Tiguan Haldex All-Wheel Drive - Freel2

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Service TrainingSelf Study Program 861803Tiguan Haldex All-Wheel Drive

Volkswagen of America, Inc.Volkswagen AcademyPrinted in U.S.A.Printed 3/2008Course Number 861803 2008 Volkswagen of America, Inc.All rights reserved. All information contained in this manual isbased on the latest information available at the time of printingand is subject to the copyright and other intellectual propertyrights of Volkswagen of America, Inc., its affiliated companiesand its licensors. All rights are reserved to make changes atany time without notice. No part of this document may bereproduced, stored in a retrieval system, or transmitted in anyform or by any means, electronic, mechanical, photocopying,recording or otherwise, nor may these materials be modifiedor reposted to other sites without the prior expressed writtenpermission of the publisher.All requests for permission to copy and redistributeinformation should be referred to Volkswagen of America,Inc.Always check Technical Bulletins and the latest electronicrepair information for information that may supersede anyinformation included in this booklet.Trademarks: All brand names and product names used inthis manual are trade names, service marks, trademarks,or registered trademarks; and are the property of theirrespective owners.

ContentsIntroduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Drivetrain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4All-Wheel Drive Clutch Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Knowledge Assessment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25NoteThis Self-Study Program provides informationregarding the design and function of newmodels.This Self-Study Program is not a Repair Manual.Important!This information will not be updated.For maintenance and repair procedures,always refer to the latest electronicservice information.iii

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IntroductionVolkswagen has used a Haldex clutch for the4MOTION all-wheel drive since 1998. A newgeneration of the all-wheel drive clutch is now usedby Volkswagen for the first time in the Tiguan.Introductionslip at other wheels. The distribution of the driveforces to the axles is variable and depends on thedriving conditions. The new all-wheel drive clutch in4MOTION responds rapidly to any driving situationand maintains the best possible traction at all times.The new all-wheel drive clutch is controlledelectronically. It allows torque to be transmitted tothe drive wheels that have traction regardless ofS414 002

OverviewOverviewHistoryIn 1998, 4MOTION drive replaced synchro all-wheeldrive at Volkswagen. While the synchro all-wheeldrive used a visco clutch, an all-wheel clutch byHaldex was used for the first time in the 4MOTIONdrive.First Generation Haldex ClutchWith this hydraulic multiplate clutch, the all-wheeldrive could be controlled electronically. Apart fromslip control, the control module also allowed handlingdynamic driving conditions such as curves, speed,and overrun, or load operation.Function of Haldex ClutchesThe first two generations of the Haldex clutch usea rotational speed difference between the front andrear axles to operate. A pump effect is generatedusing a cam plate, rollers, and two reciprocatingpistons working in parallel. This creates oil pressurethat compresses the multiplate clutch througha working piston. The drive torque transferreddetermines the amount of pressure applied.S414 003Generation II Haldex Clutch from Model Year 2004The pressure on the multiplate disks of the clutch isregulated through: Suction valves Pressure valves Electronic control valve Control module S414 004

OverviewHaldex Generation IVAll-Wheel Drive ClutchThe power transfer through the multiplate pack ofthe generation IV all-wheel drive clutch is nearlyidentical to the previous Haldex models. Generatingthe pressure with an electric pump is a new feature.The torque to be transferred is determined by AllWheel Drive Control Module J492 through theselection of Haldex Clutch Control Valve N373. Speeddifferences between the front and rear axles are nolonger a prerequisite for activating the all-wheel driveclutch.Advantages Clutch selection independent from the drivingsituation Rapid torque build-up Permanent rear wheel drive capacity Unrestricted compatibility with the slip controlsystems (e.g. ESP, ABS)Technical Features Electro-hydraulically controlled multiplate clutch Integrated in the rear axle drive Simplified hydraulic circuit Optimized demand-controlled pump selectionS414 005

DrivetrainDrivetrain4MOTION Drivetrain SystemThe front wheels are conventionally driven by thefront axle differential. At the same time, the torque istransferred to the propeller shaft by this differentialthrough the angle transmission.Depending on the degree of engagement of the allwheel drive clutch, a torque that matches the drivingsituation is transmitted to the rear axle drive.EngineAngle TransmissionPropeller ShaftRear Axle DriveAll-Wheel Drive ClutchTransmissionFront Axle DifferentialRear Axle DifferentialS414 007

DrivetrainAngle TransmissionThe angle transmission increases the torque to thepropeller shaft by a factor of 1.6. The diameter of theshaft can be smaller for this reason, since it transfersa smaller torque. In the rear axle drive, the torque isreduced again by the same factor of 1.6.Output toRight WheelOutput toPropeller ShaftDrive from Transmissionand Output to Left WheelS414 008Power FlowThe force is transferred from the spur gear tothe propeller shaft by the differential cage of thedifferential, the hollow shaft with crown wheel, andthe pinion.FromTransmissionDifferential CageHollow ShaftOutput toLeft WheelSpur GearOutput toRight WheelPinionCrown WheelOutput toPropeller ShaftS414 009

DrivetrainPropeller ShaftThe propeller shaft has two parts. They are linkedby a center joint. Flexible disk joints are used tomake the connection to the transfer case and theall-wheel drive clutch. A rotational vibration absorberis permanently attached to the rear flexible disk jointand cannot be serviced separately. It reduces thetransfer of engine vibrations through the rear axledifferential to the body.Center JointFlexible Disk Jointwith RotationalVibration AbsorberFlexibleDisk JointDirection of TravelS414 010Rear Flexible Disk JointCenter JointThe rear axle transmission and the propeller shaftare balanced during production. For this reason thedrivetrain does not require balancing in the vehicle.The center joint is press-fitted and cannot beseparated. This results in a compact and light designand the roll bellows is better protected.RotationalVibrationAbsorberNo BalancingRequiredRoll BellowsS414 011 S414 012

DrivetrainRear Axle DriveThe all-wheel drive clutch is integrated in the rearaxle drive.Crown WheelRear Axle Drive PinionAll-Wheel Drive ClutchMultiplate PackRear Axle DifferentialAll-Wheel DriveClutch Oil ReservoirDrive ShaftAll Wheel DriveControl Module J492S414 013

DrivetrainFunction of the All-WheelDrive ClutchThe all-wheel drive clutch between front and rearaxle drives controls the drive torque to the rear axle.Depending on the degree of engagement, the allwheel drive clutch directs the required drive torqueto the rear axle.All-Wheel Drive Clutch ComponentsMultiplate PackAccumulatorOil FilterHaldex ClutchPump V181Haldex ClutchControl Valve N373All Wheel DriveControl Module J492Oil Circuit ComponentsMultiplate ClutchS 414 014Haldex ClutchControl Valve N373All Wheel DriveControl Module J492AccumulatorHaldex ClutchPump V181 S414 064

All-Wheel Drive Clutch DetailsAll-Wheel Drive Clutch DetailsOverviewThe individual all-wheel drive clutch componentgroups are shown here to provide a betterunderstanding of how they work.Mechanical AssemblySpring PlateNeedle BearingThrust PlatesWorking PistonsNeedleBearingDrive HubMultiplate PackClutch CageS414 015Electro-Hydraulic Assembly and All Wheel DriveControl Module J492All WheelDrive ControlModule J492Haldex ClutchControl Valve N373AccumulatorHaldex Clutch Pump V181Oil FilterS414 040

All-Wheel Drive Clutch DetailsMechanical AssemblyThe following sub-groups belong to the mechanicalassembly: Multiplate clutch Working piston Spring plateThe entire assembly creates the frictional connectionbetween front and rear axles. The multiplate packis compressed when pressure is applied to theworking piston. Depending on the contact pressure,a different torque (up to 1770 lbs-ft or 2400 Nm) canbe transferred.Multiplate PackThe multiplate pack consists of friction plates andsteel plates, with one thrust plate in the front andone in the rear.The friction plates have internal teeth that engage thedrive hub. The steel plates engage the clutch cagewith external teeth. The number of plates dependson the vehicle type.Steel PlateMultiplate ClutchThe multiplate clutch consists of the drive hub, themultiplate pack and the clutch cage.FrictionPlateDrive HubThe drive hub is driven by the propeller shaft via theflange.ThrustPlateS414 042Thrust PlateS414 041FromPropellerShaftMultiplate PackS414 052Drive HubS414 05110

All-Wheel Drive Clutch DetailsClutch CageThe clutch cage is connected with the pinion of therear axle by a spline, and transfers the drive torque tothe rear axle.Rear Axle PinionClutch CageS414 053SplinesS414 043Working PistonThe working piston is a cylindrical piston.FunctionWhen actuating the clutch, the pressure of theworking piston is transferred to the multiplate packvia a needle bearing. The working piston does notturn. The multiplate pack, on the other hand, rotatesat drive speed.NeedleBearingS414 054Working PistonS414 044Spring PlateThe spring plate is located on the oil pressure side ofthe working piston.Oil Pressure SideSpring PlateFunctionIt creates a preload which pushes the working pistonin place. This removes the play from the multiplatepack and the needle bearings.S414 045S414 05511

All-Wheel Drive Clutch DetailsElectro-Hydraulic AssemblyThe electro-hydraulic assembly consists of theHaldex Clutch Pump V181, the oil filter, theaccumulator, and the Haldex Clutch Control ValveN373.Haldex Clutch Pump V181The Haldex Clutch Pump V181 is a reciprocatingpiston pump and is installed in the lower sectionof the all-wheel drive clutch. It generates the oilpressure. The accumulator in the oil circuit is filledregularly. It is requested by the All Wheel DriveControl Module J492 depending on the demand.FunctionThe bores of the cylinder housing each contain apiston with a locating pin and a return spring. Withthe help of an angular ball bearing, the piston andlocating pin are moved in stroke fashion when thecylinder housing turns so that oil is drawn in at thebottom and is discharged compressed at the topafter 180 degrees of rotation.S414 046Compressed OilIs DischargedOil IsDrawn InThe oil filter is a no-maintenance fleece filter. A checkvalve is integrated in the oil filter housing whichprevents the oil pressure to the Haldex Clutch PumpV181 from dropping.12To AccumulatorBallBearingEffects of FailureWhen the Haldex Clutch Pump V181 fails, oilpressure cannot be generated. Torque is no longertransferred to the rear axle.Oil FilterCylinderHousingPistonLocating PinFrom OilReservoirReturn SpringS414 022

All-Wheel Drive Clutch DetailsAccumulatorThe compact design of the accumulator includesthree parallel acting springs and is positioned on topof the clutch. It adjusts the oil pressure using springforce and keeps it at 435 psi (30 bar).From Pump to ValveSystem without Pressure:The springs of the accumulator are relieved.Return to Oil ReservoirSystem with Working Pressure:The pressure chamber is filled by the pump. Thepressure piston is pushed back and the spring isunder tension.Return ChannelPressure PistonS414 016PressureChamberReturn to Oil ReservoirReturn ChannelS414 017PressureChamberIf the oil pressure exceeds 435 psi (30 bar), thereturn channels become accessible, the pressure inthe direction of the oil reservoir is reduced, and oilreturns to the reservoir.Return ChannelReturntoOil ReservoirS414 01813

All-Wheel Drive Clutch DetailsHaldex Clutch Control Valve N373TaskThe Haldex Clutch Control Valve N373 controls theworking pressure that is passed on to the workingpistons. Pressure increases in proportion to theelectric current applied to the solenoid. Pressure isprecisely defined for each current value.SpringNeedleTo Oil ReservoirTo Working PistonBoreRegulating ChamberFrom AccumulatorSolenoid CoilControl PistonMagnet CoreElectrical ConnectorS414 01914

All-Wheel Drive Clutch DetailsFunctionThe Haldex Clutch Pump V181 and the accumulatorhave built a pressure of 435 psi (30 bar). (1)1Oil Pressure435 psi (30 bar)2WorkingPressureGeneratedApplying an electrical current to the solenoid coilgenerates a magnetic force the amount of whichdepends on the current applied. This moves thecontrol piston up, opens the flow, and the workingpressure is generated. (2)When the desired working pressure has beenreached, the balance of force described belowis established so that the flow is closed and theworking pressure maintained. (3)The working pressure is applied to the workingpiston and in the control piston regulating chamber.The pressure in the regulating chamber works in thesame direction as the return force of the spring andsupports it as counteracting force to the magneticforce. A balance of force is achieved.S414 020Spring ForceCompressionForceWhen the full current is applied, the intake on thebottom remains open and the entire oil pressuregenerated by Haldex Clutch Pump V181 is used asworking pressure.If the clutch has to be opened, no more current willbe applied to the solenoid coil, the control pistonreturns to its original position, and the pressure isrelieved by routing oil to the oil reservoir.3Flow agnetic ForceS414 021Effects of FailureIf the Haldex Clutch Control Valve N373 fails, the allwheel function is no longer available.Working PressureRouted to Oil ReservoirS414 02315

All-Wheel Drive Clutch DetailsAll Wheel Drive Control ModuleJ492TaskAll Wheel Drive Control Module J492 regulates thepump operating times and Haldex Clutch ControlValve N373. The amount of pressure is solelydetermined by the valve position. A temperaturesensor is located on the printed circuit board ofAll Wheel Drive Control Module J492 where itsmeasured values indicate the oil temperature.All Wheel Drive Control Module J492 is integratedin the CAN data bus drive. This allows precisecontrol of the system with only one sensor. Basedon data on the driving situation, the All WheelDrive Control Module J492 determines the desiredpressure so that the amount of all-wheel driveclutch engagement and transfer are adjusted to thesituation.In case of ESP or ABS intervention, ABS ControlModule J104 determines the amount of all-wheeldrive clutch engagement via All Wheel Drive ControlModule J492.Effects of FailureBecause Haldex Clutch Control Valve N373 can nolonger be selected, no more working pressure isgenerated. The clutch is disengaged and the rear axleis no longer driven.All Wheel DriveControl Module J492S414 02416

ControlsControlsOil CircuitThe electro-hydraulic components build up the oilpressure, controlling the contact pressure on themultiplate clutch.Working PistonHaldex ClutchControl Valve N373Spring PlateReturnAccumulatorMultiplate ClutchAll WheelDrive ControlModule J492Oil FilterOil ReservoirStrainerHaldex ClutchPump V181System Without PressureThe illustration shows the system in thedepressurized state. As long as the engine is offand only the ignition is turned on, All Wheel DriveControl Module J492 is selected but no pressure isgenerated.S414 027A Pressureless System Is Needed in These SituationsRoll DynamometerTowingThe Haldex Clutch Control Valve N373 is openedwithout current.Because a small amount of pressure isapplied through the spring plate, a speedof 31 mph (50 km/h) and a distance of31 miles (50 km) may not be exceededwhen towing with one axle raised.S414 030S414 03117

ControlsPressure Buildup at Engine Startthrough the accumulator. The working pressure issolely controlled through Haldex Clutch Control ValveN373, which can adjust the contact pressure on theworking piston according to the demand.When the engine is started, Haldex Clutch PumpV181 is activated. Haldex Clutch Pump V181 isselected as soon as an engine speed of 400 rpm isreached. It delivers oil via the filter to the accumulatoruntil a pressure of 435 psi (30 bar) is reached in theoil circuit. Haldex Clutch Control Valve N373 is closedby All Wheel Drive Control Module J492 so that theworking pressure is passed on to the working pistonand the multiplate pack is compressed.This working pressure may lie between 0%, such aswhen braking, and 100%, as when accelerating.Controlled Working PressureStartingWhen starting to drive and when accelerating, theentire rear axle drive torque is immediately available.Oil Pressure0 – 435 psi (0 – 30 bar)DrivingIn each driving situation, the pressure betweenpump and valve is kept constant at 435 psi (30 bar)S414 029Working PistonHaldex ClutchControl Valve N373Oil Pressure 0 – 435 psi (0 – 30 bar)Spring PlateOil Pressure435 psi (30 bar)ReturnAccumulatorMultiplate ClutchOil FilterOil ReservoirStrainerAll WheelDrive ControlModule J492Haldex ClutchPump V181S414 02818

ControlsDriving ScenariosDrive Torque at the Rear AxleStarting or AcceleratingA high drive torque is required at the rear axle. Thevalve closes completely and the contact pressure canreach its maximum.Control Range100%0%Starting/AcceleratingS414 056Fast DrivingOnly a low torque is required at the rear axle. Thecontact pressure is controlled according to demand(control range).100%0%BrakingNo torque is transferred to the rear axle whenbraking. The valve is opened and the pressure on theworking piston is reduced. The clutch is disengaged.Control RangeFast DrivingParking ManeuversOnly a low torque is transferred during parkingmaneuvers. The drivetrain is not under tension. Theclutch is controlled according to demand (controlrange).S414 057S414 033S414 058S414 049S414 059S414 034100%0%StoppingThe clutch is disengaged as long as the vehicle isbeing braked. When the vehicle is stopped, the precontrol uses the signal from the accelerator position.When starting to drive, the pressure is built up againand full torque capacity is available.SS414 032Braking100%0%Stopping100%0%Control RangeParking ManeuversS414 057S414 03519

ControlsCritical Driving SituationsDriving on Slippery RoadsThe working pressure is controlled according todemand.Signals come from ABS Control Module J104, whichdetects slippage through the speed sensors andcalculates the required traction.ESP or ABS InterventionWhen a wheel slip control system is activated, theamount of clutch engagement is controlled indirectlythrough the ABS Control Module J104. For example,the clutch may be disengaged entirely for an ABSintervention while it can be engaged for an ESPintervention.Drive Torque at the Rear AxleControl Range100%0%Driving on Slippery RoadsESP or ABS InterventionS414 036S414 060Starting with Slip (On Ice or Snow)The all-wheel clutch is engaged when both wheelsof the front axle spin. The rear axle takes on all of thedrive force.S414 065If only one wheel of the front axle spins, theElectronic Differential Lock (EDL) becomes active.The spinning wheel is braked and the drive force ofthe other wheel is increased. At the same time

4MOTION all-wheel drive since 1998. A new generation of the all-wheel drive clutch is now used by Volkswagen for the first time in the Tiguan. The new all-wheel drive clutch is controlled electronically. It allows torque to be transmitted to the drive wheels that have traction regardless of S414_002 slip at other wheels. The distribution of the .

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