The 6.3L W12 FSI Engine Audi of America, LLC Service Training Printed in U.S.A
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Self-Study Program 920113 The 6.3L W12 FSI Engine Audi of America, LLC Service Training Printed in U.S.A. Printed 6/2011 Course Number 920113 ©2011 Audi of America, LLC All rights reserved. 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 Audi of America, LLC., 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 modifi ed 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 Audi of America, LLC. Always check Technical Bulletins and the latest electronic service repair literature for information that may supersede any information included in this booklet. Table of Contents Introduction . 1 6.3L W12 FSI Engine . 2 Overview . 2 Specifi cations . 3 Components . .4 Cylinder Block . 4 Crankshaft . 5 Pistons and Connecting Rods . 6 Chain Drive . 7 Crankcase Breather . 8 Fine Oil Separation . 9 Cylinder Head . 10 Oil Supply . .12 Oil Circuit . 14 Oil Pump . 15 Air Supply . .16 Intake Air Flow System. 16 Secondary Air System . 18 Vacuum Supply . 20 Cooling System . .22 Overview . 22 Coolant Thermostat . 23 Fuel System . .24 Overview . 24 Fuel Rails . 26 High Pressure Injectors . 28 Engine Management . .30 System Overview . 30 Exhaust System . .36 Overview . 36 Exhaust Flaps . 37 Special Tools . .38 Knowledge Assessment . .39 i The Self-Study Program provides introductory information regarding the design Reference Note and function of new models, automotive components, or technologies. The Self-Study Program is not a Repair Manual! All values given are intended as a guideline only. ! For maintenance and repair work, always refer to current technical literature. ii Introduction A 12-cylinder engine is the pinnacle of engine The engine is exceptionally smooth running, design and a hallmark of luxury class vehicles. and only at high engine loads and speeds do Twelve-cylinder engines have been used in the the car’s occupants sense any of this supreme Audi A8 model line since 2001. power at work. Over time, Audi’s engineers have thoroughly The high fuel economy of the 6.3L W12 FSI revised the W12, increasing its displacement engine, when compared with its competitors, to 6.3 liters and equipping it with direct fuel is mainly the result of technologies from Audi’s injection for greater power and effi ciency. modular effi ciency platform, which is used The 6.3L W12 FSI engine gives the 2011 A8L throughout the A8 model line. sports car performance: zero to 60 in just under 4.9 seconds and an electronically limited top speed of 155 mph (250 km/h). 490_002c 1 6.3L W12 FSI Engine Overview – 12-cylinder gasoline engine with four rows of – Two cylinder heads with four valves per three cylinders arranged in a W confi guration cylinder and two camshafts per bank with – More compact dimensions than a comparable hydraulic camshaft adjusters V8 engine – Engine is controlled by a multi-element chain • Length: 19.6 in (500 mm) drive (optimized for low friction) • Width: 27.5 in (700 mm) – FSI direct injection with twin high-pressure fuel pumps, twin fuel rails and six-port high • Height: 27.5 in (700 mm) pressure injectors – Recuperation system for energy recovery during deceleration phases 490_004 Reference For further information about W12 engine design, refer to Self-Study Program 921403, 6.0L W12 Engine in the Audi A8L. 2 Specifi cations 536.4 hp (400 kW) 516.2 lb ft (700 Nm) 482.7 hp (360 kW) 479.4 lb ft (650 Nm) 429.1 hp (320 kW) 442.5 lb ft (600 Nm) Power in hp (kW) 375.4 hp (280 kW) 405.6 lb ft (550 Nm) Torque in lb ft (Nm) 321.8 hp (240 kW) 368.7 lb ft (500 Nm) 268.2 hp (200 kW) 331.9 lb ft (450 Nm) 214.5 hp (160 kW) 295.0 lb ft (400 Nm) 160.9 hp (120 kW) 258.1 lb ft (350 Nm) hp (kW) lb ft (Nm) 53.6 hp (40 kW) 184.3 lb ft (250 Nm) 0 10002000 3000 4000 5000 6000 7000 490_001 Engine Code CEJA Engine type 12-cylinder W type engine with a V angle of 15° and a bank angle of 72° Displacement 384.3 cu in (6299 cc) Maximum power 493.4 hp (368 kW) @ 6200 rpm Maximum torque 460.9 lb ft (625 Nm) @ 4750 rpm Valves per cylinder 4 Bore 3.38 in (86.0 mm) Stroke 3.55 in (90.4 mm) Compression ratio 11.8 : 1 Firing order 1-7-5-11-3-9-6-12-2-8-4-10 Engine weight 544.5 lb (247 kg) Engine management Bosch MED 17.1.6 Fuel grade 91 AKI Exhaust emission standard ULEV II Four air-gap insulated manifold CAT modules, each with a close- Exhaust gas aftertreatment coupled ceramic catalytic converter and twin oxygen sensors 3 Components Cylinder Block Compared with the 6.0L W12 engine, cylinder The cylinder block is cast from a lightweight, bore has been enlarged from 3.30 in (84.0 mm) high strength aluminum-silicon alloy. The to 3.38 in (86.0 mm). bottom section has a cast iron crossmember with embedded main bearing pedestals. Cylinder block 267_098 Front of engine Integrally cast main bearing pedestals for crankcase bearings Bearing crossmember Oil pan top section Oil pan bottom section 490_005 4 Crankshaft The forged crankshaft has a 12° crankpin offset angle. This allows the fuel mixture of each cylinder to be ignited at the ideal interval of every 60° of crankshaft rotation. Cylinder bank 1 (right side) Cylinder bank 2 (left side) 490_006 Front of engine Gear for separate oil pump chain drive Split-pin connecting rod bearing journal Oil supply port for the connecting rod bearings Connecting rod bottom section Transverse bore in the crankshaft Connecting rod bearing 5 Pistons and Connecting Rods The pistons are forged from high strength light Forged piston alloy and have angled crowns to compensate for the cylinder bank angle. The shape of the piston crowns have been designed especially for the FSI engine. The design of the W12 engine necessitated the use of high pressure injectors with different placement angles in the cylinder head. For this reason, the “outer” cylinders (1, 3, 5, 8, 10 and 12) have different pistons than the “inner” cylinders (2, 4, 6, 7, 9 and 11). Rectangular ring Minute ring Oil scraper ring 490_019 Pistons of cylinders 2, 4, 6, 7, Pistons of cylinders 1, 3, 5, 8, 9 and 11 (inner cylinders) 10 and 12 (outer cylinders) 490_008 490_007 Extra narrow trapezoidal connecting rods are used 490_009 6 Chain Drive The timing gears and chain drive are located on Secondary Drives the transmission side of the engine. The chain drive is divided into primary and secondary The two secondary drives are driven by the drives. intermediate gear. The two camshafts are driven by a single chain per cylinder bank. Chains are All components of the chain drive are designed guided by sliding rails. to last the lifetime of the engine, and cannot be adjusted by service personnel. The chain tensioners work on the same principle as in the primary drive. However, the tensioning force of the chain tensioner does not act on Primary Drive the tensioning rail, but rather on a mounted tensioning lever. The primary drive is driven by a sprocket on the crankshaft. A simplex roller chain drives At the end of the tensioning lever, a sprocket an intermediate gear, which provides speed running on ball bearings engages the secondary reduction and drives the secondary drives. chain. The chains of the secondary drives must be removed to take off the cylinder heads. The chain is guided by a sliding rail. Chain tensioning is provided by a spring-loaded chain tensioner, which is assisted and damped by engine oil from the oil supply circuit. Cylinder bank 1 Sliding rail Cylinder bank 2 490_010 Tensioning gear of cylinder bank 1 Intermediate shaft gear Front of engine Chain tensioner Sliding rail Sliding rail Crankshaft sprocket (primary drive) 7 Crankcase Breather Blow-by gases are introduced directly into the The separated engine oil drips from the cylinder heads via vent lines connected directly channel walls and is collected in a pan in the oil to the cylinder head covers on the belt side of separator module. From here, the oil runs along the engine. These blow-by gases fl ow into the a return line and drains into the timing case at oil separator module of the crankcase breather, the back of the engine. which is located on top of the engine between Pre-treated blow-by gases then fl ow through the two intake modules. a fi ne oil separator, continuing through the The engine oil fi ller cap is located on the pressure control valve. separator module. When fi lling, oil fl ows through Blow-by gases are introduced directly into the the vent lines into the engine. intake manifold of cylinder bank 1 through a Blow-by gases are channelled through the coarse plastic pipe connected to the intake manifold of oil separator in the oil separator module. The cylinder bank 1. If the vacuum inside the intake coarse oil separator has multiple labyrinth-like manifold is too high, the pressure control valve channels with collecting walls which retain most in the oil separator module closes.