AUDI Self Study Program 204 – ESP Electronic Stability Programme SSP-204-ESP

Service.

ESP

Electronic Stability Programme

Design and function

204

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ESP is the abbreviation for
“Electronic stability programme”.

The system's task is to assist the driver
in demanding driving situations, e.g. if a wild
animal suddenly runs across path of vehicle, and
also to compensate for overreaction on the part
of the driver and to prevent loss of vehicle
stability.
However, ESP is not intended for speed manics to
try and defy the laws of physics.

A responsible driving style adapted to the
prevailing road and traffic conditions is therefore
still essential.

In the course of this booklet, we will explain how
ESP is based on the proven anti-lock braking
system (ABS) and its related systems - TCS, EDL,
EBD and EBC - and we will describe the various
versions of ESP which we use in our vehicles.

The Self-Study Programme

is not a Workshop Manual.

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NEW Important

Note

Please always refer to the relevant Service Literature

for all inspection, adjustment and repair instructions.

2

Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Basic physical principles. . . . . . . . . . . . . . . . . . . . . . . . 7

Driving dynamic control . . . . . . . . . . . . . . . . . . . . . . . 9

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Design and function of ESP . . . . . . . . . . . . . . . . . . . . . 16

Functional diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Self-diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

ITT Automotive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Design and function of ESP . . . . . . . . . . . . . . . . . . . . . 38

Functional diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Self-diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

3

Introduction

Retrospective

Ongoing technical advances in the motor vehicle
industry have seen vehicles with increasing
performance and power output come onto the
market. Even in the early days, designers were
confronted with the question of how to keep this
technology manageable for the average driver.
In other words: What systems would be required
to ensure maximum braking safety and assist the
driver?

Purely mechanical precursors to the modern-day
anti-lock braking system were first conceived as
long ago as the 1920s and 1940s. However, these
systems were not suited to the task in hand
because they were too slow.

The electronics revolution in the 1960s made anti­lock braking systems feasible. Such systems have
become more and more efficient with the further
development of digital technology. Today, we
regard not only ABS, but also systems such as
EDL, EBD, TCS and EBC, as everyday
technology. Today’s state of the art is reflected in
ESP, which is now ready for production. However,

our engineers are already thinking one step
further.

What does ESP do?

The electronic stability programme is one of the
vehicle's active safety features.
It is also known as a "driving dynamic control
system".
Expressed in simple terms, ESP is an anti-skid
programme.
It recognises when the vehicle is in danger of
skidding and compensates when the vehicle
breaks out.

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Plus-points:

- ESP is not an independent system. In fact it is
based on other traction control systems.
That is why it also includes the performance
features of these systems.

- It relieves the burden on the driver.

- The vehicle remains manageable.

- It reduces the accident risk if the driver
overreacts.

4

M

Brevity is the soul of wit

However, since there are so many vehicle systems that sound alike, abbreviations can be confusing. That
is why we have summarised the most commonly used concepts for you below.

ABS

A nti-lock B raking S ystem

This system prevents the wheels from locking
while braking. Despite the system’s powerful
braking effect, track stability and steerability are
re-tained.

TCS

T raction C ontrol S ystem

This system prevents the driven wheels from
spinning, e.g. on ice or gravel, by intervening in
the brake and engine management systems.

EBD

E lectronic B rake Pressure D istribution

This system prevents overbraking of the rear
wheels before ABS takes effect or if ABS is
unavailable, due to specific fault states.

ESP

E lectronic S tability P rogramme

This system prevents the vehicle from skidding by
selectively intervening in the brake and engine
management systems. The following
abbreviations are used also:

- ASMS ( A utomatic S tability
anagement S ystem),

- DSC ( D ynamic S tability C ontrol),

- DDC ( D riving D ynamic C ontrol),

-VSA ( V ehicle S tability A ssist) and

- VSC ( V ehicle S tability C ontrol).

EBC

E ngine B raking C ontrol

This system prevents the driven wheels from lock­ing due to the engine braking effect when the
accelerator pedal is released suddenly or when
the vehicle is braked with a gear engaged.

EDL

E lectronic D ifferential L ock

This system makes it possible to drive away on
road surfaces where each wheel has a different
degree of traction by braking the wheel which is
spinning.

5

Introduction

These two different systems used are within the
Group for various vehicle types.

To prevent skidding, a driving dynamic control system such as ESP must be able to control brake
activation within a fraction of a second. The return flow pump for the anti-lock braking system produces
the pressure required. To improve the delivery rate of the pump, there must be sufficient pre-pressure
provided on the suction side.
The fundamental difference between the systems made by BOSCH and ITT Automotive is how this pre­pressure is built up.

BOSCH

BOSCH ITT AUTOMOTIVE

Audi A8 Golf ‘98

Audi A6 Audi A3, Audi TT

Audi A4 Skoda Oktavia

Passat ‘97 New Beetle

Seat Toledo

ITT Automotive

In the Bosch system, the pre-pressure is
generated by a charge pump. This pump is
known as the hydraulic pump for driving
dynamic control and is attached to a common
bracket located below the hydraulic unit. The ESP
control unit and the hydraulic unit are separated.

204_086204_085

In the ITT system, the pre-pressure is generated
by an active brake servo. It is also known as a
booster. The hydraulic unit and the control unit
form a single module.

6

F = 9.81 N

Basic physical principles

Forces and moments

A body is subjected to different forces and
moments. If the total of the forces and moments
acting on the body equals zero, the body is at
rest. If this total does not equal zero, the body is
moving in the direction of the resultant force of
this total.

The most widely known force to man is that of
gravity. The force of gravity acts in the direction
of the centre of the earth.
If you suspend a 1 kilogram weight from a spring
balance in order to measure the forces that
occur, the balance will give a reading of 9.81
Newtons for the force of gravity.

2

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1

3

4

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I

II

II

Additional forces which act on a vehicle are:

- Tractive force (1 )

- Brake pressure (2) which counteracts

tractive force

- Lateral forces (3) which preserve the

vehicle's steerability and

- Adhesion forces (4 ) resulting from friction and

gravity, among other things.

Vehicles are also subjected to the following
forces:

- Yaw moments (I) which try to rotate the

vehicle about its vertical axis
as well as

- Wheel moments and moments of inertia (II )

which try to retain the direction in which
the vehicle is moving

- Plus other forces such as aerodynamic drag.

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7

Basic physical principles

Interaction between some of these forces can be described using of the Kamm friction circle. The radius
of the circle is defined by the adhesion force between the road surface and the tyres. In other words, the
lower the adhesion force, the smaller the radius (a): the higher the adhesion force, the larger the
radius (b).

The basis of the friction circle is a
forceparallelogram comprising lateral force (S ),
brake power or tractive force (B) and a resultant
total force (G ).

As long as the total force lies within the circle, the
vehicle is in a stable state (I). If the total force
exceeds the circle, the vehicle is no longer
controllable (II ).

Consider the inter-relationships between the
forces at play:

1. The magnitudes the brake pressure and lateral
force are such that the total force lies within the
circle. The vehicle is steerable without any
problem.

I

a

S

G

1

B

S

G

II

B

S

B

G

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B

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2

2. Now brake pressure is increased.
Lateral force is low.

S

3. Total force equals brake pressure.
The wheel locks up. The vehicle can no longer be
controlled since there are no lateral forces.

G

B

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A similar relationship exists between input power
and lateral force. If the lateral forces are zero

3

because input power is fully utilised, the driven
wheels will spin.

S = 0

B = G

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8

Driving dynamic control

Control process

Before ESP can respond to a critical driving
situation, it must answer two questions:

a - In what direction is the driver steering?

b - In what direction is the vehicle moving?

The system obtains the answer to the first

1

3

question from the steering angle sensor (1) and
the speed sensors at the wheels (2).

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I

4

The answer to the second question is supplied by
measuring the yaw rate (3 ) and lateral
acceleration (4).

If the information received provides two different
answers to questions a and b, ESP assumes that
a critical situation can occur and that
intervention is necessary.

A critical situation may manifest itself in two
different types of behaviour of the vehicle:

I. The vehicle threatens to understeer.
By selectively activating the rear brake on the
inside of the corner and intervening in the
engine and gearbox management systems, ESP
prevents the vehicle fromovershooting the corner.

II

II. The vehicle threatens to oversteer
By selectively activating the front brake on the
outside of the corner and intervening in the
engine and gearbox management systems, ESP
prevents the vehicle from skidding.

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9

Driving dynamic control

As you can see, ESP can counteract both oversteer and understeer.
For this purpose, it is also necessary to initiate a change of direction without direct intervention in the
steering.

The basic principle is the same as for tracked
vehicles.

When a bulldozer wants to negotiate a left-hand
bend, the track on the inside of the corner is
braked and the outer track is accelerated.

To return to the original direction of travel, the
track which was previously on the inside of the
corner and now on the outside of the corner is
accelerated and the other track is braked.

ESP intervenes along much the same lines.

Here is an example of how such a situation is handled by a vehicle without ESP.

The vehicle must avoid an obstacle which
suddenly appears. At first, the driver steers very
quickly to the left and to then immediately to the
right.

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The vehicle swerves due to the driver’s steering
wheel movements and the rear end breaks away.
The driver is no longer able to control the
resulting rotation about the vertical axis.

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Now let us observe how a vehicle handles the
same situation with ESP .

The vehicle attempts to avoid the obstacle.
From the data provided by the sensors, ESP
recognises that the vehicle is losing stability.
The system calculates its counteraction measures:
ESP brakes the left-hand rear wheel. This
promotes the turning motion of the vehicle. The
lateral force acting on the front wheels is
retained.

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As the vehicle swerves to the left, the driver
steers to the right. To help the driver steer into the
over-steer, the front right wheel is braked. The
rear wheels roll freely in order to ensure an
optimal build-up of lateral forces acting on the
rear axle.

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The preceding lane change can cause the
vehicle to roll about its vertical axis. To prevent
the rear end from breaking away, the front left
wheel is braked. In highly critical situations, the
wheel may be braked very heavily in order to
limit the build-up of lateral forces on the front
axle (Kamm circle).

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Once all instabile operating states have been
corrected, ESP ends its corrective intervention.

11

Overview

The system and its components

As mentioned already, the electronic stability
programme is based on the proven traction
control system.
However, it has several key additional features:

●

The system can recognise and compensate for
instable vehicle operating states at an early
stage, such as skidding.

Control unit

For this purpose, several additional components
are required.

Before we explain ESP in greater detail, here is
an overview of these components.

BOSCH

Brake servo

ITT

Brake pressure sensor

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BOSCH / ITT

Two makes of ESP system are fitted to VOLKSWAGEN vehicles.
One system is supplied by BOSCH and the other by ITT Automotive. Even
though both systems have identical tasks and basic principles, they differ from
one another in their component parts.
When ordering spare parts, you should note the system on which you are
working.

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BOSCH/ITT Automotive

Longitudinal acceleration

sensor (only Quattro/Syncro)

ITT

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Steering angle sensor

BOSCH / ITT

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Wheel sensors at front and rear

wheels

BOSCH / ITT

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Charge pump

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Hydraulic

unit

Yaw rate sensor

BOSCH

Lateral acceleration sensor

BOSCHBOSCHBOSCH

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13

System overview

BOSCH

Sensors

Probe for TCS/ESP E256

Brake light switch F

Brake pedal switch F47

speed sensors
rear right G44
front right G45
rear left G46
front left G47

Steering angle sender G85

Lateral acceleration sender G200

ABS control unit with
EDL/TCS/ESP J104 ,
in footwell on front
right at engine
bulkhead

14

Brake pressure sender G201

Yaw rate sender G202 ,
in footwell on front left in front of central control
system for convenience system

Auxiliary signals

Engine management
Gearbox management system

BOSCH

Actuators

Return flow pump relay - ABS J105 ,
in protective housing for control units,
in engine compartment on front left

Return flow pump for ABS V39

Solenoid valve relay - ABS J106 ,
in protective housing for control units,
in engine compartment on front left

ABS intake valves N99, N101, N133, N134

ABS exhaust valves N100, N102, N135, N136

Driving dynamic control valve -1- N225
Driving dynamic control valve -2- N226

Driving dynamic control high-pressure valve -1-

N227

Driving dynamic control high-pressure valve -2-

N228

Hydraulic pump for driving dynamic control V156

Control unit for display unit in
dash panel insert J285
ABS warning lamp K47
Warning lamp for brake system K118
TCS/ESP warning lamp K155

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Auxiliary signals

Engine management system
Gearbox management system
Navigation management system

Diagnosis plug connection

15

Design and function of ESP

Control cycle

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12

3

MONITORING

2

1 ABS control unit with EDL/TCS/ESP

2 Hydrualic unit with charge pump

3 Brake pressure sender

4 Lateral acceleration sender

5 Yaw rate sender

6 Button for TCS/ESP

7 Steering angle sender

8 Brake light switch

6

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9

The speed sensors provide a continuous stream
of data on speeds for each wheel.

The steering angle sensor is the only sensor
which supplies data directly via the CANbus to
the control unit. The control unit calculates the
desired steering direction and the required
handling performance of the vehicle from both
sets of information.

4

5

7

8

10

13

CONTROL

ESP

ABS

EDLTCS EBD MSR

MONITORING

14 15

18

1

19

16

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9-12 Speed sensor

13 Diagnosis wire

14 Warning lamp for brake system

15 ABS warning lamp

16 TCS/ESP warning lamp

17 Vehicle and driver behaviour

18 Intervention in engine management

19 Intervention in gearbox control unit

(vehicles with automatic gearbox only)

ESP decides:

- what wheel to brake or accelerate and to
what extent,

- whether engine torque is reduced and

- whether the gearbox control unit is activated
on vehicles with automatic gearbox.

16

The lateral acceleration sensor signals to the
control unit when the vehicle breaks away to the
side, and the yaw rate sensor signals when the
vehicle begins to skid. The control unit calculates
the actual state of the vehicle from these two sets
of information.

If the nominal value and actual value do not
match, ESP performs corrective intervention
calculations.

The system then checks to see if intervention was
successful from the data it receives from the
sensors.

If this is the case, ESP ends intervention and
continues to monitor the vehicle's handling
characteristics.
If this is not the case, the intervention cycle is
repeated.

When corrective intervention is taking place, this
is indicated to the driver by the flashing
ESP lamp.

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BOSCH

ABS control unit with
EDL/TCS/ESP J104

In the Bosch version, the control unit and the
hydraulic unit are separated. The control unit is
located on the right in the front footwell.

Design and function

The ABS control unit comprises a
high-performance microcomputer.

Since a high level of fail-safety is required, the
system has two processing units as well as its own
voltage monitoring device and a diagnoscs
interface.

Electric circuit

The control unit J104 obtains its power supply via
the positive connection in the dash panel wiring
loom.

A/+

S

J104

The two processing units utilise identical software
for information processing and monitoring one
another.
Dual-processor systems of this type have what is
known as active redundancy.

Effects of failure

In the unlikely event of the control unit failing, the
driver will only have use of the standard brake
system without ABS, EBS, TCS and ESP.

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Self-diagnosis

The following faults are detected:
Control unit defective
Power supply failure

17

Design and function of ESP

Steering angle sender G85

is mounted on the steering column between the
steering column switch and the steering wheel.
The centring ring with slip ring for the airbag is
integrated in the steering angle sender and
located on the base of the steering angle sender.

Task

The sender transfers the steering wheel lock
angle to the ABS control unit with EDL/TCS/ESP.
An angle of ±720° corresponds to four full turns
of the steering wheel.

Centring ring with slip ring
for driver's airbag

Effects of failure

Without the information supplied by the steering
angle sensor, ESP would be unable to determine
the desired direction of travel. The ESP function

fails.

Self-diagnosis

After replacing the control unit or the sensor, the
zero position must be re-calibrated.

- Steering angle sender - no communication

- Wrong setting

- Mechanical fault

- Defective

- Implausible signal

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Electric circuit

G85 is the only sensor of the ESP system which
transfers information direct via CANbus to the
control unit. After turning on the ignition, the
sensor initialises itself as soon as the steering
wheel has been rotated through an angle of 4.5°.
This is equivalent to a turning movement of
approx. 1.5 cm.

J104

S

18

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G85

J105
J106

Faults can occur if the track has become maladjusted.
Make sure that the sensor is connected securely to the steering wheel.

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19

BOSCH

Design

The angle is measured using the principle of the

B

e

c

a

d

light barrier.

The basic components are:

- a light source (a)

- an encoding disc (b)

- optical sensors (c+d) and

- a counter (e) for full revolutions

The encoding disc comprises two rings:
the absolute ring and the incremental ring.
Both rings are scanned by two sensors each.

4

1

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2

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3

Function

5

We can simplify the setup by arranging an
incremental hole template ( 1) and an absolute
hole template ( 2) side by side. The light source
(3) is positioned in between the hole templates.
The optical sensors (4+5) are located on the
outside.

Light impinging on a sensor through a gap
generates a signal voltage. If the light source is
covered, the voltage breaks down again.

Moving the hole templates produces two
different voltage sequences. The incremental
sensor supplies a uniform signal, since the gaps
follow each other at regular intervals. The
absolute sensor generates an irregular signal,
since light passes through the gaps in the
template at irregular intervals. By comparing
both signals, the system can calculate how far
the hole template has moved. The absolute part
determines the starting point of the movement.

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Designed for only one turning motion, the
steering angle sender uses the same principle.

Design and function of ESP

Lateral acceleration sender G200

For physical reasons, this sensor should be
located as closely as possible to the vehicle’s
centre of gravity. This is why it is installed in the
footwell below the driver's seat.

Task

G200 determines whether and to what extent
lateral forces are causing the vehicle to lose
directional stability.

Effects of failure

Without the lateral acceleration measurement,
the actual vehicle operating state cannot be
calculated in the control unit. The ESP function
fails.

Self-diagnosis

The diagnosis establishes whether an open
circuit has occurred, or a short circuit to positive
or GND exists.
The system is also able to determine whether the
sensor is defective or not.

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Electric circuit

The lateral acceleration sender is connected to
control unit J104 by three wires.

J104

20

G200

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This sensor is highly sensitive to damage.

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BOSCH

Design

Expressed in simple terms, the lateral
acceleration sender comprises a permanent

4

1

3

2

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magnet (1), a spring ( 2 ), a damper plate (3 ) and
a Hall sensor (4).

The permanent magnet, spring and damper form
a magnetic system. The magnet is securely
connected to the spring and can oscillate back
and forth over the damper plate.

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a

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a

Function

When lateral acceleration (a) acts on the vehicle,
the permanent magnet tracks this movement
after a time lag caused by its mass moment of
inertia. This means that the damper plate,
together with the sensor housing and the vehicle
as a whole, moves away below the permanent
magnet which initially remains at rest.

U

This movement generates electrical eddy currents
within the damper plate. These eddy currents in
turn build up a field opposing the magnetic field
of the permanent magnet.
The strength of the overall magnetic field is
reduced in this way. This causes the
Hall voltage (V) to change.
The voltage change is directly proportional to
lateral acceleration.

U

That means that the more movement there is
between the damper and magnet, the weaker
the magnetic field will become and the more the
Hall voltage will change. The Hall voltage
remains constant if no lateral acceleration exists.

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U

Design and function of ESP

Yaw rate sender G202

This sensor should also be located as closely as
possible to the vehicle's centre of gravity.
In the Passat ‘98, this sensor is housed in the
footwell on the front left in front of the central
control unit for the convenience system.

Task

The yaw rate sender incorporates space
technology. Its task is to determine whether
torque is acting on a body. Depending on its
installation position, it can detect rotation about
one of the axes in space. In the ESP, the sensor
must determine whether the vehicle is rotating
about its vertical axis.

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This process is known as measuring the yaw rate.
A sensor which operates according to a
gyroscopic principle has been used in the
BOSCH system until now. However, this sensor
will be superseded by a combined transverse
acceleration and steering yaw rate sensor which
functions according to a different principle.

Design and function

An integral component is a small, metallic hollow
cylinder (1 ). Eight piezoelectric elements (2) are
attached to the hollow cylinder. Four of these
elements induce resonance vibration (a) in the
hollow cylinder. The other four elements
“observe” whether the vibration nodes of the
cylinder change. This is precisely what happens
when torque acts on the hollow cylinder. The
vibration nodes shift (b). This is measured by the
piezo elements and is signalled to the control
unit which calculates the yaw rate based on this
data.

Vibration node

1

2

a

B

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22

BOSCH

Combined Sensor

Lateral acceleration sender G200
Yaw rate sender G202

In future, both senders will be combined in a
housing.

The advantages of this are:

- smaller fitting dimensions,

- exact alignment of both sensors face to face

- this alignment cannot be changed - and

- stronger design

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The components are mounted on a printed circuit
board and operate according to
micromechanical principles.
The sensor is connected by a six-pin connector.
Lateral acceleration is measured according to a
capacitive principle.

The yaw rate is determined by measuring the
Coriolis acceleration which occurs.
Here is an example:

If you fire a canon ball horizontally in the
northern hemisphere, for example, it will no
longer appear to travel in a straight line to an
observer rotating with the earth. This is caused
by a force which accelerates the ball against the
direction of rotation of the earth and causes it to
deviate from its straight path –or what is known
as the Coriolis force.

Coriolis force

Direction of rotation
of earth

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23

Design and function of ESP

Design of lateral acceleration sender

The sender is a tiny component on the printed
circuit board of the combined sensor.

Expressed in simple terms, the lateral
acceleration sender is a capacitor plate with a
moving mass which is suspended so that it can
move back and forth. Two additional,
permanently mounted capacitor plates enclose
the movable plate in such a way as to form two
series-connected capacitors (K1 and K2). The
quantity of electricity which the two capacitors
can absorb can now be measured by means of
electrodes. This quantity of electricity is known as
capacitance C.

Function

As long as no acceleration acts on this system,
the measured quantities of electricity (C1 and C2)
of the two capacitors are of equal magnitude.

Stationary plate

Direction of travel

Capacitor plate with
movable mass

K1

Suspension

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K2

Stationary plate

Electrode

If lateral acceleration acts on the system, the
inertia of the movable mass at the centre plate
causes this part opposite the fixed plate to move
against the direction of acceleration. This causes
the spacing between the plates to change and
this also changes the quantities of electricity of
the partial capacitors.

The spacing of the plates at capacitor K1
increases and the associated capacitance C1
decreases.

The spacing of the plates of K2 decreases and
capacitance C2 therefore increases.

C1 = C2

C1 < C2

C2

C1

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24

Direction of travel

North pole

South pole

Substrate

Vibrating mass

Conductors

BOSCH

Design of yaw rate sender

The yaw rate sender is mounted on the same
board, but is physically separate from the lateral
acceleration sensor.

This design can also be explained in simple
terms.
Imagine a vibrating mass suspended in a
support in a constant magnetic field located
between the north pole and south pole. Printed
circuits representing the actual sensor are
attached to this vibrating mass.

In the actual sender, this configuration exists
twice for reasons of reliability.

Linear vibration corresponding to
AC voltage applied

V~

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Function

If you apply an AC voltage (V~), the part
containing the conductors begins to oscillate in
the magnetic field.

If angular acceleration acts on this structure, the
oscillating mass behaves like the canon ball
described above due to its inertia. It ceases to
oscillate back and forth because a Coriolis
acceleration occurs. Since this occurs in a
magnetic field, the electrical behaviour of the
conductors changes.
When measured, this change therefore shows
the magnitude and direction of the Coriolis
acceleration. The evaluation electronics calculate
the yaw rate from this data.

Yaw rate
Coriolis acceleration

25

Design and function of ESP

Brake pressure sender G201

is bolted to the hydraulic pump for driving
dynamic control.

Task

The brake pressure sender signals the
momentary pressure in the brake circuit to the
control unit.
From this, the control unit calculates the wheel
braking forces and the longitudinal forces acting
on the vehicle. If ESP intervention is necessary,
the control unit allows for this value when
calculating the lateral forces.

Effects of failure

Without values for current brake pressure, the
system is no longer able to calculate the lateral
forces correctly. The ESP function fails.

Self-diagnosis

The diagnosis establishes whether an open
circuit exists or whether a short circuit to positive
or earth has occurred. The system is also able to
recognise whether the sensor is defective.

204_071

Electric circuit

The brake pressure sender is connected to the
control unit J104 by three wires.

J104

G201

204_105

26

Do not remove the pressure sensor from the
hydraulic pump.
It must be replaced together with the pump.

BOSCH

Design

The core of the sensor is a piezoelectric
element (a) on which the brake fluid pressure can
act plus the sensor electronics (b).

ab

1

2

204_033

204_034

Function

When the brake fluid applies pressure to the
piezoelectric element, the charge distribution in
the element changes.
If the piezoelectric element is not subjected to
pressure, the electric charges are distributed
uniformly (1 ). If the piezoelectric element is
subjected to pressure, the electric charges are
shifted in space (2). An electrical voltage is
generated.

The higher the pressure, the greater the extent to
which the charges are separated. The voltage
rises. This voltage is amplified by the built-in
electronics and transmitted to the control unit in
the form of a signal.

The voltage level is therefore a direct measure of
the brake pressure applied.

204_035

27

Design and function of ESP

Button for TCS/ESP E256

This button is located on the dash panel insert,
depending on the vehicle type.

It allows the driver to de-activate the ESP
function. When the driver depresses the brake
pedal or presses the button again, it re-activates
the ESP function. If the driver forgets to re­activate ESP, the system re-activates itself when
the engine is restarted.

It makes sense to de-activate the ESP function in
the following situations:

- when trying to free the vehicle from deep
snow or loose surfaces by rocking the car
back and forth,

- when driving with snow chains fitted, and

- to run the vehicle on a dynamometer.

The system cannot be de-activated while ESP
intervention is in progress or above a certain
speed.

Effects of failure

If the ESP button is defective, the ESP function
cannot be de-activated. A malfunction is
indicated on the dash panel insert by the TCS/
ESP warning lamp.

204_060

Electric circuit

+

S

28

Self-diagnosis

The self-diagnosis cannot detect a defective
button.

L71

E256

J104

204_113

204_062

Electric circuit

Both lines of the hydraulic pump are connected
to control unit J104.

BOSCH

The hydraulic pump for
driving dynamic control V156

is mounted below the hydraulic unit in the engine
compartment on a common support.

Task

In an ABS system, a small quantity of brake fluid
must be pumped through the brake pedal
against a high pressure. This task is performed
by the return flow pump. However, the return
flow pump cannot provide a large quantity of
brake fluid at low or zero pedal pressure
because the brake fluid has a viscosity that is too
high at low temperature.
The ESP system therefore requires an additional
hydraulic pump in order to build up the
necessary pre-pressure on the suction side of the
return flow pump.

The pressure for pre-charging is limited by a
nozzle in the master cylinder.
The hydraulic pump for driving dynamic control
itself is not regulated.

J104

204_106

V156

Effects of failure

The ESP function can no longer be executed.
ABS, EDL and TCS are not impaired.

Do not repair the hydraulic pump. It must be replaced as a whole.
As a replacement part, the pump is already filled with brake fluid. Do not remove the plug
prematurely. Do not use an empty hydraulic pump.

Self-diagnosis

The self-diagnosis indicates open circuit as well
as short circuit to positive and GND.

29

Design and function of ESP

The hydraulic unit

It is mounted on a support in the engine
compartment. The exact fitting location may vary
depending on vehicle type. In the Passat 97, for
example, it is located on the driver's side on the
suspension strut tower.

Task

The hydraulic unit has two diagonally split brake
circuits.

Compared with older ABS units, the hydraulic
unit has been extended by the addition of a
changeover valve and an intake valve per brake
circuit. The return flow pump is now self-priming.

The changeover valves are as follows:
Driving dynamic control valve -1- N225 and
Driving dynamic control valve -2- N226.

The intake valves are as follows:

Driving dynamic control high-pressure valve -1­N227, and
Driving dynamic control high-pressure valve -2­N228.

The individual wheel brake cylinders are
activated by the valves in the hydraulic unit.
Three states are possible by activating the intake
and exhaust valves of a wheel brake cylinder in
the hydraulic unit:

204_072

Electric circuit

J104

N99 N100 N101 N102 N133 N134 N135 N136 N225 N226 N227 N228 V39

204_107

Effects of failure

If proper functioning of the valves cannot be
assured, the complete system is de-activated.

Self-diagnosis

30

- Raise pressure

- Hold pressure

- Reduce pressure

Control valves N225 and N226 as well as the
high-pressure control valves N227 and N228
are checked for open circuit and short circuit to
positive/GND.

G

B

h

F

ac

d

e

204_036

BOSCH

Functional diagram

Let us now examine a single brake circuit and
one particular wheel in the combination.
The partial brake circuit comprises:
Control valve N225 (a),
High-pressure valve N227(b),
Intake valve (c),
Exhaust valve (d),
Wheel brake cylinder (e),
Return flow pump (f),
Hydraulic pump for driving dynamic control (g)
and brake servo (h).

Raise pressure

204_037

When the ESP performs corrective intervention,
the hydraulic pump for driving dynamic control
begins
to convey brake fluid from the reservoir to the
brake circuit. As a result, brake pressure is
quickly available at the wheel brake cylinders
and return flow pump.
The return flow pump begins to convey brake
fluid in order to continue raising the brake
pressure.

Hold pressure

The intake valve closes. The exhaust valve
remains closed. The pressure cannot escape from
the wheel brake cylinders .
The return flow pump stops and N227 closes.

204_038

204_039

Reduce pressure

N225 switches to the opposite direction.
The intake valve remains closed while the
exhaust valve opens. The brake fluid can flow
back through the tandem master cylinders into
the reservoir.

31

Functional diagram

BOSCH

A/+

D

S

L71

S S S

E256

A/+

G44 G45 G47

F

F47

J104

G46

S

N99 N100 N101 N102 N133 N134 N135 N136 N225 N226 N227 N228 V39

204_092

Components

A/+ Positive connection
D Ignition switch

E256 Button for TCS/ESP

F Brake light switch
F47 Brake pedal switch

G44 Rear right speed sensor
G45 Front right speed ssensor
G46 Rear left speed sensor
G47 Front left speed sensor
G85 Steering angle sender
G200 Lateral acceleration sender
G201 Brake pressure sender

J106

G202 Yaw rate sender, in footwell on front left,

in front of central control system for
convenience system

J104 ABS control unit with EDL/TCS/ESP,

in footwell on front right, at engine bulkhead

J105 Relay for return flow pump - ABS,

in protective housing for control units,
in engine compartment on front left

J106 Relay for solenoid valves - ABS,

in protective housing for control units,
in engine compartment on front left

J285 Control unit for display unit

in dash panel insert

K47 ABS warning lamp
K118 Warning lamp for brake system
K155 TCS/ESP warning lamp

J105

32

BOSCH

E

V156

S

G85

G200

K47

J285

K155 K118

D

C

B

A

J104

G202G201

Input signal

Output signal

Positive terminal

Earth

CANbus

N99 ABS intake valve, front right
N100 ABS exhaust valve, front right
N101 ABS intake valve, front left
N102 ABS exhaust valve, front left
N133 ABS intake valve, rear right
N134 ABS intake valve, rear left
N135 ABS exhaust valve, rear right
N136 ABS exhaust valve, rear left
N225 Driving dynamic control valve -1­N226 Driving dynamic control valve -2­N227 Driving dynamic control high pressure valve -1­N228 Driving dynamic control high pressure valve -2-

S Fuse

V39 Return flow pump for ABS
V156 Hydraulic pump for driving dynamic control

204_092A

A Handbrake warning switch connection
B Navigation system (only on vehicles with navigation

system)
C Engine management system
D Gearbox management system (only vehicles with

automatic gearbox)
E Diagnosis wire

33

Self-diagnosis

Self-diagnosis can be performed with fault
readers V.A.G 1551 and V.A.G 1552.

The following functions are available:

00 - Automatic test procedure,
01 - Interrogate control unit version,
02 - Interrogate fault memory,
04 - Start basic adjustment,
05 - Erase fault memory,
06 - End of output,
08 - Read measured value block and
11 - Login procedure.

The interface between the diagnostic unit and
ESP system is the diagnosis plug connection.
The exact fitting location is dependent on the
vehicle type.

34

Warning lamps and buttons in the diagnosis

BOSCH

If a fault occurs while corrective intervention is in
progress, the system tries its best to complete
corrective intervention. At the end of the
corrective process, the subsystem is de-activated
and the warning lamp is activated.

Faults and activation of warning lamps are
always saved to the fault memory.

The ESP function can be de-activated by pressing
the button for TCS/ESP.

Ignition "on"

Warning lamps

Warning lamp for brake system K118

ABS warning lamp K47

TCS/ESP warning lamp K155

K118 K47 K155

System OK

TCS/ESP intervention

TCS/ESP button off
ABS remains active,
ESP is de-activated when coasting and accelerating, but
remains active during ABS intervention

TCS/ESP failure
Fault at yaw rate sender, lateral acceleration sender, steering
angle sender or brake pressure sender;
in eventof ABS failure, emergency ESP function remains
active.
EBD remains active.

ABS failure
All systems switch off

204_900

35

System overview

ITT Automotive

Sensors

Button for TCS/ESP E256

Brake light switch F

ESP brake recognition switch F83,
in brake servo

Speed sensor G44, G45, G46, G47

Steering angle sender G85

ABS control unit with
EDL/TCS/ESP J104,
in engine compartment
on left

Lateral acceleration sender G200

Brake pressure sender -1- G201
at master brake cylinder

Yaw rate sender G202,
in footwell on front left, in front of
central control system for convenience system

Brake pressure sender -2- G214,
at master brake cylinder

Longitudinal acceleration sender G249,
at right-hand A pillar (only 4-wheel drive vehicles)

Auxiliary signals

Engine management system
Gearbox management system system

36

Actuators

ITT Automotive

Return flow pump for ABS V64

ABS intake valve N99, N101, N133, N134

ABS exhaust valve N100, N102, N135, N136

Driving dynamic contro valve -1- l N225
Driving dynamic contro valve -2- N226

Driving dynamic control high pressure valve -1-

N227

Driving dynamic control high pressure valve -2-

N228

Magnetic coil for brake pressure N247,
in brake servo

Relay for brake light suppression J508,
on auxiliary relay carrier above relay plate

Control unit with display unit in
dash panel insert J285
ABS warning lamp K47
Warning lamp for brake system K118
TCS/ESP warning lamp K155

Auxiliary signals

Engine management system
Gearbox management system
Navigation management system

204_093

Diagnosis plug connection

37

Design and function of ESP

Control circuit

11

12

MONITOR

6

17

9

3
4

5

7

8

10

13

CONTROL

ABS

EDLTCS EBD EBC

MONITOR

ESP

14 15

1 Hydraulic unit with control unit

for ABS with

EDL/TCS/ESP

2

18

1

19

16

204_074

2 Active booster with

brake pressure sender and

release switch

3 Longitudinal acceleration sender

(quattro/syncro only)

4 Lateral acceleration sender

5 Yaw rate sender

6 Button for TCS/ESP

7 Steering angle sender

8 Brake light switch

9-12 Speed sensor

13 Diagnosis wire

14 Warning lamp for brake system

15 ABS warning lamp

16 TCS/ESP warning lamp

17 Vehicle and driver behaviour

18 Intervention in engine management

19 Intervention in gearbox control unit

(only vehicles with automatic

gearbox)

The only differences between the control circuits
are the way in which the pre-pressure is built up
and the inclusion of an additional brake pressure
sender on the tandem master cylinder.

The control process has been described above.
If actual and nominal vehicle handling deviate
from one another, the system performs corrective
intervention calculations until the information
supplied by the sensors indicates that vehicle

On 4-wheel drive vehicles, a longitudinal

stability has been restored.
acceleration sender is also included in the
control circuit.

Here, the brake booster assumes the role of the
hydraulic pump for driving dynamic control.
There is a magnetic coil for brake pressure and a
switch for brake recognition in the brake servo.

For a more detailled description of the control process, please turn to page 16.

38

ITT Automotive

ABS control unit with EDL/TCS/ESP
J104

is combined with the hydraulic unit to form of an
assembly; its electronic design is similar to that of
the Bosch control unit.

Function

- Control of ESP, ABS, EDL, TCS, EBD
and EBC functions,

- Continuous monitoring of all
electrical components, and

- Diagnostic support during servicing work in
the workshop

Effects of failure

In the unlikely event of the control unit failing
completely, the driver only has use of the
standard brake system without ABS, EDL, EBD,
EBC, TCS and ESP.

Electric circuit

Control unit J104 obtains its supply via the
positive connection in the dash panel wiring
loom.

+

+

204_063

After turning on the ignition, the control units
perform a self-test. All electrical connections are
continously monitored and the solenoid valves
are periodically tested for proper functioning.

Self-diagnosis

The following faults are detected:
Control unit defective
Control unit incorrectly encoded
Fault in power supply
Hydraulic pump defective
Implausible signals for ABS operation
Drive train databus

S SS

A

N99 N100 N101 N102 N133 N134

J104

N135

N136 N225 N226 N227 N228 V64

204_117

39

Design and function of ESP

Steering angle sender G85

is mounted on the steering column between the
steering column switch and the steering wheel.
The centring ring and coil spring for the airbag
are integrated in the steering angle sender and
located on its base.

Task

The steering angle sender signals the angle
through which the driver turns the steering wheel
clockwise or anticlockwise to the ABS control unit
with EDL/TCS/ESP.
The steering angle sender can measure an angle
of ±720°, i.e. four full turns of the steering wheel.

Centring ring and coil spring
for driver's airbag

204_064

Effects of failure

Without the information supplied by the steering
angle sensor, ESP is unable to determine the
desired direction of travel. The ESP function fails.

Self-diagnosis

After replacing the control unit or the sensor, the
zero position must be re-calibrated.

- Steering angle sender - no communication

- Wrong setting

- Mechanical fault

- Defective

- Implausible signal

J104

J217 J... J217 J...

G85

++

Electric circuit

G85 is the only sensor of the ESP systems which
transfers its information directly to the control
unit over the CANbus. After turning on the
ignition, the sensor is initialised by turning the
steering wheel through 4.5°.
This is equivalent to a turning movement
of approx. 1.5 cm.

204_108

40

For details of design and function, please turn to page 19.

204_065

ITT Automotive

Lateral acceleration sender G200

For physical reasons, this sensor should be as
close to the centre of gravity of the vehicle as
possible. Under no circumstances may the fitting
location and alignment of the sensor be
changed. It is located on the right-hand side next
to the steering column and is secured to the yaw
rate sender on a bracket.

Task

G200 determines what lateral forces can be
transferred. G200 therefore provides a sound
basis for assessing what vehicle movements are
controllable under the prevailing road
conditions.

Electric circuit

The lateral acceleration sender is connected to

the control unit J104 by three wires.

J104

G200

204_109

Effects of failure

Without the measurement of lateral acceleration,
the actual vehicle operating state cannot be
calculated in the control unit. The ESP function
fails.

Self-diagnosis

The diagnosis establishes whether an open
circuit has occurred or a short circuit to positive
or GND exists.
The system recognises whether the sensor signal
is plausible.

This sensor is also very sensitive to damage.

41

Design and function of ESP

Design

The lateral acceleration sender operates
according to a capacitive principle.
What does this mean?

Imagine that the sensor comprises two capacitors
connected in series. The common, central
capacitor plate can be moved by applying a
force.

Each capacitor has a capacitance, i.e. it can
absorb a certain amount of electric charge.

Function

As long as no lateral acceleration is acting on
the central plate, the gap between the central

plate and the outer plates remains constant, with
the result that the electrical capacitance of the
two capacitors is equal.

If lateral acceleration acts on the central plate,
the one gap increases and the other decreases.
The capacitance of the partial capacitors also
changes.

204_040

204_041

42

The electronics can determine the direction and
quantity of lateral acceleration from a change in
capacitance.

204_042

ITT Automotive

Yaw rate sender G202

The required installation position close to the
vehicle's centre of gravity was made possible by
mounting the yaw rate sender, together with the
lateral acceleration sender, on a bracket.
Unlike the BOSCH combined sensor system, the
ITT uses two separate sensors which can be
replaced individually.

Task

G202 ascertains whether torque is acting on a
body. Depending on the installation position, it
can detect rotation about one of the axes in
space. In the ESP, the sensor must determine
whether the vehicle has rotated about its vertical
axis. This process is known as measuring the yaw
rate.

Electric circuit

The yaw rate sender is connected to the control
unit J104 by three wires.

J104

204_066

Effects of failure

Without the measurement of the yaw rate, the
control unit is unable to ascertain whether the
vehicle has begun to swerve.
The ESP function fails.

Self-diagnosis

The diagnosis establishes whether an open
circuit has occurred or a short circuit to positive
or GND exists.
The system also ascertains whether the sensor
signal is plausible.

G202

204_110

43

Design and function of ESP

Design

A basic component of ESP is a micromechanical
system with a double tuning fork comprising a
silicon crystal housed in a small electronic
component on the sensor board.

Here is a simplified drawing of the double tuning
fork. Its mid-section is connected to the other
silicon element which we have ommited here for
the sake of clarity.

The double tuning fork comprises an exciter
tuning fork and a measuring tuning fork.

Function

Applying an AC voltage induces a sympathetic
voltage in the silicon tuning fork.
The two halves are matched so that the exciter
tuning fork has a resonance vibration at exactly

11kHz and the measuring tuning fork at 11.33kHz.
Applying an AC voltage at a frequency of
exactly 11 kHz to the double tuning fork induces
sympathetic vibration in the exciter tuning fork,
but not in the measuring tuning fork.

Exciter

tuning fork

Connection to

other silicon body

Measuring

tuning fork

204_077

The exciter tuning

fork vibrates in

resonance

44

A tuning fork vibrating in resonance reacts more
slowly to the application of force than a non­oscillating mass.

AC voltage at a

frequency of 11kHz

The
measuring
tuning fork
does not
vibrate in
resonance

204_078

Sympathetic vibration

BOSCH

This means that,whereas angular acceleration
causes the other half of the double tuning fork
and the remainder of the sensor together with
the vehicle to move, the oscillating part of the
double tuning fork lags behind this movement.
As a result, the double tuning fork becomes
twisted like a corkscrew.

The twisting effect changes the charge
distribution in the tuning fork. This is measured
by electrodes, evaluated by the sensor electrics
and transmitted to the control unit in the form of
a signal.

Torque

204_088

45

Design and function of ESP

Longitudinal acceleration sender G249

is located on the A pillar on the right and is only
required on 4-wheel drive vehicles.

On vehicles that are driven at one axle only, the
system calculates the vehicle's longitudinal
acceleration from the data supplied by the
sender for brake pressure, the signals supplied
by the speed sensors on the wheels and
information from the engine management
system.

On 4-wheel drive vehicles fitted with Haldex
viscous coupling, the front and rear wheels are
joined by a rigid coupling. The calculated true
vehicle road speed, which is determined from the
individual speeds, may be too inaccurate under
certain conditions at low coefficients of friction
and when the Haldex viscous coupling is closed.
The longitudinal acceleration measured is used
to verify the calculated vehicle road speed.

Self-diagnosis

204_067

Effects of failure

Without the additional measurement of
longitudinal acceleration on 4-wheel drive
vehicles, it may be impossible under
unfavourable conditions to determine the
vehicle's road speed accurately.
The ESP and TCS functions fail. The EBD function
remains active.

Electric circuit

The longitudinal acceleration sender is
connected to control unit J104 by three wires.

46

The diagnosis establishes whether an open
circuit has occurred or a short circuit to positive
or GND exists. The system also recognises
whether the sensor signal is plausible or not.

For further details of design and function, please turn to
page 42.
This sender is installed rotated through 90° in relation to the
lateral acceleration sender.

J104

G249

204_111

ITT Automotive

Button for TCS/ESP E256

This button is located on the dash panel insert,
depending on vehicle type.

It enables the driver to de-activate the ESP/TCS
function. This is indicated by the TCS/ESP
warning lamp.
Pressing this button again re-activates the TCS/
ESP function.
If the driver forgets to re-activate the TCS/ESP
function, the system re-activates itself when the
engine is restarted.

It makes sense to de-activate the ESP function
in the following situations:

Electric circuit

+

S

J104

204_060

- when trying to free the vehicle from deep
snow or loose surfaces by rocking the car
back and forth,

- when driving with snow chains fitted and

- for running the vehicle on a dynamometer.

The system cannot be de-activated while ESP
intervention is in progress.

Effects of failure

If the ESP button is defective, the ESP function
cannot be de-activated.

Self-diagnosis

L71

The self-diagnosis does not detect a defective
button.

204_113

E256

47

Design and function of ESP

Brake pressure sender - 1 - G201
Brake pressure sender - 2 - G214

Both senders are bolted to the tandem master
cylinder.

Task

To ensure maximum safety, there are two brake
pressure senders. In this case, too, the system has
a redundant design.

As with the BOSCH ESP system, the task of this
system is to supply measured values for
calculating the braking force and for controlling
the pre-charging function.

Effects of failure

It is practically impossible for both sensors to fail
simultaneously. If the control unit does not
receive a signal from one of the two senders, the
ESP function is disabled.

Self-diagnosis

The diagnosis establishes whether an open
circuit has occurred or a short circuit to positive
or GND exists.
The system also checks whether the signals of the
two sensors are plausible or not.

204_070

Electric circuit

Each of the brake pressure senders is connected
to control unit J104 by three wires.

J104

J104

48

G201

G214

204_114 204_115

Design

ITT Automotive

204_043

a

For the sake of clarity, we are using here a
simplified diagram of the plate capacitor in the
interior of the sensor (a) on which brake fluid
pressure can act.

Function

Due to the gap (s) between the two plates, the
capacitor has a defined capacitance C.
This means that it can absorb a certain amount

Both sensors are capacitive-type sensors.

s

of electric charge.
Capacitance is measured is Farady.

C

204_044

One plate is fixed, the other can be moved by
brake fluid pressure.

s

1

C

1

204_045

When pressure acts on the movable plate, the
gap (s
and the capacitance C

) between the two plates becomes smaller

1

increases.

1

If the pressure drops again, and the plate moves
back.
The capacitance is again low.

A change in capacitance is therefore a direct
measure of pressure change.

204_046

49

Design and function of ESP

Active brake servo with tandem master cylinder

The active brake servo or booster differs
fundamentally from the previous model. Over
and above the usual function, i.e. increasing the
foot pressure on the brake pedal by means of a
partial vacuum which is generated by the intake
manifold or from a vacuum pump, the active
brake servo assumes the task of building up the
pre-pressure for ESP intervention. This is
necessary since the intake capacity of the return
flow pump is not always sufficient to generate
the required pressure. The reason for this is the
high viscosity of the brake fluid at low
temperatures.

Advantage of the active brake servo:

- No additional installation work is necessary

Effects of failure

If the magnetic coil or switch F83 fails, the ESP
function will no longer be available.

Self-diagnosis

The following faults are detected:
open circuit,
short circuit to positive or GND and
defective component.

204_073

Electric circuit

J104

50

N247

F83

204_116

Design

ITT Automotive

aB

c

N247

d

e

204_050

First of all, let us observe an overview of the
design.

The booster comprises a modified tandem
master cylinder (a) and the brake servo (b).
The brake servo is subdivided into a vacuum part
(c) and a pressure part (d) which are separated
by a diaphragm. It also has a valve piston and
magnet unit (e).

The valve piston and magnet unit is electrically
connected to the ESP system.

It comprises:

- ESP brake recognition switch F83,

- magnetic coil for brake pressure N247,

- various air ducting valves
which we shall not explain here in greater
detail.

F83

switch closed

switch open

204_051

1

2

1

2

204_052

The ESP brake recognition switch is also known
as the “release switch”.
It is a two-way switch.
If the brake pedal is not activated, the mid­position contact is connected to signal contact 1.
If the pedal is activated, signal contact 2 closes.
Since only one contact is always closed, the
signal which the switch generates is always
clearly defined.
The release switch therefore offers a high level of
intrinsic safety.

51

Design and function of ESP

Function of valve piston and magnet unit

The valve piston and magnet unit produce the
pre- pressure of 10 bar which is required on the
suction side of the return flow pump even if the
brake pedal is not operated by the driver.

If the system recognises that ESP intervention is
necessary and that the driver has still not
activated the brake pedal, the control unit for
ABS/EDL/TCS and ESP activates the magnetic
coil for brake pressure.

Magnetic coil

Metal core

204_053

A magnetic field is built up inside the magnetic
coil and draws a metal core into the coil. This
movement causes the valves within the valve
piston and magnet unit to open. A quantity of air

sufficient to build up the required pre-pressure of
10 bar then flows into the brake servo.

If the nominal pre-charging pressure is
exceeded, the electric current supply to the
magnetic coil is reduced. The metal core retracts
from the coil and the pre-pressure drops. On
completion of the ESP control cycle or when the
brake is operated by the driver, the control unit
switches the magnetic coil off.

204_055A

52

204_054A

1

2

204_056

1

2

204_057

ITT Automotive

Function of ESP brake recognition switch

The brake recognition switch informs the ESP
system when the driver applies the brakes. If the
mid-position contact in the switch is closed at
signal contact 1, the system assumes that it has to
generate the necessary pre-pressure by itself.

When the driver operates the brake pedal, the
magnetic coil is moved in the direction of the
master brake cylinder. This causes the mid­position contact in the switch to change over
from signal contact 1 to signal contact 2,
indicating to the system that the driver has
applied the brake. Since the required pre­pressure is now generated by the driver
depressing the pedal, the magnetic coil need not
be activated.

J508

J104

M21

F

Relay for brake light suppression J508

When the ESP system activates the magnetic coil,
the brake pedal may move as a result of
tolerances to such an extent that the brake light
switch closes the contact to the brake lights.

To ensure that following road users are not
irritated by this, relay J508 interrupts the
connection to the lights for the duration of
magnetic coil activation.

53

Design and function of ESP

Hydraulic unit

is mounted on a support in the engine
compartment. The exact fitting location may vary
depending on vehicle type.

Task

The hydraulic unit has two diagonally split brake
circuits.

Compared with previous ABS units, the hydraulic
unit has been extended to include an extra
change-over valve and intake valve per brake
circuit. The return flow pump is now self-priming.

204_063

The changeover valves are:
Driving dynamic control valve -1- N225 and
Driving dynamic control valve- 2- N226.

The intake valves are:
Driving dynamic control high pressure valve -1­N227 and

Driving dynamic control high pressure valve -2­N228.

A distinction is made between three system
operating states:

- Increase pressure

- Hold pressure and

- Reduce pressure

Effects of failure

If proper functioning of the valves cannot be
assured, the complete system is de-activated.

54

Self-diagnosis

All valves and the pumps are monitored
continuously. If electrical faults occur, the control
unit must be replaced.

F

204_080

ITT Automotive

Functional diagram

h

B

G

a

d

e

c

Here, too, we shall only observe one wheel in a
brake circuit. The basic components are:
Control valve N225 (a),
Driving dynamic control high pressure valve
N227 (b),
Intake valve (c),
Exhaust valve (d),
Wheel brake cylinder (e),
Return flow pump (f),
Active brake servo (g) and
Low-pressure accumulator (h).

Increase pressure

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204_082

The booster builds up a pre-pressure to enable
the return flow pump to draw in the brake fluid.
N225 closes, N227 opens.
The intake valve remains open until the wheel
has been braked to the extent required.

Hold pressure

All valves are closed.

Reduce pressure

The exhaust valve is open, N225 is open or
closed depending on pressure level. N227 and
the intake valve are closed.
Brake fluid is conveyed via N225 and the
tandem master cylinders to the reservoir.

204_083

55

Functional diagram

ITT Automotive

D

S

E20

L71

Input signal

Output signal

CANbus

E256

Positive

Earth

A/+

S S

G44/45/46/47

J217 J... J217 J...

G85

G202G200

J104

N99/101/133/134 N100/102/135/136

56

204_094

Components

A/+ Positive connection

D Ignition switch

E20 Controller for light

switches and instruments

E256 Button for TCS/ESP

F Brake light switch
F9 Handbrake warning switch
F34 Brake fluid warning contact
F83 ESP brake recognition switch,

in the brake servo

G44-47 Speed sensor
G85 Steering angle sender
G200 Lateral acceleration sender

G201 Brake pressure sender -1-

at master brake cylinder

G202 Yaw rate sender, in footwell

on front left, in front of central
control system for convenience system

G214 Brake pressure sender -2-,

at master brake cylinder

G249 Longitudinal acceleration sender

in right-hand A pillar

J... Engine management control units
J104 ABS control unit with EDL/TCS/ESP,

in footwell on front right at engine bulkhead

J217 Control unit for auto. gearbox, in plenum

chamber at centre
J285 Control unit for display unit in dash panel insert
J401 Control unit for navignation system with

CD-ROM drive

ITT Automotive

S

J217

G214G201

N225 N226 N227 N228 V64

G249***

J104

F83

J401**J401**

N247

A

J508

K155

K14 K118

***

M21

F

K47

J285

F34

F9

J508 Relay for brake light suppression,

on auxiliary relay carrier
above relay plate

K14 Handbrake warning lamp
K47 ABS warning lamp
K118 Brake system warning lamp
K155 TCS/ESP warning lamp

L71 Lighting for switch/TCS

M21 Lamp for left brake light and tailight

N99/101 ABS intake valve
/133/134
N100/102 ABS exhaust valve
/135/136
N225 Driving dynamic control valve -1-

204_094A

N226 Driving dynamic control valve -2-

N227 Driving dynamic control high-pressure valve -1-

N228 Driving dynamic control high-pressure valve -2-

N247 Magnetic coil for brake pressure, in brake servo

S Fuse

V64 Return flow pump for ABS

A Diagnosis line

* Vehicles with automatic gearbox only
** Vehicles with navigation system only
*** Vehicles with four-wheel drive only

57

Self-diagnosis

Self-diagnosis can be performed with fault
readers V.A.G 1551 and V.A.G 1552.

The following functions are available:

00- Automatic test procedure,
01 - Interrogate control unit version,
02- Interrogate fault memory,
03 - Actuator diagnosis
04 - Initiate basic adjustment ,
05 - Erase fault memory,
06 - End of printout,
08 - Read measured value block and
11 - Login procedure.

The interface between the diagnostic unit and
the ESP system is the diagnosis plug connection.
The exact fitting location is dependent on the
vehicle type.

Special features

The following display group numbers are
available in Function 04 “Initiate basic
adjustment”:

60 - Zero adjust for

steering angle sender,

63 - Zero adjust for

lateral acceleration sender,

66 - Zero adjust for

sensors for brake pressure and

69 - Zero adjust for

longitudinal acceleration sender
(only 4-wheel drive vehicles)

Zero adjust is necessary when one of the
components is replaced.

For a detailed description of the procedure,
please refer to the Golf 1998 Workshop Manual,
the booklet entitled “Running gear self-diagnosis
for ABS
Documented ABS systems: EDL, EBC, TCS, ESP”.

Speed sensor faults

If at least once speed sensor is defective, the ABS
warning lamp and the TCS/ESP warning lamp
are switched on. The related systems are then de­activated.
The EBD function remains active.

If this speed sensor fault no longer occurs during
the self-test or at a road speed of more than 20
kph, the warning lamps go off.

58

Warning lamps and buttons in the diagnosis

ITT Automotive

If a fault occurs while corrective intervention is in
progress, the system tries its best to complete
corrective intervention. At the end of the
intervention process, the related subsystem is de­activated and the warning lamp is activated.

Faults and activation of warning lamps are
always saved to fault memory.

The ESP function can be de-activated by pressing
the button for TCS/ESP.

Ignition "on"
The lamps go off after approx. 3 s if system is OK

Warning lamps

Brake system
warning lamp K118

ABS warning
lamp K47

TCS/ESP warning
lamp K155

K118 K47 K155

System OK

TCS/ESP intervention

TCS/ESP failure or
TCS/ESP button off
ABS/EDL and EBD remain active.

ABS/EDL failure
All systems are shut down, EBD remains active
e.g. only one speed sensor is defective.

ABS/EDL and EBD failure
All systems are shut down
e.g. two or more speed sensors are defective.

Brake fluid level too low
All systems are active.

59

Service

Use of spare parts

Please bear in mind that some of the sensors,
such as the yaw rate sender or lateral
acceleration, are highly sensitive measuring
instruments incorporating space technology.

Calibrating the sensors and sender

After replacing the steering angle sender G85 or
control unit J104, the new sender must be
calibrated. This means that the sensor must learn
the straight-ahead position of the steering wheel.

Therefore:

●

Transport spare parts in their original
packaging and do not unpack them until
shortly before they are due to be installed.

●

Do not drop parts.

●

Do not place heavy objects on the sensors.

●

During installation, pay attention to the exact
installation position.

●

Make sure you observe the rules for
cleanliness at the workplace.

For a detailed description of the procedure,
please refer to the relevant Workshop Manual.

Please not that the yellow dot in the inspection
glass at the base of the steering angle senders is
fully visible. It indicates that the sensor is in the
0° CCS position.

After replacing the senders for pressure, lateral
acceleration and (if applicable) longitudinal
acceleration, these senders must also be
calibrated using fault readers V.A.G 1551 and
V.A.G 1552.

The yaw rate sender is calibrated automatically.

60

61

Test your knowledge

1. What statement on the longitudinal acceleration sender is true?

a) It is only required on 4-wheel drive vehicles.

b) It must always be at the vehicle's centre of gravity.

c) If it is defective, the ESP and ABS functions are de-activated.

The EBD function remains active.

2. When is it appropriate to de-activate the ESP system?

a) When freeing the vehicle from deep snow or a loose surface by rocking vehicle back and forth.

b) on black ice.

c) when driving with snow chains.

d) when running the vehicle on a dynamometer.

3. What sensor signals to the ESP control unit that the vehicle has swerved?

a) The steering angle sender.

b) The lateral acceleration sender.

c) The longitudinal acceleration sender.

4. The vehicle threatens to oversteer.
How does the ESP system re-stabilise the vehicle?

a) Only by braking the front wheel on the inside of the corner.

b) Only by braking the front wheel on the outside of the corner.

c) By braking the front wheel on the outside of the corner and

by intervening in the engine and gearbox management systems.

c) By braking the front wheel on the inside of the corner and

by intervening in the engine and gearbox management systems.

5. What system components are tested by the self-diagnosis.

a) The hydraulic pump for driving dynamic control V156.

b) The button for TCS/ESP E256.

c) The yaw rate sender G202.

d) The lateral acceleration sender G200.

Glossary

.

Force

is a directed physical parameter. It causes a
freely movable body to change shape or
accelerate.
A body on which no forces are acting remains in
a state of rest or constant linear movement. A
body is therefore in a state of rest when the total
of all forces acting on it equals zero.
The SI units of force are Newtons (N),
1N = 1m · kg/s

2

Acceleration

is a change of speed in the units of time
according to quantity or direction.
The unit of acceleration is m/s

2

.
In the case of a linear movement, acceleration
involves an increase or decrease in velocity
(negative acceleration, deceleration,
braking).

Capacitance

The measure (C) of electrical charge defined as
the relationship between a quantity of charge
(Q) to a voltage (V) where
C=Q/U. 1F = A

·

s

4

/kg · m

2

= A · s

2

/V = C/V.

2

Capacitance is dependent on the geometric
layout of the conductor and the dielectric
constant of the material in which the conductors
are located. Two metal plates which are
separated by a narrow gap are known as
capacitors.

Coriolis acceleration

Named after the French physicist Gustav­Gaspard Coriolis, 1792 - 1843.
The effect of the Coriolis force is an apparent
deflection of the path of an object that moves
within a rotating coordinate system. The object
does not actually deviate from its path, but it
appears to do so because of the motion of the
co-ordinate system.

Torque or moment

is generally a quantity, e.g. force, pulse, charge,
mass or area, which is multiplied by a distance
(e.g. lever) or distance squared. Example:
torque, pulse moment, moment of inertia,
magnetic moment.

Pressure

is defined as a force f; p=f/a acts on a unit of
area a.
The units of pressure are Pascal (Pa), bar (1 bar =

5

10

Pa), 1 Pa = N/m
common units of kp/m
longer used. The pressure of a gas in a vessel is
determined by the force which induces a change
in movement of the gas molecules when they
collide with the walls of the vessel.

2

= J/m

3

. The previously

2

, psi and Torr are no

The Corioilis effect is most apparent in the path
of an object moving longitudinally. On the Earth
an object that moves along a north-south path,
or logitudinal line, will undergo apparent
deflection to the right in the Northern
Hemisphere and to the left in the Southern
Hemisphere. If the co-ordinate system is referred
to as the reference frame, only an observer
within the reference frame can observe this
phenomenon.

62

Glossary

Coulomb

Charles-Augustin de Coulomb, French physicist
and engineer , 14.06.1736 - 23.08.1806.
The unit of electric charge Q bears his name.
1C = A · s in SI basic units

Newton

Sir Isaakc Newton, English physicist and
mathematician, 04.01.1643 - 31.03.1727.
His publications, which had a seminal influence
on physical and astronomical research, include
the “Philosophiae naturalis principia
mathematica” (1687, Mathematical Principles of
Natural Philosophy). Together with the principles
of mechanics, they are the foundation on which
classical theoretical physics is based.
Newton assumed an absolute view of space,
time and motion. Since Mach, Lorentz, Poincaré
and Einstein, a relativistic view of space, time
and motion contrary to Newton's theory has
become generally accepted.

SI units

SI is the abbreviation for “Système International
d’Unités” ( International System of Units). It
comprises seven basic units from which all other
physical and chemical units can be derived.

The basic units are:

Length metres [m]
Mass kilogrammes [kg]
Time seconds [s]
Electrical current intensity Ampere [A]
Thermodynamic temperatureKelvin [K]
Amount of substance Mol [mol]
Luminous intensity Candela [cd]

Faraday

Michael, Engl. physicist and chemist,

22.09.1791 - 25.08.1867.
Faraday discovered electromagnetic induction
and defined the basic layws of electrolysis,
among other things.
The unit of electrical capacitance is named after
him: 1 farad [F]= 1 C/V.

5. a), c), d)

4. c)

3. b)

2. a), c), d)

1. a), c)

Solutions

63

204

For internal use only. © VOLKSWAGEN AG, Wolfsburg

All rights reserved. Technical specifications subject to change without notice.

840.2810.23.20 Technical status: 07/98

❀

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