This is how it works:

A constant voltage is applied to the fuel composition sender by the engine control unit.

Contact pins
Water level OK Fuel

The contact pins are surrounded by diesel fuel.

Because diesel fuel has a low level of
450
conductivityconductivity, there is a high signal
response. In this way, the engine control unit V

detects that the water level is OK and sends the

information to the dash panel insert. The preglow
warning lamp K29 does not light up.

304_050
Water

Water level not OK

The contact pins are surrounded by water.

Because water has a high level of conductivity,
450
there is a low signal response. The engine control
unit detects that the water level is too high and V

sends the information to the dash panel insert.

The glow period warning lamp K29 will be
actuated in the dash panel insert and it will flash.
Flashing indicates a fault in the engine manage-
ment system. The engine should be checked in a
specialist workshop.

304_055

Wiring colour key

Positive Earth Input signal CAN drive train

databus

31
 Engine management

Actuators

Unit injector solenoid valves, cylinders 1 - 6

N240 … N244 and N245,
Unit injector solenoid valves, cylinders 7 - 10
N303 … 306

The unit injector solenoid valves are secured to

the unit injector bodies by union nuts.
The solenoid valves are actuated by the engine
control units.
These control start of delivery and the amount of
fuel injected.

As soon as a unit injector solenoid valve is

actuated by the engine control unit, the valve
needle is pushed onto its seat by the magnetic
coil and this closes the path of fuel to the
compression chamber of the unit injector.
Thereafter, injection will start.

The amount of fuel injected is determined by the

actuating period of the solenoid valve. As long
304_022
as the unit injector solenoid valve is closed, fuel
Unit injector solenoid valve
will be injected into the combustion chamber.

Effects of failure

If a unit injector solenoid valve should fail in its

function, the engine will not run smoothly and
performance will be impaired.

The unit injector solenoid valve has two safety

functions. If the valve stays open, pressure
cannot be built up in the unit injector. If the valve
stays closed, the compression chamber of the
unit injector can no longer be filled. In both
cases, no fuel can be injected into the cylinder. Unit injector solenoid valve

304_032

32
Turbocharger positioning motors V280
and V281 (V10-TDI-engine)

The turbocharger positioning motors are bolted

to a bracket beneath the turbocharger. One con-
trol unit can be found in each positioning motor.

Task

The positioning motors are actuated by the

304_010
respective engine control unit via a CAN
databus. This improves regulation and fault Turbocharger 2
diagnosis. The improvement is thanks to positioning motor V281 Turbocharger 1
information about guide vane positioning and positioning motor V280
detected faults that the engine control units
receive. The turbocharger guide vanes are
actuated via a rod assembly.
The turbocharger positioning motor is
Effects of failure designed specifically for use with the
turbocharger. For this reason, both
If the positioning motors fail in their function, parts should be only be removed or
charge pressure control is no longer possible. The replaced together.
amount of fuel injected is limited according to the It is critical that reference be made to
engine speed and engine performance will be the workshop manual.
impaired.

Charge pressure limitation solenoid valve N75

(R5-TDI-engine)

The charge pressure limitation solenoid valve can

be found beneath the variable turbocharger. 304_078

Task Effects of failure

The charge pressure limitation solenoid valve is The vacuum unit is filled with atmospheric
actuated by the engine control unit. Vacuum is pressure. Charge pressure is lower as a result
built up in the vacuum unit for guide vane and engine performance is impaired.
adjustment depending on the duty cycle.

33
 Engine management

Exhaust gas Exhaust gas

Exhaust gas recirculation solenoid valves N18 recirculation valve 2 N213 recirculation valve N18
and N213

The solenoid valves for exhaust gas recirculation

can be found on the suspension strut domes on
each side. The valves are electro-pneumatic.

Task

The valves are actuated with a duty cycle by the

engine control unit depending on the map. In this
way, the control pressure for the recirculation valve
can be set. The cross section of the exhaust Exhaust gas
manifold is changed in the exhaust gas recirculation valve
recirculation valve depending on the control
pressure and the amount of recirculated exhaust
gas set.

Effects of failure

If the signal fails, exhaust gas recirculation may no

longer be possible.
304_012
Intake manifold
flap motor 2 V275 Intake manifold
Intake manifold flap motors V157 and V275 flap motor V157

The V10-TDI-engine has two electrically adjustable

intake manifold flaps and there is one electric
motor for each flap. These can be found directly in
front of the respective exhaust gas recirculation
valve.

Task

– With the electrically adjustable intake manifold

flaps, differences between air intake pressure
and exhaust gas pressure are generated in 304_011
certain operating conditions. Effective exhaust
gas recirculation is guaranteed thanks to the
differences in pressure.
– When the engine is switched off, the flap is Effects of failure
closed and the flow of air interrupted. In this
way, less air is drawn in and compressed which In case of failure, effective exhaust gas
helps smooth run-down of the engine. recirculation is no longer possible.

34
Intake manifold flap changeover valve N239
(R5-TDI-engine)

The intake manifold flap changeover valve can

be found on the right-hand suspension strut
dome.
304_048

Task Effects of failure

When the engine is switched off, the intake If the changeover valve fails in its function, the
manifold flap changeover valve is actuated by intake manifold flap will stay in the open
the engine control unit. Following this, the intake position. If this happens, strong jolts will be
manifold flap is closed and the flow of air noticeable when the engine is switched off.
interrupted. In this way, less air is drawn in and
compressed and the engine will run down
smoothly as a result.

EGR cooler changeover valves N345 and N381

(Phaeton only)

The exhaust gas recirculation cooler changeover

valves can be found in the vicinity of the exhaust
gas recirculation cooler.
304_048

Task Effects of failure

The changeover valve is actuated by the engine If the changeover valve fails in its function, the
control unit depending on the temperature. It exhaust gas cooling flap will stay in the closed
clears the path from the vacuum pump to the position and the exhaust gas will no longer be
membrane valve, the exhaust gas cooling flap cooled. This can lead to an increase in nitrogen
is actuated and the path through the cooler is oxide emissions.
cleared.

35
 Engine management

Exhaust gas recirculation cooler

(Phaeton only)

The V10-TDI-engine in the Phaeton is equipped

with independent coolers for the exhaust gas
recirculation system.

The pneumatically controlled flaps for exhaust

gas cooling allow activation of the cooler from a
coolant temperature of 50 oC.

304_014
Cooler for exhaust gas recirculation

To valve
Cooler for exhaust gas recirculation for exhaust gas recirculation

From
exhaust manifold
From
exhaust manifold
304_031

Vacuum unit

Coolant connection
Coolant distribution to switch unit
with flap for exhaust gas cooling

36
 To valve
for exhaust gas recirculation
Without exhaust gas cooling
Cooler for exhaust gas recirculation

304_037
Coolant From
connection Flap for exhaust manifold
Coolant exhaust gas cooling

The engine and the catalyst are cold. The exhaust gas cooling flap is closed. The exhaust gases are
directed past the cooler and are therefore not cooled. In this way, the engine will reach its effective
operating temperature quickly.

With exhaust gas cooling To valve

for exhaust gas recirculation
From exhaust manifold
to cooler through flow

304_025

Flap for
Coolant exhaust gas cooling

The engine and the catalyst have reached effective operating temperature. The exhaust gas cooling flap is
open. The exhaust gas is directed through the cooler and is therefore cooled.
The combustion temperature is reduced due to the cooled exhaust gases and a greater amount of
exhaust gas can be recirculated. In this way, fewer nitrogen oxides are produced and carbon build-up is
avoided.

37
 Engine management

Fuel pumps G6 and G23

Both electrical fuel pumps are installed in the fuel tank.

– Fuel pump G23 with fuel gauge sender G – Fuel pump G6 with fuel gauge sender 3 G237
and a suction jet pump can be found in the and a suction jet pump can be found in the
main chamber of the fuel tank. secondary chamber of the fuel tank.

Actuation of both electrical fuel pumps is done in parallel sequence via the fuel pump relay J17.

Fuel pump G23

Fuel pump G6
(presupply pump)
Fuel gauge sender G

Fuel gauge sender 3 G237

Suction jet pump 2

Suction jet pump 1

304_049

Suction jet pump 1 draws fuel from the main chamber into the presupply reservoir of fuel pump G6 and
suction jet pump 2 pumps out the secondary chamber into the presupply reservoir of fuel pump G23.
Both suction jet pumps are driven by the electrical fuel pumps.

Effects of failure

If one pump fails, engine performance will be The maximum speed is unattainable and the
impaired due to a restriction in the amount of engine will not run smoothly at high revs.
fuel supplied.

38
Thermostat for map-controlled
engine cooling F265

The thermostat for map-controlled engine

cooling can be found in the coolant distribution
housing. It has the task of switching between the
large and small coolant circuits. To do this, it is
actuated by the engine control unit according to
the engine operating conditions. Maps are
stored in the engine control unit which contain
temperature specifications depending on the
engine load.

Map-controlled engine cooling has the

advantage that the coolant temperature can be 304_016
adapted to the current operating conditions of
Coolant distribution housing
the engine. This helps to reduce fuel consumption
in the part-throttle range and also exhaust gas
emissions.

304_029

Coolant distribution housing

Spring

Resistance heater

A more detailed description of the

map-controlled engine cooling can Expanding material
be found in Self-Study Programme element
No. 222 "Electronically Controlled Plunger pin
Cooling System".

39
 Engine management

Additional coolant pump relay J496,

Continued coolant circulation pump V51 Continued coolant circulation pump V51

The continued coolant circulation pump can be

found on cylinder bank 1 on the vibration
damper side.
Due to the high working current, the pump is
actuated via a relay.
The additional coolant pump relay is installed in
the electronics box which can be found in the
plenum chamber.

Task

When the engine is switched off, the continued

coolant circulation pump will remain activate for
a maximum of 10 minutes. In this way, controlled 304_027
cooling of the engine is achieved. Vibration damper

Effects of failure

If the replay or the continued coolant circulation

pump fail, continued coolant circulation is no
longer possible. If the relay is defective, a fault
will be stored. A defective pump cannot be
detected.

Electrical actuation

The engine control unit actuates the continued

coolant circulation pump via the additional
coolant pump relay.
J496
V51
M

J623 Engine control unit 1

J496 Additional coolant pump relay J623
V51 Continued coolant circulation pump
304_067

40
Fuel cooling pump relay J445 and fuel cooling
pump V166 (Touareg) Fuel cooling pump V166

The fuel cooling pump can be found on cylinder

bank 1 on the vibration damper side.
The pump is actuated via a relay due to the high
working current.
The relay for the fuel cooling pump is installed in
the electronics box which can be found in the
plenum chamber.

Task

The engine control unit actuates the fuel cooling

pump relay at and above a fuel temperature of
approximately 70 oC. The engine control unit
sends a working current to the fuel cooling pump
and the fuel cooler is then surrounded by 304_009
coolant. Fuel temperature will drop.
Vibration damper

Effects of failure

If the fuel cooling relay or fuel cooling pump fail,

fuel will no longer be cooled. The fuel tank and
the fuel gauge sender could become damaged.
A defective relay is stored as a fault. A defective
pump cannot be detected.

Electrical actuation

The fuel cooling pump is actuated via fuel

cooling pump relay J445 by engine control unit 1
J623.
J445
V166
M

J623 Engine control unit 1

J445 Fuel cooling pump relay J623
V166 Fuel cooling pump
304_068

41
 Engine management

Right solenoid valve for electro-hydraulic

engine mounting N145 (Phaeton)

The V10-TDI-engine in the Phaeton features

hydraulically dampening engine mountings.

These engine mountings reduce the transmission

of engine vibration to the body and in doing so
provide a high level of driving comfort.

304_041

Right solenoid valve for

electro-hydraulic engine
mounting N145

Right engine mounting

Left engine mounting

Left engine bracket

Right engine bracket

Engine carrier

304_040

42
 This is how it works:

The hydraulically dampening engine mountings The road speed and engine speed are used as
are actuated pneumatically via solenoid valve input signals.
N145. The engine mountings reduce vibrations
that are transmitted to the body by the engine
across the entire throttle range.

Engine control unit 1 J623

Control unit for ABS
with ESP J104
(road speed)

Engine speed
sender G28

Right solenoid valve for

From vacuum electro-hydraulic engine
pump mounting N145

Engine Engine
mounting, right mounting, left

304_042

More detailed information about the function of the engine mountings can be found in
Self-Study Programme No. 249 "Management of the W8 Engine in the Passat".

43
 Engine management

Functional diagram for V10-TDI-engine Key

F Brake light switch Q10 Glow plugs

30 30 F8 Kick-down switch ... Q19
15 15 F47 Brake pedal switch
F60 Idle switch V51 Continued coolant circulation pump
F265 Thermostat for map-controlled engine V157 Intake manifold flap motor
cooling V166 Fuel cooling pump
V275 Intake manifold flap motor 2
G6 Fuel pump (presupply pump) V280 Turbocharger 1 positioning motor
G23 Fuel pump V281 Turbocharger 2 positioning motor
G
G28 Engine speed sender
J317 G31 Charge pressure sender Z19 Lambda probe heating
G39 Lambda probe Z28 Lambda probe heating 2
J689
G40 Hall sender
A A G42 Intake air temperature sender
G62 Coolant temperature sender
G70 Air mass meter
G79 Accelerator pedal position sender
G81 Fuel temperature sender Additional signal
G83 Coolant temperature sender
B B
radiator outlet 1 CAN drive train databus (high)
C C C
D D G108 Lambda probe 2 2 CAN drive train databus (low)
G133 Fuel composition sender 3 Radiator fan output stage 1
V157 V280 V281 F265 F47 F J17 G108 Z28 V275 G246
G246 Air mass meter 2 4 Radiator fan output stage 2
J496 J445 J52 N145 H J495
G248 Fuel temperature sender 2 5 Coms lead (diagnosis connection)
M M M V51 V166 λ M N213 N381
G299 Intake air temperature sender 2 6 Cruise control system switch
M M M M
G447 Charge pressure sender 2 (ON/OFF)
G23 G6
N18 N345 7 Road speed signal
J17 Fuel pump relay
Q10...Q14 Q15...Q19 8 Alternator terminal DFM
J52 Glow plug relay
1 9 Starter relay J...
J317 Voltage supply relay - term. 30
J445 Fuel cooling pump relay
2
J495 Glow plug relay 2
J496 Additional coolant pump relay
J623 Engine control unit 1
J623 J624 J624 Engine control unit 2
J689 Voltage supply relay 2 term. 30 A
B
N18 Exhaust gas recirculation valve C
E G D
N145 Electro-hydraulic engine mounting Connections within functional diagram
F E F solenoid valve E
N213 Exhaust gas recirculation valve 2 F
+ N240 Unit injector solenoid valves G
H
λ ... N245
N303
3 4 5 6 7 8 9 1 2 5
... N306
N240 N241 N242 N243 N244 G81 G62 G83 G133 G31 G42 G40 G28 F60/F8 G79 G70 G39 Z19 N245 N303 N304 N305 N306 G248 G447 G299
N345 EGR cooler changeover valve
N381 EGR cooler changeover valve 2
H 304_001

44 45
 Engine management

Functional diagram for V10-TDI-engine Key

F Brake light switch Q10 Glow plugs

30 30 F8 Kick-down switch ... Q19
15 15 F47 Brake pedal switch
F60 Idle switch V51 Continued coolant circulation pump
F265 Thermostat for map-controlled engine V157 Intake manifold flap motor
cooling V166 Fuel cooling pump
V275 Intake manifold flap motor 2
G6 Fuel pump (presupply pump) V280 Turbocharger 1 positioning motor
G23 Fuel pump V281 Turbocharger 2 positioning motor
G
G28 Engine speed sender
J317 G31 Charge pressure sender Z19 Lambda probe heating
G39 Lambda probe Z28 Lambda probe heating 2
J689
G40 Hall sender
A A G42 Intake air temperature sender
G62 Coolant temperature sender
G70 Air mass meter
G79 Accelerator pedal position sender
G81 Fuel temperature sender Additional signal
G83 Coolant temperature sender
B B
radiator outlet 1 CAN drive train databus (high)
C C C
D D G108 Lambda probe 2 2 CAN drive train databus (low)
G133 Fuel composition sender 3 Radiator fan output stage 1
V157 V280 V281 F265 F47 F J17 G108 Z28 V275 G246
G246 Air mass meter 2 4 Radiator fan output stage 2
J496 J445 J52 N145 H J495
G248 Fuel temperature sender 2 5 Coms lead (diagnosis connection)
M M M V51 V166 λ M N213 N381
G299 Intake air temperature sender 2 6 Cruise control system switch
M M M M
G447 Charge pressure sender 2 (ON/OFF)
G23 G6
N18 N345 7 Road speed signal
J17 Fuel pump relay
Q10...Q14 Q15...Q19 8 Alternator terminal DFM
J52 Glow plug relay
1 9 Starter relay J...
J317 Voltage supply relay - term. 30
J445 Fuel cooling pump relay
2
J495 Glow plug relay 2
J496 Additional coolant pump relay
J623 Engine control unit 1
J623 J624 J624 Engine control unit 2
J689 Voltage supply relay 2 term. 30 A
B
N18 Exhaust gas recirculation valve C
E G D
N145 Electro-hydraulic engine mounting Connections within functional diagram
F E F solenoid valve E
N213 Exhaust gas recirculation valve 2 F
+ N240 Unit injector solenoid valves G
H
λ ... N245
N303
3 4 5 6 7 8 9 1 2 5
... N306
N240 N241 N242 N243 N244 G81 G62 G83 G133 G31 G42 G40 G28 F60/F8 G79 G70 G39 Z19 N245 N303 N304 N305 N306 G248 G447 G299
N345 EGR cooler changeover valve
N381 EGR cooler changeover valve 2
H 304_001

44 45
 Service

Self-diagnosis

Diagnosis

On vehicle diagnosis, testing and information

systems VAS 5051 and VAS 5052:

– Guided fault finding* and

– Vehicle self-diagnosis

can be selected.

Operating mode "Guided fault finding"

checks all vehicle-specific control units for stored

faults and automatically compiles an individual
testing plan based on the results.
This plan is carried out in conjunction with ELSA
information, such as current flow diagrams or
workshop manuals, selected to aid fault finding.
304_051

In addition to this, you can also compile your

own testing plan. The tests you choose from the
selection of functions and components will be
added to the testing plan and can be carried out
as a diagnostic sequence in any order.

Operating mode "Vehicle Self-Diagnosis"

can be used in the same way as normal but no

additional information is available from ELSA.

304_052

More detailed information about

guided fault finding can be found in
chapter 7 of the VAS 5051 operating
handbook.
* Not with vehicle diagnosis and
service information system VAS 5052

46
Workshop Equipment

Designation Tool

Test box
V.A.G 1598/42

304_083

Adapter lead
V.A.G 1598/39-1

304_084

Adapter lead
V.A.G 1598/39-2

304_085

47
 Test your knowledge

Which answers are correct?

One or more answers could be correct.

1. Which special features does Bosch EDC 16 have?

a) It is designed for both single control unit and double control unit concepts.

b) It was designed exclusively for the V10-TDI-engine.

c) It has torque-orientated engine management.

2. Which statements about the V10-TDI-engine are correct?

a) The basic functions for cylinder bank 1 are carried out by engine control unit 1
and the basic functions for cylinder bank 2 by engine control unit 2.

b) Information that is received by engine control unit 1 is sent to engine control unit 2
via an internal CAN databus.

c) Engine control unit 1 is responsible for injection and exhaust gas recirculation and
engine control unit 2 is responsible for the remaining functions.

3. On the V10-TDI-engine, how are the engine control units allocated to the cylinder banks?

a) The engine control units have different part numbers.

b) The engine control units are coded using VAS 5051.

c) In the connector for engine control unit 2 J624 there is an additional coding link
which facilitates allocation.

48
4. On the V10-TDI-engine, Lambda probes calculate the remaining oxygen content in the
exhaust gas. In this way, ...

a) the amount of fuel injected is adapted.

b) the amount of nitrogen oxide in the exhaust gas is calculated.

c) the amount of recirculated exhaust gas is corrected.

5. Why is an independent cooler for exhaust gas recirculation used on the V10-TDI-engine in the
Phaeton?

a) To prevent excessive warm-up periods of the engine caused by cooled exhaust gases.

b) So that the coolant does not get too hot.

c) To prevent increased carbon dioxide and carbon monoxide emissions during warm-up.

6. What are the advantages of turbocharger positioning motor actuation via the CAN drive
train databus?

a) More precise regulation is made possible as the position of the guide vanes is detected.

b) More precise fault diagnosis is made possible as detected faults are sent to the engine
control units.

c) It is cheaper.

49
 Test your knowledge

7. Which statements about the fuel cooling pump are correct?

a) The fuel cooling pump operates continually while the engine is running.

b) The fuel cooling pump can be found in the Touareg on the V10-TDI-and R5-TDI-engines.

c) The fuel cooling pump is actuated when the fuel temperature is approximately 70 °C.

8. The engine speed sender G28 on the V10-TDI-engine ...

a) sends its signals directly to both engine control units.

b) sends its signals to engine control unit 1 J623 and these are then passed on
to engine control unit 2 J624 via an internal CAN databus.

c) sends its signals to engine control unit 1 J623 and these are then passed on
to engine control unit 2 J624 via a separate cable.

1. a, c; 2. a, b; 3. c; 4. c; 5. a, c; 6. a, b; 7. b, c; 8. c

Answers

50
Notes

51
Service. 304

For internal use only. © VOLKSWAGEN AG, Wolfsburg

All rights reserved. Technical specifications subject to change without notice.
000.2811.24.20 Technical status: 11/02

❀ This paper is produced from

non-chlorine-bleached pulp.