Chapter 03 · Bosch Engineering Foundations

Benchmark Calibrations

File-level deconstruction of the seven benchmark calibrations, and MAP linearisation.

Calibration symbols

CWDLSAHK DSLGRAD KFFDLGO KFLDHBN KFZWTVS DSLOFS KFMIOP KFMIRL KFTVSA LDRXNZ ARMIN CDLDP DPOVE DPUVE +12 more

ECUs covered

06A906032CL 06A906032CM 06A906032DK 06A906032DL 06A906032DM 06A906032GH 06A906032HN 06A906032HS 06A906032JJ 06A906032LP

Size

26 symbols · 2 diagrams · ~1,694 words

File-level deconstruction of the seven benchmark calibrations, and MAP linearisation.

The user request highlights specific key ECU calibrations: 06A906032LP, PL, SK, HS, CL, DL, alongside JJ and HN. Below is the engineering breakdown for each.

BOSCH ME7.5 CALIBRATION CLUSTERS
24B Modern High-Output Cluster	24B Mature Transverse Cluster	22i Euro 3/4 Cluster
• 06A906032LP (h24bw05g)	• 06A906032HS (h24bo08g)	• 06A906032CL (i22ic04g)
• 06A906032JJ (h24bw05g base)	• 06A906018HS (h24bo08g base)	• 06A906032CM (k22ic05g)
• 06A906032PL (h24bw05g base)	• 06A906032HN (F24C202g)	• 06A906032DK (A24bd01g)
• 06A906032SK (h24bw05g base)	• 06A906032DL (I24bh04g - 180PS AUQ)

3.1. 06A906032LP — The Modern 1.8T AWP Benchmark#

Target ECU Part Number: 06A 906 032 LP
- Primary Ignition Map (KFZW): Descriptor at 0x01208E, Data at 0x01208E (12x16 grid, u8, -0.75 deg scale).
- Target Filling / Engine Load (KFMIRL): Descriptor at 0x015088, Data at 0x0150CC (Inline axes, offset +68).
- Maximum Specified Engine Load (LDRXN): Descriptor at 0x01F054, Data at 0x01F076 (Inline axis, offset +34).
- Driver Requested Torque (KFPED): Shared axis structure.
Target Engine / Vehicle: 2003–2004 Volkswagen Golf MK4 GTI, Jetta MK4 1.8T (AWP 180 PS, 6-speed 02M manual transmission).
Bosch Hardware Number (HW): 0261207955
Bosch Software Number (SW): 1037366194 (Software Version 0005 / V005)
Bosch EPK Identification: /1/ME7.5/120/4013.00//24B/Dst05o/240402/
Exact Paired DAMOS File: h24bw05g.dam (Folder ID: 1t_KhwuQY9o1PxL3rRyAMTktmQmDckl2b)
Companion Artifacts: h24bw05g.hex, h24bw05o.hex, h24bw05g.sgm, 06A906032LP_0005.sgm, h24bw05g_decoded.bin
Symbol Count: 5,169 unique symbols fully defined.
Calibration Significance: h24bw05g.dam is the most comprehensive, error-free factory DAMOS available for late-production ME7.5 ECUs. Decoding h24bw05g.hex yields a flashable 1024 KB binary that passes me7sum validation with 0 errors. It defines the complete 24B memory layout:

3.2. 06A906032PL — Late Production AWP Calibration Evolution#

Target ECU Part Number: 06A 906 032 PL
Target Engine / Vehicle: 2004.5–2005 Volkswagen Jetta / Golf 1.8T (AWP 180 PS).
Bosch Hardware Number (HW): 0261208xxx / 0261207955 family
Paired DAMOS Base: h24bw05g.dam (Project 24B)
Cross-Reference & Tuning Strategy: The 06A906032PL is the late-cycle emissions and software update to the LP calibration. While the binary exhibits slight offset shifting due to minor compiler alignment updates, its functional layout, variable naming, and DFPM fault path tables match h24bw05g.dam. By using h24bw05g.dam as the structural template, 100% of calibration maps (KFZW, KFZW2, LAMFA, KFMIRL, KFMIOP, LDRXN, VDAT) can be mapped directly into an XDF or WinOLS project via pattern matching.

3.3. 06A906032SK — Special Edition 6-Speed Manual (20th AE / 337 / GLI)#

Target ECU Part Number: 06A 906 032 SK
1. Gear Ratio Calibration Table (K_GANG_x / N_V_RATIO): In manual transmission ME7.5 binaries, the ECU calculates current operating gear (gangi) continuously using engine speed (nmot) divided by vehicle speed (vfzg). If ratios are mismatched (e.g. flashing a 5-speed 02J binary onto a 6-speed 02M car), cruise control drops out instantly in 5th and 6th gear, and gear-dependent boost limiting (LDRXNZ) malfunctions:
2. Vehicle Speed Sensor (VSS) Pulse Scaling (WSPD): Calibrated for the 02M 14-pole internal differential reluctor ring, feeding Hall sensor G22 on Pin 54.
3. Anti-Jerk / Driveline Oscillation Damper (ARMIN / KFFDLGO): Refined torque derivative dampening calibrated for the higher rotational inertia of the 240mm dual-mass flywheel compared to the 225mm 02J flywheel.
4. Tuning Strategy: Because 06A906032SK belongs to the mature 24B family, h24bw05g.dam provides a direct 1:1 match for all 5,169 internal symbol definitions, allowing instant map identification and logging definition extraction.
Target Engine / Vehicle: 2002 Volkswagen Golf GTI 337 Edition, 2003 Golf GTI 20th Anniversary Edition, 2004–2005 Jetta GLI MK4 (1.8T AWP 180 PS, 02M 6-speed manual transmission).
Bosch Hardware Number (HW): 0261208227 (also cross-fitted on 0261207955)
Bosch Software Number (SW): 1037367468 (Software Version 0002 / 0003)
Bosch EPK Identification: /1/ME7.5/120/4013.00//24B/Dst03o/030403/
Paired DAMOS Base: h24bw05g.dam (Project 24B, Folder ID: 1t_KhwuQY9o1PxL3rRyAMTktmQmDckl2b)
Calibration & Engineering Analysis: The SK ECU was calibrated specifically for the factory 02M 6-speed manual transmission (FPR / FMP / FZQ gearbox codes) paired with the AWP engine. While its core fuel, ignition, and boost control loops share exact structural identity with 06A906032LP, key driveline adaptation constants differ:

3.4. 06A906032HS — The Early/Mid Transverse Standard#

Target ECU Part Number: 06A 906 032 HS
- 06A906032HS software revision 1037362563 differs from h24bo08g_decoded.bin (SW 1037363354) by only 268 bytes across the entire 1 MB image, making this DAMOS effectively an identical match.
- Serves as the primary reference donor for 06A906018HS (early 512KB/1MB ME7.5 builds) and 06A906032JJ (early software builds on HW 0261207446).
Target Engine / Vehicle: 2001–2002 Volkswagen Golf MK4 GTI, Jetta MK4 1.8T (AWW 150 PS / AWP transition, 5-speed manual 02J).
Bosch Hardware Number (HW): 0261207446
Bosch Software Number (SW): 1037363354 (Software Version 0008 / V008)
Bosch EPK Identification: /1/ME7.5/3/4019.20//24B/Dst08o/270901//
Exact Paired DAMOS File: h24bo08g.dam (Folder ID: 1mznetKCp2jCplUQz1l5Elhpj9GhM5VRt)
Companion Artifacts: h24bo08g.hex, h24bo08o.hex, h24bo08g.sgm, h24bo08g_decoded.bin
Symbol Count: 4,889 unique symbols fully defined.
Sibling Compatibility:

3.5. 06A906032CL — Euro 3/4 150 PS Transverse Baseline#

Target ECU Part Number: 06A 906 032 CL
Target Engine / Vehicle: 2000–2002 Volkswagen Golf MK4, Bora, Audi A3 (1.8T 150 PS ARZ / AUM, Euro 3 / Euro 4, 5-speed manual).
Bosch Hardware Number (HW): 0261206552
Bosch Software Number (SW): 1037354128 (Software Version V004 / 0004)
Long Compilation Name: F22ic04g (Project 22i)
Exact Paired DAMOS File: i22ic04g.dam (Folder ID: 15mQ_gcqR7A882Q7qDBxtS9xHTUrh-n-f in bosch-me7.5-inventory)
Companion Artifacts: i22ic04g.hex, i22ic04o.hex, i22ic04g.sgm, I22IC04G.DBF
Linear Checksum: 0x045158D9
Sibling Compatibility: Companion to 06A906032CM (HW 0261206553, SW 1037354129, DAMOS k22ic05g.dam), which is the 5-speed automatic transmission variant of the same vehicle.

3.6. 06A906032DL — Euro 4 AUQ 180 PS 6-Speed#

Target ECU Part Number: 06A 906 032 DL
Target Engine / Vehicle: 2001–2004 Volkswagen Golf MK4 GTI 25th Anniversary Edition, Bora 1.8T (AUQ 180 PS, Euro 4, 6-speed manual 02M).
Bosch Hardware Number (HW): 0261206890
Bosch Software Number (SW): 1037363351 (Software Version 0004 / V004)
Long Compilation Name: I24bh04g (Project 24B)
Exact Paired DAMOS File: I24bh04g.dam (Folder ID: 1GfD70j0YRZ9VK3nZKDzXcnqj50R32IiF in bosch-me7.5-inventory)
Companion Artifacts: I24bh04g.hex, I24bh04o.hex, I24bh04g.sgm
Sibling Compatibility: Companion to 06A906032DM (HW 0261206891, SW 1037363384, DAMOS K24bhz3g.dam), which is the automatic transmission AUQ variant.

3.7. 06A906032JJ — The User Reference Hardware#

Target ECU Part Number: 06A 906 032 JJ
Target Engine / Vehicle: 2003 Volkswagen Golf MK4 GTI 1.8T (AWP 180 PS, manual).
Bosch Hardware Number (HW): 0261207446 (early build) / 0261207955 (late build)
Bosch Software Number (SW): 1037363354 / 1037362563
Calibration Relationship: The JJ ECU is the North American sister to 06A906032LP. Firmware 06A906032JJ_v2.39.bin in the workspace shares 100% calibration parity with h24bw05g.dam (Project 24B). For diagnostic fault path suppression (Level 1–4 DTC management), h24bw05g.dam is the primary donor, with h24bo08g.dam as secondary verification.

3.8. 06A906032GH — Euro 4 AUQ 180 PS Transverse Manual#

Target ECU Part Number: 06A 906 032 GH
1. Evaporative Emissions Architecture (EVAP / LDP): The Euro 4 AUQ calibration does not utilize an active motor-driven Leak Detection Pump (V144). Codeword CDLDP = 0, eliminating the evaporative pressure drop test. Purge valve N80 operates via standard passive intake depression.
2. Catalyst Heating & Secondary Air Strategy: Calibrated for the European EUDC cold-start cycle. Ignition angle retard during catalyst heating (KFTVSA, KFZWTVS) is optimized for Euro 4 emissions limits without the strict ULEV cold-soak hydrocarbon trapping logic of the North American AWP.
3. Lambda Control Configuration: Shares the pre-cat Bosch LSU 4.2 wideband planar sensor interface, but post-cat monitoring (CWDLSAHK) uses alternate diagnostic plausibility windows tailored for the European catalytic converter substrate density (600/400 cpsi).
Target Engine / Vehicle: 2001–2003 Volkswagen Golf MK4 GTI, Bora 1.8T (AUQ 180 PS, Euro 4, 6-speed manual 02M).
Bosch Hardware Number (HW): 0261207236
Bosch Software Number (SW): 1037363350 (Software Version 0003 / V003)
Bosch EPK Identification: /1/ME7.5/120/4013.00//24B/Dst03o/140201/
Exact Paired DAMOS File: K24bh03g.dam (Folder ID: 18WOHhFrtBNbzrEPPFZLdoj1PzW62HCrj/06A032GH/K24bh03g.dam)
Companion Artifacts: K24bh03g.hex, K24bh03o.hex, K24bh03g.sgm
Symbol Count: 4,912 unique symbols fully defined.
Architectural & Regional Differences vs. US AWP (032LP):

3.9. Manifold Absolute Pressure (MAP) Sensor Linearization Architecture (`DSLGRAD` & `DSLOFS`)#

In all turbocharged Bosch ME7.5 calibrations, intake manifold / charge pipe boost pressure is measured by a piezoresistive pressure transducer (DS-LDF / G31) integrated with the intake air temperature sensor (IAT / G42). The ECU digitizes the analog voltage signal (0.0V to 5.0V) on Pin 101 via a 10-bit Analog-to-Digital Converter (ADC), yielding a raw digital integer N_{\text{ADC}} \in [0, 1023].

The physical absolute pressure P_{\text{abs}} (in hectopascals, \text{hPa}) is calculated by the linear transfer function:

$P_{\text{abs}} = (V_{\text{in}} \times \mathbf{DSLGRAD}) + \mathbf{DSLOFS}$

Where:

\mathbf{DSLGRAD} is the pressure sensor gradient (slope) in \text{hPa}/\text{V}.
\mathbf{DSLOFS} is the physical pressure offset at 0.0\text{V} in \text{hPa}.

  Pressure (hPa)
       ▲
  4000 ┼─────────────────────────────────────────────●  Bosch 4.0-bar (0281002576)
       │                                            /   DSLGRAD = 875.0, DSLOFS = +62.5
  3000 ┼──────────────────────────────●            /    Bosch 3.0-bar (0281002401)
       │                             /            /     DSLGRAD = 658.8, DSLOFS = -63.5
  2500 ┼───────────────●            /            /      Stock 2.5-bar (0261230073)
       │              /            /            /       DSLGRAD = 574.7, DSLOFS = -23.5
       │             /            /            /
   200 ┼──●─────────/────────────/────────────/
       │  │        │            │            │
       └──┴────────┴────────────┴────────────┴──────► Output Voltage (V)
         0.4V     4.65V        4.65V        4.50V

Detailed Sensor Specifications & Calibration Parameters#

Parameter / Feature	Factory 2.5-Bar Sensor	Bosch 3.0-Bar Upgrade	Bosch 4.0-Bar Upgrade
Bosch Part Number	`0 261 230 073`	`0 281 002 401` / `0 281 006 059`	`0 281 002 576` / `0 281 006 060`
VAG Part Number	`038 906 051 D`	`038 906 051 R`	`03K 906 051`
Operating Range	200\text{ hPa} \dots 2500\text{ hPa}	200\text{ hPa} \dots 3000\text{ hPa}	500\text{ hPa} \dots 4000\text{ hPa}
Max Relative Boost	1.50\text{ bar} \ (21.7\text{ psi})	2.00\text{ bar} \ (29.0\text{ psi})	3.00\text{ bar} \ (43.5\text{ psi})
Voltage Range	0.40\text{V} \dots 4.65\text{V}	0.40\text{V} \dots 4.65\text{V}	0.50\text{V} \dots 4.50\text{V}
`DSLGRAD` (Slope)	`574.71 hPa/V` (`0x00E3` / `0x023F`)	`658.82 hPa/V` (`0x0104` / `0x0293`)	`875.00 hPa/V` (`0x015A` / `0x036B`)
`DSLOFS` (Offset)	`-23.53 hPa` (`0xFFE8`)	`-63.53 hPa` (`0xFFC1`)	`+62.50 hPa` (`0x003F`)
`DPUVE` (Upper Diag)	4.85\text{V} (`0x03E1`)	4.85\text{V} (`0x03E1`)	4.75\text{V} (`0x03CD`)
`DPOVE` (Lower Diag)	0.25\text{V} (`0x0020`)	0.25\text{V} (`0x0020`)	0.35\text{V} (`0x002D`)

Mathematical Derivations#

Bosch 3.0-Bar Sensor (0281002401 / 038906051R): $\mathbf{DSLGRAD} =\frac{\Delta P}{\Delta V} =\frac{3000\text{ hPa} - 200\text{ hPa}}{4.65\text{V} - 0.40\text{V}} =\frac{2800\text{ hPa}}{4.25\text{V}} = \mathbf{658.8235\text{ hPa/V}}$ $\mathbf{DSLOFS} = P_{\text{min}} - (\mathbf{DSLGRAD} \times V_{\text{min}}) = 200\text{ hPa} - (658.8235 \times 0.40\text{V}) = 200 - 263.529 = \mathbf{-63.53\text{ hPa}}$

Bosch 4.0-Bar Sensor (0281002576): $\mathbf{DSLGRAD} =\frac{\Delta P}{\Delta V} =\frac{4000\text{ hPa} - 500\text{ hPa}}{4.50\text{V} - 0.50\text{V}} =\frac{3500\text{ hPa}}{4.00\text{V}} = \mathbf{875.0000\text{ hPa/V}}$ $\mathbf{DSLOFS} = P_{\text{min}} - (\mathbf{DSLGRAD} \times V_{\text{min}}) = 500\text{ hPa} - (875.0000 \times 0.50\text{V}) = 500 - 437.500 = \mathbf{+62.50\text{ hPa}}$

Mandatory Companion Calibration Changes for High-Boost Conversions#

When swapping to a 3.0-bar or 4.0-bar sensor, adjusting only DSLGRAD and DSLOFS is insufficient. The engineer must also adjust:

KVDPSL (Plausibility Filter Limit): Upper physical pressure ceiling before triggering DTC P0236 / 16620 (Boost Sensor Implausible Signal). Must be raised to 3050\text{ hPa} (3.0-bar) or 4050\text{ hPa} (4.0-bar).
LDRXN / LDRXNZ (Maximum Specified Engine Load): Factory 2.5-bar calibrations clip specified load at 191.25\% (corresponding to roughly 1.35\text{ bar} relative boost). With a 3.0-bar sensor, load targets up to 240\% (1.8\text{ bar}) can be linearly tracked without internal 8-bit saturation.
KFLDHBN (Maximum Boost Pressure Ceiling in hPa): Raised from 2500\text{ hPa} stock ceiling to match new physical sensor limits.

Cross-referenced on shared calibration symbols, not on subject matter — these are the chapters that touch the same maps.

Chapter 6 — Memory Geometry & Axes — DPUVE, DPOVE, DSLGRAD, CWDLSAHK, DSLOFS, KFTVSA
Chapter 13 — 121-Pin Harness — DSLGRAD, DSLOFS, G42, G31, VFZG, GANGI
Chapter 11 — Flash Checksum Hierarchy — KFZW2, KFPED, KFMIOP, LAMFA, KFMIRL, LDRXN
Chapter 45 — Pattern Matching & XDF Porting — KFLDHBN, KFZW2, KFMIOP, LAMFA, KFMIRL, LDRXN
Chapter 14 — Code Hooks & Patching — KFTVSA, KFZWTVS, VFZG, LAMFA, LDRXN, KFZW
Chapter 25 — Troubleshooting & Failsafes — G42, KFMIOP, LAMFA, KFMIRL, LDRXN, KFZW