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The Volkswagen 2.0 Liter Chain-Driven TSI Engine Volkswagen Group of America, Inc

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The Volkswagen 2.0 Liter Chain-Driven TSI Engine Volkswagen Group of America, Inc Service Training Self-Study Program 824803 The Volkswagen 2.0 Liter Chain-Driven TSI Engine Volkswagen Group of America, Inc. Volkswagen Academy Printed in U.S.A. Printed 5/2008 Course Number 824803 ©2008 Volkswagen Group of America, Inc. All rights reserved. All information contained in this manual is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Volkswagen Group of America, Inc., its affi liated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, nor may these materials be modified or reposted to other sites without the prior expressed written permission of the publisher. All requests for permission to copy and redistribute information should be referred to Volkswagen Group of America, Inc. Always check Technical Bulletins and the latest electronic repair information for information that may supersede any information included in this booklet. Trademarks: All brand names and product names used in this manual are trade names, service marks, trademarks, or registered trademarks; and are the property of their respective owners. Contents Introduction ...............................................................................1 Engine Mechanicals ...................................................................3 Lubrication System .................................................................20 Crankcase Ventilation System ................................................25 Cooling System .......................................................................27 Air Intake System ....................................................................30 Fuel System ..............................................................................36 Exhaust System .......................................................................43 Engine Management System .................................................44 Service ......................................................................................48 Knowledge Assessment ..........................................................51 Note Important! This Self-Study Program covers information on For testing, adjustment and repair the Volkswagen 2.0 Liter Chain-Driven TSI Engine. procedures, always refer to the latest This Self-Study Program is not a Repair Manual. electronic service information. This information will not be updated. i Page intentionally left blank Introduction Technical Description Four Cylinder, Four Valve, TSI Turbocharged Gasoline Engine Engine Block Engine Management – Cast iron crankcase – MED 17.5 engine control module – Balancer shafts in crankcase – Hot-fi lm air mass fl ow with integral temperature – Forged steel crankshaft sensor – Sump-mounted oil pump — chain-driven by – Throttle valve with contactless sensor crankshaft – Map-controlled ignition with cylinder-selective, – Timing gear chain — front end of engine digital knock control – Balancer — chain-driven at front end of engine – Single-spark ignition coils Cylinder Head Turbocharging – 4-valve cylinder head – Integral exhaust turbocharger – 1 INA intake camshaft adjuster – Charge-air cooler – Boost pressure control with overpressure Intake Manifold – Electrical wastegate valve – Tumble fl ap Exhaust Fuel Supply – Single-chamber exhaust system with close- coupled pre-catalyst – Demand controlled on low and high-pressure ends – Multi-port high-pressure injector Combustion Process – Fuel straight injection 1 Introduction 2.0L Chain-Driven TSI Engine 201 (150) 265 (360) 243 (330) 220 (300) 161 (120) 200 (270) 177 (240) 121 (90) 155 (210) 133 (180) 110 (150) 80 (60) 88 (120) 67 (90) 40 (30) 44 (60) 22 (30) 0 0 01000 20003000 4000 5000 6000 7000 Engine speed in RPM Specifications Engine Code CCTA - CBFA Type of Engine Inline 4-Cylinder TSI Engine Displacement 121 cu in (1984 cm3) Maximum Power 200 hp (147 kW) at 5100 - 6000 rpm Maximum Torque 206 lb ft (280 Nm) at 1700 - 5000 rpm Number of Valves Per Cylinder 4 Bore 3.2 in (82.5 mm) Stroke 3.7 in (92.8 mm) Compression Ratio 9.6 : 1 Firing Order 1-3-4-2 Engine Weight 317 lb (144 kg) Engine Management Bosch MED 17.5 Fuel Grade 95/91 RON Exhaust Emission Standard ULEV (CCTA) - SULEV (CBFA) 2 Engine Mechanicals Cylinder Block The cylinder block has a closed-deck confi guration The undersides of the pistons are cooled by engine and is made of cast iron. It houses the fi ve-bearing oil supplied by spray jets mounted on the cylinder crankshaft assembly and the two balancer shafts. block. The housing for mounting the chain drives is The cylinder block is sealed on the transmission side integrated in the block. The cylinder liners are by a sealing fl ange and gasket. fi nished in a three-stage fl uid jet honing process. 3 Engine Mechanicals Oil Pan The oil pan consists of two sections. The bottom section is made of sheet steel (deep drawn, punched, and catalytically coated). It houses The upper section is made of an aluminum alloy Oil Level Sensor G12 and the drain plug. (AlSi12Cu) and reinforces the crankcase through a bedplate effect. It also houses the oil pump. The bottom section is bolted to the upper section and sealed with a liquid sealant. The upper section is bolted to the crankcase and sealed with a liquid sealant. The oil pan has an integral honeycomb insert made of polyamide to prevent oil churning when the vehicle is driven aggressively. Aluminum Alloy Oil Pan Top Section Polyamide Honeycomb Insert Stamped Steel Oil Pan Bottom Section 4 Engine Mechanicals Crankshaft The fi ve main bearing crankshaft is made of forged The crankshaft main bearings are a two component steel and induction hardened. Optimal balancing is type. Axial play of the crankshaft is controlled by achieved by using eight counterweights. thrust washers at the middle support bearing. To additionally reinforce the crankshaft assembly, Bronze bushings are press-fi t into the small three inner main bearing caps are cross-bolted to the trapezoidal upper end of the connecting rods. cylinder block. The lower end of the connecting rods are cracked to Trapezoidal Connecting Rod (Small End) ensure a precision fi t and reduce movement of the Material: 36MnVS4 bearing cap under load. Length: 5.82 in (148 mm) The upper and lower bearing shells of the connecting rod are not identical in composition. The upper Big-End Bearing: 1.88 in (47.8 mm) bearing shell is a two-component composite Small-End Bearing: 0.82 in (21 mm) bearing while the lower shell is a three-component composite bearing. Piston Wrist Pin Wrist Pin Retaining Clip Bronze Connecting Rod Bushing Trapezoidal Shaped Small End of Connecting Rod Connecting Rod Upper Bearing Shell Main Bearing Cap Connecting Rod Cap Cross-Bolted Main Bearing Caps and Bolts 5 Engine Mechanicals Gears are coded for assembly — they can only be installed one way Vibration Damper Chain Sprocket Center Bolt Spur Gear Drive The chain drive sprocket is mounted to the On the transmission side of the engine, a dual crankshaft face and driven by a spur gear forged in mass fl ywheel or torque converter (depending on the crankshaft. The other end of the chain sprocket transmission) is mounted to the crankshaft with also has a spur gear surface which drives the eight bolts. vibration damper. This method of joining allows high torque to be transmitted to the chain sprocket and vibration damper while keeping the diameter of the components small. This allows better sealing by the radial shaft seal at the vibration damper hub. Special tools are required during disassembly/assembly of these components to prevent damage to the gears. 6 Engine Mechanicals Pistons The pistons are specially designed for the TSI engine with a cast-in ring land for the upper piston ring. Coated skirts are used to help reduce frictional losses. The upper piston ring is rectangular, the second piston ring is a taper-faced ring, and the oil scraper ring is a beveled ring with expander. The 31CrMoV wrist pins are held in place by snap rings. The bottom side of the pistons are cooled by engine oil from spray jets mounted on the cylinder block. 7 Engine Mechanicals Cylinder Head L M K N J O P I H G Q R F E D C S T B A 8 Engine Mechanicals The 4-valve cylinder head is cast from aluminum The cylinder head cover adds support by acting as a alloy. Intake and exhaust valves are actuated by roller ladder frame and does not have to be disassembled cam followers supported by hydraulic valve lifters. to remove the cylinder head. The intake and exhaust camshafts are chain-driven. The diagonal opening and sealing face simplifi es The variable timing of the intake camshaft is drive chain installation. accomplished through the INA camshaft adjustment system (page 11). Features – Crossfl ow cylinder head made of ASi10Mg – Single valve spring made of steel – Three-layer metal head gasket. – Roller cam followers running in needle bearings, – Intake ports divided by baffl e plate hydraulic valve clearance adjustment – Cylinder head cover made of AlSi9Cu3 with – Hydro-formed, assembled intake camshaft with integrated ladder frame, bolted to cylinder head variable valve timing, dwell angle 190°, valve lift and sealed with liquid sealant 10.7 mm – Intake valve: solid-stem valve, chrome-plated with – Hydro-formed, assembled exhaust camshaft with reinforced seat press-fi t drive gear, dwell angle 180°, valve lift 8 mm
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