Service.

Self-Study Programme 249

Engine Management of
the W8 Engine in the Passat

Motronic ME 7.1.1
 The Motronic engine management system of the
W8 engine enables high power output with mini-
mal fuel consumption through adaptation to all
operating modes. The heart of the Motronic
system is the electronic control unit (J220). It pro-
cesses incoming signals and transmits adjustment
commands for controlling the subsystems. At the
same time, the control unit serves the diagnosis
of subsystems and components.

S249_001

For further information on the W8 engine, please refer to SSP 248 „The W Engine Concept“.

NEW Important
Note

This self-study programme explains the design Please always refer to the relevant Service literature for current
and function of new developments. inspection, adjustment and repair instructions.
The contents are not updated.

2
Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Subsystems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Functional diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Test your knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3
 Introduction

The Motronic ME 7.1.1

The regulation of the W8 engine is performed by
the Motronic ME 7.1.1. The management system of
the W8 engine is, in many respects, the same as
that of the VR6-V4 engine. These are the tasks of
the engine management system:

- Optimisation of the fuel-air mixture for all

operating modes
- Reduction of fuel consumption S249_002

- Regulation of combustion
- Monitoring and regulation of exhaust
emissions.

The control unit is located in the electrics box in

the plenum chamber.

S249_003

The control unit performs the following functions:

- Regulation of injection
- Regulation of ignition (ignition system with single-spark ignition coils)
- Regulation of idling speed
- Stereo lambda regulation of exhaust emissions
- Fuel tank ventilation system
- Electronic power control
- Cruise control system
- Secondary air system
- Knock control
- Continuously variable inlet valve timing, two-position exhaust valve timing
- Control of engine mountings
- Regulation of coolant temperature
- Regulation of electric vacuum pump
- ESP
- Self-diagnosis

4
The engine control unit in the CAN data bus

The engine control unit communicates with the control units in other vehicle systems.
Data is exchanged through the CAN data bus, which joins the individual control units in a single system.

Drivetrain CAN
ABS Steering angle
control unit sensor Dash panel insert

CAN High
Engine control
unit
CAN Low

Gearbox Airbag Air conditioning

control unit control unit control unit Immobiliser

S249_004

Through the CAN data bus, data are exchanged between the engine control unit and

- the ABS control unit

- the gearbox control unit
- the airbag control unit
- the steering angle sensor
- the air conditioning control unit
- the dash panel insert (control unit with display unit in dash panel insert)
- the immobiliser.

For further information, please refer to SSP 186 „The CAN Data Bus“.

5
 System overview

Sensors

G70 Air mass meter

G42 Intake air temperature sender

G28 Engine speed sender

G62 Coolant temperature sender

G83 Coolant temperature sender

radiator outlet

G39 Lambda probe

G108 Lambda probe II
Dash panel insert J285
G130 Lambda probe after catalyst (control unit with display unit
in dash panel insert)
G131 Lambda probe II after catalyst

G40 Hall sender 1, G163 Hall sender 2

G300 Hall sender 3, G301 Hall sender 4

Radiator fan 2
G61 Knock sensor 1, G66 Knock sensor 2 control unit J293
G198 Knock sensor 3, G199 Knock sensor 4

J338 Throttle valve control part

G187 Throttle valve drive angle sender 1
G188 Throttle valve drive angle sender 2

Accelerator pedal module with

G79 Accelerator pedal position sender 1
G185 Accelerator pedal position sender 2

E45 Cruise control switch Engine control unit J220

E227 Cruise control „Set“ button

F Brake light switch

F47 Cruise control system brake pedal switch
CAN

F36 Clutch pedal switch

G294 Brake servo pressure sensor Diagnosis connection

(only with automatic gearboxes)

6
 Actuators

J17 Fuel pump relay, G6 Fuel pump

J 338 Throttle valve control part

G186 Throttle valve drive

N30 Injector, cylinder 1, N31 Injector, cylinder 2

N32 Injector, cylinder 3, N33 Injector, cylinder 4

N83 Injector, cylinder 5, N84 Injector, cylinder 6

N85 Injector, cylinder 7, N86 Injector, cylinder 8

N70 Ignition coil 1, N127 Ignition coil 2

N291 Ignition coil 3, N292 Ignition coil 4

N323 Ignition coil 5, N324 Ignition coil 6

N325 Ignition coil 7, N326 Ignition coil 8

N205Inlet camshaft timing adjustment valve 1, N208 valve 2

N318 Exhaust camshaft timing adjustment valve 1, N319 valve 2

N80 Activated charcoal filter system solenoid valve 1

N112 Secondary air inlet valve

V101 Secondary air pump motor,

J299 Secondary air pump relay

J271 Motronic current supply relay

J496 Additional coolant pump relay, V36 Water pump

F265 Map-controlled engine cooling thermostat

N144 Electro-hydraulic engine mounting solenoid valve

V7 Radiator fan, V177 Radiator fan 2

J569 Brake servo relay,

V192 Vacuum pump for brake servo
S249_005
(only for automatic gearboxes)
7
 Subsystems

The fuel injection system

Input signals for calculating injection periods

● Engine load signal from air mass meter

● Intake air temperature
● Signal from throttle valve control part
● Signal from engine speed sender
● Coolant temperature
● Signal from Lambda probes
● Signal from accelerator pedal module
● Signal from Hall senders

1 Fuel tank
2 Fuel pump
3 Filter
4 Fuel rail
5 Fuel pressure regulator
3 6 Injectors
2 1
7 Engine control unit
8 Accelerator pedal module
5
9 Air mass meter with sender
for intake air temperature
6 6
6 6 10 Engine speed sender
11 Temperature sender (G62)
6 12 Lambda probes
6
6 6 13 Throttle valve control part

4 14 Hall senders

11 12 13 14
8 9 10
7

S249_006

The fuel pump, which is located in the fuel tank, The quantity of fuel injected is determined solely
pumps fuel through the fuel filter to the injectors. by the length of the period during which the
The injectors are connected to each other by the injector is open. The pressure regulator regulates
fuel rail. Injection occurs sequentially. Using the the injection pressure in the fuel rail and regula-
input signals, the control unit calculates the tes the return flow of excess fuel to the fuel tank.
necessary fuel quantity and the required injec-
tion period.

8
The ignition system
Input signals for calculating the ignition timing

● Signal from engine speed sender

● Engine load signal from air mass meter
● Signal from throttle valve control part
● Coolant temperature
● Signal from knock sensors
● Signal from Hall senders
● Signal from accelerator pedal module

1 Single-spark ignition coils

with output stage
2 Engine control unit
3 4 5 6 7 8 3 Air mass meter
4 Engine speed sender
5 Temperature sender (G62)
9 6 Throttle valve control part
2
7 Knock sensor
1 8 Accelerator pedal module
9 Hall senders
10
10 Spark plugs

10

1
9
S249_007

The ignition timing is calculated according to a

map stored in the engine control unit on the basis
of the input signals.

9
 Subsystems

Knock control
Unfavourable operating conditions can lead to self-ignition (pre-ignition knock).
Consequently, the ignition timing must be adjusted.

Input signals

● Signal from knock sensors

● Signal from Hall senders
● Engine temperature

1 Single-spark ignition coils

with output stage
2 Engine control unit
3 Knock sensors
4 Hall senders
2 3
4 5 Spark plugs
1

3
4

4 3 3

S249_008

Each bank of the W8 engine is equipped with When knocking is detected in a cylinder, the
two knock sensors mounted on the crankcase. To engine management system changes the ignition
prevent the connectors in the wiring harness from timing of the knocking cylinder (by retarding the
being interchanged on the sensors, the connec- firing point) until the knocking ceases.
tions are colour coded. The knock signals can be
related to individual cylinders with the aid of the When the affected cylinder no longer has the
Hall signals. tendency to knock, the control unit returns the
ignition timing to its former setting (advancing
the firing point).

10
Variable valve timing
The task of variable valve timing is to set the best valve timing for the operating modes idle, maximum
power and torque. Variable valve timing optimises the ratio between fresh air and exhaust gas. This is
referred to as internal exhaust gas recirculation. The overlap angle, during which the inlet valve is
already opening while the exhaust valve is not yet closed, determines the quantity of „recirculated“
exhaust gas.

Input signals

● Signal from Hall senders

● Signal from engine speed sender
● Engine load signal from air mass meter
● Coolant temperature
● Oil temperature

1 Solenoid valves
2 Engine control unit
7 6
3 Air mass meter
3 4 5
4 Engine speed sender
5 Temperature sender
1 at engine outlet
6 Hall senders
6 7 Oil temperature

2 1

S249_009
6

To adjust the camshafts, the engine control unit The camshafts are adjusted according to a map
requires information on engine speed, engine stored in the engine control unit, whereby the
load, engine temperature, positions of the inlet camshafts can be continuously adjusted. The
crankshaft and camshafts and, from the dash camshaft adjusters on the exhaust camshafts are
panel insert via CAN, oil temperature. The always moved by the engine control unit to one
engine control unit actuates the solenoid valves end position or the other.
according to operating mode.

For further information, please refer to SSP 246 „Variable Valve Timing with Fluted Variator“.

11
 Subsystems

Stereo lambda regulation

The task of the lambda regulation is to maintain a lambda value of 1 during combustion so that exhaust
gases can be optimally cleaned in the catalyst.

Input signals

● Signal from engine speed sender

● Engine load signal from air mass meter
● Signal from lambda probes
● Coolant temperature

1 Injectors
6 5 2 Engine control unit
3 Air mass meter
4 7 4 Engine speed sender
3 1 5 Pre-catalyst
lambda probes
6 After-catalyst
lambda probes
7 Coolant temperature

2
1

6 5

S249_010

During stereo lambda regulation, separate regu- Using this signal, the control unit calculates the
lation loops, each including a catalyst, a pre- momentary composition of the fuel-air mixture.
catalyst probe and an after-catalyst probe, When deviation from the specified value occurs,
determine the correct fuel-air mixture for each the injection period is corrected.
cylinder bank.
In addition, adaptive lambda regulation takes
The lambda probes inform the control unit of the place. (The control unit adapts to the operating
residual oxygen content in the exhaust gas. conditions and stores the learnt values.)

For further information, please refer to

SSP 175 „On-Board Diagnosis System
II“.

12
The fuel tank ventilation system
Input signals for fuel tank ventilation regulation

● Engine speed
● Engine load signal from air mass meter
● Engine speed
● Signal from lambda probes
● Signal from throttle valve control part

1 Fuel tank;
2 Activated charcoal filter
3 Solenoid valve for
5 6 activated charcoal filter
7 8 9
4 Engine control unit
5 Air mass meter
3 6 Engine speed sender
7 Temperature sender
4
at engine outlet
8 Lambda probes
9 Throttle valve control part

249_011

The fuel tank ventilation system prevents fuel This briefly changes the fuel-to-air ratio. The
vapour which develops in the tank from escaping change in the mixture is registered by the
to the atmosphere. The fuel vapour is stored in lambda probes, causing lambda regulation to be
the activated charcoal filter. After evaluating the activated by the engine control unit and the mix-
input signals, the engine control unit actuates the ture settles back to lambda = 1.
solenoid valve.
The fuel vapour stored in the activated charcoal
filter is directed through the intake manifold to
the engine for combustion.

For further information, please refer to

SSP 231 „Euro On-Board Diagnostic
System“.

13
 Subsystems

The cruise control system (CCS)

With the aid of the cruise control system, a vehicle speed above 30 km/h can be specified. This speed
will then be maintained without driver intervention.

Input signals

● Engine speed
● Engine load signal from air mass meter
● Vehicle speed
● Signal „brake operated“
● Signal „clutch operated“
● „On“ and „off“ signals from CCS switch

1 Throttle valve control part

2 Engine control unit
3 Air mass meter
4 Engine speed sender
8
3 4 5 Brake pedal switch
5 6
6 Clutch pedal switch
7 CCS switch
8 Vehicle speed
Feedback: Operation of
2 Throttle valve positioning motor
position

S249_012

The signal from the CCS switch goes to the The signal „brake operated“ or „clutch operated“
engine control unit which in turn actuates the causes the cruise control system to be switched
throttle valve control part. off.
The throttle valve control part opens the throttle
valve according to the speed set. If the vehicle is
equipped with a multi-function steering wheel,
an additional CCS switch is located on the stee-
ring wheel. For further information, please refer to
SSP 195 „The 2.3 ltr. V5 Engine“.

14
Electronic power control
Input signals

● Signal from accelerator pedal module

● Additional signals

1 Throttle valve control part

Additional signals
2 Engine control unit
● Cruise control system
3 Accelerator pedal module
● Air conditioning system
4 Electronic power control
● Lambda regulation
(EPC) warning lamp
● Automatic gearbox
5 Ignition,
● ABS
Fuel injection
● Power-assisted steering
● Alternator

S249_013

The driver’s input, i.e. the signals from the accele- This realisation is achieved via the throttle valve
rator pedal, are transmitted to the engine control (which is adjusted by an electric motor), the igni-
unit, which uses these signals to calculate, in tion and the fuel injection. The ESP warning lamp
consideration of the additional signals, the opti- indicates to the driver that there is a fault in the
mal realisation of the torque demand. electronic power control system.

For further information, please refer to SSP 210 „Electronic Power Control“.

15
 Subsystems

The secondary air system

Input signals

● Signal from lambda probes

● Coolant temperature
● Engine load signal from air mass meter
● Engine speed

1 Secondary air pump relay

2 Secondary air pump
7 3 Secondary air inlet valve
8 11 4 Combination valve
5 Catalyst
3 6 Engine control unit
2 7 Air mass meter
8 Temperature sender
1
2 at engine outlet
6 4 4 9 Pre-catalyst lambda probes
10 After-catalyst lambda probes
11 Engine speed sender

10 5 9 9 5 10

S249_014

The secondary air system reduces the exhaust The input signals enter the engine control unit,
emissions following a cold start. During the which then actuates the secondary air pump and
warm-up phase, the level of unburned hydrocar- the secondary air inlet valve simultaneously via
bons is elevated. The catalyst cannot process this the secondary air pump relay. Vacuum from the
amount because it has not yet attained its opera- secodary air inlet valve operates the combina-
ting temperature, but a mixture of lambda = 1 tion valve. The secondary air pump briefly forces
must be attained. Blowing in air behind the air into the exhaust gas stream behind the
exhaust valve enriches the exhaust gas with oxy- exhaust valve. Beginning at partial load, the
gen, and post-combustion occurs. The heat secondary air system is switched off.
released warms the catalyst more quickly to its
operating temperature.

16
Engine mounting regulation
Input signals

● Signal from engine speed sender

● Vehicle speed

1 Electro-hydraulic engine
3 mounting solenoid valve
5
2 Engine mounting
4
3 Engine control unit
4 Engine speed sender
5 Vehicle speed

To intake manifold

2 2

S249_015

The hydraulically damped engine mountings with Depending on the engine speed and the vehicle
electro-pneumatic actuation reduce the transmis- speed, the engine control unit actuates the sole-
sion of engine oscillation to the body over the noid valve. The solenoid valve switches between
entire engine speed range. the damped engine mounting state in idling
mode and the undamped engine mounting state
in driving mode.

17
 Subsystems

Coolant temperature regulation

Coolant temperature regulation enables the coolant temperature to be adapted to the current operating
mode of the engine.

Input signals

● Engine speed
● Engine load signal from air mass meter
● Coolant temperature at engine outlet
● Coolant temperature at radiator outlet
● Vehicle speed

1 Map-controlled engine cooling

thermostat
2 Radiator fan
3 Radiator fan 2
7 8 9 10 4 Radiator fan 2 control unit
5 Water pump
6 Engine control unit
4 5 7 Air mass meter
6 1 2
8 Engine speed sender
9 Temperature sender at engine
CAN
outlet
10 Temperature sender at radiator
3
outlet
11 Speed signal from
11 S249_016 ABS control unit J104

If, after the input signals have been evaluated, a

larger cooling capacity is required, the map-con-
trolled engine cooling thermostat is actuated,
opening the larger coolant circuit. To increase the
cooling capacity, both radiator fans are actuated
by the engine control unit, whereby radiator fan
2 is switched on by the radiator fan 2 control
unit.
For further information, please refer to
SSP 222 „Electronically Mapped Coo-
ling System“.

18
The regulated vacuum pump system
(only for vehicles with automatic gearboxes)

Input signals

● Signal from pressure sensor for brake servo

1 Relay
2 Electric vacuum pump
3 Engine control unit
4 Pressure sensor for brake servo
5 Anti-return valve
3 6 To intake valve
4 7 Brake servo

7
5
2 5
S249_017

Vehicles with an automatic gearbox are equip- The pressure sensor measures the current pres-
ped with an electric vacuum pump. sure and sends this value to the engine control
This pump supports the brake servo by ensuring unit. The engine control unit compares the actual
that there is sufficient vacuum at the connection value with the stored specification and actuates
point for the brake servo. vacuum pump for brakes V192 via brake servo
relay J569.

For further information, please refer to SSP 257 „Electronic Vacuum Pump for Brake Servo
Unit“.

19
 Sensors

Air mass meter G70 with intake air temperature sender G42

Air mass meter G70 with backflow recognition

and intake air temperature sender G42 are inte-
grated in one component which is located in the
intake tract at the air filter housing. The air mass
meter determines the mass of the inducted air
and sender G42, the temperature.

S249_018

Use of the signal Effects of failure

The air mass meter signal is used for calculating If the signal fails, the engine control unit calcula-
all functions dependent on engine speed and tes a substitute value.
load like, for example, injection period, ignition
timing, variable valve timing and fuel tank venti-
lation.
For further information, please refer to
SSP 195 and SSP 252.

Engine speed sender G28

The engine speed sender G28 is located in the
gearbox housing. It senses the teeth of the dual-
mass flywheel. On the basis of these signals, the
engine control unit determines the engine speed
and the crankshaft position.
The gap in the sender wheel serves as a refe-
rence point for the engine control unit.

S249_019

Use of the signal Effects of failure

This signal is used to calculate the injection time, If the signal fails, the engine cannot run.
the injection quantity and the ignition timing. Fur-
ther, it is used for variable valve timing and tank
ventilation.

For further information, please refer to

SSP 127 „VR 6 Engine“.

20
Coolant temperature senders G62 and G83
The actual values of the coolant temperature are
measured at two different points. Coolant tempe-
rature sender G62 is located on the engine block
(at the coolant outlet) and coolant temperature
sender G83 on the radiator outlet.

S249_020

Sender G62
Coolant outlet at rear of engine Sender G83 at radiator outlet

S249_021 S249_022

Use of signal Effects of signal failure

The signals of both temperature senders G62 If the signal fails, the control unit uses a substitute
and G83 serve the coolant temperature regula- temperature stored in it. The fans go into emer-
tion in the coolant circuit. gency operation (both fans run).
The signal from temperature sender G62 is used
as an input signal for calculating injection peri-
ods and ignition timing, for idling speed regula-
tion, for fuel tank ventilation and for the
secondary air system.

For further information, please refer to

SSP 222 „Electronically Mapped Coo-
ling System“.

21
 Sensors

Lambda probes
The broad-band lambda probes G39, G108
Broad-band lambda probe

Each is located in the exhaust manifold of its spe-

cific bank upstream to the catalyst (pre-catalyst
probe). With the wide-band lambda probe, the
oxygen content in the exhaust gas can be deter-
mined over a wide measuring range.

S249_023

The two-state lambda probes G130, G131

Each is located in the exhaust manifold of its spe-

cific bank downstream to the catalyst (after-cata-
lyst probe).

G108

Use of signal Exhaust manifold

bank II
The pre-catalyst probe supplies the signal for
fuel-air mixture preparation. G131

Catalyst
The after-catalyst probe serves for checking the
function of the catalyst and the lambda regula-
tion loop. S249_024

Two-state lambda probe

Effects of signal failure

If the pre-catalyst probe fails, no lambda regula-

tion can occur. Adaptation is blocked. Emergency
running dependent on map control takes place.
S249_025

If the post-catalyst probe fails, lambda regula-

tion continues. The function of the catalyst cannot
be monitored.
For further information, please refer to
SSP 175 „On-Board Diagnose II“ and
SSP 231 „Euro-On-Board-Diagnose“.

22
Brake servo pressure sensor G294
(only for vehicles with automatic gearbox)

The brake servo pressure sensor is located in the

plenum chamber below the vacuum line to the
brake servo. It transmits a voltage signal to the
engine control unit.

S249_027

Effects of signal failure

If the signal fails, the engine control unit calcula-

tes the pressure in the brake servo on the basis of
the input values for engine load, engine speed,
throttle valve position and brake light switch, and
actuates the vacuum pump.

S249_026

For further information, please refer to SSP 257 „Electronic Vacuum Pump for Brake Servo
Unit“.

23
 Sensors

Hall senders G40, G163, G300, G301

All Hall senders are located in the timing chain

cover of the engine. They have the task of infor-
ming the engine control unit of the positions of
the inlet and exhaust camshafts by sensing a
quick-start sender wheel located on the respec-
tive camshaft.

S249_028

Quick-start Hall sender

sender wheel

S249_029

Exhaust II Inlet II Inlet I Exhaust I

G301 G163 G40 G300

Use of signal Effects of signal failure

Hall senders G40 and G163 indicate to the If a Hall sender fails, the camshafts cannot be
engine control unit the positions of the inlet adjusted. However, the engine continues to run,
camshafts and Hall senders G300 and G301, the and will also start again after it is shut off.
positions of the exhaust camshafts.
The signals of all four Hall senders serve as input
signals for variable valve timing as well as for
the calculation of sequential injection and igni-
tion timing.
The signal from sender G40 is also used for
determining the TDC point of the No. 1 cylinder.

For further information, please refer to

SSP 127 „VR 6 Engine“.

24
Knock sensors G61, G66, G198, G199

The electronic regulation of ignition timing is

based on cylinder-specific knock control. The W8
engine has two knock sensors on each bank,
located on the crankcase.

G198

G199

S249_033 S249_030

G61

G66

S249_031 S249_032

Use of signal Effects of signal failure

The knock sensors indicate to the engine control If a knock sensor fails, the ignition timing of the
unit when knocking combustion occurs. It initiates affected cylinders is retarded. If all knock sensors
an ignition timing adjustment until the knocking fail, the engine management system switches to
ceases. emergency knock control, during which the igni-
tion timing is generally retarded so that the maxi-
mum engine output is not available.

For further information, please refer to

SSP 127 „VR 6 Engine“.

25
 Sensors

The accelerator pedal module

The accelerator pedal module is located on the

pedal cluster and consists of

● the accelerator pedal

● the accelerator pedal position sender G79
and S249_034
● the accelerator pedal position sender 2 G185.

Both senders are sliding contact potentiometers

located on a common shaft.
Every change in the accelerator pedal position S249_035
changes the resistance of the sliding contact
potentiometers and consequently the voltage
transmitted to the engine control unit.

Senders

Use of signal Effects of signal failure

The signals from the accelerator pedal position If a sender fails, the pedal value is limited to a
senders serve to communicate the driver’s input defined value. At full load, the output is
to the engine control unit and also as kickdown increased slowly. If the signals between G79 and
information for the automatic gearbox. G185 implausible, the lower value is used.
The EPC (electronic power control) warning lamp
indicates a fault.

If both senders fail, the engine will run only at

idle and does not respond to the accelerator
pedal.
No separate switch is used for kick-
down information. A mechanical pres- The EPC (electronic power control) warning lamp
sure point is integrated in the gas indicates a fault.
pedal module which communicates
the „kickdown feeling“ to the driver.

For further information, please refer to

SSP 210 „Electronic Power Control“.

26
Brake light switch F and brake pedal switch F47

The brake light switch and the brake pedal switch

are located together in one component on the
pedal cluster.

Use of signal:

Both switches supply the engine control unit with

the signal „brake operated“. This leads to the
S249_037 cruise control system being switched off.

Clutch pedal switch F36

The clutch pedal switch is located on the pedal
cluster.

Use of signal

The signal indicates to the engine control unit

when the clutch pedal is operated, at which point
the cruise control system is switched off. When
the clutch pedal is operated, the quantity of fuel
injected is briefly reduced to prevent the engine
S249_036 speed from increasing while the gear is changed,
reducing the jolt when load returns.

27
 Sensors / Actuators

Throttle valve control part J338

The throttle valve control part is located on the

intake manifold and has the task of providing the Throttle body Intake connection
engine with the required quantity of air under all
conditions. Throttle valve drive

It differs from the control part installed in the VR6

engine in that the intake connection has a grea-
ter diameter. This is necessary because the W8
engine has a greater need for air due to its grea-
ter displacement. Further, the connection for
throttle valve heating has been eliminated.

S249_038

Throttle valve Throttle valve drive angle

senders 1+2

To open or close the throttle valve as well as to Both angle senders transmit the current position
adjust a particular throttle valve setting, the of the throttle valve to the engine control unit.
engine control unit actuates the electric motor for
throttle valve drive.

Effects of signal failure

If the throttle valve drive fails, the throttle valve is If both angle senders fail, the throttle valve drive
automatically drawn to the emergency running is switched off. The engine will only run at an
position, permitting limited operation with an increased idling speed.
increased idling speed.

If an angle sender fails, the maximum output will

not be available.
However, the engine can be started and the
vehicle driven.
For further information, please refer to
SSP 210 „Electronic Power Control“.

28
Fuel pump G6
The fuel pump is installed directly in the fuel tank.
With the aid of the pressure regulator, it creates
a pressure of 4 bar in the fuel system.
To supply the engine, fuel is delivered from the
fuel pump G6 through the fuel filter to the fuel
rail.

G6 S249_039
Effects of failure
S249_040

If the fuel pump fails, no fuel is delivered.

The engine stops.

In addition, fuel pump G23 is located in the additional fuel tank and a suction-jet pump in the
fuel tank. The fuel pump G23 is actuated by fuel pump control unit J538 and delivers fuel from
the additional fuel tank to the main fuel tank. The suction-jet pump ensures that fuel from the
left chamber of the fuel tank reaches the fuel pump G6. Neither fuel pump G23 nor the suc-
tion-jet pump are actuated by the engine control unit.

For further information, please refer to SSP 261 „The Passat W8“.

Fuel pump relay J 17

The fuel pump relay actuates the fuel pump
when it receives an impulse from the engine con-
trol unit.

S249_041 Effects of failure

For further information, please refer to If the relay fails, the engine cannot be started.
SSP 127 „VR 6 Engine“.

29
 Actuators

Injectors N30, N31, N32, N33, N83, N84, N85, N86

The injectors are actuated by the engine control S249_042

unit according to the firing order.
They are secured with retaining clips directly to a
common fuel rail and inject atomised fuel imme-
diately before the inlet valve.

Effects of failure
S249_043
If individual injectors fail, fuel is not injected at
that position. This means that the engine runs at
reduced output. For further information, please refer to
SSP 127 „VR 6 Engine“.

Single-spark ignition coils

N70, N127, N291, N292, N323, N324, N325, N326
The single-spark ignition coils deliver only one S249_045
spark via the spark plugs, and one is fitted at
each cylinder.

An output stage and an ignition coil are combi-

ned in each element so that the engine manage-
ment system can influence the ignition
individually for each cylinder.

Effects of failure

If an ignition coil fails, injection is switched off for

that cylinder.
This prevents damage to the catalyst.

S249_044

30
Inlet camshaft timing adjustment valves 1 N205 and 2 N208 and
Exhaust camshaft timing adjustment valves 1 N318 and 2 N319

The solenoid valves are integrated in the control In the process, valves N205 and N208 are
housing of the camshaft adjuster. They direct the responsible for the continuous adjustment of the
oil pressure to the camshaft adjusters according inlet camshafts and valves N318 and N319, for
to the specifications of the engine control unit in the adjustment of the exhaust camshafts. The
regard to the direction and distance of adjust- exhaust camshaft adjusters can only be set to the
ment. Fluted variators are used as camshaft end positions „advanced“ or „retarded“.
adjusters.

Inlet camshaft
Fluted variator N205 N318
S249_047

Exhaust camshaft
Fluted variator

S249_046
Control housing

Effects of signal failure

The reference point for all four cams-
If an electrical wire to the camshaft adjusters is hafts is „retarded“.
defective or if a camshaft adjuster fails, no cams-
haft adjustment can take place. In the event of an
electrical fault, the camshafts remain in their
reference positions (emergency running positi-
ons). For further information, please refer to
SSP 246 „Variable Valve Timing with
Fluted Variator“.

31
 Actuators

Activated charcoal filter system solenoid valve 1 N80

Opening the solenoid valve empties the activa-

ted charcoal filter and directs the collected fuel
vapour to combustion.

Effects of signal failure

If current is interrupted, the valve remains shut

and tank ventilation cannot occur.
S249_049
To intake manifold

For further information, please refer to

SSP 174 „Changes in the VR6 Engine“.

From activated
S249_048 charcoal filter

Secondary air inlet valve N112

This solenoid valve is switched by the engine con-

trol unit and controls the combination valve via a
vacuum line.

S249_051

Effects of failure

If the control unit signal fails, the combination

valve cannot be opened.
The secondary air pump cannot inject air.

For further information, please refer to

S249_050
SSP 174 „Changes in the VR6 Engine“.

32
Combination valve
Vacuum from the secondary air inlet valve ope-
rates the combination valve, opening the path
for air from the secondary air pump to the secon-
dary air duct in the cylinder head. At the same
time, the valve prevents hot exhaust gases from
S249_055 reaching the secondary air pump.

S249_053

Secondary air pump V101

The secondary air pump transports fresh air for
the secondary air system.

S249_052 Effects of failure

If the current supply is interrupted, no air is trans-

ported.

S249_054

Secondary air pump relay J299

The secondary air pump relay is actuated by the
engine control unit to switch on the secondary air
pump.

S249_041
Effects of failure

The secondary air pump will not run.

S249_056

For further information, please refer to SSP 174 „Changes in the VR6 Engine“ and SSP 217 „The
V8 V5 Engine“.

33
 Actuators

Water pump V36

The water pump V36 is located on the left side (in

direction of travel) of the engine compartment on
the suspension strut mounting.
Depending on the coolant temperature at the
radiator and engine outlets, the pump will be
operated after the engine is shut off on the basis
of a map. The water pump is responsible for cir-
culating coolant so that the engine block cools
S249_057
uniformly.

Vacuum pump for brake servo V192

(only for vehicles with automatic gearboxes)

The regulated electric vacuum pump is located

on the left side of the engine compartment under
a cover and supports the brake servo.

S249_061

Effects of failure

Under certain circumstances (frequent braking)

sufficient vacuum cannot be built up.

S249_060

For further information, please refer to SSP 257 „Electronic Vacuum Pump for Brake Servo
Unit“.

34
Map-controlled engine cooling thermostat F265

The thermostat is inserted in the upper part of the

crankcase from above. The thermostat switches
between the small and the large cooling circuits.
The individual engine operating phases require
different engine temperatures. The thermostat is
actuated by the engine control unit according to
S249_058 the needs. A map is stored in the engine control
unit to attain the desired temperature.
Resistance
heater
Wax element

S249_059
Lifting pin

Effects of failure

At a temperature of 110° C or above, the large

cooling circuit is opened and the radiator fans For further information, please refer to
are actuated. SSP 222 „Electronically Mapped Coo-
ling System“.

Engine mountings
Two hydraulically damped engine mountings ensure improved driving comfort. They reduce the transmis-
sion of engine vibration to the body.

Right engine mounting Right engine support Left engine support

Right engine
console Left engine mounting
Cap

Mounting cover

Front cross member S249_062 Vacuum connection

S249_095
Left engine console

35
 Actuators

Function of engine mountings

The engine oscillation on a bad road surface is damped by the flow of a liquid (glycol mixture) between
chambers 1 and 2. The task of the damping is to reduce resonant engine oscillation due to uneven road
surface. The damping is dependent on the form (length and diameter) of the spiral-shaped channel and
is adapted to the particular engine in the vehicle.

Engine mounting - idling position

Engine vibration
Solenoid N144 under current Connecting
channel

Atmosphere
Glycol mixture

Chamber 1

Nozzle bodies

Chamber 2

Valve plate
Positioning spring
S249_101 To engine mounting S249_096
Vacuum connection
To intake manifold

The engine mounting is pneumatically actuated Opening the connecting channel changes the
by the 3/2-way solenoid. The electro-hydraulic damping. The mounting is dynamically soft,
engine mounting valve directs vacuum or which reduces the transmission of engine vibra-
atmospheric pressure to the positioning spring of tion at idling speed.
the engine mounting. When current is applied,
the valve plate lifts, opening the connection bet-
ween the intake manifold and the engine moun-
ting. The vacuum present at the vacuum
connection of the engine mounting pulls the posi-
Nozzle bodies
tioning spring downwards, which opens the con-
necting channel between chambers 1 and 2.
Exchange of fluid
through connecting
channel

S249_102

36
Engine mounting - driving mode

At a speed of about 5 km/h, the engine control Due to the atmospheric pressure at the posi-
unit cuts off current to the solenoid valve. The tioning spring, the connecting channel between
valve plate of the solenoid valve closes the con- chambers 1 and 2 closes. The exchange of fluid
nection to the intake manifold. Via the solenoid (glycol mixture) between the two chambers
valve, atmospheric pressure reaches the posi- occurs through the spiral-shaped channel in the
tioning spring of the engine mounting. nozzle bodies.

Spiral-shaped
Engine vibrations
Resting state channel
(no current to solenoid valve N144) Connecting
channel

Glycol mixture
Atmosphere

Chamber 1
Nozzle bodies

Chamber 2

Valve plate S249_097

To engine mounting
S249_100 Positioning
Vacuum connection spring
To intake manifold

The damping characteristics (level of damping

and resonance) are adapted to the requirements
of the engine in the vehicle through the length
and diameter of the spiral-shaped channel. The
damping lies in the range of agitation by
unevenness in the road.

Nozzle bodies

Exchange of fluid through Effects of failure

the spiral-shaped chan-
nel. The engine mountings characteristics below 5
km/h change.
S249_086

37
 Functional diagram

Functional diagram
Kl. 30
Kl. 15

J271

S S S
S

E45 E227

N30 N31 N32 N33 N83 N84 N85 N86

J220

N 70 N127 N291 N292 N323 N324 N325 N326

S249_070
E45 - CCS switch N70 - Ignition coil 1
E227 - CCS button N127 - Ignition coil 2
J220 - Motronic control unit N291 - Ignition coil 3
J271 - Motronic current supply relay N292 - Ignition coil 4
N30 - Injector, cylinder 1 N323 - Ignition coil 5
N31 - Injector, cylinder 2 N324 - Ignition coil 6
N32 - Injector, cylinder 3 N325 - Ignition coil 7
N33 - Injector, cylinder 4 N326 - Ignition coil 8
N83 - Injector, cylinder 5 P - Spark plug connector
N84 - Injector, cylinder 6 Q - Spark plug
N85 - Injector, cylinder 7 S - Fuse
N86 - Injector, cylinder 8

38
 Kl. 30
Kl. 15
Brake
lights

b
a a

S S S

F36 F47 F N80 N112 G70 G294

J220

G61 G66 G198 G199

G83
S249_071

F - Brake light switch J220 - Motronic control unit

F36 - Clutch pedal switch N80 - Activated charcoal filter system solenoid valve 1
F47 - CCS brake pedal switch N112 - Secondary air inlet valve
G61 - Knock sensor 1 S - Fuse
G66 - Knock sensor 2
G198 - Knock sensor 3
G199 - Knock sensor 4
G70 - Air mass meter Colour coding/Key
G83 - Coolant temperature sender = Input signal
G294 - Brake servo pressure sensor = Output signal
(only for automatic gearboxes) = Positive
= Earth
= CAN data bus

39
 Functional diagram

Kl. 30
Kl. 15

b b
a a

G79 G185 G39 G130 G108 G131

J220

J293

J338

G187 G188 G186

S249_072

A - CAN Low J - Diagnosis wire

B - CAN High J220 - Motronic control unit
G39 - Lambda probe J293 - Radiator fan control unit
G108 - Lambda probe II J338 - Throttle valve control part
G130 - Lambda probe after catalyst S - Fuse
G131 - Lambda probe II after catalyst
G79 - Accelerator pedal position sender
G185 - Accelerator pedal position sender 2 Colour coding/Key
G186 - Throttle valve drive = Input signal
G187 - Throttle valve drive angle sender 1 = Output signal
G188 - Throttle valve drive angle sender 2 = Positive
H, I - Radiator fan control = Earth
= CAN data bus

40
 Kl. 30
Kl. 15
J17

b
a

S S S S

J569 J299 J496

N144 N205 N318 N319 N208 F265

V192 V101 V36

J220

G6

G28 G40 G163 G300 G301 G62

S249_073

F265 - Map-controlled engine cooling thermostat J496 - Additional coolant pump relay
G6 - Fuel pump J569 - Brake servo relay
G28 - Engine speed sender N144 - Electro-hydraulic engine mounting solenoid valve
G40 - Hall sender 1 N205 - Inlet camshaft timing adjustment valve 1
G163 - Hall sender 2 N208 - Inlet camshaft timing adjustment valve 2
G300 - Hall sender 3 N318 - Exhaust camshaft timing adjustment valve 1
G301 - Hall sender 4 N319 - Exhaust camshaft timing adjustment valve 2
G62 - Coolant temperature sender S - Fuse
J17 - Fuel pump relay V36 - Water pump
J220 - Motronic control unit V101 - Secondary air pump
J299 - Secondary air pump relay V192 - Vacuum pump for brakes

41
 Service

Self-diagnosis
The engine control unit enables a broad self-diagnosis of all subsystems and electrical components.

These vehicle diagnosis systems are used for communication:

● VAS 5051
● VAS 5052

With the vehicle diagnosis, testing and information system VAS 5051,

● Vehicle self-diagnosis
● Testing
● Guided fault finding and
● Administration

can be performed.

VAS 5051

VAS 5052
Vehicle Diagnosis and Service Information System
Version -GB- / V01.02 20/08/2001

Vehicle
self-diagnosis

Testing

Guided
fault finding

Administration

Help

S249_089
S249_080

The use of the vehicle diagnosis system VAS 5051 is explained in

SSP 202 „Vehicle Diagnosis, Testing and Information System VAS 5051“.

42
With the vehicle diagnosis and service information system VAS 5052,

● Vehicle self-diagnosis
● Service Information System and
● Administration

can be performed.

VAS 5052

S249_081

The use of the vehicle diagnosis system VAS 5052 is explained in

SSP 256 „VAS 5052“.

43
 Service

Read fault memory

When faults occur in the system, they will be detected by self-diagnosis and stored in the fault memory.
With function 02, the fault memory can be read using the vehicle diagnosis systems.

The following components are monitored by self-diagnosis.

G70
J17, G6
G28
J338
G62
G83 N30, N31,
N32, N33
G39 N83, N84,
G108 N85, N86
G130
G131 J285 N70, N127,
N291, N292
G40, G163, N323, N324,
G300, G301 N325, N326

J293
G61, G66, N205, N208,
G198, G199 N318, N319

J338 N80
N112

G79, J299, V101

G185
J271

E45, E227 J220 J496, V36

F265
F, F47
N144
CAN

F36 V7, V177

JG294 J569, V192

S249_105

Please note that Repair group 01 is integrated in „Guided fault finding“. In it, you will also find
the functions „Read measured value block“ and „Final control diagnosis“.

44
Erase fault memory

This function erases the contents of the fault memory following „Read fault memory“. However, the readi-
ness code and various adaptation values such as the camshaft and lambda adaptation values will also
be erased. To ensure that the fault memory is properly erased, the ignition must be switched off once.

Following „Erase fault memory“, one must check whether the camshafts have readapted them-
selves. Without adaptation, camshaft adjustment will not occur, resulting in a noticeable loss
in power. There are two ways to adapt the camshafts:

● Idle the engine briefly after erasing the fault memory and restarting the engine.
● Initiate basic settings following the instructions in the workshop manual.

Erasing the fault memory should be carefully considered because the readiness code will be
erased simultaneously, and „Create readiness code“ will be required.
The readiness code must always be created following a repair so that it will not be erased in
the course of further work. The readiness code can be created with the VAS 5051 using the
function „Guided fault finding“.

Readiness code

After the entire number of diagnoses has been performed, an 8-digit readiness code is set. Each position
of the number code may have the value 0 (diagnosis performed) or 1 (diagnosis not performed). The rea-
diness code does not provide any information about whether a fault exists in the system. A lit-up exhaust
warning lamp is the visual indication of one or more detected and stored faults.

A vehicle must only leave the workshop and be delivered to the customer after the readiness
code has been generated.

For more information about the readiness code, please refer to SSP 175 as well as SSP 231.

45
 Test Your Knowledge

1. The engine control unit receives the signal for engine load from

a. the lambda probes.

b. the air mass meter.

c. the accelerator pedal module.

2. Which tasks does the secondary air system perform?

a. It elevates exhaust emissions during the cold start phase.

b. It ensures that the engine operates with excess air.

c. The secondary air system increases performance in the partial-load range.

d. Secondary air injection brings the catalyst up to operating temperature more quickly.

3. What is the task of the brake servo pressure sensor G294?

a. The signal identifies faults in the brake system.

b. In brake systems with ESP, the pressure sensor is screwed directly into the hydraulic unit and
measures the current pressure in the brake system.

c. The pressure sensor measures the momentary pressure at the connection for the brake servo.

4. The coolant temperature is regulated using a map stored in the engine control unit.
The coolant temperature in any engine operating mode

a. is measured by a temperature sender and transmitted to the engine control unit.

b. is measured by two temperature senders and transmitted to the engine control unit.

46
5. If a temperature sender fails

a. the radiator fans go to emergency running mode.

b. the engine stops.

c. the control unit uses a substitute temperature stored in the engine control unit.

6. The electro-hydraulic engine mountings can change in their mounting characteristic.

A pneumatic 3/2-way solenoid valve is actuated by the engine control unit. Which
statements are true?

a. Current is supplied to the solenoid valve at 5 km/h.

b. Current is cut off to the solenoid valve at 5 km/h.

c. Current is supplied to the solenoid valve at idling speed.

d. The characteristic of the engine mounting when the solenoid does not receive current
is dynamically „soft“.

7. The readiness code

a. can be created with the VAS 5051 using the function „Guided fault finding“.

b. is an 8-digit code. From this code, one can determine whether the diagnoses were performed
or not.

c. provides information about faults which exist in the system.

47
 Notes

48
49
 Notes

50
51
Answers
1.) b
2.) d
3.) c
4.) b
5.) a, c
6.) b, c
7.) a, b
 249

For internal use only © VOLKSWAGEN AG, Wolfsburg

All rights reserved. Technical specifications subject to change without notice
140.2810.68.20 Technical status 11/01

❀ This paper was produced from

non-chlorine-bleached pulp.