subassemblies are then

transported in glass elevators to a different

level, where they are joined into a complete

vehicle and the final assembly process

takes place.

Once the manufacturing process has been

completed, each Phaeton is once again

placed on the overlapping conveyor belt

before receiving its finishing touches and

its final check.

Delivery

An exclusive automobile cries out for the

appropriate stage-management of its

delivery. Customers are the center of

attention in the transparent factory’s

emotionally and technologically impressive

discovery area.

Potential Phaeton owners are treated to a

birds-eye view of production via live video

image during a Virtual Production Tour.

6

Introduction

Phaeton Technical Innovations

This is an overview. Detailed descriptions of

the individual topics can be found in this

and other Phaeton Self-Study Programs.

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• Rear window heated by practically

invisible tungsten threads.

• Fenders and spare tire recess made of

plastic.

• Extremely narrow body jointing,

PVC-free underbody protection.

• Doors, engine hood and luggage

compartment lid made of aluminum.

• Fully-galvanized body.

• Taillights with two-color

LED technology.

• Antennas invisibly

integrated in the

rear window.

• Superior paint, scratch resistant,

exceptional brilliancy.

• Air-conditioned 12- and 18-position

seats, keyless access function,

Adaptive Cruise Control,

multi-function steering wheel.

• Infotainment system with navigation

and radio/CD; CD changer in the

glove compartment; four-zone

air conditioning.

7

Introduction

• Xenon headlights with automatic

headlight range control.

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• Surrounding illumination with front, rear, and forward lighting

simplifies orientation when getting out of the car in the dark.

• Air suspension with automatic control.

• Electro-mechanical high-pressure nozzles for cleaning headlights.

• Side and rear windows made of twin-pane laminated safety glass.

8

Specifications

Introduction

• Length

203.74 inches (5175 mm)

• Width

74.92 inches (1903 mm)

• Height

57.09 inches (1450 mm)

• Wheelbase

118.15 inches (3001 mm)

• Fuel tank capacity

23.8 gallons (90 liters)

• Front track width

64.09 inches (1628 mm)

64.09 in

(1628 mm)

• Rear track width

63.46 inches (1612 mm)

• Permitted gross vehicle weight

5732 – 6592 pounds (2600 – 2990 kg)

(depending on the engine)

• Curb weight

4398 – 5320 pounds (1995 – 2413 kg)

(depending on the engine)

• Luggage compartment space

13 cubic feet (368 liters)

• Drag coefficient

0.32 C

D

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203.74 in

(5175 mm)

118.15 in

(3001 mm)

63.46 in

(1612 mm)

57.09 in

(1450 mm)

74.92 in

(1903 mm)

9

Aerodynamics

The Phaeton has a low drag coefficient of

0.32 C

D

.

This level was achieved by combining

several design elements:

• The underbody has an extremely

smooth design.

• The windshield wipers are recessed.

• The body gap dimensions are

very narrow.

• The front has an arrow-shaped design.

• The body is lowered at higher

vehicle speeds.

Introduction

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Small features such as the retractable

headlight cleaning nozzles, the

antenna-free body, and the smooth

body transitions are also responsible for

this low drag coefficient.

10

Engines

The 4.2-Liter V8-5V Gasoline Engine

Emphasis was placed on the following

development objectives:

• Compliance with future

exhaust-emission regulations.

• Reduction of fuel consumption.

• Increase in torque and power.

• Improvement of comfort and

convenience.

• Reduction of engine weight.

• Increased use of shared components.

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Alloys are used extensively:

• The cylinder heads and oil sump top

section are made of aluminum.

• The valve covers are die-cast magnesium

coated with a thin synthetic material to

prevent corrosion.

• The cylinder block is aluminum.

11

Engines

Technical Data – 4.2-Liter V8-5V

Gasoline Engine

• Type

V8 engine with 90 degree V-angle,

five valves per cylinder, and variable

intake and exhaust valve timing

• Displacement

255 cu in (4172 cm

3

)

• Bore

3.32 in (84.5 mm)

• Stroke

3.66 in (93.0 mm)

• Compression ratio

11:1

• Maximum power output

310 bhp (228 kW) @ 6200 rpm

• Maximum torque

302 lbs-ft (410 Nm) @ 3000 to 4000 rpm

• Engine management

Motronic ME 7.1.1

• Firing sequence

1-5-4-8-6-3-7-2

• Fuel type recommendation

Premium unleaded gasoline (91 AKI)

The specified power data is

only possible if 91 AKI fuel is

used. A reduction in power

output must be expected if

lower grade fuel is used.

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hp kW

335 250

302 225

268 200

235 175

201 150

168 125

134 100

101 75

67 50

34 25

Torque

Output

2000 4000 6000

Speed (rpm)

lbs-ft Nm

369 500

332 450

295 400

258 350

221 300

184 250

148 200

111 150

74 100

37 50

0

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12

Engines

The 6.0-Liter W12 Gasoline Engine

With the W12 engine, Volkswagen is

offering a 12-cylinder engine in its lineup for

the first time ever. It is the most powerful

engine version available in the Phaeton.

Mechanical Innovations

• Cylinder block made of aluminum.

• Bottom crankshaft bearings in gray cast

iron bearing blocks.

• Oil pump driven by a chain.

• Very compact engine.

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Engine Management

• Dual control module concept.

• Secondary air injection.

• Exhaust gas recirculation.

13

Engines

The specified power data is

only possible if 91 AKI fuel is

used. A reduction in power

output must be expected if

lower grade fuel is used.

Please refer to

The W Engine Concept,

Self-Study Program Course

Number 821203 and

The Phaeton W12 Engine

Management System,

Self-Study Program Course

Number 892303 for more

detailed information on the

W engine concept.

hp kW

442 330

402 300

362 270

322 240

282 210

241 180

201 150

161 120

121 90

80 60

40 30

lbs-ft Nm

487 660

443 600

398 540

354 480

310 420

266 360

221 300

177 240

133 180

89 120

44 60

0

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Technical Data –

6.0-Liter W12 Gasoline Engine

• Type

W engine with four valves per cylinder

• Displacement

366 cu in (5998 cm

3

)

• Bore

3.31 in (84 mm)

• Stroke

3.55 in (90.186 mm)

• Compression ratio

10.75:1

• Maximum power output

414 bhp (309 kW) @ 6000 rpm

• Maximum torque

406 lbs-ft (550 Nm) @ 3500 rpm

• Engine management

Motronic ME 7.1.1

• Firing sequence

1-12-5-8-3-10-6-7-2-11-4-9

• Fuel type recommendation

Premium unleaded gasoline (91 AKI)

• Exhaust treatment

Three-way catalytic converters

2000 4000 6000

Speed (rpm)

Torque

Output

14

Fuel Supply

Fuel Delivery System

Fuel Tank

The fuel tank is mounted on the vehicle

underbody close to the rear axle. It has a

capacity of 23.8 gallons (90 liters). Due to

its external shape, it consists of a main fuel

tank chamber and a secondary fuel tank

chamber.

Each fuel tank chamber has an electric fuel

pump and a suction jet fuel pump.

Secondary

Fuel Tank

Chamber

Each electric fuel pump is assigned two

senders for fuel supply: a fuel sender and a

level sender.

The four senders for fuel supply transmit

their signals directly to the Control Module

with Indicator Unit in Instrument Panel

Insert J285.

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Reserve Fuel Tank

(only in vehicles with

gasoline engines)

Fuel Pump G6

Main

Fuel Tank

Chamber

Fuel Filter

Suction Jet Pump 1

Suction Jet Pump 2

Transfer

Fuel Pump

G23

15

Transmissions

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Automatic Transmissions

Depending on the engine application

and marketing area, the Volkswagen

Phaeton is available with a five-speed

automatic transmission or a six-speed

automatic transmission.

Both automatic transmissions are currently

already in use in other Volkswagen vehicles.

They have been modified and adapted for

installation in the Phaeton. An electro-

hydraulic system is used to control them.

The Transmission Control Module J217

registers operating conditions, driver input,

and external influences such as travelling

uphill or downhill. Gear selection is made

by the Transmission Control Module J217

based on all incoming data.

Five-speed automatic transmission features:

• Dynamic shift program and sport

shift program.

• Regulated torque converter

lockup clutch.

• Tiptronic shift program.

Five-Speed Automatic Transmission 01L

• Installed in the Phaeton equipped with

the 6.0-liter W12 engine.

• A Torsen center differential is integrated

in this transmission to distribute the

torque to all four wheels.

• Maximum torque transmission:

413 lbs-ft (560 Nm).

16

Transmissions

Six-Speed Automatic Transmission 09F

This specially-developed automatic

transmission is used in Phaetons equipped

with the 4.2L V8-5V engine.

Compared with the five-speed automatic

transmissions, the six-speed automatic is

especially characterized by:

• Improved driving performance.

• Reduction of fuel consumption and

exhaust emissions.

• Mass reduction of approximately

30.9 pounds (14 kg).

• Reduction of the number of components

by approximately 30%.

• Excellent quality and highly

responsive shifting.

• Maximum input torque: 553 lbs-ft

(750 Nm).

Like the five-speed automatic, the

six-speed automatic transmission 09F

also has:

• Dynamic shift program and sport

shift program.

• Regulated torque converter

lockup clutch.

• Tiptronic shift program.

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