Curso Volkswagen 2003 G3 GOL Station.ppt

Curso Volkswagen 2003 G3 GOL Station.ppt

1. WWW.ELEMECAOUTO.BLOGSPO
T.COM

2. Sumario
Crash test

3. Dimenciones
3/5 Puerta S.WAGON PICK- UP
2468
1388
1384
4131
1628
1902
1455
117
2599
1388
1384
4463
1640
1903
1483
154
2468
1388
1384
3883
1628
1902
1415
120
Cotas y pesos
A – Batalla
B - Distancia delantera (ejes)
C – Distancia trasera (ejes)
D – Largo
E - Ancho
Ancho con espejos
F – Altura (descargado)
G – Altura libre con carga maxima

4. Ergonomia y estilo

5. Ergonomia y estilo

6. Parati
Parati
Parati
Ergonomia y estilo

7. Tableros de instrumento
Inyeccion
electronica
Frenos ABS 5.3
Air-bag15
17
25
03
Tecnologia y
Seguridad
01
Inmobilizado
r
SistemasCodigos

8. Tecnologia y
Seguridad
Tableros de instrumento
Inyeccion
electronica
Frenos ABS 5.3
Air-bag15
17
25
03
01
Inmobilizado
r
SistemasCodigos

10. 13,9 - 3000
UNF
1596
Dados Tecnicos
Identificacion del motor
Potencia max. (cv / KW - rpm) 92 / 68 - 5500
Cilindrada (cm
3
)
Par max. (kgfm - rpm)
Motor EA 827

11. Motor EA 827

12. Motor EA 827

13. Motor EA 827

14. Motor EA 827

15. Motor EA 827

16. Motor EA 827

17. Motor EA 827

18. Motor EA 827

19. Motor EA 827

20. Motor EA 827

21. Componentes del Sistema
Sensores Actuadores
Unidad
del Motor
J382
Bobina de encendido (N152)
Valvulas inyectoras
N30, N31, N32, N33
Rele (J17)
Bomba de
combustible(G6)
Válvula para purga de aire
del depósito (N80)
Corretor de ralenti
Rele de plena potencia
A/C
Conector de
diagnostico
(Sensor Convinado)
Transmisor de presión
(G71) e Temperatura del
aire de admisión
(G42)
Transmisor Hall (G40)
Sonda Lambda (G39)
Sensor de
picado
(G61)
Sensor de temperatura
(G62)
Sensor da posicion
de la mariposa(G69)
Linia 30
A/C Señal

22. 720° (2 vueltas del motor)
Sensor Hall
PMS 1° Cil. PMS 4° CilPMS 3° Cil PMS 2° Cil
72° 66° 6° APMS
Marca OT (Primero ciliindro PMS)

23. Esquema ElectricoEsquema Electrico

24. Puesta a punto
Motor EA 827

25. AZN
8,6 / 84,0 - 3500
999
Specifications
Identificacion del motor
Potencia max. (cv / KW - rpm) 57,0 / 42,0 - 5200
Cilindrada (cm
3
)
Par motor (kgfm / Nm - rpm)
Motor EA 827

26. Magneti Marelli
4SV
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
la gestión del motor Magneti Marelli 4LV
Caracteristicas
Motor EA 111

27. la carcasa del árbol de
levas y la culata hacen un
par
Culata
Motor EA 111

28. Intake
Outlet
Balancine
s de
rodillos
Sistema RSH
Motor EA 111

29. Motor EA 111
Sistema RSH

30. Motor EA 111
Sistema RSH

31. Motor EA 111
Sistema RSH

32. Motor EA 111
Sistema RSH

33. Motor EA 111
Sistema RSH

34. El Colector de Admisión en Material Plástico
Motor EA 111

35. Bomba de Aceite Duocentric
Motor EA 111

36. Motor EA 111
Bomba de Aceite Duocentric

37. Inyector de Aceite
Motor EA 111

38. Motor EA 111
Bielas
CraqueoCorte

39. Canal de lubrificación
Motor EA 111
Bielas

40. Motor EA 111
Brida de estanqueidad con retén de PTFE

41. G 28
G 40
G 187
G 188
G 62
G 71
G 42
G 39
G 61
G 36
F / F 47
G 79
G 185
G 6
J 17
N 30... N 33
N 152
G 185
Z 19
N 80
K 132
Unidad del motor
J 448
Unidad de
Inmobilizador
J 362
Motor EA 111

43. Motor EA 111
El transmisor del número de revoluciones del motor G28

44. Motor EA 111
Distribución estática de alta tensión
Circuito eléctrico
Transformador de encendido

45. Motor EA 111
Transmisor Hall G40

46. Motor EA 111
Transmisor Hall G40

47. Motor EA 111
Transmisor Hall G40

48. Motor EA 111
Transmisor Hall G40

49. 720° (2 vueltas del motor)
Sensor Hall
TDC 1ro Cil. TDC 4to CilTDC 3ro Cil TDC 2do Cil
72° 66° 6° BTDC
Distribuidor montado en OT (primeiro cilindro em
PMS)
Motor EA 111

50. Emisiones – Proconve Fase III
12g / km
0,6g / km1,4g / km
1,2g / km 0,3g / km
2g / km
2,5% 0,5%
400PPM 250PPM
Fase II Fase IIIGases de escape
Monóxido de Carbono
(CO)
Hidrocarburos (HC)
Porcentage de CO en
velocidad media
Óxidos nitricos (NOx)
Porcentage de CO en
velocidad media

51. P.M.S. (2V)
referencia
Protecion
plastica de
referencia
punto de
referenci
a
Punto
correcto de la
correa
dentada
cuando los
dos punteros
esten juntos
Dente
chanfrado de
referecia de
la polea
Sincronismo
Motor EA 111

52. Electric Diagram

54. Electronic Power Control

55. System Description
Electronic Power Control

56. Control Process
Electronic Power Control

57. Electronic Power Control
S
E
N
S
O
R
S
A
C
T
U
A
T
O
R
S
E C U

58. Monitoring Function
Electronic Power Control

59. Accelerator Pedal Module
Sliding contact path
Sender
Electronic Power Control

60. Throttle Valve Control Unit J 338
Electronic Power Control

61. G187
G188
Function
Electronic Power Control

62. Brake Light Switch (F) and Brake Pedal Switch (F 47)
Electronic Power Control

63. Clutch Pedal Switch F 36
Electronic Power Control

64. Fault Indicator Lamp
Electronic Power Control

66. Clutch System
Clutch locking position

67. Gear box 013
2
nd
speed gear
3
rd
speed gear
Main axle
Rear speed
gear
Rear speed
1
st
speed gear
Gear Box
4
th
speed
gear
Pinion axle
5
th
speed gear
Gear Box

68. Gear Box
Gear
Internal
ring
Intermediate
ring
Synchronizing
ring
Synchronizing
ring
Synchronizing
sleeve
Intermediate
ring
Synchronizing body
Internal
ring
Gear

69. Adjust of ring gear and pinion assembly
Speed Transmission

71. 1 : 4,5
Servo-brake load ratio
Brakes System
Generation III

72. Brakes System

73. Brakes System

75. Springs
Service Training
Rate = N/mm Linear Progressiv
e
Super
Progressiv
e
F (N)
Deflection

76. Comfort Front Suspension
Current Suspension
Strut
Comfort Suspension Strut

77. Not Centered “S” Type Springs
7 coils - lower
distance
between coils
5 coils - higher
distance
between coils

78. Auxiliary Spring - Rear Suspension
Current Comfort

79. Comfort Suspension Strut
Current Comfort
Steering
arms
Support
plates

80. Steering Trapezium
Steering arm
Current system
Comfort
system
Steering gear
Steering rods
Steering arm
GOL 1.0 GOL 1.0

81. Steering System

83. Atom
Electrons
Protons
Nucleu
sNeutron
s

84. Electrical Current
ConductorFree electrons
BATTERY
Positive
pole
Negativ
e pole
Customers

85. Wiring Diagram
Switch
Resistor
Lamp
(+)
( - )

86. 3087
86
85
Relay
C
o
m
m
a
n
d

l
i
n
e
W
o
r
k
i
n
g

l
i
n
e
Command
coil
30(+)86( - )
85(+) 87
Relay - Wiring diagram
Command
current
85(+)Positive on
86( - )Negative
Working
current
30(+)Permanent
positive
87 Consumer supply

87. Electrical Measurement Instruments

88. Reading and Interpreting Wiring Diagrams
Line 31
Fuse 20A
(Line 30)
Fuse 10A
(Line 15)
Fuse 30A
(line 30)
Line 30
Electrical
central
Cooling
system
relay
Line 15

89. Coolant
temperatur
e sensor
Coolant
temperatur
e indicator
Wiring (1)

90. Circuit
Number
High / low
beam switch
Beam Switch Connection

92. Front
harness
Harnesses
Panel
harness
Rear harness
Electrical
central
Cover harnessInjection harnessDoors harness

93. Front
harness
Harnesses
Panel
harness Rear harness
Electrical
central
Injection harness Doors harness

94. Electrical Central Connectors
Lock after
fitting
connectors
Pos.
Orange
Black
Red
Gray
Blue
Brown
White
Yellow
Green
Pane
l
Pane
l
Pane
l
Pane
l
Rear
Fron
t
Fron
t
Fron
t
Pane
l
Harnes
s
Color
B
C1
C4
C2
C3
E1
D
E2
A

95. Ignition and Start Switches
Ignition
and
accessories
15 and X
Unlocked
Unlocked
Locked
15 and 50
Ignition
and start
Circuits
supplied
Lines
supplied
Steering
wheel
Key position

96. Combined Switches
Stop
Ignitio
n
Star
t
Key introduced
Key removed
Momentar
y light
signal
Lights
commutin
g
High and
low beams
L
O
Automatic
wiper
Front wiper /
cleaner
Rear w
iper /
cleaner
W
i
p
e
r

-

s
p
e
e
d

2
W
i
p
e
r

t
i
m
i
n
g
O
ff
M
o
m
e
n
t
a
r
y

w
i
p
e
r

a
c
t
i
v
a
t
i
n
g
II
I
OJ
W
i
p
e
r

-

s
p
e
e
d

1
3
0
5
6
5
6
a
P
L
PP
R
L5
6
b
R4
9
a
S5
0
3
0
P X1
5
5
3
b
3
1
5
3
a
5
3
a
5
3
J T H
R
OH
O
7
1

97. Electrical Distribution Central
Relays
Fuses
Locking
ruleFaste-
ning
Power
supply
Suppor
t pins
Double contacts
Plastic
bearings
Metalli
c bars
Insula-
tors
Power
supply

98. Location of Fuses
Electrical centralElectrical central

99. Wiring DiagramWiring Diagram
1 AVP Electronic Management System
Fuses positioning
S13 - Main power, 1 AVP control
unit (Management System)
(15A), lambda probe
S14 - Fuel pump, Canister
valve, cylinder injection
valves (15A)
Front view
Note:
S13 and S14 represent fuses
13 and 14 respectively, in the
electric central.

100. Relays
1st speed
cooling motor relay
2nd speed
cooling motor relay

101. Wiring DiagramWiring Diagram
Relays positioning
R7 X contact relief relay (black)
Top view

102. Auxiliary Support
5
325 911 261.1
377 906 383 Blac
k
BlueA/C load cut-off
Fuel pump
POS. ColorNameRelay no.
4

104. Dash Panel Insert

105. Temperature Indicator
Dash Panel Insert

106. Fuel Indicator
Dash Panel Insert

107. Speed Limit Monitor - SLM
Dash Panel Insert

108. Dash Panel Insert
L15
Left/Right turn
signal
Fuel sensor
Air-bag
Ground L31
Coolant
temperatura
Engine oil pressure
Tachometer
Battery load L61
Defroster
Immobilizer
ABS
Lighting
Open door
Coolant level
Positive L30
Tail light L58
Speedometer
High beam L56a
Headlight L56
RPM
km/h
Oil
pressure
Temperature
Line K of VAG
Level
D
a
s
h

P
a
n
e
l

I
n
s
e
r
t

109. Diagnostic Connector
Dash Panel Insert

110. Warming Lights
C

112. Alarm system (TOP
model)
Alarm System

113. Activated/
Deactivated
and Car finder
Unlocked
luggage
compartment
Lamp does not
light up
Separate remote control
and key
Pushing the
locking clips
Batteries
Remote Control
Alarm System

114. Remoto Control Programming
Alarm System

115. Synchronism
Alarm System

116. Electric Circuit Diagram ( TOP Alarm)
Alarm System

118. Immobilizer Control Unit
Engine Control Unit
Immobilizer system

119. Immobilizer Control Unit
Engine Control Unit
Coil/Antenna
Diagnosis Connector
Key
Immobilizer Components
Immobilizer system

120. Immobilizer Control Unit
Engine Control Unit
Key with Transponder
Immobilizer Function
Immobilizer system

121. Secret code
Recipient = VWB.SBC.IMOCOD or
[email protected]
Title = Secret code – 07 digits
Code type = Immobilizer
Immobilizer unit
Identification number
Service manage´s name = Mr. José Gomes
= VWZ9ZOV7000658
Secret Code Request
Immobilizer system

122. Fixed Code
Rotative
Code
Cryptography Code
Immobilizers Types
Immobilizer system

124. News

125. Body Stiffness

126. Cut off Points

127. Front Bumper and Its Fastenings

128. Hood
Section C-C
Current
Section C-C
New
C
C

129. Hood’s Detail
Current New

130. Doors

131. Windows

132. Roof
Detail R3 Detail T3

133. News

134. Rear Bumper

135. Front Bumper and Its Fastenings

136. Windows

137. Windshield Wiper

138. Front Seat Adjusting
Current
New
Strength

140. Refrigeration Cicle
Expansion
valve
Discharge Suction
Evaporator
Cool
air
Flow
Compresso
r
Heat
Condenser
Filter
C
O
O
L

A
I
R
H
E
A
T

141. Refrigerant Circuit
Expansion valve
Dryer
filter
Evaporator
Condenser

142. Variable Compressor
Driving shaft
Floating disc
Piston
Intake/Impeler valve
PistonFloating disc

143. High Refrigeration
High pressure
Low pressure
Regulator valve
Folded spring 2
Folded spring 1
Pressure inside
the chamber
Spring 2Spring 1
Pressure inside
the chamberDimensioned tube

144. Low Refrigeration
High pressure
Low pressure
Regulator valve
Folded spring 2
Folded spring 1
Pressure inside
the chamber
Spring 2Spring 1
Pressure inside
the chamberDimensioned tube

145. Expansion Valve
Sphere
Inlet (from filter)Outlet (to compressor)
Outlet (to
evaporator
)
Inlet (from
evaporator)Temperatur
e sensor

146. Expansion Valve
Low presure
outlet (to
compressor)
Low presure
intlet (from
evaporator)
High presure
intlet (from
filter)
High presure
outtlet (to
evaporator)

147. Evaporator
Brazing
Plate BPlate A 1
2
3
Tubes
2

148. Working Cycle
Pressure switch
O
ff
On
180 220 PSI
Electro-fan (2nd speed)
On
Compresor Line
O
ff
2832 370455 PSI
Thermostat
O
ff
O
n
Closed
Opened
531,50,3
Temp. °C

149. Inlet Outlet
Drying element
Dryer Filter for HFC 134a

150. Spring Loaded

151. A/C Components Wiring Diagram
Line 30 Line X Line 30
Fuse 10
25A
Fuse24
26A
Fuse 4
40A
E1/1 C3/3 A/3 L 30 L 30
Electrical
central
Line 30
Fuse 14
15A
A /4
Full
power
relay
3086
8587
A/C
relay
3086
8587
Pressur
e switch
41
23
3086
8587
2nd speed
relay
3086
8587
1st speed
relay
Radiator
thermal
switch
1st speed
resistor
1 2 A/C compressor
Resistor
Air housing
electro-fan
Thermos-
tat
Motor
control
unit
5
35
1 2 3 4
Speed switch
Recirculation
servo-motor
Recirc
Button
leds
A/C7
2
4
1
3
6
5
L58

153. Airbag system
Gas Generator
Cover
Airbag
Gas Generator
Airbag
Cover
Types of Gas Generator
Driver Side
Passenger Side

154. Airbag system
AIRBAG components
Piezo electric
sensor
Electromechanic
sensor
Control Unit
Diagnosis
Connector
Contact
Unit
Gas Generator
(Passenger side)
Gas Generator
(Driver side)
Fault Lamp
Indicator

155. Airbag system
AIRBAG control unit

156. Airbag system
The range of AIRBAG
trigger
+ 30°
+ 30°
Center

157. Airbag system
Car
Time in thousandth
of sec.
Driver Passanger
AIRBAG triggered

158. Airbag system
EXTREME MANEUVER
MINOR FRONT
COLISION
CAPSIZE
LATERAL COLISION REAR COLISION
Airbag does not trigger when.....