Engine Management Of The W8 Engine In The Passat

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Service.Self-Study Programme 249Engine Management ofthe W8 Engine in the PassatMotronic ME 7.1.1

The Motronic engine management system of theW8 engine enables high power output with minimal fuel consumption through adaptation to alloperating modes. The heart of the Motronicsystem is the electronic control unit (J220). It processes incoming signals and transmits adjustmentcommands for controlling the subsystems. At thesame time, the control unit serves the diagnosisof subsystems and components.S249 001For further information on the W8 engine, please refer to SSP 248 „The W Engine Concept“.NEWThis self-study programme explains the designand function of new developments.The contents are not updated.2Please always refer to the relevant Service literature for currentinspection, adjustment and repair instructions.ImportantNote

Table of ContentsIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Subsystems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Functional diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 38Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Test your knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . 463

IntroductionThe Motronic ME 7.1.1The regulation of the W8 engine is performed bythe Motronic ME 7.1.1. The management system ofthe W8 engine is, in many respects, the same asthat of the VR6-V4 engine. These are the tasks ofthe engine management system:- Optimisation of the fuel-air mixture for alloperating modes- Reduction of fuel consumption- Regulation of combustion- Monitoring and regulation of exhaustemissions.S249 002The control unit is located in the electrics box inthe plenum chamber.S249 003The control unit performs the following functions:-4Regulation of injectionRegulation of ignition (ignition system with single-spark ignition coils)Regulation of idling speedStereo lambda regulation of exhaust emissionsFuel tank ventilation systemElectronic power controlCruise control systemSecondary air systemKnock controlContinuously variable inlet valve timing, two-position exhaust valve timingControl of engine mountingsRegulation of coolant temperatureRegulation of electric vacuum pumpESPSelf-diagnosis

The engine control unit in the CAN data busThe 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 CANABSSteering anglecontrol unitsensorDash panel insertCAN HighEngine controlunitCAN LowGearboxAirbagAir conditioningcontrol unitcontrol unitcontrol unitImmobiliserS249 004Through the CAN data bus, data are exchanged between the engine control unit and-the ABS control unitthe gearbox control unitthe airbag control unitthe steering angle sensorthe air conditioning control unitthe 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 overviewSensorsG70 Air mass meterG42 Intake air temperature senderG28 Engine speed senderG62 Coolant temperature senderG83 Coolant temperature senderradiator outletG39 Lambda probeG108 Lambda probe IIDash panel insert J285G130 Lambda probe after catalystG131 Lambda probe II after catalyst(control unit with display unitin dash panel insert)G40 Hall sender 1, G163 Hall sender 2G300 Hall sender 3, G301 Hall sender 4Radiator fan 2G61 Knock sensor 1, G66 Knock sensor 2G198 Knock sensor 3, G199 Knock sensor 4control unit J293J338 Throttle valve control partG187 Throttle valve drive angle sender 1G188 Throttle valve drive angle sender 2Accelerator pedal module withG79 Accelerator pedal position sender 1G185 Accelerator pedal position sender 2E45 Cruise control switchE227 Cruise control „Set“ buttonFF47Engine control unit J220Brake light switchCruise control system brake pedal switchCANF36Clutch pedal switchG294 Brake servo pressure sensor(only with automatic gearboxes)6Diagnosis connection

ActuatorsJ17Fuel pump relay, G6 Fuel pumpJ 338 Throttle valve control partG186 Throttle valve driveN30 Injector, cylinder 1, N31 Injector, cylinder 2N32 Injector, cylinder 3, N33 Injector, cylinder 4N83 Injector, cylinder 5, N84 Injector, cylinder 6N85 Injector, cylinder 7, N86 Injector, cylinder 8N70 Ignition coil 1, N127 Ignition coil 2N291 Ignition coil 3, N292 Ignition coil 4N323 Ignition coil 5, N324 Ignition coil 6N325 Ignition coil 7, N326 Ignition coil 8N205Inlet camshaft timing adjustment valve 1, N208 valve 2N318 Exhaust camshaft timing adjustment valve 1, N319 valve 2N80 Activated charcoal filter system solenoid valve 1N112 Secondary air inlet valveV101 Secondary air pump motor,J299 Secondary air pump relayJ271 Motronic current supply relayJ496 Additional coolant pump relay, V36 Water pumpF265 Map-controlled engine cooling thermostatN144 Electro-hydraulic engine mounting solenoid valveV7S249 005Radiator fan, V177 Radiator fan 2J569 Brake servo relay,V192 Vacuum pump for brake servo(only for automatic gearboxes)7

SubsystemsThe fuel injection systemInput signals for calculating injection periods Engine load signal from air mass meterIntake air temperatureSignal from throttle valve control partSignal from engine speed senderCoolant temperatureSignal from Lambda probesSignal from accelerator pedal moduleSignal from Hall senders1Fuel tank2 Fuel pump32156Filter4Fuel rail5Fuel pressure regulator6Injectors7Engine control unit8Accelerator pedal module9Air mass meter with senderfor intake air temperature66310 Engine speed sender611 Temperature sender (G62)66612 Lambda probes613 Throttle valve control part14 Hall senders48910111213147S249 006The fuel pump, which is located in the fuel tank,pumps fuel through the fuel filter to the injectors.The injectors are connected to each other by thefuel rail. Injection occurs sequentially. Using theinput signals, the control unit calculates thenecessary fuel quantity and the required injection period.8The quantity of fuel injected is determined solelyby the length of the period during which theinjector is open. The pressure regulator regulatesthe injection pressure in the fuel rail and regulates the return flow of excess fuel to the fuel tank.

The ignition systemInput signals for calculating the ignition timing Signal from engine speed senderEngine load signal from air mass meterSignal from throttle valve control partCoolant temperatureSignal from knock sensorsSignal from Hall sendersSignal from accelerator pedal module1 Single-spark ignition coilswith output stage2 Engine control unit3456783 Air mass meter4 Engine speed sender5 Temperature sender (G62)96 Throttle valve control part27 Knock sensor18 Accelerator pedal module9 Hall senders1010 Spark plugs91019S249 007The ignition timing is calculated according to amap stored in the engine control unit on the basisof the input signals.9

SubsystemsKnock controlUnfavourable 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 temperature1 Single-spark ignition coilswith output stage2 Engine control unit3 Knock sensors24 Hall senders345 Spark plugs153451433S249 008Each bank of the W8 engine is equipped withtwo knock sensors mounted on the crankcase. Toprevent the connectors in the wiring harness frombeing interchanged on the sensors, the connections are colour coded. The knock signals can berelated to individual cylinders with the aid of theHall signals.10When knocking is detected in a cylinder, theengine management system changes the ignitiontiming of the knocking cylinder (by retarding thefiring point) until the knocking ceases.When the affected cylinder no longer has thetendency to knock, the control unit returns theignition timing to its former setting (advancingthe firing point).

Variable valve timingThe task of variable valve timing is to set the best valve timing for the operating modes idle, maximumpower and torque. Variable valve timing optimises the ratio between fresh air and exhaust gas. This isreferred to as internal exhaust gas recirculation. The overlap angle, during which the inlet valve isalready opening while the exhaust valve is not yet closed, determines the quantity of „recirculated“exhaust gas.Input signals Signal from Hall sendersSignal from engine speed senderEngine load signal from air mass meterCoolant temperatureOil temperature1 Solenoid valves2 Engine control unit67343 Air mass meter54 Engine speed sender5 Temperature sender1at engine outlet6 Hall senders627 Oil temperature1S249 0096To adjust the camshafts, the engine control unitrequires information on engine speed, engineload, engine temperature, positions of thecrankshaft and camshafts and, from the dashpanel insert via CAN, oil temperature. Theengine control unit actuates the solenoid valvesaccording to operating mode.The camshafts are adjusted according to a mapstored in the engine control unit, whereby theinlet camshafts can be continuously adjusted. Thecamshaft adjusters on the exhaust camshafts arealways moved by the engine control unit to oneend position or the other.For further information, please refer to SSP 246 „Variable Valve Timing with Fluted Variator“.11

SubsystemsStereo lambda regulationThe task of the lambda regulation is to maintain a lambda value of 1 during combustion so that exhaustgases can be optimally cleaned in the catalyst.Input signals Signal from engine speed senderEngine load signal from air mass meterSignal from lambda probesCoolant temperature1 Injectors62 Engine control unit53 Air mass meter4374 Engine speed sender15 Pre-catalystlambda probes6 After-catalystlambda probes7 Coolant temperature2165S249 010During stereo lambda regulation, separate regulation loops, each including a catalyst, a precatalyst probe and an after-catalyst probe,determine the correct fuel-air mixture for eachcylinder bank.The lambda probes inform the control unit of theresidual oxygen content in the exhaust gas.Using this signal, the control unit calculates themomentary composition of the fuel-air mixture.When deviation from the specified value occurs,the injection period is corrected.In addition, adaptive lambda regulation takesplace. (The control unit adapts to the operatingconditions and stores the learnt values.)For further information, please refer toSSP 175 „On-Board Diagnosis SystemII“.12

The fuel tank ventilation systemInput signals for fuel tank ventilation regulation Engine speedEngine load signal from air mass meterEngine speedSignal from lambda probesSignal from throttle valve control part56789341Fuel tank;2Activated charcoal filter3Solenoid valve foractivated charcoal filter4Engine control unit5Air mass meter6Engine speed sender7Temperature senderat engine outlet8Lambda probes9Throttle valve control part21249 011The fuel tank ventilation system prevents fuelvapour which develops in the tank from escapingto the atmosphere. The fuel vapour is stored inthe activated charcoal filter. After evaluating theinput signals, the engine control unit actuates thesolenoid valve.The fuel vapour stored in the activated charcoalfilter is directed through the intake manifold tothe engine for combustion.This briefly changes the fuel-to-air ratio. Thechange in the mixture is registered by thelambda probes, causing lambda regulation to beactivated by the engine control unit and the mixture settles back to lambda 1.For further information, please refer toSSP 231 „Euro On-Board DiagnosticSystem“.13

SubsystemsThe cruise control system (CCS)With the aid of the cruise control system, a vehicle speed above 30 km/h can be specified. This speedwill then be maintained without driver intervention.Input signals Engine speedEngine load signal from air mass meterVehicle speedSignal „brake operated“Signal „clutch operated“„On“ and „off“ signals from CCS switch8345Feedback:2Throttle valve61Throttle valve control part2Engine control unit3Air mass meter4Engine speed sender5Brake pedal switch6Clutch pedal switch7CCS switch8Vehicle speedOperation ofpositioning motorposition17S249 012The signal from the CCS switch goes to theengine control unit which in turn actuates thethrottle valve control part.The throttle valve control part opens the throttlevalve according to the speed set. If the vehicle isequipped with a multi-function steering wheel,an additional CCS switch is located on the steering wheel.14The signal „brake operated“ or „clutch operated“causes the cruise control system to be switchedoff.For further information, please refer toSSP 195 „The 2.3 ltr. V5 Engine“.

Electronic power controlInput signals Signal from accelerator pedal module Additional signals1 Throttle valve control partAdditional signals2 Engine control unit Cruise control system3 Accelerator pedal module Air conditioning system4 Electronic power control Lambda regulation(EPC) warning lamp Automatic gearbox5 Ignition, ABSFuel injection Power-assisted steering Alternator32154S249 013The driver’s input, i.e. the signals from the accelerator pedal, are transmitted to the engine controlunit, which uses these signals to calculate, inconsideration of the additional signals, the optimal realisation of the torque demand.This realisation is achieved via the throttle valve(which is adjusted by an electric motor), the ignition and the fuel injection. The ESP warning lampindicates to the driver that there is a fault in theelectronic power control system.For further information, please refer to SSP 210 „Electronic Power Control“.15

SubsystemsThe secondary air systemInput signals Signal from lambda probesCoolant temperatureEngine load signal from air mass meterEngine speed7811321641Secondary air pump relay2Secondary air pump3Secondary air inlet valve4Combination valve5Catalyst6Engine control unit7Air mass meter8Temperature sender2at engine outlet49Pre-catalyst lambda probes10 After-catalyst lambda probes11 Engine speed sender10599510S249 014The secondary air system reduces the exhaustemissions following a cold start. During thewarm-up phase, the level of unburned hydrocarbons is elevated. The catalyst cannot process thisamount because it has not yet attained its operating temperature, but a mixture of lambda 1must be attained. Blowing in air behind theexhaust valve enriches the exhaust gas with oxygen, and post-combustion occurs. The heatreleased warms the catalyst more quickly to itsoperating temperature.16The input signals enter the engine control unit,which then actuates the secondary air pump andthe secondary air inlet valve simultaneously viathe secondary air pump relay. Vacuum from thesecodary air inlet valve operates the combination valve. The secondary air pump briefly forcesair into the exhaust gas stream behind theexhaust valve. Beginning at partial load, thesecondary air system is switched off.

Engine mounting regulationInput signals Signal from engine speed sender Vehicle speed1 Electro-hydraulic engine3mounting solenoid valve52 Engine mounting43 Engine control unit4 Engine speed sender5 Vehicle speedTo intake manifold122S249 015The hydraulically damped engine mountings withelectro-pneumatic actuation reduce the transmission of engine oscillation to the body over theentire engine speed range.Depending on the engine speed and the vehiclespeed, the engine control unit actuates the solenoid valve. The solenoid valve switches betweenthe damped engine mounting state in idlingmode and the undamped engine mounting statein driving mode.17

SubsystemsCoolant temperature regulationCoolant temperature regulation enables the coolant temperature to be adapted to the current operatingmode of the engine.Input signals Engine speedEngine load signal from air mass meterCoolant temperature at engine outletCoolant temperature at radiator outletVehicle speed1Map-controlled engine coolingthermostat2 Radiator fan76198210453Radiator fan 24Radiator fan 2 control unit5Water pump6Engine control unit7Air mass meter8Engine speed sender9CANTemperature sender at engineoutlet10 Temperature sender at radiator3outlet11 Speed signal from11S249 016ABS control unit J104If, after the input signals have been evaluated, alarger cooling capacity is required, the map-controlled engine cooling thermostat is actuated,opening the larger coolant circuit. To increase thecooling capacity, both radiator fans are actuatedby the engine control unit, whereby radiator fan2 is switched on by the radiator fan 2 controlunit.For further information, please refer toSSP 222 „Electronically Mapped Cooling System“.18

The regulated vacuum pump system(only for vehicles with automatic gearboxes)Input signals Signal from pressure sensor for brake servo1 Relay2 Electric vacuum pump3 Engine control unit4 Pressure sensor for brake servo5 Anti-return valve36 To intake valve47 Brake servo17552S249 0176Vehicles with an automatic gearbox are equipped with an electric vacuum pump.This pump supports the brake servo by ensuringthat there is sufficient vacuum at the connectionpoint for the brake servo.The pressure sensor measures the current pressure and sends this value to the engine controlunit. The engine control unit compares the actualvalue with the stored specification and actuatesvacuum pump for brakes V192 via brake servorelay J569.For further information, please refer to SSP 257 „Electronic Vacuum Pump for Brake ServoUnit“.19

SensorsAir mass meter G70 with intake air temperature sender G42Air mass meter G70 with backflow recognitionand intake air temperature sender G42 are integrated in one component which is located in theintake tract at the air filter housing. The air massmeter determines the mass of the inducted airand sender G42, the temperature.S249 018Use of the signalEffects of failureThe air mass meter signal is used for calculatingall functions dependent on engine speed andload like, for example, injection period, ignitiontiming, variable valve timing and fuel tank ventilation.If the signal fails, the engine control unit calculates a substitute value.For further information, please refer toSSP 195 and SSP 252.Engine speed sender G28The engine speed sender G28 is located in thegearbox housing. It senses the teeth of the dualmass flywheel. On the basis of these signals, theengine control unit determines the engine speedand the crankshaft position.The gap in the sender wheel serves as a reference point for the engine control unit.S249 019Use of the signalEffects of failureThis signal is used to calculate the injection time,the injection quantity and the ignition timing. Further, it is used for variable valve timing and tankventilation.If the signal fails, the engine cannot run.For further information, please refer toSSP 127 „VR 6 Engine“.20

Coolant temperature senders G62 and G83The actual values of the coolant temperature aremeasured at two different points. Coolant temperature sender G62 is located on the engine block(at the coolant outlet) and coolant temperaturesender G83 on the radiator outlet.S249 020Sender G62Coolant outlet at rear of engineSender G83 at radiator outletS249 022S249 021Use of signalEffects of signal failureThe signals of both temperature senders G62and G83 serve the coolant temperature regulation in the coolant circuit.The signal from temperature sender G62 is usedas an input signal for calculating injection periods and ignition timing, for idling speed regulation, for fuel tank ventilation and for thesecondary air system.If the signal fails, the control unit uses a substitutetemperature stored in it. The fans go into emergency operation (both fans run)

the W8 Engine in the Passat Motronic ME 7.1.1 Self-Study Programme 249 Service. 2 . that of the VR6-V4 engine. These are the tasks of the engine management system: . 6 Engine speed sender 7 Temperature sender at engine outlet 8 Lambda probes 9 Throttle valve control part

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