Service Training

Self-Study Program 822703

Volkswagen 4.2L V8 FSI Engine

Volkswagen Group of America, Inc.

Volkswagen Academy
Printed in U.S.A.
Printed 5/2008
Course Number 822703
2008 Volkswagen Group of America, Inc.
All rights reserved. All information contained in
this manual is based on the latest information
available at the time of printing and is subject to
the copyright and other intellectual property rights
of Volkswagen Group of America, Inc., its affiliated
companies and its licensors. All rights are reserved
to make changes at any time without notice.
No part of this document may be reproduced,
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without the prior expressed written permission of
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All requests for permission to copy and redistribute
information should be referred to Volkswagen Group
of America, Inc.
Always check Technical Bulletins and the latest
electronic repair information for information that may
supersede any information included in this booklet.
Trademarks: All brand names and product names
used in this manual are trade names, service marks,
trademarks, or registered trademarks; and are the
property of their respective owners.

Contents
Introduction ............................................................................... 2

Engine Mechanical .................................................................... 4

Engine Management ............................................................... 20

Functional Diagram ................................................................. 32

Service ...................................................................................... 36

Knowledge Assessment .......................................................... 37

Note

This Self-Study Program covers information on

the Volkswagen 4.2L V8 FSI Engine.
This Self-Study Program is not a Repair Manual.
This information will not be updated.

Important!

For testing, adjustment and repair

procedures, always refer to the latest
electronic service information.

Introduction
Technical Features
The 4.2 Liter V8 4V FSI engine is the most recent example of the Fuel Straight Injection engines from
Volkswagen. It is the successor to the 4.2 Liter V8 5V engine and is used in the Touareg.
The 2.0 Liter turbocharged FSI was the first engine introduced by VW with direct injection technology.
Following its success, the 3.6 Liter V6 FSI and 4.2 Liter V8 4V FSI were introduced.
Bosch Motronic MED 9.1.1
Fuel Straight Injection (FSI)
Electronic Throttle (Electronic Pedal Control)
Two hot film mass airflow sensors
Electronically regulated cooling system
Adjustment of the variable intake manifold and
intake manifold flap change-over by means of an
electric motor
Continuous inlet and exhaust camshaft timing
adjustment
Two-piece cylinder block
Chain drives for camshafts and ancillary drives
mounted on the flywheel side of the engine
Spur gear drive for ancillary units
Secondary air injection system

4.2L V8 FSI Engine

S388_003

Introduction
Technical Data
Torque lb ft (Nm)

Power hp (kW)

368 lb ft (500 Nm)

402 hp (300 kW)

332 lb ft (450 Nm)

362 hp (270 kW)

295 lb ft (400 Nm)

322 hp (240 kW)

258 lb ft (350 Nm)

282 hp (210 kW)

221 lb ft (300 Nm)

241 hp (180 kW)

184 lb ft (250 Nm)

201 hp (150 kW)

147 lb ft (200 Nm)

160 hp (120 kW)

111 lb ft (150 Nm)

120 hp (90 kW)

74 lb ft (100 Nm)

80 hp (60 kW)

37 lb ft (50 Nm)

40 hp (30 kW)

0
0

0
1000 2000 3000 4000 5000 6000 7000 8000

rpm

S388_004

Engine Code

BAR

Type

8 cylinders with 90 V angle

Displacement in

254 cubic in (4163 cc)

Bore in

3.32 in (84.5 mm)

Stroke in

3.65 in (92.8 mm)

Valves per Cylinder

Compression Ratio

12.5 : 1

Maximum Output

350 hp (257 kW) at 6800 rpm

Maximum Torque

325 lb ft (440 Nm) at 3500 rpm

Engine Management

Bosch Motronic MED 9.1.1

Fuel

Premium plus unleaded RON 98 or premium unleaded RON 95

Exhaust Gas Treatment

4 catalytic converters, 4 O2 sensors, secondary air system

Emissions Standard

LEV II

Engine Mechanical
Chain Drive
In chain drive D, the crankshaft drives the drive chain
sprocket for ancillary drives. This is used to drive the
spur gear for the ancillary units.

In the 4.2l V8 4V FSI engine, the camshafts and

ancillary units are driven by a total of four roller
chains on two levels. The chain drive is maintenancefree and reduces the over-all length of the engine.
The crankshaft drives the two drive gears for the
camshaft timing chains via chain drive A. In turn,
these two drive gears drive the camshaft adjusters
for the exhaust and intake camshafts via chain drives
B and C.

The chains are tensioned by hydraulic spring

tensioners.

Chain Drive A

Chain Drive B

Chain Drive C

S388_005

Chain Drive D

Engine Mechanical
Ancillary Unit Drive
The ancillary units (engine coolant pump, power
steering pump and A/C compressor) are driven by
the crankshaft via chain drive D, a spur gear drive, a
gear module and four intermediate shafts.

The gear module is used to adapt the rotational

speed and therefore the delivery rate of the engine
coolant and oil pumps.

Air Conditioner Compressor

Coolant Pump

S388_006

Oil Pump
Gear Module

Power Steering Pump

Engine Mechanical
Intake System
As in the 4.2 Liter V8 5V engine used previously in
the Touareg, the fresh air intake system is designed
with two branches, therefore reducing pressure
losses.

Both intake tracts are brought together upstream of

a common throttle valve module. Each intake track is
equipped with a mass airflow sensor.

4.2L V8 FSI Intake System

Throttle Valve Module

Variable Inlet Manifold

Mass Air Flow

(MAF) Sensor
G70

Mass Air Flow

(MAF) Sensor
2 G246

Intake Manifold Flaps

S388_007

Intake Manifold
The two-stage variable intake manifold is
manufactured from die-cast magnesium.
It houses the change-over flaps to vary the length of
the intake runners as well as the flaps that change
the airflow path near the intake valves.

Change-Over Flap

S388_008

Intake Manifold Flaps

Engine Mechanical
Variable Intake Manifold
Switching between the long and short intake
manifold runners is determined by a performance
map of the Engine Control Module.
In the lower engine speed range, the long intake
manifold runners are used (torque position)
In the upper engine speed range, the short intake
manifold runners are used (output position)
The change-over flaps are actuated by an electric
motor on command from the Engine Control
Module.
The change-over flaps have sealing lips to ensure
that the long intake manifold remains leak-tight in
the torque position.

S388_009

Variable Intake
Manifold Runner
Motor V183

Intake Manifold Runner

Position Sensor G336

Selector Shaft with

Change-Over Flaps

Intake Manifold
Flaps

Intake Manifold Flap Change-Over

The intake manifold flaps are installed in the two
intake manifold lower sections. They are actuated,
depending on load and engine speed, by an intake
manifold flap motor and two linkage systems.
At low load and engine speed, they are actuated
and close off the lower section of the intake ports.
This results in cylindrical-shaped air flow into the
cylinder.
At high load and engine speed, they are not
actuated, and lie flush against the surface of the
intake port in order to avoid flow losses.
Due to emission-relevant reasons, the positions
of the intake manifold flaps are monitored by two
intake manifold flap potentiometers.

S388_010

Separating
Plate

Intake Flap
Motor V157

Intake Manifold Runner

Position Sensor 2 G512

Engine Mechanical
Cylinder Block

Crankshaft Drive

The cylinder block is manufactured from an

aluminum-silicon alloy by means of low-pressure
gravity die casting. It is characterized by high
strength, very low cylinder warming and good
thermal dissipation.

The crankshaft is manufactured from high-quality

tempered steel, and is supported by five bearings.

To obtain the narrowest cylinder webs possible,

cylinder liners have been omitted.

Forged pistons are used for reasons of strength. The

piston crowns have been adapted to the combustion
process involved in FSI technology, and support the
circular flow of air in the cylinder. The piston skirts
are coated with Ferrostan, which contains iron. This
prevents direct contact between the pistons and the
cylinder walls, reducing wear.

The large ends of the connecting rods are cracked

during manufacture. This ensures a tight, precise fit
of the cap after the bearing has been installed.

Final cylinder bore surface machining is carried out in

a three-stage honing and exposure process. During
this process, the aluminum is separated from the
surface and the silicon is exposed in the form of
extremely small and particularly hard particles. These
finally form the wear-resistant contact surface for the
pistons and the piston rings.
The ladder frame is manufactured from an aluminumsilicon alloy by means of die casting. Cast-in bearing
caps manufactured from cast iron with nodular
graphite reinforce the ladder frame and absorb the
majority of the flow of force. Due to their thermal
expansion, which is lower than that of aluminum at
high temperatures, they limit main bearing clearance.

Cracked
Connecting Rod

Piston Skirt

The ladder frame design with bearing caps offers

high longitudinal and transverse stiffness.
S388_012

Cylinder Block
Piston Crown
Crankshaft

Cast-In
Bearing Cap

Ladder Frame

S388_011

Engine Mechanical
Cylinder Heads

Camshaft Adjustment System

The 4-valve cylinder heads are manufactured from

an aluminum alloy. This material provides very good
thermal conductivity and high strength.

The gas exchange processes in the combustion

chamber has a significant influence on output,
torque and exhaust gas emissions. The camshaft
adjustment system allows these gas exchange
processes to be adapted to the engines
requirements.

The separating plates for intake manifold flap

change-over are installed in the intake ports
The injectors are fitted on the intake side in the
cylinder head
The high-pressure fuel pumps are driven by dual
cams on the intake camshafts

Camshaft adjustment is carried out continuously

by vane adjusters, and has a maximum of 42. The
position of the camshafts are detected by means of
four Hall senders.

The cylinder head cover is made of plastic and

contains a labyrinth oil separator

When the engine is not running, the vane adjusters

are locked using a spring-loaded locking pin.

The camshafts are fully-assembled (the camshaft

lobes are mated to the camshaft by a hydroforming process) and are driven by chain
The exhaust valves are filled with sodium. This
reduces the temperature at the valve by 212F
(100C)
Cylinder
Head
Cover

The intake camshafts are set to the retarded

position and the exhaust camshafts to the
advanced position. To achieve this, a return spring
is installed in the exhaust camshaft vane adjusters.

Crankcase
Ventilation
System

Intake Adjuster

Hall
Sender

S388_014

High-Pressure Fuel
Pump with Fuel
Metering Valve
S388_013

Fully Assembled
Camshaft

Exhaust Adjuster with

Return Spring

Engine Mechanical
Oil Supply
During development of the oil supply system,
emphasis was placed on achieving the lowest
possible oil flow while providing sufficient
lubrication.
As a result, the camshaft adjusters and various
friction bearings were optimized. This engines oil
flow of 53 qt (50 l) per minute at 7000 rpm at a
temperature of 248F (120C) is very low.

The advantage is that the oil remains in the oil sump

for a longer period of time, and that better water
and hydrocarbon (uncombusted fuel) degasification
is possible. Additionally, a smaller oil pump can be
used. This results in reducing the necessary drive
power and therefore, lowering fuel consumption.
A baffle plate in the area of the intake connection
ensures that no oil, which has been worked into a
foam by the oil pump, is drawn into the oil system.
The oil is cooled by an oil-water heat exchanger.

Cylinder
Bank 1

Chain Tensioner

Oil Filter Module

Cylinder
Bank 2

Hydraulic
Camshaft
Adjustment

Oil Pressure
Control Valve

Oil Cooler
(Coolant)

Oil Pump
(Gear)

Oil Sump
Upper
Section

S388_017

Baffle Plate

10

Oil Sump
Lower
Section

Engine Mechanical
Oil Pump

Oil Filter Module

The oil pump is located inside the oil sump upper

section and is bolted to the ladder frame. Oil intake
is first through a base filter located on the suction
side of the pump. All engine lubrication points are
supplied from the pressure side of the oil circuit.

The oil filter module is designed as a full-flow filter.

It is located in the inner V of the engine and the filter
element can be easily replaced without special tools.

Cap
Pressure
Oil Side

Return from
the Engine

Filter Element
Consisting of
Polymer Mat

S388_019

Base Filter
Suction Side

S388_020

To the
Engine
Circuit

From the
Oil Pump
Pressure Side

11

Engine Mechanical
Crankcase Breather and Ventilation System
Crankcase Breather System

Crankcase Ventilation System

The crankcase breather system is used to flush fresh

air through the crankcase. As a result, water vapor
and low-boiling hydrocarbons are removed from the
crankcase and diverted back into the engine intake
air to be burned.

Because of the crankcase ventilation system, the

uncombusted hydrocarbons (blow-by gases) are
returned to the combustion process and do not
escape into the outside air.

The air is removed downstream of the air filter, and

is guided into the inner V of the cylinder block by a
non-return valve. A restrictor downstream of the nonreturn valve ensures that only the correct quantity of
fresh air is supplied to the crankcase.

To minimize the oil contained in the blow-by gases,

they are separated by a labyrinth oil separator in the
cylinder head cover and a three-stage cyclonic micro
oil separator.
In the cylinder head cover, the gas encounters
impact plates, where the larger oil droplets are
separated. The gases are then channeled by hoses to
the micro oil separator. Here, the smaller oil droplets
are separated off, preventing intake valve coking.
The induction point downstream of the throttle valve
module is integrated into the engine cooling circuit to
prevent it from freezing.

Cooling Circuit
Connection for
Heating
Crankcase
Breather
System

Vent Line

S388_023

Non-Return Valve
(Crankcase Breather
System)
Micro Oil
Separator

12

Pressure
Limiting Valve

Engine Mechanical
Three-Stage Cyclonic Micro Oil Separator
The quantity of uncombusted hydrocarbons and oil vapor is dependent on the engine load and speed. The oil
mixed with unburned hydrocarbons is separated by a three-stage cyclonic micro oil separator.
Because cyclonic oil separators only perform well in a low volumetric flow range, one, two or three cyclones are
released in parallel depending on the quantity of gas.
Low Engine Load/Speed Low Gas Flow
At low engine load and speed, the gas flow is low.
The gas flows past the control plunger into the first
cyclonic oil separator. Here, the oil still present in
the gas is pressed outwards by centrifugal force,
adheres to the wall and drips into the oil collection
chamber.
The oil collection chamber contains an oil drain valve,
which is closed by the pressure in the crankcase
when the engine is running. When the engine is
switched off, the valve opens and the collected
oil flows into the oil sump through a hose located
below the level of the oil. The pressure control
valve ensures a constant pressure level and good
crankcase ventilation.

From the
Cylinder
Head
Cover

Control
Plunger

Pressure
Control
Valve

Oil Collection
Chamber

To the
Induction
Point
Downstream
of the
Throttle
Valve
Module

S388_024

Oil Drain
Valve

Increasing Engine Load/Speed Increasing Gas

Flow

Control Plunger
Shifted

As the engine load and speed increases, so to does

the flow of the blow-by gases. The higher the flow,
the greater the force which acts on the control
plunger. The control plunger force overcomes the
spring force and releases the access ducts to further
cyclones.

S388_026

13

Engine Mechanical
Bypass Valve Opens Very High Gas Flow
The bypass valve ensures that the pressure in the
crankcase does not become excessive.

Bypass
Valve
Open

Gases Flow
Past the
Cyclones

If the pressure in the crankcase increases rapidly, for

example due to a jammed control plunger or piston
ring flutter (may occur at high engine speeds and
low load), the cyclones are no longer able to cope
with this pressure increase. The pressure continues
to rise and now opens the bypass valve. Part of the
blow-by gases now flow past the cyclone and are
guided to the intake manifold directly through the
pressure control valve.
S388_050

14

Engine Mechanical
Engine Cooling Circuit
The cooling system is designed as a longitudinal
cooling system. The coolant flows in on the intake
side, through the cylinder head gasket and into the
head, where it flows out through the timing chain
cover. Cylinder web cooling has been improved by
drilling coolant ducts with cross-sections into the
webs. Forced flow through these bores is ensured
with the aid of specifically sealed water ducts.
In addition, the engine is equipped with an
electronically controlled cooling system.

In the partial load range which is not critical with

regards to engine knock, the coolant temperature
is regulated to 221F (105C). In the lower partial
load range, the thermodynamic advantages
and reduced friction result in a fuel saving of
approximately 1.5%.
In the full load range, the coolant temperature is
regulated to 194F (90C) by the map-controlled
engine cooling system thermostat. This creates
cooler combustion chambers and better cylinder
charging with reduced knock tendency.
Heating System
Heat Exchanger
Recirculation
Pump V55

Engine Coolant Temperature

(ECT) Sensor G62

Expansion Tank

Oil Cooler

Coolant Pump
Map Controlled
Engine Cooling
Thermostat F265

Engine Coolant
Temperature (ECT) Sensor
(on Radiator) G83
Alternator
Radiator

S388_016

15

Engine Mechanical
Fuel System
The fuel pressure of up to 102 psi (7 bar) in the
low-pressure fuel system is generated by an
electric transfer fuel pump, which is actuated by
the engine control module through Fuel Pump
Control Module J538.

The fuel system is a requirement-controlled fuel

system. This means that both the electric transfer
fuel pump and the two high-pressure fuel pumps
only deliver the amount of fuel required by the
engine at that particular moment. As a result, the
electrical and mechanical power requirements are
reduced and fuel consumption is lowered.

The fuel pressure of 363 psi (25 bar) to 1523

psi (105 bar) in the high-pressure fuel system is
generated by two mechanical high-pressure fuel
pumps, each of which is driven via a dual cam by
the intake camshafts.

The fuel system is sub-divided into a low-pressure

and a high-pressure fuel system.

To minimize fuel pressure pulsations, both highpressure fuel pumps deliver fuel into a common
fuel line to the fuel rails. In addition, the high
pressure delivery has been designed so that
pressure impulses of the pumps are offset at the
common rail.
Cylinder Fuel Injectors
1 through 4 N30-N33

Fuel Pressure
Sensor G247

Fuel Metering
Valve N290
Fuel
Rail

Fuel Metering
Valve 2 N402

Pressure
Limiting
Valve
1740 psi
(120 bar)

Cylinder Fuel Injectors

5 through 8 N83-N86

Low Fuel
Pressure
Sensor G410

Fuel Filter
Integrated
into Tank

Leakage Line

Fuel Tank

16

S388_027

Engine Mechanical
Exhaust System
The exhaust system is a twin-branch design. This
means that each cylinder head has a separate
exhaust tract.
The exhaust manifolds are insulated sheet metal
manifolds with a gas-tight inner shell. This airgap insulation enables a compact design and fast
heating. Additional heat shields are no longer
necessary. The exhaust manifolds are secured to the
cylinder heads using clamping flanges.

The starter and main catalytic converter substrate

material is comprised of ceramic.
Both exhaust tracts end in the front silencer. There,
the sound waves overlap and noise emissions
decrease. Two exhaust pipes lead from the front
silencer to the rear silencer. Both exhaust pipes are
routed separately in the interior of the rear silencer.
The exhaust gas flows into the outside air via two
tailpipes.

Two broadband oxygen sensors are installed

downstream of the exhaust manifolds and two
oxygen sensors downstream of the pre-catalytic
converters.

Exhaust
Manifold
with Air-Gap
Insulation
Heated Oxygen
Sensor (HO2S)
2 G108

Heated Oxygen
Sensor (HO2S) G39

Oxygen Sensor (O2S) Behind Three Way

Catalytic Converter (TWC) G130

Starter
Catalytic
Converters
Oxygen Sensor (O2S) 2
Behind Three Way Catalytic
Converter (TWC) G131

Front Silencer
Main
Catalytic
Converters
Rear Silencer

17

Engine Mechanical
Secondary Air Injection System
To heat the catalytic converters as quickly as
possible, the fuel mixture is enriched during coldstarting and warm-up. This results in a higher
percentage of uncombusted hydrocarbons in the
exhaust gas during this period.
Because of the air injection downstream of the
exhaust valves, the exhaust gases are enriched
with oxygen, leading to oxidation (afterburning) of
the hydrocarbons and the carbon monoxide. The
heat released during this process also heats the
catalytic converter, helping it to reach its operating
temperature faster.

The secondary air injection system is comprised of:

Secondary Air Injection (AIR) Pump Relay J299
Secondary Air Injection (AIR) Pump Motor V101
Two self-opening combination valves
Input signals:
Signal from the Oxygen Sensors (for system
diagnosis)
Engine Coolant Temperature Sensors
Mass Airflow Sensor load signals

Connection on
the Air Filter

Secondary Air
Injection Pump

S388_029

Combination Valves
(Self-Opening)

18

Engine Mechanical
Secondary Air Injection
The secondary air injection system is activated during cold-starting, at the start of the warm-up phase and for
test purposes as part of OBD II requirements. In this case, the engine control module actuates the secondary air
pump through the secondary air pump relay. When the pressure is present at the combination valves, they open
and the air flows downstream of the exhaust valves. Afterburning takes place.

Function of the Combination Valves

The combination valves are self-opening valves. This means that they are opened through the pressure generated
by the secondary air pump, and not by vacuum as in the previous secondary air systems.

Combination Valve Closed

The pressure in the combination valves corresponds
to ambient pressure. The valves are closed.

Diaphragm

From the Spring

Secondary
Air Pump

Valve Stem
Hollowed Out
Valve Disk
Closed
S388_015

Exhaust
Gas Side

Combination Valve Open

If the current for the secondary air pump is activated
by the relay, it begins to deliver air. Pressure builds
up due to the fact that the combination valve is
closed. This is present at the valve disk and, through
the hollowed-out valve stem, at the diaphragm. If a
pressure of approximately 6.5 psi (450 mbar) above
ambient pressure acts on the diaphragm and the
valve disk, the valve opens.
The air delivered by the secondary air pump now
flows downstream of the exhaust valves and
afterburning takes place.

Diaphragm
From the
Secondary
Air Pump

Valve Disk
Open

To the
Exhaust
Valves

S388_057

19

Engine Management
System Overview
Sensors
Mass Air Flow (MAF) Sensors, G70, G246
Intake Air Temperature (IAT) Sensor G42
Engine Speed (RPM) Sensor G28
Throttle Position (TP) Sensors G79, G185

Camshaft Position (CMP) Sensors G40, G163,

G300, G301

Data Link Connector

Throttle Valve Control Module J338

Throttle Drive Angle Sensors [for Electronic
Power Control (EPC)] G187, G188
Intake Manifold Runner Position Sensors G336, G512

Low Fuel Pressure Sensor G410

Engine Control
Module J623

Fuel Pressure Sensor G247

CAN Drive Bus
Engine Coolant Temperature (ECT) Sensor G62

Engine Coolant Temperature (ECT) Sensor

(on Radiator) G83
Knock Sensors G61, G66, G198, G199

Oxygen Sensors G39, G108

Oxygen Sensors G130, G131

Brake Light Switch F
Brake Pedal Switch F47
Brake Booster Pressure Sensor G294

Additional Input Signals

20

Engine Management
Actuators
Motronic Engine Control Module (ECM)
Power Supply Relay J271
Fuel Pump (FP) Control Module J538
Transfer Fuel Pump (FP) G6
Fuel Metering Valves N290, N402
Cylinder Fuel Injectors 1 through 8 N30-33, N83-N86
Evaporative Emission Canister
Purge Regulator Valve N80
Throttle Valve Control Module J338
Throttle Drive [for Electronic Power Control
(EPC)] G186
Intake Flap Motor V157
Variable Intake Manifold Runner Motor V183

Camshaft Adjustment Valves (intake) N205, N208

Camshaft Adjustment Valves (exhaust) N318, N319

Ignition Coils with Power Output Stages
N70, N127, N291, N292, N323-N326
Map Controlled Engine Cooling Thermostat N265
Coolant Circulation Pump Relay J151
Recirculation Pump V55
Oxygen Sensor (O2S) Heaters Z19, Z28
Oxygen Sensor (O2S) Heaters [behind Three
Way Catalytic Converter (TWC)] Z29, Z30
Secondary Air Injection (AIR) Pump Relay J299
Secondary Air Injection (AIR) Pump Motor V01
Coolant Fan Control (FC) Control Module J293
Coolant Fan V7
Coolant Fan Control (FC) Control Module 2 J671
Coolant Fan 2 V177
Brake Booster Relay J569
Brake System Vacuum Pump V192

S388_030

Additional Output Signals

21

Engine Management
CAN Networking
The diagram below shows the control units with
which Engine Control Module J623 communicates
through the CAN data bus and exchanges data.

J428

J285

J533
T16
J623

J217

J644

CAN Drive Data Bus

J104

J197

J518

CAN Convenience
Data Bus

J234

J646

J519

G85
J255
J527

22

S388_031

G85 Steering Angle Sensor

J518 Access/Start Control Module

J104 ABS Control Module

J519 Vehicle Electrical System Control Module

J197 Adaptive Suspension Control Module

J527 Steering Column Electronic Systems Control Module

J217 Automatic Transmission Control Module

J533 Data Bus On Board Diagnostic Interface

J234 Airbag Control Module

J623 Engine Control Module

J255 Climatronic Control Module

J644 Energy Management Control Module

J285 Instrument Cluster Control Module

J646 Differential Control Module

J428 Distance Regulation Control Module

T16 Data Link Connector

Engine Management
Sensors
Mass Air Flow Sensor with Intake Air Temperature Sensor G42 and Mass Air Flow Sensor 2 G246
To minimize pressure losses, the intake tract has a
twin-branch design. The most accurate possible air
mass signal is achieved using two Mass Air Flow
Sensors. Mass Air Flow Sensor G70 is installed
along with Intake Air Temperature Sensor G42 in the
intake tract on the cylinder bank 1 side. Mass Airflow
Sensor G246 is installed in the intake tract on the
cylinder bank 2 side.
Mass Air Flow Sensor
with Intake Air
Temperature Sensor
G42 (Cylinder Bank 1)

The engine control module calculates the mass

and the temperature of the air from the signals
transmitted by the two Mass Air Flow Sensors and
the Intake Air Temperature Sensor.

Mass Air Flow

Sensor 2 G246
(Cylinder Bank 2)

S388_032

Signal Use

Effects in the Event of Failure

The signals are used to calculate all load- and

engine speed-dependent functions. These include
the injection period, ignition timing or camshaft
adjustment.

If one or both Mass Air Flow Sensors fail, the throttle

valve position and the engine speed are used as
correction values.
If the intake air temperature sender fails, a fixed,
substitute value is used by the Engine Control
Module.

23

Engine Management
Camshaft Position Sensors G40, G163, G300, G301
Camshaft Position Sensors G40 and G300 are located on cylinder bank 1 and Camshaft Position Sensors G163
and G301 are located on cylinder bank 2.
By scanning a quick-start sender wheel, the engine control module recognizes the position of each cylinder
banks intake and exhaust camshafts
Cylinder Bank 1

Camshaft Position
Sensor G40

Camshaft Position Sensor G40 intake camshaft

Camshaft Position Sensor G300 exhaust camshaft

S388_033

Camshaft Position
Sensor G300

Cylinder Bank 2

Camshaft Position
Sensor G163

Camshaft Position Sensor G163 intake camshaft

Camshaft Position Sensor G301 exhaust camshaft
Signal Use
The signals are used to detect the first cylinder at
the firing position, for camshaft adjustment, and to
calculate the injection point and the ignition timing.
Effects in the Event of Signal Failure
No further camshaft adjustment takes place if a
Camshaft Position Sensor fails. The engine continues
to run and also re-starts again after switching off
because of run-on recognition, however, torque and
power are reduced.

24

S388_034

Camshaft Position
Sensor G301

Engine Management
Low Fuel Pressure Sensor G410
This sensor is installed in the supply line to the
two high-pressure fuel pumps. It measures the
fuel pressure in the low-pressure fuel system and
transmits a signal to the engine control module.

Low Fuel Pressure

Sensor G410

S388_035

Signal Use

Effects in the Event of Signal Failure

The signal is used by the engine control module to

regulate the low-pressure fuel system. Following the
sensor signal, the engine control module transmits a
signal to Fuel Pump (FP) Control Module J538, which
then regulates Transfer Fuel Pump G6 as required.

If the fuel pressure sensor fails, the fuel pressure is

regulated by a fuel pressure pilot control system. The
fuel pressure is then approximately 94.2 psi (6.4 bar).

25

Engine Management
Fuel Pressure Sensor G247
The sensor is located in the inner V of the cylinder
block, and is connected to the fuel rail by a separate
fuel line. It measures the fuel pressure in the highpressure fuel system and transmits the signal to the
engine control module.

Fuel Rail

Signal Use
The engine control module evaluates the signals and
regulates the pressure in the fuel rail pipes via the
two fuel metering valves.
Effects in the Event of Signal Failure
If Fuel Pressure Sensor G247 fails, no further
high fuel pressure is built up. The engine runs in
emergency mode with low fuel pressure. Power and
torque are reduced.

26

S388_036

Fuel Pressure
Sensor G247

Engine Management
Intake Manifold Runner Position Sensors G336 and G512
The two intake manifold flap potentiometers are
secured to the intake manifold and are connected
to the shaft for the intake manifold flaps. They
recognize the position of the intake manifold flaps.

Intake Manifold Runner

Position Sensor 2 G512

S388_037

Intake Manifold Runner

Position Sensor G336

Signal Use

Effects in the Event of Signal Failure

The position is important, as intake manifold changeover affects air flow in the combustion chamber and
the inlet air mass. The position of the intake manifold
flaps is therefore relevant to the exhaust gas, and
must be checked via self-diagnosis.

If the signal from the position sensor fails, the

position of the intake manifold flaps at the time of
failure and the relevant ignition timing are used as
substitute values. Power and torque are reduced and
fuel consumption increases.

27

Engine Management
Actuators
Transfer Fuel Pump G6
The electric fuel pump and the fuel filter are
combined to form a fuel delivery unit. The fuel
delivery unit is located in the fuel tank.
Task
Transfer Fuel Pump G6 delivers the fuel in the
low-pressure fuel system to the high-pressure fuel
pump. It is actuated with a PWM signal by Fuel
Pump Control Module J538.
Transfer Fuel Pump G6 always supplies the quantity
of fuel required by the engine at the present
moment in time.
S388_038

Effects in the Event of Failure

Fuel Pump G6

If Transfer Fuel Pump G6 fails, engine operation is no

longer possible.

Fuel Pump Control Module J538

Fuel Pump Control Module J538 is mounted under
the rear seat on the cover for the electronic fuel
pump.
Task
The Fuel Pump Control Module receives a signal
from the Engine Control Module and controls the
electronic fuel pump with a PWM signal (pulse-width
modulated). It regulates the pressure in the lowpressure fuel system between 72.5 psi (5 bar) and
101.5 psi (7 bar).
Effects in the Event of Failure
If Fuel Pump Control Module J538 fails, engine
operation is not possible.

28

S388_039

Fuel Pump Control

Module J538

Engine Management
Fuel Metering Valves N290 and N402
The fuel metering valves are located at the sides of
the high-pressure fuel pumps.

Fuel Metering
Valve N402

Task
They have the task of making the required quantity
of fuel available at the required fuel pressure in the
fuel rail pipe.
Effects in the Event of Failure
The metering valves are open when current is
not supplied. This means that high pressure is not
built-up and the engine runs with the existing fuel
pressure from Transfer Fuel Pump G6. As a result,
output and torque are significantly reduced.

S388_040

Fuel Metering
Valve N290

29

Engine Management
Intake Camshaft Adjustment Valves N205 and N208
Exhaust Camshaft Adjustment Valves N318 and N319
These solenoid valves are attached to the cylinder
head covers.

Camshaft Adjustment
Valve N205 (Intake)

Task
Depending on actuation by the engine control unit,
they distribute the oil pressure to the camshaft
adjusters according to the adjustment direction and
adjustment travel.
Both camshafts are infinitely adjustable:
Intake camshaft, 42 crank angle
Exhaust camshaft 42 crank angle
Maximum valve overlap angle 47 crank angle
S388_041

Camshaft Adjustment
Valve 1 N318 (Exhaust)

Effects in the Event of Failure

Camshaft Adjustment
Valve 2 N208 (Intake)

If an electrical cable to the camshaft adjusters

is defective or a camshaft adjuster fails due to
mechanical jamming or insufficient oil pressure, no
further camshaft adjustment is carried out. Power
and torque are reduced.

S388_042

Camshaft Adjustment
Valve 2 N319 (Exhaust)

30

Engine Management
Variable Intake Manifold Runner Motor
V183
The variable intake manifold motor is bolted to the
intake manifold.

Variable Intake Manifold

Runner Motor V183

Task
The motor is actuated by Engine Control Module
J623 depending on engine load and speed. The
motor actuates the change-over flaps via a shaft and
switches to the torque (long runners) or the output
position (short runners).
Effects in the Event of Failure
If Variable Intake Manifold Runner Motor V183 fails,
intake manifold change-over is no longer possible.
The intake manifold remains in the position in which
the change-over flaps were located at the time of
failure. Power and torque are reduced.
S388_043

Intake Flap Motor V157

The intake manifold flap motor is bolted to the
variable intake manifold.
Task

Intake Flap
Motor V157

The motor is actuated by Engine Control Module

J623 depending on engine load and speed. Using
two operating rods, it adjusts four intake manifold
flaps per cylinder bank.
If these are actuated, they close part of the intake
port in the cylinder head. This leads to circular
air movement in the cylinder head and improves
mixture formation.
Effects in the Event of Failure
If Intake Flap Motor V157 fails, the intake manifold
flaps can no longer be actuated. This leads to a
deterioration in combustion and a reduction in
output and torque. The fuel consumption also
increases.

S388_044

31

Functional Diagram

J271

30
15
87a

J285

G6

S
J285
J538

N85

N33

N83

N32

N86

N31

N84

N30

J285

G169

N326

N325

N323

N292

N291

N70

N127

N324

J623

G79
P
Q

P
Q

P
Q

P
Q

P
Q

P
Q

P
Q

P
Q

31

32

Battery

N70

Ignition Coil 1 with Power Output Stage

Fuel Level Sensor

N83-

Cylinder 5 Fuel Injector to

G6

Transfer Fuel Pump

N86

Cylinder 8 Fuel Injector

G79

Throttle Position (TP) Sensor

N127 Ignition Coil 2 with Power Output Stage

G169 Fuel Level Sensor 2

N291 Ignition Coil 3 with Power Output Stage

G185 Accelerator Pedal Position Sensor 2

N292 Ignition Coil 4 with Power Output Stage

J271

Motronic Engine Control Module (ECM) Power Supply Relay

N323-Ignition Coil 5 with Power Output Stage to

J285

Instrument Cluster Control Module

N326 Ignition Coil 8 with Power Output Stage

J538

Fuel Pump Control Module

Spark Plug Connector

J623

Engine Control Module

Spark Plugs

N30-

Cylinder 1 Fuel Injector to

Fuse

N33

Cylinder 4 Fuel Injector

G185

Functional Diagram

J757

S
G39/Z19

N290

S
G108/Z28

G130/Z29

G131/Z30

N402

J623

J338
G186

G187

G188

G61

G66

G198

G199

G28

G163

S388_045

G28

Engine Speed Sensor

J757

Engine Component Power Supply Relay

G39

Heated Oxygen Sensor (HO2S)

N290 Fuel Metering Valve

G61

Knock Sensor 1

N402 Fuel Metering Valve 2

G66

Knock Sensor 2

Fuse

G108 Heated Oxygen Sensor (HO2S) 2

Z19

Oxygen Sensor (O2S) Heater

G130 Oxygen Sensor (O2S) Behind Three Way Catalytic Converter

Z28

Oxygen Sensor (O2S) Heater 2

G131 Oxygen Sensor 2 (O2S) Behind Three Way Catalytic Converter

Z29

Oxygen Sensor (O2S) 1 (Behind Three Way Catalytic

Converter) Heater

Z30

Oxygen Sensor (O2S) 1 (Behind Three Way Catalytic

Converter) Heater

G163 Camshaft Position Sensor 2

G186 Throttle Drive for Electronic Power Control (EPC)
G187 Throttle Drive Angle Sensor 1 for Electronic Power Control (EPC)
G188 Throttle Drive Angle Sensor 2 for Electronic Power Control (EPC)
G198 Knock Sensor 3
G199 Knock Sensor 4
J338

Throttle Valve Control Module

J623

Engine Control Module

Positive
Ground
Input Signal
Output Signal
Bi-Directional Cable
CAN Data Bus

33

Functional Diagram

J151

J623

G163

G40

G336

G512

G247

G62

G300

G301

Battery

J293

Coolant Fan Control (FC) Control Module

F265

Map Controlled Engine Cooling Thermostat

J623

Engine Control Module

G40

Camshaft Position Sensor

J671

Coolant Fan Control (FC) Control Module 2

G62

Engine Coolant Temperature Sensor

N205 Camshaft Adjustment Valve 1 (Intake)

G163 Camshaft Position Sensor 2

N208 Camshaft Adjustment Valve 2 (Intake)

G247 Fuel Pressure Sensor

N318 Camshaft Adjustment Valve 1 (Exhaust)

G300 Camshaft Position Sensor 3

N319 Camshaft Adjustment Valve 2 (Exhaust)

G301 Camshaft Position Sensor 4

Fuse

G336 Intake Manifold Runner Position Sensor

V7

Coolant Fan

G512 Intake Manifold Runner Position Sensor 2

V157 Intake Flap Motor

J151

V177 Coolant Fan 2

Coolant Circulation Pump Relay

V183 Variable Intake Manifold Runner Motor

34

F265

V157
A

V183

J671

N319

V177

J293

N318

N208

V7

N205

Functional Diagram

J708

J569

J299
B

J255

S
V55

V192

V101

F47

F
J508

J623

m
G410

G83

G294

G70

G42

G246

3
K

N80
1

Back-Up Light Switch

2 CAN Data Bus

3 CAN Data Bus
S388_045

Starter

J623

Engine Control Module

Brake Light Switch

J708

Residual Heat Relay

F47

Brake Pedal Switch

N80

Evaporative Emission Canister Purge Regulator Valve

G42

Intake Air Temperature Sensor

Fuse

G70

Mass Air Flow Sensor

V55

Recirculation Pump

G83

Engine Coolant Temperature Sensor (on Radiator)

V101 Secondary Air Injection Pump Motor

G246 Mass Air Flow Sensor 2

V192 Brake System Vacuum Pump

G294 Brake Booster Pressure Sensor

Positive

G410 Low Fuel Pressure Sensor

Ground

Dash Panel Insert

Input Signal

J255

Climatronic Control Module

Output Signal

J299

Secondary Air Injection Pump Relay

Bi-Directional Cable

J508

Brake Light Disable Relay

CAN Data Bus

J569

Brake Booster Relay

35

Service
Special Tools

Designation
Thrust piece
T 40051

Thrust piece
T40052

Camshaft clamps
T40070

Locking pins
T40071

Key
T40079

36

Tool

Application
For installing A/C compressor drive
sealing ring

For installing power steering pump

drive sealing ring

For locking camshafts on cylinder

bank 1 and cylinder bank 2

For locking chain tensioners for

chain drives A, B, C, D

For pre-tensioning inlet and exhaust

camshafts after installing the
camshaft timing chain

Knowledge Assessment
An on-line Knowledge Assessment (exam) is available for this Self-Study Program.
The Knowledge Assessment may or may not be required for Certification.
You can find this Knowledge Assessment at:

www.vwwebsource.com

For Assistance, please call:

Volkswagen Academy
Certification Program Headquarters
1 8774914838
(8:00 a.m. to 8:00 p.m. EST)
Or, E-Mail:

[email protected]

37

822703

Volkswagen Group of America, Inc.

2200 Ferdinand Porsche Drive
Herndon, VA 20171
Printed in the U.S.A.
May 2008