Design and Function - TDIClub

1 Service TrainingSelf Study Program 820433 The EA288 Diesel engine FamilyDesign and Function Volkswagen Group of America, AcademyPrinted in 2/2014 Course Number SSP 820433 2014 Volkswagen Group of America, 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 affiliated 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 requests for permission to copy and redistribute information should be referred to Volkswagen Group of America, check Technical Bulletins and the latest electronic repair information for information that may supersede any information included in this : 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 Self-Study Program provides information regarding the Design and Function of new Self-Study Program is not a Repair Manual.

2 This information will not be maintenance and repair procedures, always refer to the latest electronic service !Introduction .. 1 engine Mechanics .. 4 engine Management System .. 40 Service .. 67 Knowledge Assessment .. 71 Page intentionally left blank1 IntroductionEA288 Diesel engine FamilyVolkswagen is introducing a new family of diesel engines in the 2015 Golf. The engine family has the designation EA288 (EA = Entwicklungsauftrag [development order]).The Design of this new generation of diesel engines was based on the existing EA189 engine family. Displacement, cylinder spacing, stroke and bore ratio are shared between the EA189 and the new EA288 gasoline engines. The new EA288 engine Design forms the basis for all future inline diesel engines at Volkswagen. Several sub-assemblies were redesigned in the EA 288 family of 4-cylinder diesel engines to satisfy future emission this Self-Study Program you will learn about the structure and Design of the new EA288 TDI engine , and the functions of the individual engine Diesel Matrix (MDB)The new EA288 diesel engine family is also called a modular diesel matrix, or MDB.

3 The modular diesel system is the basis for all future inline diesel engines in the Volkswagen modular diesel matrix is a concept that involves dividing the functional engine components into modules. Depending on capacity, power output, emission standard and the vehicle class, engines can be assembled from modules and modular Design meets fuel consumption, exhaust emissions and power delivery demands. It also allows the engines to accept future modular components that meet upcoming country-specific requirements with minimal Engine1 Modular Camshaft Housing2 Cylinder Head3 Cylinder Block4 Switchable Coolant Pump5 Oil/Vacuum Pump6 Timing Drive and Accessory DriveAttachment Parts7 Exhaust Manifold Module with Turbocharger8 Intake Manifold with Water-Cooled Charge Air Cooler9 Exhaust Purification Module10 Exhaust Gas Recirculation ModuleS514_104108379245613 IntroductionTechnical DataEngine CodeCRBCD esignFour-cylinder inline engineEngine Capacity1968 mmValves per Cylinder4 Compression.

4 1 Maximum Output150 hp (110 kW) from 3500 to 4000 rpmMaximum Torque235 lb/ft (320 Nm) from 1750 to 3000 rpmEngine Management SystemBosch EDC 17 FuelUltra-Low Sulfur DieselExhaust Gas AftertreatmentExhaust gas recirculation, oxidizing catalytic converter, diesel particulate filterEmissions StandardBIN 5 Torque and Power TDI Engine10002000 3000 400025022019 016 013 010 0754528015 013 012 510 08060402510 Torque [lb/ft] engine speed [rpm]Output [hp]4 engine MechanicsCylinder BlockThe EA288 cylinder block is grey cast iron, an alloy of cast iron and flake cylinder block has deep screw threads for long cylinder head bolts. This distributes combustion forces through the cylinder-block structure, applying equal pressure distribution on the cylinder head gasket. The Design of the cooling channels in the cylinder block provides good cooling in the area between the Block TDI EngineThe cylinder block for the TDI engine is available for engines with and without balance shafts.

5 5 engine MechanicsCrankshaft GroupCrankshaftThe EA288 engine uses a forged crankshaft with five bearings to distribute the high mechancial loads. Instead of the usual eight counterweights, this crankshaft only has four counterweights to counteract the rotating forces of Design reduces the load on the crankshaft bearings. Noise emissions, which may be caused by inherent movement and vibrations in the engine , have also been toothed belt sprocket that drives the oil pump and the sprocket that drives the balance shafts are an interference fit onto the and ConrodThe pistons in the EA288 engine have no valve pockets. Instead, the dish Design of the piston crown reduces dead space and improves the swirl formation of the intake air in the improve piston ring area cooling, the pistons have a ring-shaped cooling channel into which oil is sprayed via piston spray nozzles. The conrods are cracked trapezoidal Belt Sprocket for Oil Pump DriveCamshaft Toothed Sprocket for engine Management SystemBalance ShaftPistonsConrodGear Sprocket for Balance Shaft DriveBalance Shaft6 engine MechanicsBalance ShaftsOne version of the TDI engine has a balance shaft system to reduce crankshaft inertial forces inherent in a straight four-cylinder engine .

6 The balance shaft system has two countershafts rotating in opposite directions at double the speed of the balance shafts are is driven by a gear wheel drive connected to the crankshaft. An idler gear between the crankshaft and one of the balance shafts reverses the direction of the second balance shaft. Both balance shafts and the idler gear are axially and radially mounted with roller bearings in the cylinder block to reduce components in the balance shaft system cannot be replaced in the field because the play between the gears cannot be adjusted using workshop BearingBalance ShaftCrankshaftIdler Gear for Reversing RotationRolling BearingRolling BearingRolling BearingBalance ShaftRolling BearingRolling BearingThe roller bearings are lubricated by oil mist in the cylinder block. 7 engine MechanicsToothed Belt DriveThe engine timing components are driven by the crankshaft via a toothed belt. From the crankshaft, the toothed belt is routed to the belt tensioner, over the camshaft drive wheel, to the drive wheel of the high-pressure pump for the common rail injection system, and then to the drive wheel of the coolant pump.

7 Two idler rollers ensure better meshing of the gear wheels and the toothed Component DriveThe alternator and the air conditioner compressor are driven by the crankshaft by a pulley with vibration damper and a poly V-belt. The poly V-belt is tensioned by a spring-loaded belt Drive WheelIdler RollerCrankshaft SprocketIdler RollerCoolant Pump Drive GearTensioning RollerHigh Pressure Pump Drive GearS514_008 AlternatorTensioning RollerPulley with Vibration DamperAir Conditioner Compressor8 engine MechanicsCylinder HeadThe aluminum alloy cylinder head of the EA288 engine has a cross-flow Design and a unique placement of intake and exhaust valves. The valves are operated by two camshafts. Because of the arrangement of the intake and exhaust ports, each camshaft operates intake and exhaust valves. There is not a separate intake or exhaust camshafts are driven by the crankshaft by a toothed belt and the camshaft gear of one of the camshafts. The two camshafts are joined by a spur HousingThe camshafts are integrated into a closed retaining frame by a thermal joining process.

8 They cannot be separated. This process ensures a very rigid camshaft bearing while keeping the weight low. To reduce friction, a needle bearing is used for the first bearing that receives the highest forces from the toothed belt drive. A sensor wheel for G40 Camshaft Position Sensor is located on one camshaft. The signal from the Hall sensor tells the ECM the current position of the camshafts cannot be removed from the camshaft housing. If there is damage to the camshafts or the housing, the complete assembly must be HeadCamshaft HousingS514_043 Needle BearingSpur Gear TeethHall Sensor G40 Retaining Frame with CamshaftsSender Wheel9 engine MechanicsValve LayoutFor future emission standards, the valve star has been rotated to the longitudinal axis of the engine . This means the intake and exhaust ports for each cylinder are positioned one behind the other in the direction of flow. As a result, each camshaft actuates one intake and exhaust valve per cylinder.

9 The valve layout has been designed to allow maximum air delivery with good swirl JacketThe cylinder head has an upper and lower coolant jacket. The lower coolant jacket core has a larger volume, to provide a high level of heat dissipation in the part of the cylinder head close to the combustion chamber. The flow of coolant from the upper and lower parts merge at the spur gear side of the cylinder head where it exits through a combined provide heat when the engine is cold, the coolant is channeled out of the upper and lower core, through the coolant hose connecting piece, and towards the heater core. S514_059 First Exhaust Valve, Cylinder 2 Second Intake Valve, Cylinder 2 First Intake Valve, Cylinder 2 Intake AirExhaust GasSecond Exhaust Valve, Cylinder 2 Cylinder 1S514_047 Outlet to the Connecting PieceConnecting Pieces for Coolant HosesLower Coolant Jacket CoreUpper Coolant Jacket Core10 engine MechanicsCrankcase BreatherThe crankcase breather components are integrated into the cylinder head cover, with the oil filler neck and the pressure accumulator for the engine vacuum gases are returned to the intake side through the crankcase venting takes place in several stages for efficient separation.

10 First, the blow-by gases travel from the crankshaft and camshaft chamber into the settling volume area of the cylinder head cover. This is where larger oil drops collect on the walls and drip down into the cylinder head. Then the oily gases are separated from gas fumes in a cyclone separator. The pressure control valve regulates the transfer of purified gases to the intake manifold, where they enter the combustion prevent the passages from freezing in cold climate countries, a heater element is used in the crankcase Element for Crankcase BreatherVacuum ReservoirOil Return from Fine Oil SeparatorGravity Valve for Oil ReturnPressure Regulating ValveFine Oil Separation (Cyclone)Settling Volume11 engine MechanicsOil CircuitEngine oil pressure is generated by a flow-rate controlled oil pump. The oil pump operates in either a high or low-pressure setting, depending on operating Filter ModuleCamshaft Oil GalleryHydraulic Compensation Element Oil GalleryOil Supply for TurbochargerF1 Oil Pressure SwitchF378 Reduced Oil Pressure SwitchSpray Jets for Piston CoolingCrankshaft Oil GalleryG266 Oil Level Thermal SensorTwo-Sta ge Oil Pump12 engine MechanicsOil and Vacuum PumpsThe oil pump and a vacuum pump are combined in a housing on the bottom of the cylinder block.