SSP 540 The Passat 2015 SCR and AdBlue

Service Training
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Across the globe, lawmakers and authorities are progressively lowering the limits for nitrogen oxide levels in motor
vehicle exhaust gases. One key technology in reducing nitrogen oxide emissions is the “selective catalytic
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reduction” exhaust gas treatment systemolks (SCR system). Volkswagen
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ara already fulfilled the strict nitrogen oxide
in cars as early as 2009 withistheed “Passat BlueTDI”. At the time, this model nte
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uth standard, which came into force in Europe in
limits set by the EU6 emission September
ra 2014. The SCR system has
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been enhanced and optimised to adapt the exhaust gas treatment system to the requirements of the new EA288
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This Self-study Programme will provide you with information about the new features of the SCR system using the
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The Self-study Programme shows the For current testing, adjustment and repair
design and function of instructions, refer to the relevant service
new developments. literature. Important
The contents will not be updated. note
2
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Exhaust
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gas treatment system . . . . . . . t.ee.or. . .......................... 6
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Reducing agent tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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Heater system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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AdBlue® display system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
nform
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Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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Test your knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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3
Introduction
Nitrogen oxides and the EU6 emission standard

“Nitrogen oxides” is a collective term for chemical Smog is also attributed to nitrogen oxides among
compounds containing nitrogen (N) and oxygen (O2). other things. Cutting nitrogen oxide emissions from
They include, for example, nitrogen monoxide (NO) diesel engines was a key issue in the transition from
and nitrogen dioxide (NO2). These compounds are the EU5 to the EU6 emission standard. The EU6
formed when high pressure, high temperatures and emission standard came into force in Europe in
excessive oxygen are present during combustion in September 2014. It has set the limit for nitrogen
the engine. Nitrogen oxides are partly responsible for oxides in exhaust gas at 0.08 g/km. The content is
the so-called acid rain that causes damage to forests. therefore over 50% lower compared with the EU5
emission standard.
Concepts for reducing nitrogen oxides

In order to comply with the strict emission standard Which system is used depends on the vehicle concept,
ProCarManuals.com
limits, we can employ numerous technologies that the vehicle weight and the associated assessment of
prevent the formation of nitrogen oxides during the the inertia class in the type approval tests. The inertia
combustion process. The level of nitrogen oxides that class is used AG. Volkswagen AG dforce that the vehicle
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storage catalytic converter or the selective catalytic
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The following technical measures ensure that as few nitrogen oxides as possible are produced during combustion
before an exhaust gas treatment system makes its contribution to reducing nitrogen oxides:
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• Configuring the inlet and exhaust ports in the cylinder head for optimum flow
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• High injection pressures to ensure a good mixture formation

• Optimising the combustion chamber design with the piston recess geometry
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• Low compression ratio

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• Exhaust gas recirculation to reduce the amount of oxygen in the combustion chamber and thus lower the peak
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4
Exhaust gas treatment with an NOx storage catalytic converter
If the exhaust gas is treated with an NOx storage The engine is run with a rich mixture at regular
catalytic converter, the oxidising catalytic converter in intervals to regenerate the NOx storage catalytic
the emission control module will have an additional converter. The nitrogen oxides stored in the NOx
coating. This allows the nitrogen oxides from the storage catalytic converter are converted into carbon
exhaust gas to be stored during lean operation. dioxide and nitrogen.
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The function of the NOx storage catalytic converter is described in Self-study Programme no. 526
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“The EA288 Diesel Engine Family with EU6 Compliance”.
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Exhaust gas treatment with an SCR system
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One effective way of reducing nitrogen oxide The ammonia required for the reduction process is atio
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supplied by a urea solution, the AdBlue®reducing

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gas. The abbreviation SCR stands for Selective agent. The reaction is assisted by the heat contained
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the nitrogen oxides in the exhaust gas. The nitrogen yi carried in an extra tank in the vehicle and is
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oxides (NOx) contained in the exhaust gas react with constantly injected into the flow of exhaust gas in
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ammonia (NH3) to form nitrogen (N2) and water cop
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(H2O). This chemical process takes place in a Prote AG.
reduction catalytic converter.
The design and function of the first SCR system to be used at Volkswagen Passenger Cars are
described in Self-study Programme no 424 “Exhaust Gas Aftertreatment System Selective Catalytic
Reduction”.
5
Exhaust gas treatment system
The SCR system

Overview
The following illustration shows the main components the injector for reducing agent. A coating in the diesel
of the SCR system in the Passat 2015. The reducing particulate filter, which is located in the emission
agent tank is located at the rear right underneath the control module, functions as a reduction catalytic
vehicle floor. The filler neck for filling the reducing converter. A trap catalytic converter prevents excess
agent tank is located next to the filler neck for the fuel ammonia being released into the outside air. The
tank. A delivery unit integrated into the reducing engine control unit uses the NOx sender to monitor
agent tank pumps the reducing agent from the tank to the efficiencyGof
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Filler neck for reducing agent
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Control unit for reducing agent
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Reducing agent tank with delivery unit
Reducing agent line

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Schematic diagram of SCR system
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1 Reducing agent tank 9 Trap catalytic converter

2 Reducing agent 10 NOx sender G295 with control unit for NOx
3 Filter sender J583
4 Heater for reducing agent tank (heater circuit 1) 11 Injector for reducing agent N474
Z102 12 Engine control unit J623
5 Reducing agent level sender G697 13 Heater for reducing agent line (heater circuit 2)
6 Temperature sender for reducing agent G685 Z104
7 Control unit for reducing agent heater J891 14 Reducing agent return flow pump V561
8 Diesel particulate filter (reduction catalytic 15 Pulsation damper
converter) 16 Pump for reducing agent V437
8
System overview
System overview of sensors and actuators in the SCR system for the Passat 2015
Sensors Actuators
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Reducing agent level sender G697 a u ra Pump for reducing
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Exhaust gas temperature sender 2 G448

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Exhaust gas temperature sender 4 G648 Heater for reducing

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Control unit in dash
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Heater for reducing

Temperature sender for agent line Z104
reducing agent G685
S540_029
9
System components
Emission control module
The emission control module consists of an oxidising The close-coupled location has the advantage that
catalytic converter and a diesel particulate filter. The the reduction catalytic converter quickly reaches its
diesel particulate filter has a copper-zeolite coating operating temperature after a cold start. Furthermore
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NOx sender G295 Exhaust gas temperature Injector for reducing
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Exhaust gas temperature sender 4 G648 Diesel particulate filter and reduction catalytic converter
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Injector for reducing agent N474
The injector for reducing agent N474 is a solenoid The injector has a cooling jacket due to the close-
valve. It is secured with a clamp to the inlet funnel coupled installation position and the resulting high
on the emission control module and has the task of thermal loading. This cooling jacket protects the
injecting reducing agent into the exhaust gas stream electrical connection for the injector in addition to the
behind the oxidising catalytic converter. It is activated mechanical components against overheating. The
by the engine control unit with a pulse-width- injector for reducing agent N474 has been
modulated signal for this purpose. A calculation incorporated into the low-temperature coolant circuit
model in the engine control unit is used to determine in the engine cooling system.
the required quantity of reducing agent. The model is
based on the theoretical nitrogen oxide content in the
exhaust gas mass flow. The signals from the
temperature sensors and the pressure sensors as well
as the masses of the intake air, the recirculated
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Electrical connection Connection for reducing agent line
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Effects upon failure
If the injector is defective, insufficient, too much or no reducing agent may be injected into the exhaust system.
Compliance to the emissions values is no longer possible. Depending on the defect type, the exhaust emissions
warning lamp K83 (MIL) and the AdBlue® warning display for SCR system errors will be switched on in the dash
panel insert.
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Oxidising catalytic
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Reduction catalytic
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A trap catalytic converter is integrated into the Furthermore the trap catalytic converter has a coating
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functions as a reduction catalytic converter. Any ammonia is also oxidised. This coating therefore acts
ammonia (NH3) that manages to get past the as an oxidising catalytic converter.
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emission control module will be stored on this coating
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in the trap catalytic converter. The stored ammonia is
used to convert the nitrogen oxides remaining in the
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Trap catalytic converter
Exhaust flap
Exhaust flap control unit J883
S540_006
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Coolant circuit – general overview
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The injector for reducing agent N474 has been incorporated
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1 Coolant expansion tank 12 Injector for reducing agent N474

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Coolant temperature sender G62 AG. 18 Water radiator for charge air cooler
8 Cylinder block 19 Radiator
9 Coolant pump
10 Coolant valve for cylinder head N489 Low-temperature circuit
11 Charge air cooler
High-temperature circuit
14
NOx sender G295
The NOx sender G295 is screwed into the emission Control unit for NOx sender J583
control module flange. It is located in front of the
oxidising catalytic converter in the direction of flow. NOx sender G295
The engine control unit uses the signal from the NOx
sender to determine the nitrogen oxide content in the
exhaust gas. Since the signal currents from the NOx
sender are in the microampere range, they are
processed by the control unit for NOx sender and
transmitted to the engine control unit.
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In compliance with the European On-Board Diagnosis regulations, the signals from the NOx sender G295 are
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Monitoring the efficiency of the SCR system
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In order to monitor the efficiency of the SCR system, the warning display for SCR system errors will be
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the engine control unit compares the values measured activated in the dash panel insert. Furthermore an
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by the NOx sender with a nitrogen oxide calculation entry is added to the event memory in the engine
model. If the system falls below a certain efficiency control unit. nform
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level, the exhaust emissions warning lamp K83 and

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The design and function of the NOx sender are described in Self-study Programme no. 424
“Exhaust Gas Aftertreatment System Selective Catalytic Reduction”.
15
Checking the efficiency and the quality of the reducing agent
The efficiency and the quality of the reducing agent Specific operating conditions are required for the test
are checked by the engine control unit simultaneously in which different temperatures and air mass flows
in one test. This test is performed at regular intervals are examined by the engine management system.
when the engine is in overrun phases.
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When the test conditions are met, the engine control The exhaust gas is therefore recirculated and no air
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engine switches from load operation to overrun. The still injected via the injector.
exhaust gas and its nitrogen oxide content can now
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the low-pressure exhaust gas recirculation system, the

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NOx sender G295
Control unit for NOx

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Exhaust gas recirculation control motor 2 V339
Throttle valve module J338

S540_010
16
Assessing the efficiency
During the system test, the engine control unit If the difference is too great, the efficiency of the SCR
monitors the NOx content measured by the NOx system will be assessed as too low.
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Assessing the quality of the reducing agent
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In addition to monitoring the efficiency, the engine Poor quality can arise, for example, if the reducing
control unit determines the rate at which the NOx agent tank has been filled with water instead of
concentration in the exhaust gas decreases. If the reducing agent.
rrectness of i
NOx concentration falls rapidly, the quality of the
l purpos
ProCarManuals.com
reducing agent is fine. If the NOx concentration If the engine control unit detects that the efficiency
stagnates or falls only slowly, the reducing agent level is too low or the AdBlue® has a poor quality, an
nform
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quality is assessed as poor. entry will be made in the event memory. The warning
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display for SCR system errors will appear and the
ion in
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exhaust emissions warning lamp will light up in the

te o
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dash panel insert.
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Effects of signal failure
If the signal fails, an entry will be made in the engine control unit event memory. The exhaust emissions warning
lamp K83 (MIL) and the AdBlue® warning display for SCR system errors will be switched on in the dash panel
insert.
17
AG. Volkswagen AG d
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Reducing agent tank system
oes
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AdBlue® reducing agent
erm
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The ammonia required to reduce the nitrogen oxides ole, referred to under its brand name AdBlue®
spec
is not used in its pure form, but in the form of a urea throughout the automotive industry, is used as the
t to the co
solution. In its pure form, ammonia irritates the skin reducing agent for the SCR system. It is a high-purity,
and mucous membranes, and also has a unpleasant transparent aqueous solution containing 32.5% urea.
rrectne
odour. Diesel exhaust fluid or DEF, which is commonly It is manufactured synthetically.
ss o
cial p
f inform
mer
atio
om
n
Freezing point of AdBlue®
c
i
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35
iva
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AdBlue® has a urea content of 32.5%. The reducing
um
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25
en
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Temperature in °C
t.
yi
agent has the lowest freezing point of -11°C in this Cop
Co
py
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mixing ratio. A different mixing ratio with too much yri
gh by
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op Vo
urea or too much water will cause the freezing point
c by lksw
5
ProCarManuals.com
cted agen
Prote
of AdBlue® to rise.
AG.
-5
-11
-15
0 10 20 30 40 50 60 70
Urea concentration in %
S540_032
Properties of AdBlue® Notes on handling AdBlue®
• AdBlue® freezes at temperatures below -11 °C. • Only use AdBlue® that complies with the
• AdBlue® ages at high temperatures. This results in approved manufacturer’s standard and from
the formation of ammonia and an unpleasant original containers.
odour can therefore be produced. • Drained AdBlue® must not be reused to prevent
• Contamination from foreign substances and contamination.
bacteria can render AdBlue® useless. • The reducing agent tank may only be filled using
• Urea that leaks and crystallises causes white containers and adapters approved by the
marks. These marks can be removed with water manufacturer.
and a brush (as soon as possible). • The reducing agent can irritate the skin, eyes and
• AdBlue® is highly penetrative. respiratory organs. If this fluid comes into contact
Ensure that AdBlue® does not get into electrical with skin, it should be immediately washed off with
components or connectors. plenty of water.
18
Refilling reducing agent with an AdBlue® pump
The reducing agent tank in the Passat 2015 can be

filled using the pump nozzles provided by the
. Volkswagen AG
European AdBlue® filling station network swage
n AGfor heavy does
lk not
goods vehicles. Since thesedpumps Vo fill the tank at a gu
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very high rate, the tank uth needs to be quickly vented eo
a ra
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during the filling process. c
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In contrast, when you fill the tank with a refill bottle,
rm
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the air can escape more slowly. The different filling
ot
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speeds can result in different filling quantities in the
h re
hole
reducing agent tank.
spec
es, in part or in w
t to the co
rrectness of i
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ProCarManuals.com
S540_031
nform
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Filling system gh
Filling speed
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AdBlue® pump for heavy goods vehicles
AG.
Max. 40 l/min
AdBlue® pump for cars *) 3.5–10 l/min
AdBlue® refill bottle Approx. 3 l/min
*) A wide network of AdBlue® pumps for cars is not expected in Europe before 2018.
Only fill the reducing agent tank with the intended containers and filling systems. This guarantees the
correct filling speed and prevents the tank being overfilled. Furthermore this ensures that a sufficiently
large expansion volume is retained for the reducing agent in the tank.
19
Design of tank system

In the Passat 2015, the reducing agent tank is located at the rear right underneath the vehicle floor. The tank is
made from plastic and has a volume of approximately 13 litres.
Filler neck
Breather line
Cap
Expansion section
Magnetic ring
Filler pipe
Reducing agent tank

ProCarManuals.com
AG. Volkswagen AG d
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Non-return flap
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Baffle plate
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Delivery unit
inform
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c
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S540_026
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Delivery unit Cop py
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The sensors and actuators for the reducing agent tank system are located in the delivery unit for reducing agent
Prote
cted AG.
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metering system GX19. The delivery unit is sealed to the reducing agent tank.
20
Cap
There is a diaphragm in the cap for the filler neck. It forms part of the breather system for the reducing agent tank
together with the emergency ventilation system.
Non-return flap
There is a spring-loaded non-return flap at the bottom end of the filler pipe. It prevents reducing agent escaping
from the filler neck at the end of a high-speed filling process.
Expansion section
If reducing agent rises inside the breather line during a high-speed filling process, it can be held and settle in this
expansion section.
Spiked mat and baffle plate

The spiked mat and the baffle plate reduce “sloshing noises” that are caused by reducing agent flowing back and
forth while you drive. lkswage es n
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Emergency ventilation au system ra
c
ss
ProCarManuals.com
If ventilation is not possible via the filler cap because the reducing agent has frozen, the pressure in the tank will be
ce
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compensated exclusively via the emergency ventilation system.
itte
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Magnetic ring for unlocking AdBlue® pump nozzles for heavy goods vehicles
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The filling tube on AdBlue® pump nozzles for heavy

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Magnetic switch
goods vehicles contains a magnetic switch. This
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magnetic switch functions as a safety valve to prevent

n
c
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or
the fluid being delivered into the wrong tank. It can

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only be opened with a defined magnetic field that is

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applied externally. The filler neck features a magnetic

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ring that allows you to fill the reducing agent tank op py
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with an AdBlue® pump for heavy goods vehicles. The
ht
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magnetic switch is opened by the magnetic ring when Prote
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you insert the pump nozzle.
AdBlue® S540_048
21
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Delivery module autho tee
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The delivery module is bolted to the bottom of the
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delivery unit. Two pumps are integrated into the
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Delivery unit
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delivery module:
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• Pump for reducing agent V437
spec
• Reducing agent return flow pump V561
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Both pumps are solenoid-actuated diaphragm
rrectne
pumps. They are activated by the engine control unit.
ss o
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Pump for reducing
atio
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agent V437
o
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Please observe the information and notes
thi
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va
in the workshop manual when installing

i
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ProCarManuals.com
um
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and removing the delivery module.

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op py
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t. C rig
ht return flow pump
pyri by
Vo V561
co lksw
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Prote AG. To and from the injector for
reducing agent N474
S540_012
Design
Pump for reducing agent V437
Magnetic piston
Solenoid
Piston spring
Plunger
Diaphragm
Reducing agent return
flow pump V561
Pulsation damper
Magnetic piston
Connection for
Diaphragm reducing agent line
Electrical connection
S540_015
22
AG. Volkswagen AG d
agen oes
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Pump for reducing agent V437
pt
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The pump for reducing agent is a solenoid-actuated
ot p
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diaphragm pump. The solenoid functions as a pump
h re
drive for the magnetic piston that moves the hole Delivery pump
spec
es, in part or in w
diaphragm below it up and down via a plunger. Non-
t to the co
return valves at the inlet and outlet control the supply
of reducing agent to the pump chamber. The pump
rrectness of i
delivers the reducing agent by activating the solenoid
l purpos
to move the piston. The pump draws in the reducing

agent during the return movement of the piston
nform
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caused by the spring.

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at
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Terminal 87 (+)
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Earth from J623

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Cop py
ProCarManuals.com
ht. rig
The voltage for both reducing agent rig ht
py by
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pumps is supplied via the relay for Prote
cted AG.
agen
reducing agent metering system J963.
Reducing agent return flow pump V561

The return flow pump extracts the reducing agent
partially from the supply line after the engine has
been switched off. This prevents the reducing agent
from freezing in the injection valve at low
temperatures and causing damage due to ice
expansion.
Immediately after you switch off the engine, the return

flow pump is activated by the engine control unit for
approximately 5 seconds to extract a sufficient
quantity of reducing agent from the supply line. The
injector remains closed initially so that hot exhaust
gases are not drawn into the supply line. The injector
is then opened to compensate the vacuum in the
Earth from J623
supply line during the extraction process.
Terminal 87 (+)
Return flow pump

S540_014
23
Monitoring the system pressure

Function
The pump for reducing agent V437 delivers the For this purpose, the times from the start of
reducing agent from the reducing agent tank with an energisation to the first movement and to the end
almost constant stroke volume and delivers it to the position of the magnetic piston are measured. In
injector for reducing agent N474. The quantity of addition, the strength of the current flow is evaluated.
reducing agent that is injected depends on the The engine control unit uses this data to calculate the
nitrogen oxide content in the exhaust gas. The engine pressure of the reducing agent in the SCR system.
control unit uses the injector opening time and
opening frequency to set the quantity. A pressure Examples of possible system faults:
equilibrium of approximately 6.5 bar (+/- 2 bar) is set
in the reducing agent system due to the continuous • The reducing agent line is damaged and is
injection and the constant stroke volume. The engine leaking.
control unit evaluates the current flowing through the • The pump is jammed.
pump for reducing agent in order to monitor the • The metering holes on the reducing agent injector
ProCarManuals.com
hydraulic pressure of the reducing agent in the SCR are blocked.

system. • The intake area for the delivery unit is blocked.
AG. Volkswagen AG d
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Key . Co py S540_045
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1 Reducing agent tank Prote
cted 5 Diesel particulate filter (reduction catalytic
AG.
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2 Reducing agent converter)

3 Filter 6 Engine control unit J623
4 Injector for reducing agent N474 7 Pulsation damper
8 Pump for reducing agent V437
24
Delivery unit for reducing agent metering system GX19
The delivery unit contains the sensors and actuators A filter in front of the intake prevents the SCR system
for the reducing agent tank system. It is sealed into being damaged by particles of dirt in the reducing
the reducing agent tank. The reducing agent level agent. The reducing agent drawn in from the
sender G697, the temperature sender for reducing reducing agent line by the return flow pump is fed
agent G685 and the heater for reducing agent tank back into the reducing agent tank.
Z102 have been permanently integrated into the
delivery unit. The delivery module with the reducing
agent pumps is bolted to the delivery unit and can be
exchanged if necessary.
Design
ProCarManuals.com
. Volkswage
Housing for delivery module gen AGtank Z102 n AG do
Heater for reducingaagent
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Return line for tho or
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Electrical connection
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Connection for
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reducing agent Filter

line
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PWM signal G697/G685

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Earth G697/G685
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Positive G697/G685 t.
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Positive Z102 op
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Earth Z102
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Electrical connection Temperature sender for
reducing agent G685
S540_027
25
Reducing agent level sender G697

Design and function
Reflected signal pulses
Transmitted signal pulses
AdBlue®
Reducing agent tank
Duct for ultrasonic waves

ProCarManuals.com
AG. Volkswagen AG d
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Reducing agent level sender G697 pt

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S540_016
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The reducing agent level sender G697 is an The signal from the temperature sender for reducing
h re
ole,
ultrasonic sensor. The sound waves emitted by the agent G685 is used to calculate the filling level of the
spec
sensor are guided through a duct. This prevents reducing agent. This allows the density of the
t to the co
scatter and reflections that could distort the signal. reducing agent to be taken into consideration at
The ultrasonic waves are reflected by the boundary different temperatures.
rrectne
layer between the reducing agent and the air. In this The measuring system will not work if the reducing
case, the reducing agent level is determined from the agent is frozen.
ss o
time difference between the emitted signal pulse and

cial p
f inform
the received signal pulse.

mer
atio
om
n
c
i
or
n thi
te
sd
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At least 3.5 to 4 litres of reducing agent need to be filled into the reducing agent tank before the
en
ng
t.
yi Co
engine control unit can reliably detect the new level. Cop py
ht. rig
Please observe the information in the owner’s manual. py
rig by
Vo
ht
co lksw
by
cted agen
Prote AG.
Effects of signal failure
If the signal from the reducing agent level sender fails, the filling level of the reducing agent tank cannot be
measured. The SCR system remains active, however. The AdBlue® warning display for SCR system errors lights up
in the display and the exhaust emissions warning lamp K83 is switched on.
26
Temperature sender for reducing agent G685
The temperature sender for reducing agent is a thermistor sensor with a negative temperature coefficient (NTC). It
is located in the delivery unit housing. The engine control unit evaluates the PWM signal from the temperature
sender and uses it to calculate the current temperature of the reducing agent in the reducing agent tank. The
voltage for the temperature sender is supplied via the relay for reducing agent metering system J963.
ProCarManuals.com
S540_041
AG. Volkswagen AG d
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e o agent G685
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Signal use Effects of signal failure

h re
hole
spec
es, in part or in w
t to the co
The engine control unit uses the signal from the The exhaust emissions warning lamp and the
temperature sender for reducing agent to switch on AdBlue® warning display for faults in the SCR system
the heater systems in the SCR system. Furthermore the are switched on in the dash panel insert.
rrectness of i
signal is used to calculate the filling level in the

l purpos
reducing agent tank.

nform
mercia
a
com
tion in
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te o
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27
Heater system
Reducing agent heater system

Since the reducing agent can freeze at low ambient The heater system allows the SCR system to be quickly
temperatures, the reducing agent tank and the line to prepared for operation even when the reducing
the reducing agent injector are both equipped with agent is frozen. It also ensures that sufficient
resistance heating systems. Furthermore the two defrosted reducing agent is available at all operating
solenoids in the delivery module can be energised if points.
heating is required.
AG. Volkswagen AG d
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Overview of heater system ss au ra
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Relay for reducing agent metering system J963
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Engine control unit J623 Control unit for reducing
wit
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agent heater J891
h re
ProCarManuals.com
ole,
Terminal 87 (+)
spec
t to the co
rrectness o
cial p
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c
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Ambient Heater for reducing Heater for reducing

i
Heater for Temperature

pr
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reducing agent sender for temperature agent tank Z102 agent line Z104
en
ng
t.
pump Z103 reducing agent sensor G17 yi Co
Cop py
G685 gh
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pyri by
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cted agen
Prote AG.
Function
Using the information from the ambient temperature European On-Board Diagnosis regulations require
sensor G17 and the temperature sender for reducing that the heating current is monitored to allow failure
agent G685, the engine control unit J623 determines of or a malfunction in emissions-related components
the heating requirements for the reducing agent. The to be detected. The engine control unit receives
engine control unit then activates the control unit for feedback on the actual heating current flow from the
reducing agent heater J891, which activates the control unit for reducing agent heater.
electrical power supply for the heaters.
28
Control unit for reducing agent heater J891
The control unit for reducing agent heater J891 controls
the electrical power supply to the SCR system heaters. It is
activated by the engine control unit for this purpose. In
lkswage es n
Vo ot g
the Passat 2015, it is located near the rear right of the by ua
d ran
ir se tee
luggage compartment. tho
u or
a ac
ss
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S540_034
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Heater for reducing agent tank Z102
ility
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The heater for reducing agent tank Z102 is a positive
h re
hole
spec
temperature coefficient heater element (PTC). It is
es, in part or in w
integrated into the delivery unit and heats the reducing
t to the co
agent around the pick-up point in the reducing agent
tank. The engine control unit activates it as required via
rrectness of i
the output stage of the control unit for reducing agent
l purpos
heater.
ProCarManuals.com
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S540_050
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atio
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Heater for reducing agent line Z104

o
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or c
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The heater for reducing agent line Z104 consists of a

iv
o
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rp
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stainless steel wire that is wound in a spiral around the
o
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t.
reducing agent line. It functions as a resistance-heating yi Co
Cop py
.
element and is protected on the outside by a corrugated t rig
gh ht
pyri by
Vo
plastic conduit. The heater element is activated by the co lksw
by
cted agen
Prote AG.
engine control unit via the control unit for reducing agent
heater as required. As a result, the reducing agent in the
supply line is warmed thus enabling reliable operation of Corrugated plastic conduit
the SCR system at low ambient temperatures.
Heater element
S540_042
Heater for reducing agent pump Z103

The two solenoids in the delivery module function as the
heater for reducing agent pump Z103. To achieve the
heating function, the solenoids are energised by the Solenoids
engine control unit according to the heating
requirements and thus generate heat. The solenoids are
energised constantly or intermittently depending on the
temperature. The temperature of the reducing agent
pumps is calculated by evaluating the current flow and a
temperature model in the engine control unit.
S540_036
29
Heater system
Heater circuits and heating duration
The heater control system is sub-divided into three Standby heating starts once the heating time for
heater circuits. The power for the heater circuits 1 and defrosting the reducing agent has expired. This
2 is supplied by the control unit for reducing agent ensures that a sufficient amount of defrosted reducing
wage e n
heater J891. Heater circuit 3 is operated by they Volks agent can alwayss be ot gsupplied in all operating ranges.
d b ua
e ran
engine control unit. The heater circuits areorswitched
is tee
th or
on depending on the temperatures in sthe au reducing ac
s
ce
le
agent tank, the temperature of the outside air and the
un
pt
an
d
temperature of the reducing agent pump. They

itte
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remain active for a specific time.
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ility
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Heater circuit 1 Heater circuit 2 Heater circuit 3
rrectness of i
ProCarManuals.com
l purpos
Heater element Heater for reducing agent Heater for reducing agent Heater for reducing agent
tank Z102 line Z104 pump Z103
nform
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Trigger for activation • Temperature in the tank • Temperature in the tank • Temperature in the tank
m
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• Temperature of outside air • Temperature of outside air • Temperature of outside air

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• Temperature of pump
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Activation and hea- • Approximately 20 min. at copy • Approximately 5 min. at
by
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ting duration for temperatures from -7°C to cted temperatures below -7°C agen temperatures from -7°C to
Prote AG.
defrosting -15°C in the tank and up in the tank or outside air -15°C in the tank and up
to 45 min. at -25°C and up to 21 min. at - to 45 min. at -25°C
25°C
Activation of • Temperature of outside • Temperature in tank or of • Temperature in tank or of

standby heating air: below -7°C and outside air below -5°C outside air below 0°C and
temperature in the tank pump temperature below
below +5°C +40°C
30
AdBlue® display system
AdBlue® displays in dash panel insert

The AdBlue® displays appear in the dash panel insert to inform the driver in sufficient time if the reducing agent
needs to be topped up or to indicate an error in the SCR system.
Warning display for filling level Warning display when there is an error in
the SCR system
AG. Volkswagen AG d
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Top up AdBlue! Error: AdBlue.
erm
ab
No engine start possible No engine start possible
ility
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in 1000 km. in 1000 km.
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S540_018 S540_020
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ProCarManuals.com
• When the filling level becomes too low, the reducing • If there is an error in the SCR system, the car will
agent tank needs to be filled with AdBlue®.
rrectness of i
need to be taken to a qualified workshop.

l purpos
Failing to observe the warnings will result in an engine restart lockout after the remaining range has been used up.
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You can then no longer start the engine once you switch off the ignition.
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Display strategy sequence

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Depending on the remaining range, the warning displays about the filling level or system errors are shown in
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several stages. After a specific distance has been covered, the intensity of the visual and acoustic warnings will
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increase. In addition, the warning message will be displayed repeatedly in the dash panel insert depending on the
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Remaining range Colour of warning Repeat of warning display Acoustic warning

display
From 2,400 km White The warning is repeated every 400 km or every 8 hours 1 x acoustic
and displayed in the dash panel insert. warning
The figure for the remaining range is displayed in steps
of 100 km.
From 1,000 km Yellow The warning is repeated every 100 km or every 4 hours 1 x buzzer
and displayed in the dash panel insert.
of 50 km.
From 200 km Yellow The warning is repeated every 20 km and displayed in 1 x buzzer
the dash panel insert.
of 10 km.
0 km Red Warning: engine start not possible. 3 x buzzer
31
AdBlue® warning displays about the filling level in the reducing agent tank
Filling level warning stage 1
The first request to refill reducing agent is displayed

when the remaining range that can be driven with the
available AdBlue® reaches 2,400 km. The engine
control unit calculates the remaining range on the
basis of the quantity of reducing agent in the tank and
the reducing agent consumption. Top up AdBlue!
Range:
2400 km.
S540_017

ProCarManuals.com
The warning is intensified once the remaining range

reaches 1,000 km. It is also displayed in yellow and a
warning triangle is added. You can only drive for the
displayed remaining range. If you do not refill a
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sufficient quantity of reducing agent, you will agen oes
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longer be able to restart the engineisafter
ed the nte
or No enginee o start possible
remaining range has been usedauup th and the ignition ra
ss in 1000c km.
is switched off.
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If there is no more AdBlue® in the reducing agent

rrectness of i
tank, the warning symbol will be displayed in red.

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Reducing agent needs to be refilled in order to end

the engine start lockout.
nform
mercia
a
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Top up AdBlue!
ion in
Engine cannot be
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te o
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started again.
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32
Extended display of the remaining range
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In the Passat 2016, the bAdBlueVo warning display ot g
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about the filling level
or in the reducing agent tank will tee
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be supplemented ss with indications of the minimum and
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maximum refill quantity.
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You need to refill at least as much reducing agent as
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Top up AdBlue!
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indicated by the minimum refill quantity to clear the
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No engine start
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warning from the dash panel insert. in 1000 km.
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A smaller refill quantity cannot be reliably detected
spec
Top-up quantity (l):
es, in part or in w
by the engine control unit. Min: 4.0 - Max: 11.5
t to the co
S540_047
rrectness of i
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Display of remaining range on the multifunction display

In the Passat 2016, the driver will also be able to
check the current remaining range via the
AdBlue range
multifunction display menu before the warning
range is reached.
Minimum top-up quantity km
The figure for the minimum top-up quantity indicates Top-up quantity (l):
Min.: 3.5 – Max.: 7.75
the minimum quantity of AdBlue® that needs to be
delivered into the tank to cause the display to change
after filling. S540_043
Maximum top-up quantity

The figure for the maximum top-up quantity helps you
choose a suitable refill container if you are using one.
33
AdBlue® warning displays for SCR system errors wage
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If the engine control unit detects an error au SCR system or insufficient efficiency via the NOxr asender,
insthe c a warning
s
ce
e
display will appear in the dash panel insert that indicates a malfunction in the SCR system.
nl
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System fault warning stage 1
es, in part or in w
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If a fault is detected in the SCR system and you have
rrectness of i
covered a distance of 50 km, the warning display will
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be shown in yellow. A spanner symbol will also be

displayed as a visual indicator of a system fault. The
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remaining range is 1,000 km. The distance already

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at
covered is immediately deducted from this figure. This Error: AdBlue.
om
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No engine start possible
n
c
is not based on the reducing agent tank level nor the
in t
or
in 1000 km.
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his
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reducing agent consumption.

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System fault warning stage 2
If the error in the SCR system is not rectified within the

remaining range, the engine can no longer be started
after the ignition is switched off.
Error: AdBlue.
Engine cannot
be started again.
S540_021
If there is a fault in the SCR system, this fault and the warning display can only be rectified by using the
Guided Fault Finding. In this case, refilling AdBlue® will not lead to the display in the dash panel insert
being cleared.
The restart lockout can be overridden for a further distance of 50 km by using the vehicle diagnostic
tester. This allows the vehicle to be driven to the next workshop.
34
Service
AdBlue® filling options for customers
AdBlue® pumps
The reducing agent tank in the Passat 2015 can be
filled at a pump (see page 19).
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Refill bottle
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The refill bottle contains 1.89 litres (equivalent to half
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or
a US gallon).
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Refill container
The refill container contains 5 litres. The AdBlue tank
should be refilled using the corresponding filler hose.
S540_044
35
Service
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Special tools and workshop equipment ss a ra
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Description Tool Usage
h re
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spec
AdBlue® filling system The mobile filling system VAS 6960
t to the co
VAS 6960 can be used cordlessly in workshops.
AdBlue® is filled from a 60-litre drum
via a sensor-controlled filling nozzle
rrectne
into the reducing agent tank in the
vehicle. The filling system shuts off
s
automatically when the maximum
s o
cial p
f
filling level has been reached.
inform
mer
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Filling device for AdBlue®
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Prote AG. VAS 6542 can be used to fill reducing
VAS 6542 agent tanks in a workshop. The
container VAS 6542/1 holds 10 litres.
The maximum filling level is reached
when the breather hose fills with liquid
or the container noticeably collapses.
Observe the correct height difference
between the container and filler neck.
S540_023
Mounting plate V.A.G 1383A/1 The mounting plate is used to mount

the container VAS 6542/1 securely
during the filling process with the
filling device for AdBlue® VAS 6542.
S540_049
36
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Description Tool Usage
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Test case The tools in the test case are used to
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VAS 6532 test the metering quantity and system
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pressure as part of the Guided Fault
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Vacuum box The vacuum box is used to extract

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AdBlue® from the reducing agent

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S540_025
Refractometer The refractometer is used to check the

T 10007 A concentration of urea in the AdBlue®.
S540_038
37
Test your knowledge
Which answers are correct?
One or several of the given answers may be correct.
1. How is the AdBlue® drained from the reducing agent supply line in the SCR system
for the Passat 2015 upon “ignition OFF”?
❒ a) The AdBlue® is pumped out of the reducing agent supply line by the reducing agent pump after the
reversing valve for reducing agent is actuated.
❒ b) The AdBlue® is pumped out of the reducing agent supply line by the reducing agent return flow pump.
❒ c) After “ignition off”, the AdBlue® in the reducing agent supply line is drained via the reducing agent
injector and temporarily stored in the diesel particulate filter coating.
2. How is the filling level of the reducing agent tank determined by the engine control unit
in the SCR system for the Passat 2015?
ProCarManuals.com
❒ a) By using a float with a magnet and six reed contact switches.
❒ b) By using four fill level senders made of stainless steel and evaluation electronics.
❒ c) By using an ultrasonic sensor.

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3. Which oristatement
s about monitoring the efficiency nteof the
eo SCR system in the Passat 2015 is correct?
uth ra
s a c
s
❒
ce
le
a) The efficiency of the SCR system is monitored by using an NOx sender before the emission control module.
un
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b) The efficiency of the SCR system is monitored by using an NOx sender after the emission control module.
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c) The efficiency of the SCR system is monitored by using one lambda probe before the emission control
spec
es, in part or in w
module and one after it.

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38
4. What functions does the trap catalytic converter have?
❒ a) It oxidises carbon monoxide into carbon dioxide.
❒ b) It oxidises soot particles into carbon dioxide.
❒ c) It stores excess ammonia, which is used to convert nitrogen oxides remaining in the exhaust gas into
nitrogen and water.
❒ d) It stores nitrogen oxides that are converted into nitrogen and water in a regeneration process.
5. The following warning symbol appears in the dash panel insert display.
ProCarManuals.com
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Which statement is correct? olkswag does
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S540_046
rrectness of i
❒ a) The reducing agent tank is empty. The engine can only be started again once the reducing agent tank
l purpos
has been filled.

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or
❒
m
b) The reducing agent tank is empty. The engine can only be started again once the entry in the
m
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engine control unit event memory has been deleted.

n in
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c) There is an error in the SCR system. The engine cannot be started.

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❒ d) There is an error in the SCR system. The engine can be started so that the customer can ht. Co py
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5.) c)
4.) a), c)
3.) a)
2.) c)
1.) b)
Answers:
39
540
Top up AdBlue! Error: AdBlue.
Range: Engine cannot
2400 km. be started again.
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AdBlue range
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km
Top up AdBlue!
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No engine start possible Top-up quantity (l):
in 1000 km. Min: 3.5 – Max.: 7.75
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© VOLKSWAGEN AG, Wolfsburg

All rights reserved. Subject to technical modifications.
000.2812.97.20 Technical status 07/2015
Volkswagen AG
After Sales Qualification
Service Training VSQ-2
Brieffach 1995
D-38436 Wolfsburg
❀ This paper was manufactured from pulp that was bleached without the use of chlorine.

SSP 540 The Passat 2015 SCR and AdBlue

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SSP 540 The Passat 2015 SCR and AdBlue

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Service Training

SCR Exhaust Gas Treatment

in the Passat 2015

AdBlue® display system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Nitrogen oxides and the EU6 emission standard

Concepts for reducing nitrogen oxides

storage catalytic converter or the selective catalytic

• High injection pressures to ensure a good mixture formation

• Low compression ratio

supplied by a urea solution, the AdBlue®reducing

emissions is using an SCR system to treat the exhaust

in the exhaust gas. The AdBlue®reducing agent is

Catalytic Reduction. This system specifically reduces

reduction catalytic converter.

The SCR system

Reducing agent line

Reducing agent tank with delivery unit

Reducing agent line

Schematic diagram of SCR system

1 Reducing agent tank 9 Trap catalytic converter

Exhaust gas temperature sender 2 G448

Injector for reducing

Data bus diagnostic

Exhaust gas temperature sender 4 G648 Heater for reducing

Heater for reducing

NOx sender G295 Exhaust gas temperature Injector for reducing

sender 3 G495 agent N474

Electrical connection Connection for reducing agent line

exhaust gas into nitrogen (N2) and water (H2O).

Trap catalytic converter

Exhaust flap control unit J883

Coolant circuit – general overview

1 Coolant expansion tank 12 Injector for reducing agent N474

Heat exchanger for heater Throttle valve module J338

3 Exhaust gas recirculation cooler 14 Engine oil cooler

level, the exhaust emissions warning lamp K83 and

Monitoring the quality of the reducing agent

Checking the efficiency and the quality of the reducing agent

no longer escape from the exhaust system. It is fed via

the low-pressure exhaust gas recirculation system, the

Injector for reducing agent N474 yi

NOx sender G295

Control unit for NOx

Exhaust gas recirculation control motor 2 V339

Throttle valve module J338

exhaust emissions warning lamp will light up in the

Effects of signal failure

Properties of AdBlue® Notes on handling AdBlue®

The reducing agent tank in the Passat 2015 can be

speeds can result in different filling quantities in the

reducing agent tank.

AdBlue® pump for cars *) 3.5–10 l/min

AdBlue® refill bottle Approx. 3 l/min

Design of tank system

Reducing agent tank

Spiked mat and baffle plate

The filling tube on AdBlue® pump nozzles for heavy

magnetic switch functions as a safety valve to prevent

the fluid being delivered into the wrong tank. It can

only be opened with a defined magnetic field that is

applied externally. The filler neck features a magnetic

you insert the pump nozzle.

• Pump for reducing agent V437