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SSP-801503-New Technologies 大众汽车新技术 英文版.pdf

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SSP 801503 NEW TECHNOLOGIES 大众汽车 新技术 英文
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Self-Study Program Course Number 8015032005 Volkswagen New T echnologies ?i T able of Contents Important/Note! New! This Self-Study Program covers some systems of the 2006 Passat. This Self-Study Program is not a Repair Manual. This information ?will not be updated. For testing, adjustment and repair procedures, always refer ? to the latest electronic service information. Introduction ................................................................................1 New Technologies Electric Parking Brake Overview ...............................................2 Introduction, Electric Parking Brake Features Electric Parking Brake Operation ...............................................4 Electric Parking Brake Operation, Parking Brake Operation, ?Emergency Brake Operation, Using the Emergency Brake ?Feature, AUTO HOLD Operation, Hydraulic AUTO HOLD, ?AUTO HOLD Modes Electric Parking Brake Components ........................................12 Sensors, Actuators, Rear Wheel Brake Actuators, Parking ?Brake Unit, Toothed Belt Drive, Rear Wheel Brake Actuators, ?Clutch Position Sensor G476, Electric Parking Brake Button ?E538, AUTO HOLD Button E540, Indicator Lights, Electric ?Parking Brake Control Module J540 Electric Parking Brake Communication ..................................25 Electric Parking Brake CAN-Bus Electric Parking Brake Special Features ..................................27 Automatic Brake Pad Clearance Adjustment, Brake Pad ?Replacement Mode AFS Overview ...........................................................................29 Components and Locations AFS Moving Front Lights .........................................................32 Moving Front Light Operation, Illuminated Areas, Operating ?Requirements AFS Stationary Front Lights ....................................................34 Stationary Front Light Operation, Operating Requirements ?AFS Design ................................................................................36 Adaptive Front Headlight Assembly, Moving Front Light ?Assembly, Stationary Front Light Assembly ?AFS Service ...............................................................................41 Fault Indicator ?AFS Communication ................................................................42 Sensors, Controlled Components, Control Module Network, ?CAN Communication Knowledge Assessment ...........................................................481 Introduction New T echnologies This Self-Study Program focuses on new ?features found on the 2006 Passat. These new features include:? Electric Parking Brake? Adaptive Front Lighting System2 Electric Parking Brake Overview AUTO HOLD Button E540 Clutch Position Sensor Rear Wheel Brake Actuators Electric Parking Brake ?Control Module J540 ABS Control Module J104 Electric Parking ?Brake Button E538 S346_095 Introduction This section provides detailed information ?on the electric parking brake. Topics ?covered include: system overview, ?components, operation, special features, ?CAN networking, and operational diagram.3 Electric Parking Brake Overview Electric Parking Brake Features The electric parking brake offers many ?advantages over the mechanical hand parking ?brake. Signi?cant advantages include:? Greater interior design freedom ?The hand brake lever is replaced by a ?button. This allows greater freedom when ?designing the interior, the center console ?and the footwell area? More customer features ?Through the use of electronic controls ?and CAN networking, the electric parking ?brake can integrate with the AUTO HOLD ?function? Production advantages ?The elimination of the hand brake ?lever and hand brake cables allow ?simpli?cation of the production and ?assembly process? Self-diagnosis capability ?The electric parking brake system can ?be monitored constantly Hand Parking Brake Electric Parking Brake Setting Pull hand brake lever Press button ?Releasing Release hand brake lever Apply brake pedal and press button Stop and Go Continuous setting and releasing the ?parking brake or continuous operation ?of the foot brake When AUTO HOLD is selected, the ?vehicle is automatically held at each ?stop. A Comparison of a Hand Parking Brake and the Electric Parking Brake 4 Electric Parking Brake Operation S346_088 Braking Starts 4.4 mph (7 km/hr) Vehicle at Standstill Electric Braking Hydraulic Braking Electric Parking Brake Operation The electric parking brake system provides ?the following modes of operation:? Parking brake? Emergency brake? AUTO HOLD Depending on vehicle speed when the ?brakes are applied, a distinction is made ?between static braking (vehicle speed ? less than 4.4 mph [7 km/hr] and dynamic ?braking (vehicle speed greater than 4.4 mph ?[7 km/hr]). Static braking applies and releases the ?parking brake electrically. Dynamic braking slows the vehicle via ? ABS/ESP , meaning the brakes are applied ?hydraulically. The electric parking brake’s modes of ?operation are explained in greater detail on ?the following pages.5 Electric Parking Brake Operation S346_068 S346_064 S346_070 S346_066 Parking Brake Operation The electric parking brake provides safe ?parking on grades of up to 30 percent. The ?electric parking brake is applied by pressing ?the Parking Brake button. The electric ?parking brake is released by pressing the ?brake pedal, holding it, then pressing the ?Parking Brake button. Apply The electric parking brake can be applied at ?any time even when the ignition is OFF . When the parking brake is applied with the ?ignition ON, the indicator light in the electric ?parking brake button and the indicator light ?for the brake light both come ON. If the electric parking brake is applied with ?the ignition OFF , both indicator lights come ?ON for 30 seconds and then go OFF . Release The electric parking brake can only be ?released with the ignition ON. The electric parking brake releases when ?the brake pedal and the electric parking ?brake button are pressed at the same time. If the brake pads and rotors ?cool after the vehicle sets for ?a while, the electric parking ?brake automatically tightens if ?necessary. This is a calculated ?function.6 Electric Parking Brake Operation E538 ?Electric Parking Brake Button J104 ?ABS Control Module J540 ?Electric Parking Brake Control Module ?V282 ?Left Parking Brake Motor ?V283 ?Right Parking Brake Motor ?S346_090 J104 E538 V282 V283 J540 V<4.4 mph ?(7 km/hr) Using the Electric Parking Brake The Electric Parking Brake operates as ?follows:1 . The driver presses the Electric Parking ?Brake Button E538.2. The Electric Parking Brake Control ?Module J540 communicates with the ?ABS Control Module J104 through the ?dedicated CAN-bus and determines that ?the vehicle speed is less than 4.4 mph ?(7 km/hr).3. The Electric Parking Brake Control ?Module activates the two locking ?motors on the rear wheel brakes. The ?brake is applied automatically.4. If the driver presses the electric parking ?brake button again while pressing the ?foot brake, the rear wheel parking ?brakes will release.7 Electric Parking Brake Operation Emergency Brake Operation If the brake pedal fails or is blocked, ?the vehicle can be stopped using the ?emergency brake. Apply Pressing and holding the electric parking ?brake button causes a moving vehicle to be ?braked at a rate of approximately 6m/s 2 . A warning sounds and the brake lights turn ?ON. At a vehicle speed greater than 4.4 mph ?(7 km/hr), the emergency brake applies by ?increasing hydraulic brake pressure at all ?4 wheels. Depending on the situation, the ?braking may be regulated by the ABS/ESP ?system to maintain vehicle stability. If the button is pressed at a vehicle speed ?less than 4.4 mph (7 km/hr), the parking ?brake is applied. ?Release If the vehicle speed is greater than 4.4 mph ?(7 km/hr) after emergency braking has ?occurred, the brake releases when the ?electric parking brake button is released or ?the accelerator pedal is pressed. If the vehicle has stopped, the parking ?brake will engage. When the electric parking brake ?button is pressed, the engine ?goes to idle and related features ?such as cruise control, automatic ?cruise control or AUTO HOLD are ?turned off. The emergency braking will ?function with the ignition OFF .8 Electric Parking Brake Operation E538 ?Electric Parking Brake Button J104 ?ABS Control Module J540 ?Electric Parking Brake Control Module ?V282 ?Left Parking Brake Motor ?V283 ?Right Parking Brake Motor ?S346_092 J540 V282 V283 J540 J104 Using the Emergency Brake ?Feature1 . The driver presses and holds the Electric ?Parking Brake Button E538.2. The Electric Parking Brake Control ?Module J540 communicates with the ?ABS Control Module J104 via the ? CAN-bus to determine if the vehicle ?speed is greater than 4.4 mph (7 km/hr).3. If the vehicle speed is greater than 4.4 ?mph (7 km/hr), the ABS Control Module ?J104 activates the hydraulic pump, ?builds up brake pressure and applies the ?brakes to all four wheels.4. If J538 is released or the accelerator ?pedal is pressed and J540 determines ?that the vehicle speed is still greater ?than 4.4 mph (7km/hr), the brakes are ?released.If the vehicle has stopped, the parking ?brake will be engaged.9 Electric Parking Brake Operation S346_086 S346_082 AUTO HOLD Operation AUTO HOLD assists the driver when the ?vehicle is standing still and in starting off ?events (forward or reverse travel). Activation AUTO HOLD activation can only occur if the:? Driver-side door is closed? Safety belt is buckled? Engine is running Whenever the vehicle is restarted, the ?AUTO HOLD feature must be reactivated by ?pressing the AUTO HOLD button. To activate AUTO HOLD, press the AUTO ?HOLD button in the center console. The ?indicator light in the button lights showing ?that the AUTO HOLD system is active. ?Deactivation If any one of the Activation conditions ?change, the AUTO HOLD feature turns OFF . To deactivate AUTO HOLD, press the AUTO ?HOLD button again. The indicator light in ?the button goes off showing that the AUTO ?HOLD system is inactive. The AUTO HOLD function also includes the ?following assistance features: Stop and Go Assistance Less effort is required during stop-and-go ?driving because it is no longer necessary to ?use the brake pedal to hold the vehicle still. 10 Electric Parking Brake Operation S346_084 S346_080 Start-off Assistance When AUTO HOLD is activated, start-off ?assistance automatically holds the vehicle ?in a parked position on a grade until the ?accelerator pedal is pressed. Automatic Parking Brake Application When the vehicle is stopped with the AUTO ?HOLD feature activated, and the driver-side ?door is open, the safety belt is unbuckled ?or the ignition is OFF , the parking brake will ?automatically apply. Hydraulic AUTO HOLD When the AUTO HOLD feature is ?rst ?activated, the vehicle is held in place ?hydraulically by the four wheel brakes. When the driver applies the brakes by ?pressing the brake pedal, pressure is held ?by blocking the valves in the ABS unit. The ?driver is no longer required to press the ?brake pedal to hold the vehicle in place. If the driver does not press the brake pedal ?and the vehicle starts to move after a ?detected stop, ESP is activated and brake ?pressure is applied by the ABS pump. After the vehicle is held for three minutes, ?a switch from ESP hydraulic to the ?electric parking brake is made. The vehicle ?will move away seamlessly when the ?accelerator pedal is pressed.11 Electric Parking Brake Operation E540 ?AUTO HOLD Button ?J104 ?ABS Control Module J540 ?Electric Parking Brake Control Module V282 ?Left Parking Brake Motor ?V283 ?Right Parking Brake Motor ?S346_116 3 minutes J104 E540 J540 V283 V282 J104 E540 J540 V283 V282 AUTO HOLD Modes1 . Initially AUTO HOLD prevents vehicle ?movement by hydraulically applying ?the four wheel brakes. This is set, ?monitored, and adjusted by the ABS ?Control Module J105 depending on the ?grade the vehicle is on.2. After 3 minutes, the electric parking ?brake takes over. J104 communicates ?the torque required to hold the vehicle ?to the Electric Parking Brake Control ?Module J540.3. J540 activates the left and right locking ?parking brake motors V282 and V283 on ?the rear wheel brakes. The brakes are ?now set electrically and the hydraulic ?brake pressure is reduced by J105.12 Electric Parking Brake Components Sensors Actuators Clutch Position Sensor G476 Electric Parking Brake ?Button E538 AUTO HOLD Button E540 Left Parking Brake Motor V282 Right Parking Brake Motor V283 Electric Parking Brake Control ?Module J540 ABS Control Module J104 Electric Parking Brake ?Indicator Lamp K213 Brake System Warning Lamp K118 Electric Park/Handbrake Malfunction ?Indicator Lamp K214 AUTO HOLD Indicator Lamp K237 S346_06213 Electric Parking Brake Components Rear Wheel Brake Actuators The electric rear brake actuator is an ?integral part of the rear wheel brake caliper. ?The electric motor, the multistage gear ?and the spindle drive convert the “ Activate ?Parking Brake” command into a speci?ed ?force that applies the rear brakes. Multistage Gear Brake Caliper Electric Motor ?(Locking Motor) S346_04114 Electric Parking Brake Components Parking Brake Unit Only slight movement of the brake piston ?is required to set the parking brake. The ?rotational motion of the electric motor ?is converted into a linear motion in three ?stages with an overall ratio of 1:150 (150 ?revolutions of the electric motor for each ?revolution of the spindle drive). Spindle Drive Brake Piston Swash Plate Gear Gear Housing Brake Piston Toothed Belt Electric Motor 1st stage–toothed belt drive ?The ?rst stage (ratio of 1:3) is from the ?electric motor to the swash plate gear ?input. 2nd stage–swash plate gear ?The second stage (ratio of 1:50) is ?produced by the swash plate gear. 3rd stage–spindle drive ?The spindle drive converts the rotational ?motion into linear motion. S346_032 S346_03415 Electric Parking Brake Components T oothed Belt Drive In the ?rst stage (1:3), the toothed belt ?transmits power from the electric motor to ?the swash plate gear. The toothed belt drive ?consists of:? A small gear attached to the electric ?motor ? A large gear attached to the swash plate ? A toothed belt that connects the small ?and large gears The ratio is determined by the gear sizes. Large Gear ?(Swash Plate Gear Input) S346_040 S346_046 Small Gear ?(Electric Motor Output) Toothed Belt Large Gear ? (Swash Plate Gear Input) Tab Shaft Driven Wheel ?Tab Swash Plate Swash Plate Gear Assembly The swash plate gear assembly provides ?the second stage ratio change (1:50) and ?consists of a large gear, the swash plate, ?and the driven wheel. The swash plate is prevented from rotating ?in the housing by two tabs that allow only a ?rocking motion.16 Electric Parking Brake Components Spindle Drive The spindle drive converts the rotational ?movement of the gears into a linear motion. ?The spindle is driven by the swash plate ?gear. The spindle’s direction of rotati

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