1 Service Training Self-Study Program 824803. The Volkswagen Liter Chain-Driven TSI Engine Volkswagen Group of America, Inc. Volkswagen Academy Printed in 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 affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
2 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.
3 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 3. Lubrication System .. 20. Crankcase Ventilation System .. 25. Cooling System .. 27. Air Intake System .. 30. Fuel 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 Liter Chain-Driven TSI Engine .
4 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 Engine control module Balancer shafts in crankcase Hot-film air mass flow 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.
5 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 flap 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.
6 Introduction 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. 0 1000 2000 3000 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 in ( mm). Stroke in ( mm).
7 Compression Ratio : 1. Firing Order 1-3-4-2. Engine Weight 317 lb (144 kg). Engine Management Bosch MED Fuel Grade 95/91 RON. Exhaust Emission Standard ULEV (CCTA) - SULEV (CBFA). 2. Engine Mechanicals Cylinder Block The cylinder block has a closed-deck configuration The undersides of the pistons are cooled by Engine and is made of cast iron. It houses the five-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.
8 The cylinder liners are by a sealing flange and gasket. finished in a three-stage fluid 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.
9 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 five 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-fit into the small three inner main bearing caps are cross-bolted to the trapezoidal upper end of the connecting rods.
10 Cylinder block. The lower end of the connecting rods are cracked to Trapezoidal Connecting Rod (Small End) ensure a precision fit and reduce movement of the Material: 36 MnVS4 bearing cap under load. Length: in (148 mm) The upper and lower bearing shells of the connecting rod are not identical in composition. The upper Big-End Bearing: in ( mm) bearing shell is a two-component composite Small-End Bearing: 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.