NEW
SP29-06
With the OCTAVIA 4 x 4, SKODA is enlarging
its production range with a vehicle offering
the most modern permanent all-wheel drive
technology.
Classical all-wheel drive concepts - still found
today in a large number of off-road vehicles -
in many cases make use of a rigid connection
which is engaged by means of a handshift.
A new technical feature for permanent all-
wheel drive with an additional connection at
the rigid through-drive to the rear, operated
independently of the driver, was the viscous
coupling, as fitted for example to the VW
syncro.
This was in the position only to detect wheel
slip, but not the cause of it. To ensure reliable
braking in such cases, both axles had to be
decoupled by means of a freewheel. When
reversing, the axles were again connected by
means of a lock.
A significant advance in modern all-wheel
technology has been achieved with the
development of the Haldex coupling.
The Haldex coupling can be controlled.
A processor analyses additional information
during the control cycle. It is no longer the
wheel slip alone which is decisive for the
distribution of the tractive forces, but also the
dynamic state of the vehicle.
2
The processor accesses the ABS wheel speed
sensors and the engine management system
(accelerator pedal signal) through the CAN-
BUS.
These data provide the processor with the
information which is required regarding
vehicle speed, cornering, deceleration or
acceleration, and enables it to react optimally
to the particular situation.
Advantages of the Haldex coupling
Permanent all-wheel drive with
electronically controlled multi-plate
coupling
Front-wheel drive characteristics
Rapid response (power transmission)
Instant decoupling of both axles
No stresses in the drive train when parking
and manoeuvring
No restrictions when towing vehicle with
front wheels raised
Can be fully combined with wheel slip
control systems such as ABS, EDL, TCS,
EBD and ESP
Possibility of simple test of brakes and
performance on roller dynamometer
 Contents

All-wheel Drive 4
Manual Gearbox 6
Rear Final Drive 8
Cardan Shaft 10

Modifications to 4x4 Vehicle 11

Rear axle 11
Fuel tank 12
Vehicle floor 13
Exhaust system 13
Haldex Coupling 14
System description 14
Mechanical components 16
Multi-plate coupling 20
Hydraulic System 22

System Overview 28
Sensors 30
Control Unit 36

Actuators 37
Self Diagnosis 39

Function Diagram 40
Driving Situations 42
Test Your Knowledge 44

Service Service Service Service Service Service Service Service

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OCTAVIA OCTAVIA OCTAVIA
OCTAVIA OCTAVIA OCTAVIA OCTAVIA

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You will find notes on inspection and

maintenance, setting and repair instructions
in the Workshop Manual.

3
All-wheel Drive

The 4x4 drive train

The 4x4 drive train is based on the
components of the A platform vehicles of the
Group.

A characteristic feature is the permanent all-

wheel drive with electronically controlled
multi-plate coupling - the Haldex coupling.

The new coupling is a compact unit which is

connected to the rear final drive.

Compared to front-wheel drive vehicles,

the 4x4 drive necessitated a number of
modifications or involved the introduction
of new assemblies.

The 5-speed manual gearbox is fitted

additionally with a bevel box.

The torque is transmitted from the front-wheel

drive to the rear-wheel drive by means of a
cardan shaft.

The cardan shaft is a two-section design. It is

attached at the manual gearbox by means of a
flexible joint, and at the rear final drive by
means of flexible joint with vibration damper.

SP29-64

5-speed manual gearbox with bevel box

4
 SP29-07

The engine torque is transmitted through the

manual gearbox with the front axle differential
through the bevel box to the cardan shaft.

The cardan shaft is connected to the input

shaft of the Haldex coupling.

In the Haldex coupling, the input shaft is

separated by the output shaft to the bevel box.

The torque is transmitted on through the

differential of the rear final drive to the rear
drive shafts.

The torque is only transmitted to the rear final SP29-09

drive if the multiple plates of the Haldex
coupling are closed. Final drive with Haldex coupling and bevel drive

5
Manual Gearbox

5-speed manual gearbox 02C

All-wheel drive

SP29-20

The 5-speed manual gearbox 02C is a gearbox
which has been specially developed for the
4x4 model.
The ratios of the individual gears and of the
final drive have been matched to the engine
output.
The bevel drive has to be set.
An important factor is the assignment of the
rear final drive to its bevel drive!
The ratio of the front bevel drive to the rear
bevel drive must always be 1.

The clutch is operated hydraulically.

The bevel box is attached to the side of the

manual gearbox and connected to the
differential of the manual gearbox.

The differential and the bevel box are

mounted in the same housing in taper roller
bearings.

6
 Teeth of driven gear z2
Reduction i =

Teeth of driving gear z1

z2 z1 i
st
1 gear 33 10 3.300

2nd gear 35 18 1.944

rd
3 gear 34 25 1.360

4th gear 35 34 1.029

th
5 gear 36 43 0.857

Reverse 17 10 3.060
36 20
SP29-64
Final drive 63 16 3.938

Speedo 13 22 0.591

Front/rear bevel 17 : 27 x 27 : 17 1
drive

5 4
3 2
1
R

SP29-19

The shift mechanism makes use of a cable Note:

shift. The function description of the cable
shift and the gearshift mechanism can
The internal shift mechanism is similar to that be read up in SSP 18.
of manual gearbox 02J.

7
Rear Final Drive

The rear final drive

is always assigned to the manual gearbox.
The assignment is carried out by means of
code letters.

Cross member
Final drive and
differential

Connection to
subframe

Haldex coupling SP29-21

The final drive of the rear axle consists of an The Haldex coupling is connected electrically
integrated assembly incorporating to the vehicle wiring loom.

Haldex coupling The function of the Haldex coupling does not

Bevel drive and necessitate any further connections, e.g. for
Differential. operation.

The rear final drive is connected to the

subframe with the rear axle by means of a
cross member.

Haldex coupling and rear final drive have

separate oil fillings. Note:
You can find capacities and
Final drive: Gear oil specifications of the oils in the
Haldex coupling: High-performance oil relevant Workshop Manual OCTAVIA.

8
 Differential

Final drive

Haldex coupling
Head bevel
pinion
Shaft bevel pinion

Bevel drive with Haldex coupling SP29-22

The bevel drive is formed from the shaft bevel
pinion and the head bevel pinion.
The shaft bevel pinion is part of the Haldex
coupling whereas the head bevel pinion
belongs to the final drive.
The housing of the Haldex coupling is bolted
to the housing of the final drive. This bolted
connection also determines the play of the
bevel drive when it operates.
Careful alignment of shaft bevel pinion to
head bevel pinion is an essential requirement
for long operating life and smooth running of
the bevel drive.
That is why, the shaft bevel gears and head
bevel gears are matched to each other during
the manufacturing process and checked for
optimal positioning of the contact pattern and
for quiet running.

Note:
For this reason, always refer to the
information regarding realigning a
bevel gear set.
You can find this in Workshop Manual
OCTAVIA, 5-Speed Manual Gearbox
02C All-wheel Drive.

9
Cardan Shaft
Flexible joint to manual
gearbox
CV joint
The cardan shaft is a two-section design.
The cardan shaft is attached at the manual
gearbox by means of a flexible joint.
It is attached at the rear final drive (Haldex
coupling) by means of a flexible joint with
vibration damper.
The front and rear cardan shaft tubes are
connected by means of flanges at a CV joint.
The cardan shaft is attached downstream of
the CV joint to the middle bearing at the
vehicle floor.
10
SP29-65
Flexible joint with
vibration damper
The entire cardan shaft is balanced during
manufacture in order to ensure optimal
smooth operation.
It is not possible to balance the entire cardan
shaft with workshop equipment.
If the front or rear cardan shaft tube is
damaged, it is therefore always necessary to
replace the entire cardan shaft.
Note:
Mark the position of all the parts
before removing a cardan shaft.
Re-install in the same position
otherwise the imbalance will be
excessive. This could result in damage
to the mountings and rumbling
noises.
Always store and transport the cardan
shaft in the extended position.
 Modifications 4x4 Vehicles

Modifications compared to front-wheel drive

The 4x4 concept necessitated

a new rear axle

redesigning the fuel tank
a new vehicle floor
adapting the exhaust system

Shock absorber
Anti-roll bar
Cross member

Subframe

Bonded rubber bush Haldex coupling

Wishbone

Trailing arm SP29-03

The rear axle

A double wishbone trailing arm axle An anti-roll bar is provided at the subframe
(TADW axle). of the axle to stabilise the vehicle.

The TADW axle is attached by means of Shock absorber installation position

the subframe (4-point attachment) and the
track-correcting bonded rubber bushes
fitted at each trailing arm.
The subframe is a very flat design in order
to maintain the existing available space in
the interior.
The rear final drive is bolted to a cross
member which is attached to the
subframe.
(approx. 45)
The design features of the axle attachment
for improving comfort (acoustic
decoupling to body and separate
arrangement of spring and shock
absorber), familiar from front-wheel
drive models, have been retained.
Ground clearance increased by 23 mm.

11
 Modifications 4x4 Vehicles

Fuel tank

Suction spray
pump in return-
flow line

Fuel gauge
sender G

Reservoir housing Fuel gauge sender SP29-04

with fuel pump Tunnel G169

The fuel tank has been provided with a
tunnel in order to provide the space
required for the cardan shaft running to the
rear axle.
This results in a two-section tank.
For this reason, in models fitted with petrol
engines, there is a suction spray pump in the
left tank area, which pumps fuel out of the left
side of the tank into the right side.
The suction spray pump is powered by the
fuel return flow from the two-stage fuel pump.
On models fitted with a diesel engine, an
electric fuel pump pumps fuel from the left
chamber of the tank into the right chamber.
A fuel gauge sensor is provided in each
chamber of the fuel tank.
These are operated in series.
Reserve 1 + reserve 2 = total reserve
The evaluation is carried out in the
combination processor of the dash panel
insert.

J17

+15 J220 +30

S
G Fuel gauge sender
G1 Fuel gauge
G6 Fuel pump G1
G6 G G169
G169 Fuel gauge sender 2
J17 Fuel pump relay M
J218
J218 Combination processor in dash panel insert
J220 Motronic control unit
S Fuse
31
SP29-05
12
Vehicle floor
Spare wheel well
The spare wheel well on 4x4 models has been
repositioned 250 mm to the rear.
This provides the space required for attaching
the trailing arms at the vehicle floor.
Adaptation of exhaust system
Bypass for cardan
shaft
The all-wheel drive with the cardan shaft and
new rear axle has necessitated modifications
to the exhaust system.
The front exhaust pipe has to be routed
around the cardan shaft.
Wiring loom of
Haldex coupling
SP29-42
The wiring loom for the Haldex coupling is
routed through the inside of the spare wheel
well.
This ensures that it is adequately protected
against damage from the road surface.
Exhaust system of
1.9-ltr. TDI
SP29-43
At the rear axle, it is not possible to route the
rear exhaust pipe over the axle, as is the case
at the front-wheel drive, but it has to be routed
below the axle.
The version of front exhaust pipe used always
depends on the particular engine fitted.
13
Haldex Coupling

System description of Haldex

multi-plate coupling

The Haldex coupling is an electronically

controlled electro-hydraulic coupling.
Mechanical
The complete system is installed between the
components
cardan shaft and the rear axle differential, and
operates as an interaction of the mechanical
components, the hydraulic components and
the electronic control.

The multi-plate set is located inside the

housing, and runs in its own oil bath. The
multi-plate set is compressed by the hydraulic
pressure. It is thus able to transmit a variable
torque to the rear axle. Hydraulic Electronic
The magnitude of the torque is proportional to components components
the pressure applied to the multi-plate
coupling.
SP29-40
Two axial piston pumps provide the pressure
required in the working piston to compress
the multi-plate set. These pumps are driven by
an eccentric plate (axial cam plate) by means
of the differential speed between the input
shaft and the output shaft of the Haldex
coupling.
This information comprises
An electro-hydraulic valve (control valve)
steplessly alters this pressure. wheel speed of each individual wheel
engine torque
The Haldex coupling does not have any engine speed
sensors of its own, with the exception of a driving state (straightahead driving,
temperature sensor (required for overrun, braking, ABS)
compensating for the temperature-dependent accelerator pedal position/throttle valve
oil viscosity). position

The electronic control unit (four-wheel drive
control unit) makes use of the existing
information in the vehicle for controlling the
pressure of the Haldex coupling. This
information is provided over the CAN-BUS.
The situations detected include cornering,
manoeuvring mode, acceleration phase,
different wheel circumferences. The required
stiffness of the Haldex coupling is controlled
in line with the driving state detected.

14
 The mechanical components with the rotating
and moving parts, include:

the input shaft with externally-toothed disc

carrier
the internally-toothed and externally-
toothed discs
the eccentric plate (axial cam plate) at the
internally-toothed disc carrier
the pressure rollers for the annular pistons
the shaft bevel pinion with internally-
toothed disc carrier Eccentric disc Pressure limiting
(axial cam) valve
Pressure roller
Multi-plate coupling

Shaft bevel pinion outlet Accumulator

Input shaft

Oil filter
Four-wheel drive
control unit

Annular pistons of
axial piston pumps

Electric oil
pump
Temperature sensor

Positioning motor

Control valve
SP29-71

The hydraulic system includes The electrical system includes

the pressure limiting valve the four-wheel drive control unit

the pressure valves the electric oil pump
the accumulator the positioning motor for the control valve
the oil filter the temperature sensor
the annular pistons (one working piston,
two pump pistons)
the control valve

15
Haldex Coupling

Mechanical components
The general design of the Haldex coupling at
a glance Internally-toothed disc

Axial needle bearing

Housing of Haldex coupling

Shaft bevel pinion outlet

(part of rear bevel gear drive,
which drives the rear axle)

Externally-
toothed disc

Externally-toothed disc
carrier

16
 Working piston
Pressure roller to
(annular piston) Outer pump piston
working piston
(annular piston)
Pressure roller Inner pump piston
(inner pump piston) (annular piston)

Flange to cardan shaft

Input shaft

Hydraulic oil drillings

SP29-02

Pressure roller
Pressure plate (outer pump piston)
Hydraulic block of
Haldex coupling
Internally-toothed
disc carrier
Eccentric disc (axial cam disc)
17
Haldex Coupling
Mechanical components
The input shaft is connected to the guide plate
for the pressure rollers and the outer-toothed
disc carrier.
Three pressure rollers, each offset 120, are
assigned to each piston. This ensures static
stability when transmitting the pressure.
During each revolution, the pressure rollers
for the pump pistons and for the working
piston also rotate.
Eccentric plate
Pressure plate
SP29-24
Internally-toothed disc carrier
with eccentric plate and multi-disc set with pressure
plate
The eccentric plate is part of the internally-
toothed disc carrier. It is permanently
mounted on the shaft of the bevel pinion.
The eccentric disc has three cams, each offset
axially 120 - which is why it is also known as
an axial cam disc.
The system then operates in principle like a
distributor injection pump.
18
SP29-23
Guide plate
Pressure roller
Outer-toothed
disc carrier
SP29-25
Input shaft
with guide disc for pressure rollers and outer-
toothed disc carrier
When the car is accelerated, the pressure
rollers of the pump pistons move against the
eccentric disc which is either still stationary or
rotating only slowly. A pump movement thus
begins, in other words the purely rotational
movement of the pressure rollers is converted
in the guide plate into a rotational and lifting
movement as a result of the axial cams on the
eccentric plate.
The rotary/lifting movement is transmitted by
the pressure rollers to the pump piston. These
in turn then perform only a lifting movement
and increase the pressure which then acts on
the working system.
The mechanical pump rhythm

In the same way as the eccentric plate, the

pressure plate on which the three pressure
rollers of the working piston act, also has
three axially offset raised phases.

Each raised phase of the pressure plate is

always positioned opposite a valley on the
eccentric plate.

The pressure rollers of the two pump pistons

1 and 2 are, in addition, positioned with a
phase offset. SP29-26

Pressure plate
Eccentric plate

-X-

60 120 180 SP29-28

SP29-27
1 = Pressure roller of outer
1 = Lift contour of pressure roller of outer pump pump piston
piston
3 = Pressure roller 2 = Pressure roller of
2 = Lift contour of pressure roller of inner pump
of working inner pump piston
piston
piston
3 = Lift contour of pressure roller of multi-disc set/
working piston

An even pressure pattern is achieved by each The pressure acting on the pressure roller of
of the 3 pump lifts, which are consequently the working piston is increased.
performed with a phase offset.
As a result, the multi-disc set remains fully
At the moment when the phase-offset pump pressurized and all-wheel drive is assured.
pistons 1 and 2 are not producing a pressure
(range x), the pressure plate for multi-disc
set 3 in turn has a raised phase.

19
Haldex Coupling

The multi-disc coupling

The operating principle of the multi-disc
coupling is the same as that as you are
familiar with from the automatic gearbox
(see SSP 20).

Externally-toothed discs positively

connected to the externally-toothed disc
carrier

Internally-toothed discs positively

connected to the internally-toothed disc
SP29-32
carrier

The multi-disc set of the Haldex coupling

consists of 7 externally-toothed discs and 6
internally-toothed discs.

The set of 6 internally-toothed discs is

supplemented
by the pressure plate on which the
pressure rollers of the working piston act,
by the rear contact plate which runs in the
axial needle bearing in the housing.
SP29-33

Externally-
toothed disc
Internally-toothed Externally-toothed disc carrier Pressure roller of
disc with externally-toothed discs working piston
Pressure plate
Axial needle Pressure plate
bearing
The multi-disc set constantly runs in oil.

The internally-toothed discs have a smooth

surface on both sides.

In contrast, the externally-toothed discs have

grooves on the surface of both sides.
If the disc set is pressed together as a result of
the pressure of the working piston, the oil is
thus able to flow off rapidly through the
grooves.
SP29-34
On the other hand, the disc set is constantly
lubricated in order to minimise wear. Internally-toothed
Shaft of disc carrier with
bevel pinion internally-toothed
disc Input shaft

20
The hydraulic block
Working piston
The input shaft runs through the middle of the
hydraulic block.

The pistons (1 working piston, 2 pump

pistons) are positioned centred around the
shaft.

SP29-29
Input shaft

Hydraulic block with working

piston and pump pistons

Connection of four-wheel drive

control unit

Outer pump
piston

Inner pump
piston
SP29-30

The hydraulic block contains the hydraulic

drillings to the annular pistons and to the
connection points to the oil pump, to the
control valve and to the safety valves.

The hydraulic circuit is formed by these.

M Electric oil pump

M

Control valve

Pressure limiting valve SP29-31

Valve (suction valve, pressure valve) Block diagram of hydraulic circuit

21
 Hydraulic System
Pressure rollers
Eccentric disc
Axial needle
bearing
Suction valves
Multi-disc
Working piston
coupling
Pump pistons
Hydraulic system - pressureless -
The hydraulic system is pressureless and the
multi-disc coupling is thus not operating.
There is also no pre-pressure in the hydraulic
system. The control valve is open. The
eccentric disc is running empty and the
pressure rollers of the pump pistons are not in
contact.
These conditions exist:
when the vehicle is stationary or moving
and the ignition is off
when towing vehicle with front wheels
raised (engine off and thus ignition off)
during a brake test on the roller
dynamometer (engine off and thus
emission off) when front wheels are
driven.
22
Pressure valves
Pressure limiting valve
Control
valve
Positioning
motor
Accumulator
Filter
Electric oil
pump
Strainer
pressureless SP29-35
Pressure is built up as a result of the speed
difference between the input shaft and the
output shaft only when the ignition is
switched on.
The oil pressure is regulated by valves.
The pressure limiting valve determines the
maximum pressure at the multi-disc set while
the control valve determines the torque
transmitted through the multi-disc coupling.
Note:
For the schematic presentation of the
hydraulic system, the pump pistons
have been shown positioned next to
each other and the eccentric plate
with two cams and two valleys.
As a reminder:
The pump pistons are positioned
phased-offset.
The eccentric disc has three cams
offset by 120 with a lift of 1.2 mm.
 Pressure valves
Pressure rollers
Pressure limiting valve

Control
valve

Positioning
motor

Accumulator

Filter
Suction valves
Multi-disc
Working piston Electric oil
coupling
pump

Pump pistons Strainer

Pre-pressure SP29-36
Pressureless

Pressure build-up in hydraulic system as a

result of electrical oil pump (pre-pressure)

The Haldex coupling engages within a very As a result, the cylinders behind the pump
short time. The maximum pressure is pistons are supplied with oil and the pressure
available at the latest after a rotational angle rollers are pressed and held against the
of 45. eccentric disc.

On the other hand, the multi-disc set has to
have a certain clearance if the coupling is to
be inactive, but it must also be possible,
however, to eliminate this clearance very
rapidly.
That is why the system operates with a pre-
pressure.
At the same time, the oil flows through the
control valve and through the pressure valves
to the working piston. This piston likewise
makes contact. As a result of this pre-
pressure, the play which exists in the multi-
disc set is eliminated. This ensures rapid
response of the coupling.

The pistons of the pump pistons are a floating
design and only make contact once pressure
is supplied by the electric oil pump. This
pump only operates if the ignition is switched
on and if engine speed is > 400 rpm.
The pre-pressure of 0.4 MPa (4 bar) is
determined by the accumulator. A further task
of the accumulator is to even out any pressure
variations.

The oil pump draws oil out of the pressureless

chamber of the coupling housing through a
strainer and pumps it through a filter through
the suction valves to the pump pistons.
23
Hydraulic System

Pressure valves
Working piston
Pressure roller Pressure limiting valve
Pressure plate

Control
valve

Positioning
motor

Accumulator

Multi-disc
coupling Pump piston

Pressure SP29-37
Pre-pressure
Pressureless

Pressure build-up in hydraulic system through

pump pistons (control valve closed)

The oil pressure produced by the pump
pistons flows through the pressure valves to
the working piston and to the control valve.
The closed control valve acts as a resistance
and the pressure in the cylinder of the working
piston rises.
The working piston is moved and presses
against the multi-disc coupling through the
pressure rollers and pressure plate.
The multi-disc coupling is closed and thus
creates the connection between the input
shaft and the output shaft.
The pressure at the multi-disc coupling is
determined by the control valve.
The positioning motor, which is operated by
the four-wheel drive control unit, alters the
position of the control valve. If the control
valve is fully closed, the maximum pressure is
acting on the multi-disc coupling.
The maximum pressure is determined by the
pressure limiting valve.

The torque is transmitted to the rear axle.

24
 Pressure valves

Control
valve

Accumulator

Pump pistons
Multi-disc
Working piston
coupling

Pressure SP29-38
Oil return flow
Pressureless

Pressure build-up in hydraulic system through

the pump pistons (control valve open one
third)

The pressure produced by the pump pistons
flows through the pressure valves to the
working piston and at the same time into the
control valve.
The control valve is opened one third by the
four-wheel drive control unit, in line with the
actuation. Part of the oil is able to flow back
through the accumulator into the oil chamber.
This results in a reduction in pressure so that
the coupling permits only a limited
transmission of torque.
Consequently, the coupling can also permit
reduced all-wheel drive in certain driving
situations.

25
Hydraulic System

Control
valve

Accumulator

Multi-disc
coupling Pump pistons
Working piston

Pressure SP29-39
Pressureless

Pressure build-up in hydraulic system through

the pump pistons (control valve opened)

The pressure required for the particular The pump pistons operate practically only for
driving situation is determined by the four- the pre-pressure.
wheel drive control unit.

The control valve is open. The oil now flows

through the control valve and the accumulator
back into the oil chamber.

Consequently, no build-up of pressure takes

place at the working piston. The multi-disc
coupling is open and there is also no
transmission of torque.

The accumulator maintains the pre-pressure

in the return-flow line of the control valve.
A pre-pressure of 0.4 MPa (4 bar) exists in the
return-flow line.
Note:
Pre-pressure is necessary for the rapid
response of the Haldex coupling. The
pre-pressure eliminates the play in the
multi-disc set.

26
 Summary of operating sequence of Haldex
coupling
Eccentric disc
Shaft 2
Pressure
plate
We can recognize the operating principle from
the mechanical design and the description of
the hydraulic system:
In the initial position, the input shaft 1 and
output shaft 2 are rotating at the same speed.
The hydraulic coupling is thus inactive. The
coupling is released.
Once a difference in speed exists between
shaft 1 and shaft 2, the pressure rollers and
the pump pistons at the eccentric disc begin to
pulse. Consequently, oil is drawn into the
cylinder behind the pump pistons.
At the same time, the pressure produced by
the pump pistons passes through the pressure
valves to the working piston.
The working piston compresses the multi-disc
set through the pressure rollers and pressure
plate. The coupling now has a positive
connection.
Pressure roller of
working piston Working piston
Shaft 1
Pump pistons
Pressure SP29-02
roller
If a difference in speed remains at the shafts,
the pump pistons continue to pulse and pump
oil to the working cylinder.
The working piston compresses the multi-disc
set with greater force, which results in an
increase in the torque transmitted.
If there is an increase in the torque
transmitted, the difference in speed is
reduced.
The coupling is again inactive.
Only the pre-pressure is maintained in the
hydraulic system.
The pressure build-up and the torque
transmission can be adapted to match the
particular driving situation by the four-wheel
drive control unit.
27
System Overview

Engine control unit

Engine speed sender G28

+ Engine torque

Accelerator pedal position sender G79/G185

ABS with EDL control unit J104

Wheel speed sensors G44 - G47

Longitudinal acceleration sender G249

Brake light switch F
Note:
The signal for the brake light switch
as a rule passes along the CAN
databus; in the emergency mode, it
passes over a direct wire into the four-
wheel drive control unit.

Handbrake indicator switch F9

28
 Handbrake indicator switch F9

Brake light switch F

Hydraulic temperature
sender G271

Four-wheel drive control unit J492

CAN databus

Oil pressure positioning

motor V184

Haldex coupling pump V181

Diagnostic
connection
SP29-08

29
Sensors

Note:
A number of sensors and control units
of other systems are used for
controlling the Haldex coupling
system.
You will be already familiar with the
design and operation of these.
For this reason, the section which
follows deals only with the effects
when all-wheel drive is active. The
control algorithms of the four-wheel
drive control unit are based as a
general rule on the processing of all
the signals.

Use of signal for 4x4 electronic control Effect in the event of signal For further
failure function
descriptions see
Engine control unit

Engine does not run or SSP 12, SSP 19

restricted engine running
(system-related)

SP29-66

The engine control unit operates in line

with the torque.
The following information is supplied
over the CAN-BUS to the four-wheel
drive control unit:
Engine speed
Accelerator pedal position
Engine torque

ABS control unit

In the very improbable SSP 28

likelihood of total system
failure
no 4x4 control
only normal braking
operation without ABS
SP29-67 control
The following information is supplied
over the CAN-BUS to the four-wheel
drive control unit:
Wheel speeds
Lateral acceleration
Brake operation
On models fitted with ESP, the required
ESP control takes priority over the 4x4
function

30
Use of signal for 4x4 electronic control Effect in the event of signal For further
failure function
descriptions see
Engine speed sender

Engine does not run or SSP 19, SSP 27

engine running with
substitute values (system-
related)
SP29-68

Actuation of charge pump (Haldex

coupling pump), which operates only
when ignition on and at an engine
speed of > 400 rpm.

Speed sensors of all 4 wheels

no control of all-wheel SSP 26

drive
no ABS control

Failure of a speed sensor

SP29-69
Detect change in speed of each
individual wheel and transmit wheel
speed information to the four-wheel
drive control unit. The factors detected
include cornering, manoeuvring mode,
acceleration phase, different tyre
circumferences.
does not yet result in any
restriction of four-wheel
drive.
For safety reasons, the
coupling is opened fully if no
speed signals are received.

Accelerator pedal position sender

Emergency running SSP 27

programme

SP29-70
Is used for transmitting driver request
to engine control unit and over the
CAN-BUS to the four-wheel drive
control unit. The torque at the Haldex
coupling is increased, for example, in
line with the particular driving
situation.

31
Sensors

Hydraulic temperature sensor

Temperature
The sensor is installed close to the control sensor
valve in the housing of the four-wheel drive
control unit, and the hydraulic fluid flows
around it.

It is the only sensor which is provided

additionally specifically for the Haldex
coupling.

Use of signal

The sensor detects the current temperature

of the hydraulic fluid and supplies the
information to the four-wheel drive control
unit.

This information is used for adapting the

pressure control to the changing viscosity of
the hydraulic fluid.

SP29-14

Temperature Hydraulic fluid/Viscosity Control valve

in negative range viscous opened a little further

normal 20C normal opened normally

more than 20C fluid opened slightly less

If the temperature of the hydraulic fluid rises

above 100C, the coupling is switched
pressureless. Once the temperature again
drops below 100C, pressure is again supplied
to the coupling.

Effect in the event of signal failure

All-wheel drive is switched off.

32
Longitudinal acceleration sensor
G249

It is located at the right A pillar and is required

only for all-wheel drive models with (ESP).

When the Haldex coupling is closed, the front

and rear wheels are rigidly coupled.

The real vehicle speed is calculated from the

signals supplied by the individual wheel
speed sensors and, in certain conditions, may
be too inaccurate if the friction coefficients are
low and the Haldex coupling is closed.

The measurement of the longitudinal

acceleration is used to backup the vehicle SP29-18
speed which is calculated theoretically.

Effect in the event of signal failure

Without the additional measurement of the

longitudinal acceleration, it may not be
possible to accurately calculate the real
speed of the vehicle in certain unfavourable
conditions. The ESP and ASR functions then
do not operate.

If an ESP control cycle is activated, the Haldex

coupling is opened. G249

Electric circuit

The longitudinal acceleration sensor is linked

directly to the ABS control unit J104. The data
are transferred over the CAN-BUS.
J492 J104

CAN L
CAN H SP29-17

G249 Longitudinal acceleration sensor

J104 ABS/EDL control unit
J492 Four-wheel drive control unit

33
Sensors

Handbrake indicator switch F9

The handbrake indicator switch is located
below the handbrake lever.
It operates as a normally-open contact.
Its main function is to operate the handbrake
indicator lamp K14.
Its signal is also used for information on SP29-74
handbrake operated for controlling the all-
wheel drive.

Use of signal

The information handbrake operated flows

over the wiring loom directly to the four-wheel
drive control unit J492 and also to the ABS
control unit J104.

As soon as the direct signal is detected, the

positioning motor in the control valve is
operated by the four-wheel drive control
unit and the Haldex coupling is rendered CAN L
pressureless, in other words the coupling is
opened.
CAN H

Effect in the event of signal failure

If no handbrake operated signal is received, J492 J104

it is not possible in this case to control the all-
wheel drive.

If the signal is constantly present, e.g. because

the switch is faulty, the all-wheel drive is not
controlled.

F9 K14

31 31 SP29-16

F9 Handbrake indicator switch

K14 Handbrake indicator lamp
J104 ABS/EDL control unit
J492 Four-wheel drive control unit

34
Brake light switch F
Task

The brake light switch is located at the pedal

assembly.

It operates as a normally-open contact and its

main function is to switch on the brake lights.
The function is used at the same time for
supplying a signal to the ABS control unit SP29-75
J104 and to the four-wheel drive control unit
J492.

Use of signal

The information brake operated flows over +30

the wiring loom to the ABS control unit.

This signal is also passed by the ABS control

unit over the CAN-BUS to the four-wheel drive S13
control unit. 10A
When the signal is received, the four-wheel
drive control unit operates the positioning
motor in the control valve and the Haldex
coupling is rendered pressureless.
F

Effect in the event of signal failure

If no signal is received over the CAN-BUS, the

brake operated signal which is sent over the
additional direct link to the four-wheel drive
control unit is used in this case.

J492 J104

CAN L

CAN H SP29-15

F Brake light switch

J104 ABS/EDL control unit
J492 Four-wheel drive control unit

35
Control Unit

Four-wheel drive control unit J492

The control unit is attached directly to the
housing of the Haldex coupling.

It forms a single unit together with the

positioning motor and the control valve.
The control unit is always switched on when
ignition on.

Design and function

The control unit is linked over the CAN

SP29-72
databus drive to the engine and ABS control
unit and over the vehicle wiring loom to other
sensors. It operates automatically, cannot be
switched off and analyses the following
signals which characterise the vehicle state,
and besides the pressure which should be
applied to the discs of the Haldex coupling.

Accelerator pedal signal

(driver intention recognition)
Engine speed
Engine torque
Wheel speeds, also when snow chains are
fitted to the front wheels
EBD signal (whether electronic brake
pressure distribution is active)
Brake operation

The oil pressure which is applied to the discs

of the Haldex coupling determines the torque
which is transmitted to the rear wheels.

Effect in the event of signal failure

No all-wheel drive.

Self-diagnosis

The control unit is incorporated in the self-

diagnosis of the vehicle.

36
 Actuators

Haldex coupling pump V181

The pump is installed in the housing of the
Haldex coupling.
It is an electrically driven internal gear pump
and operates as a pre-delivery pump for the
two pump pistons.

Design and function

The pump operates only when the ignition is

switched on. As soon as the engine has SP29-12
reached an idling speed of more than 400 rpm
after being started, voltage is applied to the Haldex coupling
pump by the four-wheel drive control unit. pump

The two pump pistons of the coupling are

mounted floating.
The pump delivers oil to the pump pistons
and operates the pressure rollers to move the
pump pistons against the eccentric disc.
At the same time, pressurized oil flows to the
working piston.
Internal gear
The working piston is moved against the
of pump
multi-disc set by means of its pressure rollers.
As a result, the play is eliminated at the multi-
disc set which ensures rapid response. (The
eccentric disc runs empty if the ignition is off
and the Haldex coupling remains open.) SP29-11

Effect in the event of signal failure

No all-wheel drive.
D/15
V181

Electric circuit
M
The pump is supplied directly with voltage by S51
the four-wheel drive control unit.

J492 Four-wheel drive control unit

V181 Haldex coupling pump
J492

31 31 SP29-10

37
Actuators

Oil pressure positioning motor V184

Return-flow
The positioning motor is integrated in the drilling
housing of the four-wheel drive control unit. It
is part of the control valve, an electromotive
proportioning restrictor valve, with the aid of
which it is possible to adapt the torque
transmission capability. Positioning Control pin
motor

Design and function

The positioning motor is supplied with

Pinion
voltage by the four-wheel drive control unit.
It operates as a stepping motor.
Control valve
When a command is received from the control
unit, the positioning motor alters the height of
the control pin in the control valve by means
of a pinion.

The height at which the control pin is

positioned in the control valve alters the cross Positioning
section of a return-flow drilling. motor
The pressure at the working piston of the
discs is determined in this way and the torque
transmission capability adapted accordingly.
SP29-63

Control valve closed:

Maximum pressure at the discs

Control valve partially opened:

Reduced pressure at the discs

Control valve fully opened:

No pressure at the discs.

SP29-73

38
 Self-Diagnosis

Self-diagnosis
Self-diagnosis of the Haldex coupling
electrically monitors

the signals of the sensors

the operation of the actuators
the control unit by means of a self-check.

If the control unit detects a fault or if CAN

messages are not received, it calculates a
substitute value from other signals and
provides an emergency running programme.
1 2 3
4 5 6
7 8 9
C O Q HELP
V.A.G. 1552
In the absence of vehicle speed signals, the
coupling is opened fully for safety reasons.

Self-diagnosis can be carried out with 202_CZ_002

the vehicle system tester V.A.G 1552,
SP17-29
the fault reader V.A.G 1551, or
the vehicle diagnosis, measuring and
information system VAS 5051.

The address word is:

22 - All-wheel electronics

The following functions can be read:

01 - Interrogating control unit version

02 - Interrogating fault memory
03 - Final control diagnosis
04 - Basic setting
05 - Erasing fault memory 02D 525 554 HALDEX LSC V00
06 - Ending output
07 - Coding control unit
08 - Reading measured value block Cod. ... WCC

All the faults set in the fault memory are read.

When faults are stored, the control unit

distinguishes between static and sporadic
faults.
If a fault occurs only once within several
driving cycles, it is stored as a sporadic fault. If a fault no longer occurs after 50 driving
cycles (driving cycle = ignition on and vehicle
speed of at least 20 km/h), it is erased from the
fault memory.

If the fault is again present within the driving

cycles stored in the control unit, it is stored in
the control unit as a static fault.

39
Function Diagram

+30 +30 +30

S15 S51 S13

5A 5A 10A

G249

J... J104

M V181
CAN H

CAN L

M V184 G271
J492

F9 K14
J218

K
31 31 SP29-01

40
The function diagram represents a simplified
current flow diagram.

It shows the linkages of the system

components for controlling the all-wheel
drive.

Legend of function diagram

Components Colour coding/Legend

D Ignition/starter switch = Input signal

F Brake light switch
F9 Handbrake indicator switch = Output signal
G249 Longitudinal acceleration sensor*
G271 Hydraulic temperature sensor = Battery positive
J Engine control unit
J104 ABS/EDL control unit = Earth
J218 Combination processor in dash
panel insert = Bi-directional
J492 Four-wheel drive control unit
K Diagnostic connection
K14 Handbrake indicator light
in out
V181 Haldex coupling pump
V184 Oil pressure positioning motor
S Fuse

* only on models with ESP

41
Driving Situations

A feature of the permanent all-wheel drive
with Haldex coupling is that it operates
without any action on the part of the driver,
but controls the necessary stiffness of the
coupling in line with the driving situation
detected.
The overview below helps us to rapidly
recognize the operating principle of the
Haldex coupling in particular driving
situations.

Driving situation

SP29-55 SP29-56 SP29-57

Parking Acceleration Fast driving

Difference in speed between front axle slight high low

and rear axle

Torque required at rear axle low high low

Status of multi-disc coupling slight contact High contact closed, as required

pressure pressure, up to as
much as maximum,
EDL control may
increase the contact
pressure

Input signals engine torque engine torque engine torque

engine speed engine speed engine speed
accelerator pedal accelerator pedal accelerator pedal
position position position
4 x wheel sensors 4 x wheel sensors 4 x wheel sensors

Note:
In the event of a failure of peripheral limited torques to be transmitted
systems (ABS, sensors, CAN-BUS) the without affecting safety and
Haldex coupling switches to an manoeuvrability.
emergency programme which
permits

42
 SP29-58 SP29-59 SP29-60 SP29-61 SP29-62

Driving on Driving with Braking (ABS or Towing Brake test (roller

slippery surface tyres with diffe- ESP operation) dynamometer)
rent
rolling radii
varies between low normal to high normal to high high high
and high

varies between low low 0 0 0

and high

closed, up to open or slightly open open, electric pre- open, electric pre-
maximum closed pressure pump off pressure pump off
(if ignition off) (if ignition off)

engine torque 4 x wheel sensors 4 x wheel sensors none none

engine speed through ABS to ABS control
accelerator pedal control unit unit
position brake light switch
4 x wheel sensors
CAN data transfer

Note:
The Haldex coupling also operates
when reversing!

43
Test Your Knowledge

Which answers are correct?

Sometimes only one.
But perhaps also more than one - or all!

1. The Haldex coupling operates on the basis of three main

elements. These are:

A.
B.
Mechanical system
Pneumatic system
?

?
C. Electronic system
D. Hydraulic system

2. The all-wheel drive with Haldex coupling is particularly characterised by:

A. Permanent all-wheel drive with electronically controlled multi-disc coupling.

B. Acceleration with good directional stability (front-wheel drive characteristic).
C. Delayed response.

3. The pump for the Haldex coupling is operated electrically once the engine speed is:

A. higher than 400 rpm

B. less than 400 rpm

4. The pressure rollers of the pump pistons pass through a peak and valley track on the
eccentric disc if a speed difference between the front wheels and the rear wheels.
The pump pistons pulsate and build up a pressure.
Which of the following statements are correct?

A. The pressure flows through the pressure valves to the working piston and through
its pressure rollers to the multi-disc coupling.
B. The pressure is limited by the pressure limiting valve.
C. The pressure is influenced by the control valve.

5. The accumulator

A. determines the maximum pressure.

B. determines the pre-pressure of 0.4 MPa (4 bar).
C. acts as a damper in order to smooth out pressure variations.

44
6. The positioning motor is supplied with voltage by the four-wheel drive control unit and
operates the control pinion in the control valve by means of a pinion. As a result, the
return-flow drilling is more or less closed.
Which of the following statements is correct?

A. Return-flow drilling in control valve closed = no pressure at the discs

B. Return-flow drilling in control valve open = maximum pressure at the discs

?
C. Return-flow drilling in control valve open = no pressure at the discs
D. Return-flow drilling in control valve closed = maximum pressure at the discs

7. Which sensor signals are supplied direct to the four-wheel drive control unit?

A. Longitudinal acceleration sensor

B. Handbrake switch
C. Brake light switch
D. Hydraulic temperature sensor

8. The hydraulic temperature sensor is installed in the housing of the four-wheel drive
control unit. It detects the current hydraulic fluid temperature.
What is this information used for in the control unit?

A. For adapting to the changing viscosity of the hydraulic fluid by means of the
pressure controller.
B. For emergency running.
C. For rendering the coupling pressureless if a temperature of 100C is reached.

9. If a major speed difference exists between the front and rear wheels, for example when
accelerating:

A. the torque which has to be transmitted to the rear axle is ..............................

B. the contact pressure at the multi-disc coupling is ..............................

The following input signals are of significance:

C. ....................... D. ....................... E. ....................... F. .......................

45
46
Answers

1. A., C., D.; 2. A., B.; 3. A.; 4. A., B., C.; 5. B., C.; 6. C., D.; 7. B., C., D.; 8. A., C.;
9. A = high, B = high, C = Engine torque, D = Engine speed, E = Accelerator pedal position,
F = 4 x wheel sensors

47