https://www.deylan.co.uk/golf/ecomatic/wiki/api.php?action=feedcontributions&user=Deylan&feedformat=atomGolf Ecomatic - User contributions [en-gb]2024-03-29T00:13:36ZUser contributionsMediaWiki 1.41.0https://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Brake_booster_vacuum_switch_(F190)&diff=123Brake booster vacuum switch (F190)2014-04-12T19:57:48Z<p>Deylan: /* Test procedure without diagnostic equipment */</p>
<hr />
<div>The brake booster vacuum switch (F190) informs the [[Digiswing]] control unit whether the pressure in the brake system is satisfactory.<br />
<br />
Type: open/closed<br />
Colour: Red<br />
<br />
Switch closed: below 0.7 bar (vacuum pressure too low). Measuring block status: "1"<br />
Switch open: above 0.7 bar (vacuum pressure OK). Measuring block status "0"<br />
<br />
If the switch closes (vacuum pressure too low), the engine is off, and the vehicle is moving, the engine is immediately restarted to restore vacuum to the brake circuit via the mechanical exhauster.<br />
<br />
If this switch is closed, the priority shift valve is closed and the clutch and brake circuits are separated, the engine will not switch off.<br />
<br />
== Test procedure without diagnostic equipment ==<br />
<br />
*Start engine and leave Ecomatic mode on<br />
*Find a slight downhill gradient or open stretch of road which is '''safe''' to carry out the procedure below. '''Important! If the vacuum switch is faulty you will need to push the brake pedal harder to stop the car!'''<br />
*Allow vehicle to start rolling down the gradient with engine off<br />
*Keep pressing brake pedal on and off.<br />
*As soon as the brake pedal starts to feel ever so slightly more harder to press, the engine should start up and restore brake vacuum.<br />
*If the brake pedal starts to feel much harder to press before the engine restarts, or the engine does not restart at all after servo assistance has gone, it is possible the switch is worn and is not operating at specification, or otherwise not working.<br />
<br />
== Part and ordering information ==<br />
<br />
Part number: 1H0 919 825<br />
<br />
== Additional information ==<br />
<br />
Incorrect information exists in the SSP regarding this switch. If this switch fails, engine control running lamp (K111) does not illuminate, however, the engine is still prevented from switching off.</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Golf_Ecomatic&diff=122Golf Ecomatic2014-01-10T23:00:54Z<p>Deylan: </p>
<hr />
<div>The Volkswagen Golf Ecomatic got its name from the words "Ecology" and "Automatic", and was produced late 1993 - mid 1994 with mention in press statements as early as 1992. It was ahead of it's time, and as a result was a sales failure with only approximately 4000 vehicles made. Ironically, stop-starts are now coming back in fashion, some not necessarily as good as the Ecomatic (I would say that wouldn't I?), and also are marketed as something new.<br />
<br />
If you type "Golf Ecomatic" into Google, not a lot comes up, aside from part numbers from VAGCAT and foreign online parts systems. There also isn't a lot of information about what they are anywhere, so I created this site is an attempt to inform people of what the Golf Ecomatic is and how it worked. Because I own three of them and also another Mk3, it is going to be a bit biased, so don't say you haven't been warned.<br />
<br />
== The principle ==<br />
<br />
The principle behind the Ecomatic came from the simple thought that an engine need not run if no power is needed. As soon as you lift off the accelerator, the clutch opens and the car freewheels to let it glide under its own motional energy for as far as possible, the engine then switches off after a further 1.5 seconds of inactivity to save fuel required for tickover. When you then press the accelerator, the engine restarts right away, the clutch then closes (smoothly) and takes up drive and off you go. This was pretty clever for 1994!<br />
<br />
Aside from the fuel saved when the engine is off, the freewheeling enables you to travel quite far distances in overrun as opposed to if the engine braking effect was occurring, it takes a lot of getting used, to get the best out of the freewheeling effect, as well as learn to use the brake more as the car tends to "run away", but once you have mastered it, you can start doing many "free" miles.<br />
<br />
== Brief design history and explanation ==<br />
<br />
VW decided that the most appropriate engine for the design was the 1Y diesel engine, straight forward, non-turbo diesel engine. According to the brochure, this engine was used because it was an almost instantaneous starter, as well as having a good fuel economy from a diesel engine (of course). Naturally, the car wouldn't have had much point if it was a petrol variety which offered less fuel economy than the diesel models.<br />
<br />
Automatic freewheeling and an engine switching off in motion couldn't be done with a conventional manual gearbox of course, so a manual gearbox with an automatic clutch was used (semi-automatic). A little odd as you would expect a fully automatic transmission, but the probable reason is that at the time the only automatic gearbox available was one based around the torque converter design, which wouldn't have given the car as good fuel economy, in addition to the fact that Volkswagen did not tend to fit their diesels with automatic gearboxes around that time.<br />
<br />
Modifications to the design to help pull this off involved a vacuum reservoir to provide a greater brake servo buffer, and a vacuum pump to provide vacuum to the clutch positioning valve (the vacuum system is actually quite clever, it works like this: it has a priority switching valve so that when the engine is running, the clutch vacuum is generated from the mechanical pump on the diesel engine for the brake servo, to take the wear off the vacuum pump motor, however when the engine is switched off, or when the door is opened, if the clutch vacuum is insufficient, the valve closes and the electric vacuum pump starts up to top up the clutch system, if the brake system runs out of vacuum reservoir, the engine is immediately restarted to top up the brake servo in a swift manner via the mechanical pump, the engine then provides vacuum for the brake system solely, and the electric vacuum pump has to provide vacuum to the clutch circuit, when the vacuum for the brake is restored, the valve then opens and things carry on as normal). In short, contrary to what some (including the brochure) say, the electric vacuum pump provides vacuum to the clutch system only. An electronic power steering pump to ensure steering is uninterrupted when the engine is off (there is no engine-driven pump), this pump switches on if the vehicle is moving, providing the ignition is on, an auxiliary coolant pump to keep hot water circulating round heater matrix (and engine) during switch off to ensure the blower continues to run without any heat drop-off on long periods of the engine switching off, this runs as long as the ignition is on. A larger battery to cope with long periods of switch off (92Ah), a more powerful than normal alternator (90 ampere), and an auxiliary battery (9Ah) to provide power to the lights (to ensure they do not dim), and other systems when the engine is being cranked, (and a control unit to manage the switching of batteries too).<br />
<br />
Along with various other sensors and control units to aid functioning of the systems.<br />
<br />
The heart of the system is the "digi-swing" (or DIGISWING) electronic control unit (under the water deflector, where the ECU normally is) which manages a lot of these systems, including clutch and engine management. The digi-swing controller masters the clutch operation via signals to the clutch positioner (with a fuzzy logic adaptation), switch off routine, outputs to the switches, control of the starter motor, and also has a pretty good self-diagnosis capability too. It suppresses the oil pressure and alternator warning lights when the engine is switched off. It even turns the engine on should the brake servo run out to top it up should you be going down a hill and exhaust the servo. And so it should - the point here was not a crude stop-start system to inconvenience the driver, but to make driving the car a seamless experience.<br />
<br />
The instrument cluster also has 3 additional lights: An orange "Ecomatic control lamp" to show when the Ecomatic is disabled (via the switch on the wiper stalk), this prevents the Ecomatic from freewheeling and also stops the engine turning off, you can use this at busy junctions or when you need the engine brake. A second orange "Gear display control lamp" which comes on to tell you when you should change up, and flashes when you must change down (this even takes into account throttle position, therefore if your foot is flat down the light won't come on as soon as it knows you require the lower gear), generally, this light only flashes as a reminder you are in a way too high gear, not really as an indication when you could do with changing down. The light also flashes if a gear is not properly engaged. The third is a green "Engine running control lamp" which comes on to tell you when the engine is not yet in a state to be switched on and off (it is too cold, or the battery voltage is too low, or a fault has been detected, such as the brake servo vacuum pressure is too low). It should be noted that the green lamp goes off after 1 or so minutes into the journey, so you benefit from the stop-start pretty quickly.<br />
<br />
The Ecomatic can be disabled by pushing a button on the wiper stalk, in this mode, the car does not freewheel when the accelerator is released, and the engine does not switch off -- you can also restart the engine by pushing this switch at anytime. In this mode, because the clutch is not opened when the accelerator pedal is released, a switch inside the gear lever is used to determine when you are trying to change gear, when this switch is activated, providing the accelerator pedal is released, the clutch is opened, and you can change gear, the clutch is then opened until the switch is released AND the gear monitoring switch is reporting the gear is correctly engaged. Therefore, when the Ecomatic is switched off, you must grab the gear lever in the "correct" position and move simultaneously as you release the accelerator, otherwise the clutch will not be opened. Of course, in normal operation, you don't notice any of this, but this is the technical workings of it.<br />
<br />
Whether the Ecomatic is on or off, the clutch is of course automatically opened when you are going at a speed which would cause the engine to stall, as like a normal driver would use the clutch, for example, you could come to a stop in 3rd gear, and the clutch will open as you come to a stop, the gear change indicator would flash, and the clutch would not close until either 1st or 2nd is selected (the digiswing unit is programmed to allow you to pull off from a stop in 1st or 2nd, the gearchange indicator lamp will flash in second as you do this to remind you that you are a berk however). In this manner, it is not possible to stall in an Ecomatic.<br />
<br />
All 3 lamps flash at the same time for 10 seconds if a fault is detected with the system, at minute intervals, then the green light comes on permanently to stop the engine switching off, freewheeling behaviour remains on.<br />
<br />
Driving the Ecomatic is fun, the freewheel allows you to coast for distances you never thought were possible, without using up *any* fuel, probably how the motor vehicle should have been designed in the first place. There is also a smug feeling you get from the car that the clutch is automatic, as well as the look from people when the engine starts and stops. As well as this, this car must have had hundreds of thousands of pounds invested in it, and for these reasons, you cannot help but love it.<br />
<br />
The Ecomatic from chassis number 1h-rp-491791 can run on Rapeseed Methyl Ester (RME) (biodiesel) corresponding to DIN 51606 (EN 14214). Check your dealership for further information.<br />
<br />
== Common problems ==<br />
=== Radio losing power / lights dimming when engine restarting ===<br />
<br />
If you car radio is losing electrical power when the engine is restarting, you need to replace your auxiliary battery! Mechanics do not know it is there! The battery costs around £25! It is easy to fit, the only thing that needs to be removed is the pipe from the air filter which is just two jubilee clips. <br />
<br />
== Operation Characteristics ==<br />
<br />
An initial start with the ignition key is required.<br />
<br />
The engine does not switch off until the coolant temperature has exceeded 40C, this usually takes 1-2 minutes. (Ecomatic mode is still on, as the car still freewheels).<br />
<br />
1st gear: Engine switches off if vehicle has been stopped and the accelerator pedal has not been operated within 5 seconds.<br />
<br />
2-5th gear: Engine switches off if accelerator has not been pressed for 1.5 seconds, any gear, any speed. Except if you have recently applied pressure to the gearlever (or changed gear) the control unit delays the engine turning off for an additional 5 seconds as it believes you are changing gear. If vehicle is stationary, engine will only restart by accelerator pedal if 1st gear is selected.<br />
<br />
Neutral: Engine switches off if gearlever switch has not been activated for 1.5 seconds; engine switches off regardless if you are pressing the accelerator.<br />
<br />
Reverse gear: Engine does not switch off, if engine is off and reverse is selected, engine immediately switches on.<br />
<br />
Driver's door is opened: Vacuum pump activates - if it appears to "run twice" a problem is present. Warning! If this is occurring there is danger the vacuum pump will burn out!<br />
<br />
Ignition on, engine off in Ecomatic mode with gear engaged, and the driver's door has been opened: Neutral must be briefly selected and 1st reselected before engine will restart.<br />
<br />
== Further information ==<br />
<br />
!!! Work in progress !!!</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Golf_Ecomatic:General_disclaimer&diff=121Golf Ecomatic:General disclaimer2014-01-10T22:53:20Z<p>Deylan: </p>
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<div>== Health and Safety ==<br />
<br />
'''The information contained here is for reference only, it is not necessarily accurate, therefore the writer and owner of the content assumes zero liability in how to use this information, or any damages that may come from it to you, your property, or others and others property. If you are uncertain at any point, refer to a qualified automotive technician.'''<br />
<br />
'''NEVER work on the car (i.e., on the engine) while a gear is engaged unless the key is out of the ignition and the car is completely off, and the handbrake is firmly applied. Even if the engine is switched off, it may just be in Ecomatic mode and could restart! If the clutch control unit is unplugged, vacuum pressure is lost, or a malfunction occurs, the clutch will close and the car can move off unintentionally!'''<br />
<br />
== About this Wiki ==<br />
<br />
This is a Wiki containing all the information about the Golf Ecomatic which is currently published on the Ecomatic forum.<br />
<br />
Technical accuracy is the main priority of the content of this wiki article and a fair amount of information on here can be backed up using official documentation.<br />
<br />
However, a large part of the information here has been only possible through many hours of close analysis of documents as well as close analysis of characteristics when driving on the road. This has resulted in more information being available about the car than has ever been published before, and in some cases, clarification where even official documentation is wrong. In any of these cases if not obvious it will be stated in the article.<br />
<br />
=== Technical Details ===<br />
<br />
This Wikipedia is powered by MediaWiki : http://www.mediawiki.org</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Main_Page&diff=120Main Page2014-01-10T22:50:19Z<p>Deylan: </p>
<hr />
<div>Welcome to the [[Golf Ecomatic]] [[Golf_Ecomatic:General_disclaimer|Wikipedia]]<br />
<br />
I am transitioning the list of articles which are on the Ecomatic Forum into Wiki articles on here to make them more accessible. I prefer the forum myself but whatever. For the moment, please treat the articles on the forum as the most authoritative source as they hold additional discussion as well as have pictures and diagrams, if I make any updates they go on the forum.<br />
<br />
== General Information ==<br />
*[[Golf Ecomatic]]<br />
<br />
== List of articles ==<br />
<br />
*[[Golf Ecomatic]]<br />
<br />
=== Engine/Ecomatic operation ===<br />
*[[Digiswing]]<br />
*[[Starter relay (J53)]]<br />
*[[Fuel shut-off valve (N109)]]<br />
*[[Reinforced starter motor]]<br />
*[[Tow starting]]<br />
<br />
=== Sensors/Switches ===<br />
*[[Brake light switch (F)]]<br />
*[[Door contact switch (F2)]]<br />
*[[Brake booster vacuum switch (F190)]]<br />
*[[Gear operating switch (F191)]]<br />
*[[Diesel engine stop switch (F207)]]<br />
*[[Gear display switch (F208)]]<br />
*[[Gear monitor switch (F209)]]<br />
*[[Pressure switch for clutch system F210]]<br />
*[[Load signal potentiometer (G157)]]<br />
*[[Clutch travel distance sender (G162)]]<br />
*[[Ecomatic switch (E163)]]<br />
*[[Road speed sender (G22)]]<br />
*[[Engine speed sender (G28)]]<br />
*[[Gearbox speed sender (G38)]]<br />
*[[Coolant temperature sender (G62)]]<br />
<br />
=== Vacuum/Clutch system ===<br />
*[[Console (Bracket for clutch positioner)]]<br />
*[[Clutch final control element]]<br />
*[[Mechanical vacuum pump]]<br />
*[[Vacuum reservoir]]<br />
*[[Vacuum pump relay (J318)]]<br />
*[[Electric vacuum pump (V22)]]<br />
*[[Clutch positioner vacuum valve (N183)]]<br />
*[[Clutch positioner discharge valve (N184)]]<br />
*[[Priority switch valve (N185)]]<br />
<br />
=== Electrical system ===<br />
*[[Power steering relay (J320)]]<br />
*[[Control unit for second battery and lights (J328)]]<br />
*[[Coolant pump (V50)]]<br />
*[[Power steering pump (V119)]]<br />
*[[Ecomatic instrument cluster]]<br />
*[[92Ah battery]]<br />
*[[9Ah auxiliary battery]]<br />
*[[90 ampere alternator]]<br />
<br />
=== Instrument cluster control lamps (in order of appearance on cluster) ===<br />
*Cooling system warning lamp<br />
*[[Ecomatic control lamp (K110)]]<br />
*[[Gear display control lamp (K48)]]<br />
*[[Engine running control lamp (K111)]]<br />
*[[Oil pressure control lamp (K3)]]<br />
*[[Alternator control lamp (K2)]]<br />
*Glow plug control lamp<br />
*Handbrake / brake fluid warning lamp</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Main_Page&diff=119Main Page2014-01-10T22:48:39Z<p>Deylan: </p>
<hr />
<div>Welcome to the [[Golf Ecomatic]] [[Golf_Ecomatic:General_disclaimer|Wikipedia]]<br />
<br />
I am transitioning the list of articles which are on the Ecomatic Forum into Wiki Articles on here to make them more accessible. I prefer the forum but whatever. For the moment, please treat the articles on the forum as the most authoritative source as they hold additional discussion as well as have pictures and diagrams, if I make any updates they go on the forum.<br />
<br />
== General Information ==<br />
*[[Golf Ecomatic]]<br />
<br />
== List of articles ==<br />
<br />
*[[Golf Ecomatic]]<br />
<br />
=== Engine/Ecomatic operation ===<br />
*[[Digiswing]]<br />
*[[Starter relay (J53)]]<br />
*[[Fuel shut-off valve (N109)]]<br />
*[[Reinforced starter motor]]<br />
*[[Tow starting]]<br />
<br />
=== Sensors/Switches ===<br />
*[[Brake light switch (F)]]<br />
*[[Door contact switch (F2)]]<br />
*[[Brake booster vacuum switch (F190)]]<br />
*[[Gear operating switch (F191)]]<br />
*[[Diesel engine stop switch (F207)]]<br />
*[[Gear display switch (F208)]]<br />
*[[Gear monitor switch (F209)]]<br />
*[[Pressure switch for clutch system F210]]<br />
*[[Load signal potentiometer (G157)]]<br />
*[[Clutch travel distance sender (G162)]]<br />
*[[Ecomatic switch (E163)]]<br />
*[[Road speed sender (G22)]]<br />
*[[Engine speed sender (G28)]]<br />
*[[Gearbox speed sender (G38)]]<br />
*[[Coolant temperature sender (G62)]]<br />
<br />
=== Vacuum/Clutch system ===<br />
*[[Console (Bracket for clutch positioner)]]<br />
*[[Clutch final control element]]<br />
*[[Mechanical vacuum pump]]<br />
*[[Vacuum reservoir]]<br />
*[[Vacuum pump relay (J318)]]<br />
*[[Electric vacuum pump (V22)]]<br />
*[[Clutch positioner vacuum valve (N183)]]<br />
*[[Clutch positioner discharge valve (N184)]]<br />
*[[Priority switch valve (N185)]]<br />
<br />
=== Electrical system ===<br />
*[[Power steering relay (J320)]]<br />
*[[Control unit for second battery and lights (J328)]]<br />
*[[Coolant pump (V50)]]<br />
*[[Power steering pump (V119)]]<br />
*[[Ecomatic instrument cluster]]<br />
*[[92Ah battery]]<br />
*[[9Ah auxiliary battery]]<br />
*[[90 ampere alternator]]<br />
<br />
=== Instrument cluster control lamps (in order of appearance on cluster) ===<br />
*Cooling system warning lamp<br />
*[[Ecomatic control lamp (K110)]]<br />
*[[Gear display control lamp (K48)]]<br />
*[[Engine running control lamp (K111)]]<br />
*[[Oil pressure control lamp (K3)]]<br />
*[[Alternator control lamp (K2)]]<br />
*Glow plug control lamp<br />
*Handbrake / brake fluid warning lamp</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=User:Deylan&diff=118User:Deylan2014-01-10T22:47:52Z<p>Deylan: </p>
<hr />
<div>These aren't the personal pages you're looking for.<br />
Move along now.</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Ecomatic_instrument_cluster&diff=117Ecomatic instrument cluster2012-12-23T14:03:36Z<p>Deylan: </p>
<hr />
<div>The Ecomatic instrument cluster is similar to the standard instrument cluster fitted to Mk3 Golfs. It is the analoge clock version (no rev counter).<br />
Despite not having a rev-counter, it does receive engine RPM signal. This is confirmed by the dash cluster diagnostics.<br />
If your instrument cluster loses power when the engine is restarting in ecomatic mode, you should try replacing your auxiliary battery.<br />
It has three additional lights:<br />
<br />
[k110] Ecomatic Control Lamp. <br />
*Light on <br />
**Engine Braking Mode enabled, Ecomatic mode off<br />
**engine does not turn off and car does not freewheel.<br />
<br />
[k48] Gear Display Control Lamp. <br />
*Light on<br />
**Uneconomical gear selected, gear too low, change up. <br />
*Light flashing<br />
**Too high gear or; <br />
**gear not properly engaged.<br />
<br />
[k111] Engine Running Control Lamp<br />
* Light on <br />
**Engine will not turn off - This may be because engine is too cold (most likely reason), battery voltage too low, fault detected with system.</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Ecomatic_instrument_cluster&diff=116Ecomatic instrument cluster2012-12-23T14:02:54Z<p>Deylan: </p>
<hr />
<div>The Ecomatic instrument cluster is similar to the standard instrument cluster fitted to Mk3 Golfs. It is the analoge clock version (no rev counter).<br />
Despite not having a rev-counter, it does receive engine RPM signal. This is confirmed by the dash cluster diagnostics.<br />
If your instrument cluster loses power when the engine is restarting in ecomatic mode, you should try replacing your auxiliary battery.<br />
It has three additional lights:<br />
<br />
[k110] Ecomatic Control Lamp. Light on = Engine Braking Mode enabled, Ecomatic mode off, engine does not turn off and car does not freewheel.<br />
<br />
[k48] Gear Display Control Lamp. <br />
*Light on<br />
**Uneconomical gear selected, gear too low, change up. <br />
*Light flashing<br />
**Too high gear or; <br />
**gear not properly engaged.<br />
<br />
[k111] Engine Running Control Lamp Light on = Engine will not turn off - This may be because engine is too cold (most likely reason), battery voltage too low, fault detected with system.</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Main_Page&diff=115Main Page2012-12-16T12:53:58Z<p>Deylan: </p>
<hr />
<div>Welcome to the [[Golf Ecomatic]] [[Golf_Ecomatic:General_disclaimer|Wikipedia]]<br />
<br />
I am transitioning the list of articles which are on the Ecomatic Forum into Wiki Articles on here to make them more accessible. However for the moment, please treat the articles on the forum as the most authoritative source as they hold additional discussion as well as have pictures and diagrams.<br />
<br />
== General Information ==<br />
*[[Golf Ecomatic]]<br />
<br />
== List of articles ==<br />
<br />
*[[Golf Ecomatic]]<br />
<br />
=== Engine/Ecomatic operation ===<br />
*[[Digiswing]]<br />
*[[Starter relay (J53)]]<br />
*[[Fuel shut-off valve (N109)]]<br />
*[[Reinforced starter motor]]<br />
*[[Tow starting]]<br />
<br />
=== Sensors/Switches ===<br />
*[[Brake light switch (F)]]<br />
*[[Door contact switch (F2)]]<br />
*[[Brake booster vacuum switch (F190)]]<br />
*[[Gear operating switch (F191)]]<br />
*[[Diesel engine stop switch (F207)]]<br />
*[[Gear display switch (F208)]]<br />
*[[Gear monitor switch (F209)]]<br />
*[[Pressure switch for clutch system F210]]<br />
*[[Load signal potentiometer (G157)]]<br />
*[[Clutch travel distance sender (G162)]]<br />
*[[Ecomatic switch (E163)]]<br />
*[[Road speed sender (G22)]]<br />
*[[Engine speed sender (G28)]]<br />
*[[Gearbox speed sender (G38)]]<br />
*[[Coolant temperature sender (G62)]]<br />
<br />
=== Vacuum/Clutch system ===<br />
*[[Console (Bracket for clutch positioner)]]<br />
*[[Clutch final control element]]<br />
*[[Mechanical vacuum pump]]<br />
*[[Vacuum reservoir]]<br />
*[[Vacuum pump relay (J318)]]<br />
*[[Electric vacuum pump (V22)]]<br />
*[[Clutch positioner vacuum valve (N183)]]<br />
*[[Clutch positioner discharge valve (N184)]]<br />
*[[Priority switch valve (N185)]]<br />
<br />
=== Electrical system ===<br />
*[[Power steering relay (J320)]]<br />
*[[Control unit for second battery and lights (J328)]]<br />
*[[Coolant pump (V50)]]<br />
*[[Power steering pump (V119)]]<br />
*[[Ecomatic instrument cluster]]<br />
*[[92Ah battery]]<br />
*[[9Ah auxiliary battery]]<br />
*[[90 ampere alternator]]<br />
<br />
=== Instrument cluster control lamps (in order of appearance on cluster) ===<br />
*Cooling system warning lamp<br />
*[[Ecomatic control lamp (K110)]]<br />
*[[Gear display control lamp (K48)]]<br />
*[[Engine running control lamp (K111)]]<br />
*[[Oil pressure control lamp (K3)]]<br />
*[[Alternator control lamp (K2)]]<br />
*Glow plug control lamp<br />
*Handbrake / brake fluid warning lamp</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Ecomatic_instrument_cluster&diff=114Ecomatic instrument cluster2012-12-16T12:48:36Z<p>Deylan: </p>
<hr />
<div>The Ecomatic instrument cluster is similar to the standard instrument cluster fitted to Mk3 Golfs. It is the analoge clock version (no rev counter).<br />
Despite not having a rev-counter, it does receive engine RPM signal. This is confirmed by the dash cluster diagnostics.<br />
If your instrument cluster loses power when the engine is restarting in ecomatic mode, you should try replacing your auxiliary battery.<br />
It has three additional lights:<br />
<br />
[k110] Ecomatic Control Lamp. Light on = Engine Braking Mode enabled, Ecomatic mode off, engine does not turn off and car does not freewheel.<br />
<br />
[k48] Gear Display Control Lamp. Light on = Uneconomical gear selected, gear too low, change up. Light flashing = Too high gear or gear not properly engaged.<br />
<br />
[k111] Engine Running Control Lamp Light on = Engine will not turn off - This may be because engine is too cold (most likely reason), battery voltage too low, fault detected with system.</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Alternator_control_lamp_(K2)&diff=113Alternator control lamp (K2)2012-12-16T12:46:24Z<p>Deylan: Created page with "This warning lamp is suppressed by the ECU when the engine is off to avoid it illuminating due to the engine being stopped."</p>
<hr />
<div>This warning lamp is suppressed by the ECU when the engine is off to avoid it illuminating due to the engine being stopped.</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Oil_pressure_control_lamp_(K3)&diff=112Oil pressure control lamp (K3)2012-12-16T12:46:09Z<p>Deylan: Created page with "This warning lamp is suppressed by the ECU when the engine is off to avoid it illuminating due to the engine being stopped."</p>
<hr />
<div>This warning lamp is suppressed by the ECU when the engine is off to avoid it illuminating due to the engine being stopped.</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Main_Page&diff=111Main Page2012-12-16T12:45:20Z<p>Deylan: </p>
<hr />
<div>Welcome to the [[Golf Ecomatic]] [[Golf_Ecomatic:General_disclaimer|Wikipedia]]<br />
<br />
== General Information ==<br />
*[[Golf Ecomatic]]<br />
<br />
== List of articles ==<br />
<br />
*[[Golf Ecomatic]]<br />
<br />
=== Engine/Ecomatic operation ===<br />
*[[Digiswing]]<br />
*[[Starter relay (J53)]]<br />
*[[Fuel shut-off valve (N109)]]<br />
*[[Reinforced starter motor]]<br />
*[[Tow starting]]<br />
<br />
=== Sensors/Switches ===<br />
*[[Brake light switch (F)]]<br />
*[[Door contact switch (F2)]]<br />
*[[Brake booster vacuum switch (F190)]]<br />
*[[Gear operating switch (F191)]]<br />
*[[Diesel engine stop switch (F207)]]<br />
*[[Gear display switch (F208)]]<br />
*[[Gear monitor switch (F209)]]<br />
*[[Pressure switch for clutch system F210]]<br />
*[[Load signal potentiometer (G157)]]<br />
*[[Clutch travel distance sender (G162)]]<br />
*[[Ecomatic switch (E163)]]<br />
*[[Road speed sender (G22)]]<br />
*[[Engine speed sender (G28)]]<br />
*[[Gearbox speed sender (G38)]]<br />
*[[Coolant temperature sender (G62)]]<br />
<br />
=== Vacuum/Clutch system ===<br />
*[[Console (Bracket for clutch positioner)]]<br />
*[[Clutch final control element]]<br />
*[[Mechanical vacuum pump]]<br />
*[[Vacuum reservoir]]<br />
*[[Vacuum pump relay (J318)]]<br />
*[[Electric vacuum pump (V22)]]<br />
*[[Clutch positioner vacuum valve (N183)]]<br />
*[[Clutch positioner discharge valve (N184)]]<br />
*[[Priority switch valve (N185)]]<br />
<br />
=== Electrical system ===<br />
*[[Power steering relay (J320)]]<br />
*[[Control unit for second battery and lights (J328)]]<br />
*[[Coolant pump (V50)]]<br />
*[[Power steering pump (V119)]]<br />
*[[Ecomatic instrument cluster]]<br />
*[[92Ah battery]]<br />
*[[9Ah auxiliary battery]]<br />
*[[90 ampere alternator]]<br />
<br />
=== Instrument cluster control lamps (in order of appearance on cluster) ===<br />
*Cooling system warning lamp<br />
*[[Ecomatic control lamp (K110)]]<br />
*[[Gear display control lamp (K48)]]<br />
*[[Engine running control lamp (K111)]]<br />
*[[Oil pressure control lamp (K3)]]<br />
*[[Alternator control lamp (K2)]]<br />
*Glow plug control lamp<br />
*Handbrake / brake fluid warning lamp</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=92Ah_battery&diff=11092Ah battery2012-12-15T21:23:08Z<p>Deylan: </p>
<hr />
<div>Larger battery than standard vehicle, largest battery out of the whole Mk3 range.<br />
<br />
== Technical details ==<br />
<br />
In the SSP the battery size is specified as 92Ah.<br />
In the SSP the battery size is specified as 95Ah.<br />
<br />
== Part and ordering information ==<br />
<br />
Original part number: 000 915 105 AH (95Ah 450A) (dropped)<br />
Replacement part number: 000 915 105 DK<br />
<br />
Varta sell OEM equivalents (Varta Silver and Ultra/Stop-Start recommended). The genuine battery is made by Varta anyway.<br />
<br />
== Additional information ==<br />
<br />
It is important the Ecomatic is fitted with a large and good quality battery with good CCA (cold cranking amps) to ensure the [[Reinforced starter motor|starter motor] restarts the engine quickly, and reduce strain on the [[90 ampere alternator|alternator]] and electrical consumers, the cost of replacing electronics damaged by voltage fluctuation far exceeds the extra for a good battery, the battery should also be able to take the strain from the large amount of engine starts.<br />
<br />
A poorly performing battery can result in oddities with the engine restarting procedure, such as, if the engine has been off for a while, a restart can be unsuccessful or take more than one attempt.<br />
<br />
== Push starting ==<br />
<br />
The Ecomatic can be [[Tow starting|push started]].</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=92Ah_battery&diff=10992Ah battery2012-12-15T21:22:57Z<p>Deylan: </p>
<hr />
<div>Larger battery than standard vehicle, largest battery out of the whole Mk3 range.<br />
<br />
== Technical details ==<br />
<br />
In the SSP the battery size is specified as 92Ah.<br />
In the SSP the battery size is specified as 95Ah.<br />
<br />
== Part and ordering information ==<br />
<br />
Original part number: 000 915 105 AH (95Ah 450A) (dropped)<br />
Replacement part number: 000 915 105 DK<br />
<br />
Varta sell OEM equivalents (Varta Silver and Ultra/Stop-Start recommended). The genuine battery is made by Varta anyway.<br />
<br />
== Additional information ==<br />
<br />
It is important the Ecomatic is fitted with a large and good quality battery with good CCA (cold cranking amps) to ensure the [[Reinforced starter motor|starter motor] restarts the engine quickly, and reduce strain on the [[90 ampere alternator|alternator]] and electrical consumers, the cost of replacing electronics damaged by voltage fluctuation far exceeds the extra for a good battery, the battery should also be able to take the strain from the large amount of engine starts.<br />
<br />
A poorly performing battery can result in oddities with the engine restarting procedure, such as, if the engine has been off for a while, a restart can be unsuccessful or take more than one attempt.<br />
<br />
== Tow starting ==<br />
<br />
The Ecomatic can be [[Tow starting|push started]].</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=92Ah_battery&diff=10892Ah battery2012-12-15T21:22:01Z<p>Deylan: </p>
<hr />
<div>Larger battery than standard vehicle, largest battery out of the whole Mk3 range.<br />
<br />
In the SSP the battery size is specified as 92Ah.<br />
In the SSP the battery size is specified as 95Ah.<br />
<br />
Original part number: 000 915 105 AH (95Ah 450A) (dropped)<br />
Replacement part number: 000 915 105 DK<br />
<br />
Varta sell OEM equivalents (Varta Silver and Ultra/Stop-Start recommended). The genuine battery is made by Varta anyway.<br />
<br />
It is important the Ecomatic is fitted with a large and good quality battery with good CCA (cold cranking amps) to ensure the [[Reinforced starter motor|starter motor] restarts the engine quickly, and reduce strain on the [[90 ampere alternator|alternator]] and electrical consumers, the cost of replacing electronics damaged by voltage fluctuation far exceeds the extra for a good battery, the battery should also be able to take the strain from the large amount of engine starts.<br />
<br />
A poorly performing battery can result in oddities with the engine restarting procedure, such as, if the engine has been off for a while, a restart can be unsuccessful or take more than one attempt.<br />
<br />
The Ecomatic can be [[Tow starting|push started]].</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=95Ah_battery&diff=10795Ah battery2012-12-15T21:21:24Z<p>Deylan: Redirected page to 92Ah battery</p>
<hr />
<div>#REDIRECT [[92Ah battery]]</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=92Ah_battery&diff=10692Ah battery2012-12-15T21:21:07Z<p>Deylan: </p>
<hr />
<div>Larger battery than standard vehicle, largest battery out of the whole Mk3 range.<br />
<br />
Original part number: 000 915 105 AH (95Ah 450A) (dropped)<br />
Replacement part number: 000 915 105 DK<br />
<br />
Varta sell OEM equivalents (Varta Silver and Ultra/Stop-Start recommended). The genuine battery is made by Varta anyway.<br />
<br />
It is important the Ecomatic is fitted with a large and good quality battery with good CCA (cold cranking amps) to ensure the [[Reinforced starter motor|starter motor] restarts the engine quickly, and reduce strain on the [[90 ampere alternator|alternator]] and electrical consumers, the cost of replacing electronics damaged by voltage fluctuation far exceeds the extra for a good battery, the battery should also be able to take the strain from the large amount of engine starts.<br />
<br />
A poorly performing battery can result in oddities with the engine restarting procedure, such as, if the engine has been off for a while, a restart can be unsuccessful or take more than one attempt.<br />
<br />
The Ecomatic can be [[Tow starting|push started]].</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Main_Page&diff=105Main Page2012-12-15T21:18:59Z<p>Deylan: </p>
<hr />
<div>Welcome to the [[Golf Ecomatic]] [[Golf_Ecomatic:General_disclaimer|Wikipedia]]<br />
<br />
== General Information ==<br />
*[[Golf Ecomatic]]<br />
<br />
== List of articles ==<br />
<br />
*[[Golf Ecomatic]]<br />
<br />
=== Engine/Ecomatic operation ===<br />
*[[Digiswing]]<br />
*[[Starter relay (J53)]]<br />
*[[Fuel shut-off valve (N109)]]<br />
*[[Reinforced starter motor]]<br />
*[[Tow starting]]<br />
<br />
=== Sensors/Switches ===<br />
*[[Brake light switch (F)]]<br />
*[[Door contact switch (F2)]]<br />
*[[Brake booster vacuum switch (F190)]]<br />
*[[Gear operating switch (F191)]]<br />
*[[Diesel engine stop switch (F207)]]<br />
*[[Gear display switch (F208)]]<br />
*[[Gear monitor switch (F209)]]<br />
*[[Pressure switch for clutch system F210]]<br />
*[[Load signal potentiometer (G157)]]<br />
*[[Clutch travel distance sender (G162)]]<br />
*[[Ecomatic switch (E163)]]<br />
*[[Road speed sender (G22)]]<br />
*[[Engine speed sender (G28)]]<br />
*[[Gearbox speed sender (G38)]]<br />
*[[Coolant temperature sender (G62)]]<br />
<br />
=== Vacuum/Clutch system ===<br />
*[[Console (Bracket for clutch positioner)]]<br />
*[[Clutch final control element]]<br />
*[[Mechanical vacuum pump]]<br />
*[[Vacuum reservoir]]<br />
*[[Vacuum pump relay (J318)]]<br />
*[[Electric vacuum pump (V22)]]<br />
*[[Clutch positioner vacuum valve (N183)]]<br />
*[[Clutch positioner discharge valve (N184)]]<br />
*[[Priority switch valve (N185)]]<br />
<br />
=== Electrical system ===<br />
*[[Power steering relay (J320)]]<br />
*[[Control unit for second battery and lights (J328)]]<br />
*[[Coolant pump (V50)]]<br />
*[[Power steering pump (V119)]]<br />
*[[Ecomatic instrument cluster]]<br />
*[[92Ah battery]]<br />
*[[9Ah auxiliary battery]]<br />
*[[90 ampere alternator]]<br />
<br />
=== Instrument cluster control lamps (in order of appearance on cluster) ===<br />
*Cooling system warning lamp<br />
*[[Ecomatic control lamp (K110)]]<br />
*[[Gear display control lamp (K48)]]<br />
*[[Engine running control lamp (K111)]]<br />
*Oil pressure warning lamp<br />
*Charging system warning lamp<br />
*Glow plug control lamp<br />
*Handbrake / brake fluid warning lamp</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Tow_starting&diff=104Tow starting2012-12-15T21:16:14Z<p>Deylan: </p>
<hr />
<div>An [[Ecomatic]] can be tow/push started.<br />
<br />
== Prerequisites ==<br />
<br />
*Battery has sufficient power to operate [[Digiswing|ECU]], [[Electric vacuum pump (V22)|electric vacuum pump]] (to create vacuum), and the [[Clutch final control element|clutch final control element]], as well as operate the glow plugs (if the engine is very cold).<br />
*Vacuum system pressure OK and functional.<br />
<br />
For example, it is possible the [[92Ah battery|battery]] is too flat to start the engine, however it still has sufficient power to generate vacuum and operate the clutch. Or, the battery is fine and the [[Reinforced starter motor|starter motor]] has failed.<br />
<br />
== Procedure ==<br />
<br />
*Two or more people are required. Continue only if it is safe to do so.<br />
*Select neutral<br />
*Turn ignition on, but do not attempt to start the engine.<br />
*Get the vehicle to an appreciable speed.<br />
*Once vehicle has picked up sufficient speed, select 2nd gear and release gearstick immediately.<br />
*The clutch will close automatically and the vehicle will attempt to start the engine using the momentum of the car, at this point, accelerate slightly.<br />
*The clutch should re-open to prevent stalling.<br />
*Turn on engine brake mode to prevent engine switching off.<br />
<br />
== Remedial Measures ==<br />
<br />
If battery is faulty, replace with a [[92Ah battery|correct replacement without delay.]]<br />
<br />
If the starter is faulty, use the [[Reinforced starter motor|correct replacement]].</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Main_Page&diff=103Main Page2012-12-15T21:10:30Z<p>Deylan: </p>
<hr />
<div>Welcome to the [[Golf Ecomatic]] [[Golf_Ecomatic:General_disclaimer|Wikipedia]]<br />
<br />
== General Information ==<br />
*[[Golf Ecomatic]]<br />
<br />
== List of articles ==<br />
<br />
*[[Golf Ecomatic]]<br />
<br />
=== Engine/Ecomatic operation ===<br />
*[[Digiswing]]<br />
*[[Starter relay (J53)]]<br />
*[[Fuel shut-off valve (N109)]]<br />
*[[Reinforced starter motor]]<br />
*[[Tow starting]]<br />
<br />
=== Sensors/Switches ===<br />
*[[Brake light switch (F)]]<br />
*[[Door contact switch (F2)]]<br />
*[[Brake booster vacuum switch (F190)]]<br />
*[[Gear operating switch (F191)]]<br />
*[[Diesel engine stop switch (F207)]]<br />
*[[Gear display switch (F208)]]<br />
*[[Gear monitor switch (F209)]]<br />
*[[Pressure switch for clutch system F210]]<br />
*[[Load signal potentiometer (G157)]]<br />
*[[Clutch travel distance sender (G162)]]<br />
*[[Ecomatic switch (E163)]]<br />
*[[Road speed sender (G22)]]<br />
*[[Engine speed sender (G28)]]<br />
*[[Gearbox speed sender (G38)]]<br />
*[[Coolant temperature sender (G62)]]<br />
<br />
=== Vacuum/Clutch system ===<br />
*[[Console (Bracket for clutch positioner)]]<br />
*[[Clutch final control element]]<br />
*[[Mechanical vacuum pump]]<br />
*[[Vacuum reservoir]]<br />
*[[Vacuum pump relay (J318)]]<br />
*[[Electric vacuum pump (V22)]]<br />
*[[Clutch positioner vacuum valve (N183)]]<br />
*[[Clutch positioner discharge valve (N184)]]<br />
*[[Priority switch valve (N185)]]<br />
<br />
=== Electrical system ===<br />
*[[Coolant pump (V50)]]<br />
*[[92Ah battery]]<br />
*[[Ecomatic instrument cluster]]<br />
*[[Power steering pump (V119)]]<br />
*[[9Ah auxiliary battery]]<br />
*[[90 ampere alternator]]<br />
*[[Control unit for second battery and lights (J328)]]<br />
*[[Power steering relay (J320)]]<br />
<br />
=== Instrument cluster control lamps ===<br />
*Cooling system warning lamp<br />
*[[Gear display control lamp (K48)]]<br />
*[[Ecomatic control lamp (K110)]]<br />
*[[Engine running control lamp (K111)]]<br />
*Oil pressure warning lamp<br />
*Charging system warning lamp<br />
*Glow plug control lamp<br />
*Handbrake / brake fluid warning lamp</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Gear_display_control_lamp_(K48)&diff=102Gear display control lamp (K48)2012-12-15T21:06:32Z<p>Deylan: Created page with "The gear display control lamp is the light that illuminates on the instrument cluster to warn you about an incorrect gear selection. It will flash if you are in too high gear..."</p>
<hr />
<div>The gear display control lamp is the light that illuminates on the instrument cluster to warn you about an incorrect gear selection.<br />
<br />
It will flash if you are in too high gear.<br />
<br />
It will illuminate solid if you should change up.</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Ecomatic_control_lamp_(K110)&diff=101Ecomatic control lamp (K110)2012-12-15T21:04:12Z<p>Deylan: Created page with "The Ecomatic control lamp (K110) is the orange lamp that illuminates on the instrument cluster to indicate that Ecomatic mode has been disabled and thus the engine will not tu..."</p>
<hr />
<div>The Ecomatic control lamp (K110) is the orange lamp that illuminates on the instrument cluster to indicate that Ecomatic mode has been disabled and thus the engine will not turn off and will not freewheel.<br />
<br />
The symbol is of the standard "car engine" with a handbrake symbol over the top right of it.<br />
<br />
See http://deylan.co.uk/golf/ecomatic/bbs/images/smilies/ecomatic%20control%20lamp%20k110.jpg</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Engine_running_control_lamp_(K111)&diff=100Engine running control lamp (K111)2012-12-15T21:00:46Z<p>Deylan: Created page with "The Engine running control lamp (K111) is the green lamp that illuminates on the instrument cluster to indicate that the engine will not turn itself off. It is also sometimes..."</p>
<hr />
<div>The Engine running control lamp (K111) is the green lamp that illuminates on the instrument cluster to indicate that the engine will not turn itself off.<br />
<br />
It is also sometimes called the "Ecomatic automatic override warning lamp"<br />
<br />
In certain circumstances (usually under fault conditions), the engine will not turn itself off however this lamp does not illuminate. There is no official name for this state therefore on here it has been coined "silent ecomatic automatic override".</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Coolant_pump_(V50)&diff=99Coolant pump (V50)2012-12-15T20:52:50Z<p>Deylan: </p>
<hr />
<div>The coolant pump V50 is electrically powered and is operated when the ignition is switched on, its function is to continue circulating water around the engine/heater matrix when the engine is switched off, so that the heater output does not drop-off. Not only this, it ensures that there is no localized overheating in the engine block (or elsewhere) or large temperature deviations in the coolant system when the engine switches off in Ecomatic operation by ensuring the coolant is still circulated around, therefore, it is sensible to fix this if yours is non-operational not only for comfort but for long-term engine and cooling system reliability.<br />
<br />
The 2-pin connector as well as connection pins are notorious for corrosion on this water pump, disconnect the connector and spray with electrical contact cleaner.<br />
<br />
This pump can be replaced without having to remove anything other than the pump itself, the rubber mountings can also be installed correctly into the clutch positioner console bracket from underneath the car using angled and straight pin-nose pliers if they have popped out, it is not necessary to remove the clutch positioner console bracket to re-install them correctly.<br />
<br />
Original part number: 251 965 561 A / 251965561A<br />
Replacement part number: 251 965 561 B / 251965561B (slightly different pump)<br />
<br />
The pump is made by Bosch and can be sourced directly from them or relevant suppliers, which may cost less than the main dealer price.<br />
<br />
In the UK, http://www.vwspares.co.uk sell this pump for an incredibly low price.<br />
<br />
== Testing procedure ==<br />
<br />
=== Test 1 ===<br />
<br />
Turn ignition on, but do not start engine, listen to pump and squeeze pipes leading into it, if no noise can be heard and no vibrations felt, it has probably failed, go to test 2.<br />
<br />
=== Test 2 ===<br />
<br />
#Engine is warmed up<br />
#Ecomatic mode switched on<br />
#Turn temperature dial to hot<br />
#Switch fan speed to 2<br />
#Switch vent direction to face<br />
#Allow engine to switch off via Ecomatic operation.<br />
#If heat output starts to drop off in 30 seconds or less with engine off, restart the engine, if heat comes back, then the electric coolant pump has almost definitely failed.</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Digiswing&diff=98Digiswing2012-12-15T20:27:07Z<p>Deylan: </p>
<hr />
<div>'''Digiswing/Ecomatic Control Unit J327'''<br />
<br />
Digiswing is the Ecomatic Control Unit and is an Engine and Clutch Management System. By definition it is a Powertrain Control Module (PCM) which controls the clutch operation and engine switch-off and start-up routine based on operating status and sensor input. It is located under the raintray, where the ECU normally is on other Mk3 models.<br />
<br />
== Onboard functions ==<br />
<br />
Battery voltage measurement - disables Ecomatic operation if battery voltage is too low, green light (engine running control lamp K111) illuminates.<br />
<br />
Fault recognition - recognises faults based on sensor input both by plausibility and electrically, disables Ecomatic and/or engine switch-off operation, all 3 warning lamps flash for 10 seconds, green and/or orange light then stays lit depending on fault.<br />
<br />
Fault tolerance -Various emergency running programmes and substitution of sensor data based on predetermined values and from other sensors in case of sensor/mechanical failure.<br />
<br />
Self-diagnostics - To access: Clutch electronics (12).<br />
<br />
Warning lamp suppression - suppresses warning lamps K3 (oil pressure) and K2 (alternator) during engine off phase.<br />
<br />
Gear change notification - illuminates orange light (gear display control lamp K48) [k48] when an upshift should take place, flashes orange light when a downshift should take place. This is a non-linear calculation based upon current gear selected and load signal potentiometer position.<br />
<br />
Self-learning capability - Adapts to change in components through age/adjustment.<br />
<br />
== Clutch operation strategy ==<br />
<br />
The clutch operation strategy and how it is accomplished is somewhat interesting because of the semi-automatic gearbox used in the design. Because the accelerator pedal and gearstick is operated by the driver, the clutch system has to adapt quickly and appropriately according to what the driver is doing. Various sensors are employed in the design so that the control unit has information about the current driving situation. This is accomplished very well for a car of it's time and is dynamic in it's principle of operation. For example, slamming the accelerator pedal down will cause the clutch to close quicker, to avoid excessive clutch wear, whereas light throttle will allow clutch slippage, just like a driver would do in a conventional manual gearbox. It is likely that it contains a default mapping of clutch operation and that other sensors contain a weighting to adjust the operation from the default values.<br />
<br />
== Engine start procedure ==<br />
<br />
Aside from the obvious logic used to restart the engine, the control unit uses several routines/algorithms to ensure a reliable and smooth starting procedure which may go unnoticed by the average driver.<br />
<br />
*If an engine start is called* immediately after the engine has just entered the overrun/stopped phase, two things may happen depending on the operational conditions.<br />
**If an engine startup call occurs, and the engine has only just entered the stopping phase (RPM dropping towards 0 from idle) (i.e., within less than a second of the ECU deciding to stop the engine) the ECU de-energises the fuel cutoff solenoid allowing fuel into the engine initially to prevent the engine from completely stopping, in some instances, the engine will return to idle without the use of the starter motor. This has the effect of immediately bringing the engine back to life.<br />
**If the engine speed is too low to start from the procedure above, an extremely small delay occurs (less than a 1s) before energizing the starter relay, this would prevent, for example, the starter motor trying to engage into the flywheel when it is still spinning.<br />
<br />
*When output to the [[starter relay (J53)]] is activated to restart the engine, the engine speed is monitored, if the engine remains stopped after approx. 3-4 seconds (for example, the starter motor has not engaged properly into the flywheel), the power to the relay is interrupted for approximately 1.5 seconds and then another attempt is made to start the engine. This process appears to continue indefinitely until the ECU receives a RPM signal greater than the predefined** amount indicating the engine has successfully started.<br />
<br />
== Additional information ==<br />
<br />
I have found that the accelerator pedal position threshold to restart the engine is higher (in percentage terms) in 2nd gear and above compared to 1st gear. In other words, you need to depress the accelerator pedal down less in 1st gear for the engine to restart, than you do in other gears. In certain circumstances (if the load signal potentiometer is out of adjustment, or basic setting is required) it is actually possible that the engine will switch off correctly in gears 2nd-5th, however, the engine will not switch off at all in 1st gear, and if 1st gear is selected, the engine will restart. Presumably, this is intended so that in higher gears, if a driver is "dithering", the engine will not cut out, or in, inappropriately. In addition, this is because the engine speed sender information can be used to determine what is going on while driving along.<br />
<br />
The Ecomatic should not behave like an automatic, if the vehicle creeps along in 1st gear, something is out of adjustment!<br />
<br />
== Part numbers ==<br />
<br />
1H0 927 303 / 1H0927303 - Original ECU fitted to early Ecomatics.<br />
<br />
1H0 927 303 A / 1H0927303A (this modified control unit now moves the clutch lever up or down slightly (approx. 3mm) every 10 seconds when the engine is switched off and ignition is on, this changes the diagnostic procedure required to find out whether there is a leak in the system, or if the clutch final control element is faulty. The noise emitted by the clutch control element can sound somewhat "scratchy" and is not a cause for concern. It is not known what other changes were made. It is possible that the clutch control algorithms were changed slightly to allow trailer towing as early instruction manuals did not permit trailer towing, however later did. One could also speculate that other improvements to the engine and clutch operation were made from driver feedback once the car was "out in the field".)<br />
<br />
1H0 927 303 B / 1H0927303B (unknown what revisions were made, this part was *never* available on parts catalogues. If it was, it was most likely for a very short period around 1995.)<br />
<br />
1H0 927 303 E / 1H0927303E (discontinued 2010 - no replacement available).<br />
<br />
It is not known what (if any) changes were made to B and E revisions, nor what happened to C and D.<br />
<br />
== Effects of failure ==<br />
Vehicle is not operational.<br />
<br />
== Footnotes == <br />
*Engine start call describes situation where engine has gone into the overrun phase and is called to restart, such as the accelerator pedal being depressed, engine-brake button pressed, gear stick movement, reverse selected, vacuum pressure too low.<br />
*The actual RPM threshold used to indicate that the engine has started internally to the control unit and thus to de-energise the starter relay is not known, but would suspect it is in the region of 300-400RPM, accompanied by a very brief static timing element to ensure the engine has started properly.</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Golf_Ecomatic&diff=97Golf Ecomatic2012-12-15T17:51:41Z<p>Deylan: </p>
<hr />
<div>The Volkswagen Golf Ecomatic got its name from the words "Ecology" and "Automatic", and was produced late 1993 - mid 1994 with mention in press statements as early as 1992. It was ahead of it's time, and as a result was a sales failure with only approximately 4000 vehicles made. Ironically, stop-starts are now coming back in fashion, some not necessarily as good as the Ecomatic, and also are marketed as something new.<br />
<br />
So if you type "Golf Ecomatic" into Google, not a lot comes up, aside from part numbers from VAGCAT (which is down yet again, for goodness sake!) and foreign online parts systems. There also isn't a lot of information about what they are anywhere, so this site is an attempt to inform people of what the Golf Ecomatic is and how it worked. Because I own three of them and also another Mk3, it is going to be a bit biased, so don't say you haven't been warned.<br />
<br />
The Ecomatic from chassis number 1h-rp-491791 can run on Rapeseed Methyl Ester (RME) (biodiesel) corresponding to DIN 51606 (EN 14214). Check your dealership for further information.<br />
<br />
== The principle ==<br />
<br />
The principle behind the Ecomatic came from the simple thought that an engine need not run if no power is needed. As soon as you lift off the accelerator, the clutch opens and the car freewheels to let it glide under its own motional energy for as far as possible, the engine then switches off after a further 1.5 seconds of inactivity to save fuel required for tickover. When you then press the accelerator, the engine restarts right away, the clutch then closes (smoothly) and takes up drive and off you go. This was pretty clever for 1994!<br />
<br />
Aside from the fuel saved when the engine is off, the freewheeling enables you to travel quite far distances in overrun as opposed to if the engine braking effect was occurring, it takes a lot of getting used, to get the best out of the freewheeling effect, as well as learn to use the brake more as the car tends to "run away", but once you have mastered it, you can start doing many "free" miles.<br />
<br />
== Brief design history and explanation ==<br />
<br />
VW decided that the most appropriate engine for the design was the 1Y diesel engine, straight forward, non-turbo diesel engine. According to the brochure, this engine was used because it was an almost instantaneous starter, as well as having a good fuel economy from a diesel engine (of course). Naturally, the car wouldn't have had much point if it was a petrol variety which offered less fuel economy than the diesel models.<br />
<br />
Automatic freewheeling and an engine switching off in motion couldn't be done with a conventional manual gearbox of course, so a manual gearbox with an automatic clutch was used (semi-automatic). A little odd as you would expect a fully automatic transmission, but the probable reason is that at the time the only automatic gearbox available was one based around the torque converter design, which wouldn't have given the car as good fuel economy, in addition to the fact that Volkswagen did not tend to fit their diesels with automatic gearboxes around that time.<br />
<br />
Modifications to the design to help pull this off involved a vacuum reservoir to provide a greater brake servo buffer, and a vacuum pump to provide vacuum to the clutch positioning valve (the vacuum system is actually quite clever, it works like this: it has a priority switching valve so that when the engine is running, the clutch vacuum is generated from the mechanical pump on the diesel engine for the brake servo, to take the wear off the vacuum pump motor, however when the engine is switched off, or when the door is opened, if the clutch vacuum is insufficient, the valve closes and the electric vacuum pump starts up to top up the clutch system, if the brake system runs out of vacuum reservoir, the engine is immediately restarted to top up the brake servo in a swift manner via the mechanical pump, the engine then provides vacuum for the brake system solely, and the electric vacuum pump has to provide vacuum to the clutch circuit, when the vacuum for the brake is restored, the valve then opens and things carry on as normal). In short, contrary to what some (including the brochure) say, the electric vacuum pump provides vacuum to the clutch system only. An electronic power steering pump to ensure steering is uninterrupted when the engine is off (there is no engine-driven pump), this pump switches on if the vehicle is moving, providing the ignition is on, an auxiliary coolant pump to keep hot water circulating round heater matrix (and engine) during switch off to ensure the blower continues to run without any heat drop-off on long periods of the engine switching off, this runs as long as the ignition is on. A larger battery to cope with long periods of switch off (92Ah), a more powerful than normal alternator (90 ampere), and an auxiliary battery (9Ah) to provide power to the lights (to ensure they do not dim), and other systems when the engine is being cranked, (and a control unit to manage the switching of batteries too).<br />
<br />
Along with various other sensors and control units to aid functioning of the systems.<br />
<br />
The heart of the system is the "digi-swing" (or DIGISWING) electronic control unit (under the water deflector, where the ECU normally is) which manages a lot of these systems, including clutch and engine management. The digi-swing controller masters the clutch operation via signals to the clutch positioner (with a fuzzy logic adaptation), switch off routine, outputs to the switches, control of the starter motor, and also has a pretty good self-diagnosis capability too. It suppresses the oil pressure and alternator warning lights when the engine is switched off. It even turns the engine on should the brake servo run out to top it up should you be going down a hill and exhaust the servo. And so it should - the point here was not a crude stop-start system to inconvenience the driver, but to make driving the car a seamless experience.<br />
<br />
The instrument cluster also has 3 additional lights: An orange "Ecomatic control lamp" to show when the Ecomatic is disabled (via the switch on the wiper stalk), this prevents the Ecomatic from freewheeling and also stops the engine turning off, you can use this at busy junctions or when you need the engine brake. A second orange "Gear display control lamp" which comes on to tell you when you should change up, and flashes when you must change down (this even takes into account throttle position, therefore if your foot is flat down the light won't come on as soon as it knows you require the lower gear), generally, this light only flashes as a reminder you are in a way too high gear, not really as an indication when you could do with changing down. The light also flashes if a gear is not properly engaged. The third is a green "Engine running control lamp" which comes on to tell you when the engine is not yet in a state to be switched on and off (it is too cold, or the battery voltage is too low, or a fault has been detected, such as the brake servo vacuum pressure is too low). It should be noted that the green lamp goes off after 1 or so minutes into the journey, so you benefit from the stop-start pretty quickly.<br />
<br />
The Ecomatic can be disabled by pushing a button on the wiper stalk, in this mode, the car does not freewheel when the accelerator is released, and the engine does not switch off -- you can also restart the engine by pushing this switch at anytime. In this mode, because the clutch is not opened when the accelerator pedal is released, a switch inside the gear lever is used to determine when you are trying to change gear, when this switch is activated, providing the accelerator pedal is released, the clutch is opened, and you can change gear, the clutch is then opened until the switch is released AND the gear monitoring switch is reporting the gear is correctly engaged. Therefore, when the Ecomatic is switched off, you must grab the gear lever in the "correct" position and move simultaneously as you release the accelerator, otherwise the clutch will not be opened. Of course, in normal operation, you don't notice any of this, but this is the technical workings of it.<br />
<br />
Whether the Ecomatic is on or off, the clutch is of course automatically opened when you are going at a speed which would cause the engine to stall, as like a normal driver would use the clutch, for example, you could come to a stop in 3rd gear, and the clutch will open as you come to a stop, the gear change indicator would flash, and the clutch would not close until either 1st or 2nd is selected (the digiswing unit is programmed to allow you to pull off from a stop in 1st or 2nd, the gearchange indicator lamp will flash in second as you do this to remind you that you are a berk however). In this manner, it is not possible to stall in an Ecomatic.<br />
<br />
All 3 lamps flash at the same time for 10 seconds if a fault is detected with the system, at minute intervals, then the green light comes on permanently to stop the engine switching off, freewheeling behaviour remains on.<br />
<br />
Driving the Ecomatic is fun, the freewheel allows you to coast for distances you never thought were possible, without using up *any* fuel, probably how the motor vehicle should have been designed in the first place. There is also a smug feeling you get from the car that the clutch is automatic, as well as the look from people when the engine starts and stops. As well as this, this car must have had hundreds of thousands of pounds invested in it, and for these reasons, you cannot help but love it.<br />
<br />
== Common problems ==<br />
=== Radio losing power and lights dimming on restart ===<br />
<br />
If your car radio is losing power when the engine is restarting, it is very likely you need to replace your auxiliary battery! Mechanics do not know it is there! The battery costs around £50 - £55 from the dealer, but an OEM equivalent will only set you back around £25! It is easy to fit, the only thing that needs to be removed is the pipe from the air filter.<br />
<br />
== Operation Characteristics ==<br />
<br />
An initial start with the ignition key is required.<br />
<br />
The engine does not switch off until the coolant temperature has exceeded 40C, this usually takes 1-2 minutes. (Ecomatic mode is still on, as the car still freewheels).<br />
<br />
1st gear: Engine switches off if vehicle has been stopped and the accelerator pedal has not been operated within 5 seconds.<br />
<br />
2-5th gear: Engine switches off if accelerator has not been pressed for 1.5 seconds, any gear, any speed. Except if you have recently applied pressure to the gearlever (or changed gear) the control unit delays the engine turning off for an additional 5 seconds as it believes you are changing gear. If vehicle is stationary, engine will only restart by accelerator pedal if 1st gear is selected.<br />
<br />
Neutral: Engine switches off if gearlever switch has not been activated for 1.5 seconds; engine switches off regardless if you are pressing the accelerator.<br />
<br />
Reverse gear: Engine does not switch off, if engine is off and reverse is selected, engine immediately switches on.<br />
<br />
Driver's door is opened: Vacuum pump activates - if it appears to "run twice" a problem is present. Warning! If this is occurring there is danger the vacuum pump will burn out!<br />
<br />
Ignition on, engine off in Ecomatic mode with gear engaged, and the driver's door has been opened: Neutral must be briefly selected and 1st reselected before engine will restart.<br />
<br />
== Further information ==<br />
<br />
!!! Work in progress !!!</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=9Ah_auxiliary_battery&diff=969Ah auxiliary battery2012-12-15T17:45:33Z<p>Deylan: Created page with "The 9Ah auxiliary battery is used to provide power to neccesary electrical consumers when the engine is being started, to avoid power interruptions. Original battery made by ..."</p>
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<div>The 9Ah auxiliary battery is used to provide power to neccesary electrical consumers when the engine is being started, to avoid power interruptions.<br />
<br />
Original battery made by Hoppecke<br />
<br />
<br />
If your radio and instrument cluster loses power when the engine is restarting - the first thing to do is replace this battery!!!<br />
<br />
Genuine volkswagen part number: 1H0 915 105 E (1H0915105E)<br />
OEM replacement (Varta): Varta Funstart YB9L-A2 (509 016 008) - 12V 9Ah 80A (EN) - I use this myself.<br />
<br />
Dimensions:<br />
<br />
Width: 75mm<br />
Length: 135mm<br />
Height: 139mm</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Main_Page&diff=95Main Page2012-12-15T17:44:52Z<p>Deylan: </p>
<hr />
<div>Welcome to the [[Golf Ecomatic]] [[Golf_Ecomatic:General_disclaimer|Wikipedia]]<br />
<br />
== General Information ==<br />
*[[Golf Ecomatic]]<br />
<br />
== List of articles ==<br />
<br />
*[[Golf Ecomatic]]<br />
<br />
=== Engine/Ecomatic operation ===<br />
*[[Digiswing]]<br />
*[[Starter relay (J53)]]<br />
*[[Fuel shut-off valve (N109)]]<br />
*[[Reinforced starter motor]]<br />
*[[Tow starting]]<br />
<br />
=== Sensors/Switches ===<br />
*[[Brake light switch (F)]]<br />
*[[Door contact switch (F2)]]<br />
*[[Brake booster vacuum switch (F190)]]<br />
*[[Gear operating switch (F191)]]<br />
*[[Diesel engine stop switch (F207)]]<br />
*[[Gear display switch (F208)]]<br />
*[[Gear monitor switch (F209)]]<br />
*[[Pressure switch for clutch system F210]]<br />
*[[Load signal potentiometer (G157)]]<br />
*[[Clutch travel distance sender (G162)]]<br />
*[[Ecomatic switch (E163)]]<br />
*[[Road speed sender (G22)]]<br />
*[[Engine speed sender (G28)]]<br />
*[[Gearbox speed sender (G38)]]<br />
*[[Coolant temperature sender (G62)]]<br />
<br />
=== Vacuum/Clutch System ===<br />
*[[Console (Bracket for clutch positioner)]]<br />
*[[Clutch final control element]]<br />
*[[Mechanical vacuum pump]]<br />
*[[Vacuum reservoir]]<br />
*[[Vacuum pump relay (J318)]]<br />
*[[Electric vacuum pump (V22)]]<br />
*[[Clutch positioner vacuum valve (N183)]]<br />
*[[Clutch positioner discharge valve (N184)]]<br />
*[[Priority switch valve (N185)]]<br />
<br />
=== Electrical System ===<br />
*[[Coolant pump (V50)]]<br />
*[[92Ah battery]]<br />
*[[Ecomatic instrument cluster]]<br />
*[[Power steering pump (V119)]]<br />
*[[9Ah auxiliary battery]]<br />
*[[90 ampere alternator]]<br />
*[[Control unit for second battery and lights (J328)]]<br />
*[[Power steering relay (J320)]]</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Power_steering_relay_(J320)&diff=94Power steering relay (J320)2012-12-15T17:43:28Z<p>Deylan: </p>
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<div>Relay required to operate [[Power steering pump (V119)]]</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Power_steering_relay_(J320)&diff=93Power steering relay (J320)2012-12-15T17:43:14Z<p>Deylan: Created page with "Relay required to operate Power Steering Pump (V119)"</p>
<hr />
<div>Relay required to operate [[Power Steering Pump (V119)]]</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Control_unit_for_second_battery_and_lights_(J328)&diff=92Control unit for second battery and lights (J328)2012-12-15T17:42:53Z<p>Deylan: Created page with "The control unit for second battery and lights is required to switch the power from the main battery to the auxiliary battery during an engine starting procedure, this is so p..."</p>
<hr />
<div>The control unit for second battery and lights is required to switch the power from the main battery to the auxiliary battery during an engine starting procedure, this is so power to the lights and other necessary electrical consumers (such as the instrument cluster) is not interrupted during the engine starting phase. It also therefore ensures that primary battery is used solely to crank the engine.<br />
<br />
This component has a fuse visible on the top of it.<br />
<br />
If you lose power to the radio and/or instrument cluster when the engine is restarting then it is likely the auxiliary battery is flat.</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=90_ampere_alternator&diff=9190 ampere alternator2012-12-15T17:42:24Z<p>Deylan: Created page with "Larger alternator than standard 1Y engine vehicle. Volkswagen felt it was neccessary that the ecomatic was fitted with a larger alternator due to the higher power consumption ..."</p>
<hr />
<div>Larger alternator than standard 1Y engine vehicle. Volkswagen felt it was neccessary that the ecomatic was fitted with a larger alternator due to the higher power consumption (for starter motor), and reduced charging time (engine off phase).</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Power_steering_pump_(V119)&diff=89Power steering pump (V119)2012-12-15T17:41:13Z<p>Deylan: Created page with "Electronic power steering pump, replaces engine driven power steering pump used on non-ecomatic vehicles. Pump is activated if ignition is on and vehicle is moving (for examp..."</p>
<hr />
<div>Electronic power steering pump, replaces engine driven power steering pump used on non-ecomatic vehicles.<br />
<br />
Pump is activated if ignition is on and vehicle is moving (for example freewheeling), and is always on when engine is running, including when stopped.</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Ecomatic_instrument_cluster&diff=88Ecomatic instrument cluster2012-12-15T17:40:53Z<p>Deylan: Created page with "The Ecomatic instrument cluster is similar to the standard instrument cluster fitted to Mk3 Golfs. It is the analoge clock version (no rev counter). Despite not having a rev-c..."</p>
<hr />
<div>The Ecomatic instrument cluster is similar to the standard instrument cluster fitted to Mk3 Golfs. It is the analoge clock version (no rev counter).<br />
Despite not having a rev-counter, it does receive engine RPM signal. This is confirmed by the dash cluster diagnostics.<br />
If your instrument cluster looses power when the engine is restarting in ecomatic mode, you should try replacing your auxiliary battery.<br />
It has three additional lights:<br />
<br />
[k110] Ecomatic Control Lamp. Light on = Engine Braking Mode enabled, Ecomatic mode off, engine does not turn off and car does not freewheel.<br />
[k48] Gear Display Control Lamp. Light on = Uneconomical gear selected, gear too low, change up. Light flashing = Too high gear or gear not properly engaged.<br />
[k111] Engine Running Control Lamp Light on = Engine will not turn off - This may be because engine is too cold (most likely reason), battery voltage too low, fault detected with system.</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=92Ah_battery&diff=8792Ah battery2012-12-15T17:40:29Z<p>Deylan: Created page with "Larger battery than standard vehicle, largest battery out of the whole Mk3 range. Original part number: 000 915 105 AH (95Ah 450A) (dropped) Replacement part number: 000 915 ..."</p>
<hr />
<div>Larger battery than standard vehicle, largest battery out of the whole Mk3 range.<br />
<br />
Original part number: 000 915 105 AH (95Ah 450A) (dropped)<br />
Replacement part number: 000 915 105 DK<br />
<br />
Varta sell OEM equivilants (Varta Silver and Ultra/Stop-Start recommended). The genuine battery is made by Varta anyway.<br />
<br />
It is important the Ecomatic is fitted with a large and good quality battery with good CCA (cold cranking amps) to ensure the starter motor restarts the engine quickly, and reduce strain on the alternator and electrical consumers, the cost of replacing electronics damaged by voltage fluctuation far exceeds the extra for a good battery, the battery should also be able to take the strain from the large amount of engine starts.<br />
<br />
A poorly performing battery can result in oddities with the engine restarting procedure, such as, if the engine has been off for a while, a restart can be unsuccessful or take more than one attempt.<br />
<br />
The Ecomatic can be push started.</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Coolant_pump_(V50)&diff=86Coolant pump (V50)2012-12-15T17:40:05Z<p>Deylan: Created page with "The coolant pump V50 is electrically powered and is operated when the ignition is switched on, its function is to continue circulating water around the engine/heater matrix wh..."</p>
<hr />
<div>The coolant pump V50 is electrically powered and is operated when the ignition is switched on, its function is to continue circulating water around the engine/heater matrix when the engine is switched off, so that the heater output does not drop-off. Not only this, it ensures that there is no localized overheating in the engine block (or elsewhere) or large temperature deviations in the coolant system when the engine switches off in Ecomatic operation by ensuring the coolant is still circulated around, therefore, it is sensible to fix this if yours is non-operational not only for comfort but for long-term engine and cooling system reliability.<br />
<br />
The 2-pin connector as well as connection pins are notorious for corrosion on this water pump, disconnect the connector and spray with electrical contact cleaner.<br />
<br />
This pump can be replaced without having to remove anything other than the pump itself, the rubber mountings can also be installed correctly into the clutch positioner console bracket from underneath the car using angled and straight pin-nose pliers if they have popped out, it is not necessary to remove the clutch positioner console bracket to re-install them correctly.<br />
<br />
Original part number: 251 965 561 A / 251965561A<br />
Replacement part number: 251 965 561 B / 251965561B (slightly different pump)<br />
<br />
The pump is made by Bosch and can be sourced directly from them or relevant suppliers, which may cost less than the main dealer price.<br />
<br />
In the UK, http://www.vwspares.co.uk sell this pump for an incredibly low price.<br />
<br />
Testing procedure<br />
<br />
Test 1:<br />
<br />
Turn ignition on, but do not start engine, listen to pump and squeeze pipes leading into it, if no noise can be heard and no vibrations felt, it has probably failed, go to test 2.<br />
<br />
Test 2:<br />
<br />
1) Engine is warmed up<br />
2) Ecomatic mode switched on<br />
3) Turn temperature dial to hot<br />
4) Switch fan speed to 2<br />
5) Switch vent direction to face<br />
6) Allow engine to switch off via Ecomatic operation.<br />
7) If heat output starts to drop off in 30 seconds or less with engine off, restart the engine, if heat comes back, then the electric coolant pump has almost definitely failed.</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Main_Page&diff=85Main Page2012-12-15T17:02:55Z<p>Deylan: </p>
<hr />
<div>Welcome to the [[Golf Ecomatic]] [[Golf_Ecomatic:General_disclaimer|Wikipedia]]<br />
<br />
== General Information ==<br />
*[[Golf Ecomatic]]<br />
<br />
== List of articles ==<br />
<br />
*[[Golf Ecomatic]]<br />
<br />
=== Engine/Ecomatic operation ===<br />
*[[Digiswing]]<br />
*[[Starter relay (J53)]]<br />
*[[Fuel shut-off valve (N109)]]<br />
*[[Reinforced starter motor]]<br />
*[[Tow starting]]<br />
<br />
=== Sensors/Switches ===<br />
*[[Brake light switch (F)]]<br />
*[[Door contact switch (F2)]]<br />
*[[Brake booster vacuum switch (F190)]]<br />
*[[Gear operating switch (F191)]]<br />
*[[Diesel engine stop switch (F207)]]<br />
*[[Gear display switch (F208)]]<br />
*[[Gear monitor switch (F209)]]<br />
*[[Pressure switch for clutch system F210]]<br />
*[[Load signal potentiometer (G157)]]<br />
*[[Clutch travel distance sender (G162)]]<br />
*[[Ecomatic switch (E163)]]<br />
*[[Road speed sender (G22)]]<br />
*[[Engine speed sender (G28)]]<br />
*[[Gearbox speed sender (G38)]]<br />
*[[Coolant temperature sender (G62)]]<br />
<br />
=== Vacuum/Clutch System ===<br />
<br />
*[[Console (Bracket for clutch positioner)]]<br />
*[[Clutch final control element]]<br />
*[[Mechanical vacuum pump]]<br />
*[[Vacuum reservoir]]<br />
*[[Vacuum pump relay (J318)]]<br />
*[[Electric vacuum pump (V22)]]<br />
*[[Clutch positioner vacuum valve (N183)]]<br />
*[[Clutch positioner discharge valve (N184)]]<br />
*[[Priority switch valve (N185)]]</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Clutch_positioner_vacuum_valve_(N183)&diff=84Clutch positioner vacuum valve (N183)2012-12-15T16:56:31Z<p>Deylan: Created page with "This valve is located within the clutch final control element, and opens or closes the vacuum supply to the clutch element (i.e., pulls clutch open via suction)."</p>
<hr />
<div>This valve is located within the clutch final control element, and opens or closes the vacuum supply to the clutch element (i.e., pulls clutch open via suction).</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Clutch_positioner_discharge_valve_(N184)&diff=83Clutch positioner discharge valve (N184)2012-12-15T16:55:52Z<p>Deylan: Created page with "This valve is located within the clutch control element, and opens or closes to remove vacuum (i.e., let air in) to the cluch final control element (close the clutch). This i..."</p>
<hr />
<div>This valve is located within the clutch control element, and opens or closes to remove vacuum (i.e., let air in) to the cluch final control element (close the clutch).<br />
<br />
This is possibly a PWM solenoid.</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Electric_vacuum_pump_(V22)&diff=82Electric vacuum pump (V22)2012-12-15T16:54:29Z<p>Deylan: Created page with "The vacuum pump V22 provides vacuum for the clutch system ONLY, and is operated whenever there is insufficient vacuum in the clutch system (recognized by the opening of the [[..."</p>
<hr />
<div>The vacuum pump V22 provides vacuum for the clutch system ONLY, and is operated whenever there is insufficient vacuum in the clutch system (recognized by the opening of the [[Pressure switch for clutch system F210]]).<br />
<br />
If this pump is recognized as failed, the priority switching valve is opened and the vacuum for the clutch circuit is provided by the mechanical exhauster, the engine is no longer switched off, green engine running control lamp is lit.<br />
<br />
This pump should rarely operate when in motion, and extremely rarely when the engine is running , as the vacuum should be provided by the mechanical exhauster on the diesel engine and should be shared with the brake circuit. If whilst driving a relay appears to be ticking, especially after changing gear, it is likely you have vacuum pressure problems and it would be advisable to check that the vacuum system is leak-free and that the vacuum switches are in good working order.</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Vacuum_pump_relay_(J318)&diff=81Vacuum pump relay (J318)2012-12-15T16:53:17Z<p>Deylan: Created page with "This is the relay to operate the vacuum pump V22."</p>
<hr />
<div>This is the relay to operate the vacuum pump V22.</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Vacuum_reservoir&diff=80Vacuum reservoir2012-12-15T16:52:43Z<p>Deylan: Created page with "The vacuum reservoir is located in the front left wheel housing underneath the battery, and has seperate compartments to store the clutch and brake vacuum -- the vacuum system..."</p>
<hr />
<div>The vacuum reservoir is located in the front left wheel housing underneath the battery, and has seperate compartments to store the clutch and brake vacuum -- the vacuum system sharing is done through the [[Priority switch valve (N185)]]</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Mechanical_vacuum_pump&diff=79Mechanical vacuum pump2012-12-15T16:52:06Z<p>Deylan: Created page with "The mechanical vacuum pump creates vacuum from the drive of the engine. This provides vacuum for the brake system, and clutch system depending on operational state."</p>
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<div>The mechanical vacuum pump creates vacuum from the drive of the engine. This provides vacuum for the brake system, and clutch system depending on operational state.</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Clutch_final_control_element&diff=78Clutch final control element2012-12-15T16:51:40Z<p>Deylan: </p>
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<div>This is the whole unit responsible for clutch operation (opening/closing). It has the ability to completely regulate the position of the clutch according to the demands of the [[Digiswing]] control unit, which are calculated from sensor input. As such, hill starts are no problem for the vehicle. It is bolted to a bracket which is in turn bolted to the gearbox.<br />
<br />
Listed in parts catalogue as "servo motor".<br />
<br />
Has "Pierburg" written on it - presumably made by them.<br />
<br />
The positioner is replaced as a whole unit which contains the following:<br />
<br />
Clutch control element bleeder/discharge valve N184<br />
Clutch control element vacuum valve N183<br />
Clutch travel distance sender G162<br />
<br />
== Part number information ==<br />
<br />
Volkswagen part number (dropped 1995, but fitted to all* vehicles from factory): 1H0 142 059 / 1H0142059<br />
Pierburg part number: 7.20986.10 / 7.20986.10.0<br />
<br />
Replacement part number (1995 onwards): 1H0 142 059 A / 1H0142059A<br />
Pierburg part number: 7.20986.11 / 7.20986.11.0<br />
<br />
*From limited information available, from research, I believe that when the Ecomatic was discontinued, any parts not fitted to the car at the factory or in storage were changed to revision "A" and the revision of the Pierburg part number was also incremented by 1. (even perhaps existing stock due to the different markings of the "A" and "11"). There does not appear to be any differences in the parts, and why this was done I do not know (perhaps, to make it easy to differentiate between vehicles which had an original part and one's which did not).<br />
<br />
The original VW part number no longer exists in up to date versions of the parts catalogue, however, there is absolutely no mention of the revised pierburg part number anywhere (7.20986.11), not even on the Pierburg online parts catalogue! However, this definitely exists (as I own one).<br />
<br />
== Naming information ==<br />
<br />
In English translations this part is referred to by three different names.<br />
<br />
*In the parts catalogue, it is referred to as a "Servo Motor"<br />
*In the workshop manual and on VAG-COM data it is referred to as the "Clutch positioner".<br />
*In the Ecomatic SSP it is referred to as the "Clutch final control element"</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Clutch_final_control_element&diff=77Clutch final control element2012-12-15T16:51:22Z<p>Deylan: </p>
<hr />
<div>This is the whole unit responsible for clutch operation (opening/closing). It has the ability to completely regulate the position of the clutch according to the demands of the [[Digiswing]] control unit, which are calculated from sensor input. As such, hill starts are no problem for the vehicle. It is bolted to a bracket which is in turn bolted to the gearbox.<br />
<br />
Listed in parts catalogue as "servo motor".<br />
<br />
Has "Pierburg" written on it - presumably made by them.<br />
<br />
The positioner is replaced as a whole unit which contains the following:<br />
<br />
Clutch control element bleeder/discharge valve N184<br />
Clutch control element vacuum valve N183<br />
Clutch travel distance sender G162<br />
<br />
== Part number information ==<br />
<br />
Volkswagen part number (dropped 1995, but fitted to all* vehicles from factory): 1H0 142 059 / 1H0142059<br />
Pierburg part number: 7.20986.10 / 7.20986.10.0<br />
<br />
Replacement part number (1995 onwards): 1H0 142 059 A / 1H0142059A<br />
Pierburg part number: 7.20986.11 / 7.20986.11.0<br />
<br />
*From limited information available, from research, I believe that when the Ecomatic was discontinued, any parts not fitted to the car at the factory or in storage were changed to revision "A" and the revision of the Pierburg part number was also incremented by 1. (even perhaps existing stock due to the different markings of the "A" and "11"). There does not appear to be any differences in the parts, and why this was done I do not know (perhaps, to make it easy to differentiate between vehicles which had an original part and one's which did not).<br />
<br />
The original VW part number no longer exists in up to date versions of the parts catalogue, however, there is absolutely no mention of the revised pierburg part number anywhere (7.20986.11), not even on the Pierburg online parts catalogue! However, this definitely exists (as I own one).<br />
<br />
== Naming information ==<br />
<br />
In English translations this part is referred to by three different names.<br />
<br />
In the parts catalogue, it is referred to as a "Servo Motor"<br />
<br />
In the workshop manual and on VAG-COM data it is referred to as the "Clutch positioner".<br />
<br />
In the Ecomatic SSP it is referred to as the "Clutch final control element"</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Servo_motor&diff=76Servo motor2012-12-15T16:51:01Z<p>Deylan: Redirected page to Clutch final control element</p>
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<div>#REDIRECT [[Clutch final control element]]</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Clutch_positioner&diff=75Clutch positioner2012-12-15T16:50:49Z<p>Deylan: Redirected page to Clutch final control element</p>
<hr />
<div>#REDIRECT [[Clutch final control element]]</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Clutch_final_control_element&diff=74Clutch final control element2012-12-15T16:50:09Z<p>Deylan: Created page with "This is the whole unit responsible for clutch operation (opening/closing). It has the ability to completely regulate the position of the clutch according to the demands of the..."</p>
<hr />
<div>This is the whole unit responsible for clutch operation (opening/closing). It has the ability to completely regulate the position of the clutch according to the demands of the [[Digiswing]] control unit, which are calculated from sensor input. As such, hill starts are no problem for the vehicle. It is bolted to a bracket which is in turn bolted to the gearbox.<br />
<br />
Listed in parts catalogue as "servo motor".<br />
<br />
Has "Pierburg" written on it - presumably made by them.<br />
<br />
The positioner is replaced as a whole unit which contains the following:<br />
<br />
Clutch control element bleeder/discharge valve N184<br />
Clutch control element vacuum valve N183<br />
Clutch travel distance sender G162<br />
<br />
== Part number information ==<br />
<br />
Volkswagen part number (dropped 1995, but fitted to all* vehicles from factory): 1H0 142 059 / 1H0142059<br />
Pierburg part number: 7.20986.10 / 7.20986.10.0<br />
<br />
Replacement part number (1995 onwards): 1H0 142 059 A / 1H0142059A<br />
Pierburg part number: 7.20986.11 / 7.20986.11.0<br />
<br />
*From limited information available, from research, I believe that when the Ecomatic was discontinued, any parts not fitted to the car at the factory or in storage were changed to revision "A" and the revision of the Pierburg part number was also incremented by 1. (even perhaps existing stock due to the different markings of the "A" and "11"). There does not appear to be any differences in the parts, and why this was done I do not know (perhaps, to make it easy to differentiate between vehicles which had an original part and one's which did not).<br />
<br />
The original VW part number no longer exists in up to date versions of the parts catalogue, however, there is absolutely no mention of the revised pierburg part number anywhere (7.20986.11), not even on the Pierburg online parts catalogue! However, this definitely exists (as I own one).<br />
<br />
== Naming information ==<br />
<br />
In English translations this part is referred to by three different names.<br />
<br />
In the parts catalogue, it is referred to as a "Servo Motor"<br />
In the workshop manual and on VAG-COM data it is referred to as the "Clutch positioner".<br />
In the Ecomatic SSP it is referred to as the "Clutch final control element"</div>Deylanhttps://www.deylan.co.uk/golf/ecomatic/wiki/index.php?title=Console_(Bracket_for_clutch_positioner)&diff=73Console (Bracket for clutch positioner)2012-12-15T16:48:25Z<p>Deylan: Created page with "The "Console" is a metal bracket which is bolted onto the transmission, which, in turn, the Servo Motor and Vacuum Pump are attached to. Part number: 1H0 142 303 B / 1H014230..."</p>
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<div>The "Console" is a metal bracket which is bolted onto the transmission, which, in turn, the Servo Motor and Vacuum Pump are attached to.<br />
<br />
Part number: 1H0 142 303 B / 1H0142303B<br />
<br />
Some information is provided here which is worth bearing in mind.<br />
<br />
== Failure == <br />
<br />
These can and will eventually snap in at least 1 of 2 known common places after 15 or so years of age. In fact, I am not aware of an Ecomatic which has not had to have repairs done to the clutch console.<br />
<br />
It is possible to see visually if the console has snapped without removing parts by looking carefully.<br />
<br />
Also, if you can move the clutch positioner around by hand in the engine bay, then either it has snapped or is not screwed on properly. The clutch positioner should be fixed solid in place and should not just move around freely.<br />
<br />
== Repair ==<br />
<br />
It is strongly advisable to repair this as soon as possible so that the clutch positioner is not fatigued and that the cable is not rubbing against the bracket guide piece.<br />
<br />
If it snaps, it can be welded quite easily, but make sure that if you weld it, or if you get someone to weld it, that they make a neat job of it as otherwise it may affect clutch operation, and/or the cable may rub against the guide piece.<br />
<br />
=== Removal of clutch positioner from bracket ===<br />
<br />
3 bolts hold the clutch positioner down onto the bracket, apply copious amounts of penetrating lubricant to the 3 bolts on the underside of the bracket, otherwise, you could snap the metal base of the clutch positioner!! Do not go crazy as you want to avoid getting oils/silicone/contaminants actually inside the clutch positioner which is a rubber diaphragm.<br />
<br />
=== Removal of bracket itself ===<br />
<br />
Removing the bolts that hold the bracket in place can also lead to it snapping under force. As can be noticed when buying spare parts from the scrap yard etc. Therefore if this needs to be removed, cover the bolts with penetrating lubricant and allow to soak for 24 hours before applying extreme force to the bolts.. If the bolts are not removing without excess force, try more penetrating lubricant before finally applying excessive force.<br />
<br />
Also remember to remove the 2 bolts holding the clutch cable guide piece down, then, the clutch bracket can be pulled towards you in an upwards fashion to remove it.<br />
<br />
Also, disconnect necessary wires.<br />
<br />
=== Reinstalling ===<br />
<br />
Refitting is rather simple however make sure that the clutch positioner cable is not rubbing on the metal guide piece, otherwise clutch operation will be poor and cable damage will occur!<br />
<br />
It may be necessary to remove the large plastic cable sheath near the starter motor, if the angle cannot be obtained to push the console back on.</div>Deylan