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2.0-litre Engine
233_024
New
Important
Note
Table of contents
2.0-litre/85 kW engine AQY/ATU . . . . . . . . . . . . . . . 4
Crankcase breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PTFE oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ODB II exhaust emission monitoring system . . . . . . . . . . . . . . 17
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Function diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
233_012
233_013
Series
Engine code
113
827
AQY
ATU
Type
Displacement
1984 cm3
Bore
82.5 mm
Stroke
92.8 mm
Compression ratio
Rated power output
Torque
10.5 : 1
10.0 : 1
85 kW/5200 rpm
85 kW/5400 rpm
Technical features
Differences/common features
AQY
Engine management
ATU
Motronic 5.9.2
Lambda control
Knock control
2 knock sensors
1 knock sensor
Ignition system
Rotating distributor
not fitted
Exhaust gas
treatment
Fuel
EU 4 Manual gearbox
D4 Automatic gearbox
D4 Manual gearbox
D3 Automatic gearbox
Self-diagnosis fault
warning lamp
Exhaust emission
standard
AQY
ATU
AQY
ATU
233_002
233_001
233_004
233_003
Engine AQY
AQY engine
ATU engine
without distributor,
static high-voltage
distribution;
engine suspension:
pendulum support.
with distributor, drive
by means of intermediate
shaft; conventional engine
suspension
ATU engine
Notable differences
233_019
233_005
Engine ATU
Engine AQY
Crankcase breather
Electrically heated
Breather housing
Intake manifold
Heating resistor
233_027
Task
The crankcase is fitted with a breather in order to
equalise the pressure difference inside the
crankcase.
+30
J17
S243
10A
N79
233_028
Action period
Electrical circuit
Fuel injection
Injector with air shroud
The ATU engine has no
air-shrouded injectors!
Pressure regulator
Fuel rail
Injector
Air pipe
Fuel feed
Air shroud
233_030
Advantages:
Combustion is improved.
Pollutant emissions in the exhaust gas are
reduced.
Piston
Piston design
Lightweight aluminium pistons are used. They
have a shortened, graphitised shaft and the
bearings for the piston pins are offset inwards.
Graphite
contact face
Shortened
shaft
233_031
Box shape
Piston cooling
To cool the piston more rapidly, a small amount
of the lubricating oil in the circuit is diverted to
the piston.
For this purpose, each cylinder has an oil spray
nozzle which is securely bolted to the cylinder
block and supplied with oil directly from the oil
pump via an oil duct.
233_032
10
233_033
Sensors
Valve timing
gear
Measuring
wheel
Signal utilisation
The position of the camshaft is determined via
the signal from the Hall sender.
The Hall sender also acts as a quick-start sender.
233_034
233_035
Hall sender
233_036
Important
The ATU engine has a rotating
ignition distributor which is driven
by means of the intermediate
shaft.
The Hall sender and rotor ring are located in the
distributor.
Hall sender
Rotor ring
233_006
11
233_037
12
Dust lip
Crankshaft
journal
233_038
5
p
6
p
4
3
233_008
Starting situation
System design
Engine control unit -3Secondary air pump relay -4Secondary air pump -2Secondary air control valve -5Combination valve -6-
13
5
6
p
4
3
233_009
de-energised
Secondary air system - not activated
Functional description
The secondary air system is active in two
operating states and for a limited period of time
only:
cold start
in idling mode after warm start, for self-diagnosis
The secondary air system is activated by the
engine control unit according to the prevailing
operating conditions.
State
Coolant
temperature
Period
activated
Cold start
+5 to 33oC
100s
Warm start
Idling
up to
max. 96C
10s
14
Emission control
Why is a second lambda probe necessary?
Lambda probe G39
upstream of primary
catalytic converter
Catalytic converter
233_039
15
Emission control
G28
G39
Engine
Intake air
Catalytic converter
Exhaust gas
catalytic converter
G70
G130
G28
catalytic converter
UG39
UG130
G70
G130
G39
Fuel
UV
UV
U G39
U G130
J220
233_040
16
OBD
On-Board Diagnose
5.9.2
Motronic
233_014
Electrical circuit
The warning lamp is integrated in the dash panel
insert, directly connected to the engine control
unit and registered by the fault memory.
Like all warning lamps, the exhaust gas warning
lamp lights up for several seconds when the
ignition is turned on.
If it does not go out after starting the engine or
lights up or flashes while travelling, there is a
fault in the engine electronics or certain exhaust
emissions are too high.
For the customer, this is a sign to take the vehicle
to a service workshop.
Lamp flashing:
There is a fault which can damage
the catalytic converter in this vehicle
operating state. The vehicle may still
be operated, but only using less
power.
3
2
1
4
1/min x 1000
100
80
6
7
120
140
km/h
60
40
20
160
180
200
220
240
233_007
J285
K83
32
J220
233_041
17
System overview
Motronic 5.9.2
The new Motronic 5.9.2 implements technical
improvements for starting of the engine, lower
fuel consumption and exhaust emission control.
18
Auxiliary signals:
air conditioner compressor On
A/C ready
Road speed signal
CAN-Bus L
CAN-Bus H
Control unit
for Motronic J220
Auxiliary signals:
Air conditioner compressor Off
Fuel consumption signal
19
Function diagram
Engine AQY
J17
4
ST
ST
Z19
G39 Z29
N30
N31
N32
G130 N80
G42/G70
N112
N33
+
14
J220
F60 G88
G69
J338
G6
31
G40
CAN - BUS L
K83
V60
CAN - BUS H
G28
D/+15
D/+30
+30
E45
31
F47
V101
J299
N79
M
F36
1
G66
G61
4
N152
G62
IV
II
III
Q
P
31
in
out
233_011
21
Function diagram
Engine ATU
30
15
J17
12
ST
ST
Z19
G39
Z28/G108 N80
N30
N31
N32
G72
G70
N33
+
14
J220
M
F60 G88
J338
G6
31
G69
CAN - BUS L
V60
CAN - BUS H
K83
G28
30
15
E45
31
F47
N112
J299
N79
V101
M
F36
G66
G62
G40
N152
N157
Q
P
31
in
out
233_015
23
Self-diagnosis
The readiness code
The readiness code is an 8-digit numeric code
which indicates the status of the exhaust emission
diagnoses. The diagnoses are performed at
regular intervals during normal vehicle operation.
The readiness code does n o t indicate whether
there are any faults in the system.
It indicates whether certain diagnosis have been
terminated -0- or have not been performed yet,
or have been cancelled -1-.
If the engine management system has registered a
fault and stored this fault in the fault memory, the
fault message can only be obtained with a fault
reader.
202_002
Readiness code
The readiness code for both
engines is identical.
8
0
24
Diagnostic function
Catalytic converter
Lambda probe
CAN-Bus H
CAN-Bus L
233_018
202_002
25
Technical features
233_012
26
100
200
190
180
170
160
150
140
130
M (Nm)
120
233_021
Specifications
Code:ATF (transversely mounted),
A-platform
ASU (longitudinally mounted)
Passat
Type:4-cylinder in-line engine
Displacement:1984 cm3
Bore:82.5 mm
Stroke:92.8 mm
Compression
ratio:10 : 1
Firing order:1 - 3 - 4 - 2
Rated output:88 kW (120 bhp)
Torque:175 Nm
Fuel:RON 95 unleaded
RON 91 unleaded
(reduced power and torque)
27
Overhung-mounted camshaft
Camshaft timing control
Rotation angle
Roller
Oil cushion
Advantages:
Direction of
rotation
Intake cam,
variable
Oil bore
Camshaft body
233_042
50
40
30
20
Intake port - closing - position in
10
0
-10
-20
1000
2000
3000
4000
Rigid camshaft
5000
6000
233_043
Variable camshaft
Function
The opening action at the intake valve is no
different to that on a rigid camshaft.
During the closing action, however, the cam
becomes twisted under the spring pressure
exerted by the valve spring.
28
Intake cam
Exhaust cam
Function
85 kW engine
88 kW engine
Camshaft
The shaft,
intake cam and
exhaust cam are a
single part
Adjustment
none
Timing
29
Hot film
air mass meter G70 and
intake air temperature sender G42
Throttle valve control unit J338
(EPC positioner)
Angle senders for throttle valve
drive G187 and G188
Accelerator position senders G79 and G185
CAN-Bus -
CAN-Bus +
233_023
Auxiliary signals:
Air conditioner compressor OFF
EPC fault indicator lamp
Cruise control system
Fuel consumption signal
31
J17
4
ST
ST
Z19
G39 Z29
N30
N31
N32
G130 N80
G42/G70
N33
+
14
J220/J36
+
+
G187
31
32
G6
G188
J338
G186
G79/G185
G40
G28
D/+15
+30
D/+30
J240
E45
31
F47
J299
N79
V101
N156
F36
361
G61
G62
CAN - BUS L
G66
CAN - BUS H
K83
4
N152
IV
II
III
Q
P
31
in
out
233_025
33
Auxiliary signals
1
Airbag
Colour codes/Legend
= Input signal
= Output signal
= Battery positive
= GND
= Bidirectional
= Diagnostic connection
Parts
A
D
E45
F
F36
F47
F60
Battery
Ignition switch
CCS switch
Brake light switch
Clutch pedal switch
Brake pedal switch for CCS
Idling speed switch
G6
G28
G39
Fuel pump
Engine speed sender
Lambda probe (upstream of
catalytic converter)
G40
Hall sender
G42
Intake air temperature sender
G61
Knock sensor I
G62
Coolant temperature sender
G66
Knock sensor II
G69
Throttle valve potentiometer
G70
Air-mass flow meter
G72
Intake manifold temperature sender
G79
Accelerator pedal position sender
G88
Throttle valve positioner
Potentiometer
G108
Lambda probe II
G130
Lambda probe (downstream of
catalytic converter)
G185
Accelerator pedal position sender -2G186
Throttle valve drive
(electric throttle operation)
G187
Throttle valve drive angle sender -1G188
Throttle valve drive angle sender -2J17
Fuel pump relay
J220
Motronic control unit
J299
Secondary air pump relay
J338
Throttle valve control unit
J361
Simos control unit
K83
Self-diagnosis fault warning lamp
N30...33 Injectors
N79
Heating resistor (crankcase
breather)
N80
Activated charcoal
filter system solenoid valve 1
N112
Secondary air inlet valve
N122
Output stage
N152
Ignition transformer
N156
Intake manifold change-over valve
N157
Ignition transformer output stage
O
Distributor
P
Spark plug socket
Q
Spark plugs
S
Fuse
ST
Fuse carrier
V60
Throttle valve positioner
V101
Secondary air pump motor
Z19
Heater for lambda probe
(upstream of catalytic converter)
Z28
Heater for lambda probe 2
Z29
Heater for lambda probe 1
(downstream of catalytic converter)
Oil grade
VW 50300
Engine oil
sensor
Brake pad
wear
indicator
Battery maintenancefree
(lead-calcium)
New
elements
4
1/min x 1000
100
80
6
7
120
km/h
60
40
20
140
160
180
200
220
240
New
evaluation
calculated from
and
Mileage (km) reading
Oil temperature
Fuel consumption
information
233_045
34
233_046
35
J218
+15
G266
31
31
233_048
233_049
Temperature sensor
3
2
1
4
1/min x 1000
100
80
6
7
60
40
20
120
km/h
140
160
180
200
220
240
Temperature
G266
Filling level
233_050
Oil level
Heating
phase
Oil temperature
evaluation
25 - 85 ms
High
Low
Cool-down phase 200 - 1,000 ms
233_026
37
The position of the camshaft in the AQY engine is indicated by Hall sender G40.
It has
A.
B.
C.
2.
3.
4.
38
By injecting additional air (secondary air) into the exhaust gas,the pollutants in the exhaust gas
are recombusted.
As a result,
A.
B.
C.
5.
continuously active.
only active during the cold start phase.
active during the cold start phase and in the idling phase after a warm start.
featured in both engines.
6.
The combination valve in the secondary air system on the ATU engine
A.
B.
C.
7.
8.
B.
C.
10 .
9.
distributors.
engine mounts.
numbers of knock sensors.
1. C.; 2. B., C.; 3. in the intake manifold, B.; 4. A., B.; 5. C., D.; 6. C.; 7. A., B., C.; 8. A., C.; 9. A., C.
10. A., B., C.
Solutions
39
Service.
233