The Volkswagen 2.0 Liter Chain-Driven TSI Engine

1 Service TrainingSelf-Study Program 824803 The Volkswagen LiterChain- driven TSI EngineVolkswagen Group of America, AcademyPrinted in 5/2008 Course Number 824803 2008 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 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 ofthe 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.

2 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 .. 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 This Self-Study Program covers information on the Volkswagen Liter Chain-Driven TSI Self-Study Program is not a Repair Manual. This information will not be testing, adjustment and repair procedures, always refer to the latest electronic service !Page intentionally left blank1 Introduction1 Technical DescriptionFour Cylinder, Four Valve.

3 TSI Turbocharged Gasoline EngineEngine BlockCast iron crankcase Balancer shafts in crankcase Forged steel crankshaft Sump-mounted oil pump Chain-Driven by crankshaftTiming gear chain front end of Engine Balancer Chain-Driven at front end of Engine Cylinder Head4-valve cylinder head 1 INA intake camshaft adjuster Intake ManifoldTumble fl ap Fuel SupplyDemand controlled on low and high-pressure ends Multi-port high-pressure injector Engine ManagementMED Engine control module Hot-fi lm air mass fl ow with integral temperature sensorThrottle valve with contactless sensor Map-controlled ignition with cylinder-selective, digital knock controlSingle-spark ignition coils TurbochargingIntegral exhaust turbocharger Charge-air cooler Boost pressure control with overpressure Electrical wastegate valve ExhaustSingle-chamber exhaust system with close- coupled pre-catalystCombustion ProcessFuel straight injection Chain-Driven TSI EngineEngine speed in RPM220(300)243(330)177(240)200(270)265(3 60)110(150)133(180)67(90)44(60)22(30)088 (120)155(210)121(90)80(60)201(150)161(12 0)3000400010000200050006000700040(30)0 SpecificationsEngine CodeCCTA - CBFAType of EngineInline 4-Cylinder TSI EngineDisplacement121 cu in (1984 cm3)Maximum Power200 hp (147 kW) at 5100 - 6000 rpmMaximum Torque206 lb ft (280 Nm)

4 At 1700 - 5000 rpmNumber of Valves Per in ( mm) in ( mm)Compression : 1 Firing Order1-3-4-2 Engine Weight317 lb (144 kg) Engine ManagementBosch MED Grade95/91 RONE xhaust Emission StandardULEV (CCTA) - SULEV (CBFA) Engine Mechanicals3 Cylinder BlockThe cylinder block has a closed-deck confi guration and is made of cast iron. It houses the fi ve-bearing crankshaft assembly and the two balancer housing for mounting the chain drives is integrated in the block. The cylinder liners are fi nished in a three-stage fl uid jet honing undersides of the pistons are cooled by Engine oil supplied by spray jets mounted on the cylinder cylinder block is sealed on the transmission side by a sealing fl ange and Mechanicals4 Oil PanThe oil pan consists of two upper section is made of an aluminum alloy (AlSi12Cu) and reinforces the crankcase through a bedplate effect.

5 It also houses the oil upper section is bolted to the crankcase and sealed with a liquid bottom section is made of sheet steel (deepdrawn, punched, and catalytically coated). It houses Oil Level Sensor G12 and the drain bottom section is bolted to the upper section and sealed with a liquid oil pan has an integral honeycomb insert made of polyamide to prevent oil churning when the vehicle is driven Alloy Oil Pan Top SectionPolyamide Honeycomb InsertStamped Steel Oil Pan Bottom SectionEngine Mechanicals5 CrankshaftThe fi ve main bearing crankshaft is made of forged steel and induction hardened. Optimal balancing is achieved by using eight additionally reinforce the crankshaft assembly, three inner main bearing caps are cross-bolted to the cylinder Connecting Rod (Small End)Material: 36 MnVS4 Length: in (148 mm)Big-End Bearing: in ( mm)Small-End Bearing: in (21 mm)PistonWrist Pin Retaining ClipTrapezoidal Shaped Small End of Connecting RodWrist PinBronze Connecting Rod BushingConnectingRod Upper Bearing ShellCross-Bolted Main Bearing Caps and BoltsConnectingRod CapMain Bearing CapThe crankshaft main bearings are a two component type.

6 Axial play of the crankshaft is controlled by thrust washers at the middle support bushings are press-fi t into the small trapezoidal upper end of the connecting lower end of the connecting rods are cracked to ensure a precision fi t and reduce movement of the bearing cap under upper and lower bearing shells of the connecting rod are not identical in composition. The upper bearing shell is a two-component composite bearing while the lower shell is a three-component composite Mechanicals6 The chain drive sprocket is mounted to the crankshaft face and driven by a spur gear forged in the crankshaft. The other end of the chain sprocket also has a spur gear surface which drives the 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.

7 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 the transmission side of the Engine , a dual mass fl ywheel or torque converter (depending on transmission) is mounted to the crankshaft with eight are coded for assembly they can only be installed one wayVibration DamperCenter BoltChain SprocketSpur Gear DriveEngine Mechanicals7 PistonsThe 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 31 CrMoV wrist pins are held in place by snap rings.

8 The bottom side of the pistons are cooled by Engine oil from spray jets mounted on the cylinder Mechanicals8 Cylinder HeadMLHQKIENPJSDFBRTOGCAE ngine Mechanicals9 The 4-valve cylinder head is cast from aluminum alloy. Intake and exhaust valves are actuated by roller cam followers supported by hydraulic valve intake and exhaust camshafts are variable timing of the intake camshaft is accomplished through the INA camshaft adjustment system (page 11).The cylinder head cover adds support by acting as a ladder frame and does not have to be disassembled to remove the cylinder diagonal opening and sealing face simplifi es drive chain Check valveB Sealing end capC Exhaust valveD Intake valveE Valve stem sealF Valve springG Valve spring retainerH Valve keeperI Exhaust camshaftJ Intake camshaft with INA adjusterK Cylinder head coverL Cylinder head cover screwM Screw plugN Sealing end capO Hydraulic valve clearance adjusterP Roller cam followerQ Dowel pinR Cylinder head bolt with washerS Exhaust manifold locating pinT Exhaust manifold studFeaturesCrossfl ow cylinder head made of ASi10Mg Three-layer metal head gasket.

9 Intake ports divided by baffl e plate Cylinder head cover made of AlSi9Cu3 with integrated ladder frame, bolted to cylinder head and sealed with liquid sealantIntake valve: solid-stem valve, chrome-plated with reinforced seatExhaust valve: sodium fi lled hollow-stem valve, chrome-plated and tempered with reinforced seatSingle valve spring made of steel Roller cam followers running in needle bearings, hydraulic valve clearance adjustmentHydro-formed, assembled intake camshaft with variable valve timing, dwell angle 190 , valve lift mmHydro-formed, assembled exhaust camshaft with press-fi t drive gear, dwell angle 180 , valve lift 8 mmINA Camshaft Adjuster, timing range 60 crank angle, basic position is locked in retard (enginenot running) Engine Mechanicals10 Bearing BridgeA die-cast aluminum bearing bridge mounted at the front of the cylinder head has the following tasks.

10 Supporting the camshafts Supplying pressurized oil to camshaft bearings Supplying pressurized oil to the camshaft adjuster Controlling axial movement of camshafts Mounting point for Camshaft Adjustment Valve 1 N205 The bearing bridge also serves to connect the two oil galleries of the cylinder head. A check valve and fi lter screen are integrated in the pressurized oil duct to the INA camshaft Aluminum Bearing BridgeEngine Mechanicals11 INA Camshaft Adjustment SystemThe TSI Engine uses a hydraulic vane cell adjuster on the intake camshaft to affect valve timing. Only the intake camshaft has variably adjusted timing on this Engine . Oil pressure for this task is provided by the Engine oil variable camshaft adjuster provides an adjustment range of 60 crank angle.