SSP 322 - The 2.0l FSI Engine With 4-valve Technology
Service TrainingSelf-study programme 322The 2.0l FSI engine with 4-valve technologyDesign and function
The 2.0l engine is based on the tried and tested827/113 series.Thanks to FSI technology (Fuel StratifiedInjection), the 2.0l petrol engine has taken on anew dimension. FSI engines are more economic,cleaner and more responsive than multi-pointinjection engines.They also meet today’s requirements in terms oflow consumption, environmental issues andincreased driving fun.The Volkswagen 1.4-litre/77kW FSI engine, thepioneer in this new generation of petrol engines,demonstrated these advantages at the end of2000 when it was used in the Lupo. It was thenfollowed by the 1.6-litre/81kW FSI and 1.4-litre/63kW FSI in the Polo.This self-study programme should familiarise youwith the new technical features of this engine.S322 015NEWThe self-study programme shows the design andfunction of new developments.The contents will not be updated.2For current testing, adjustment and repair instructions,refer to the relevant service literature.ImportantNote
ContentsIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Engine mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Engine management. . . . . . . . . . . . . . . . . . . . . . . . . . 10Functional diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Test yourself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
IntroductionDescription of engineUsing the Volkswagen Audi platform, the 2.0-litre FSI engine appeared for the first time in the Audi A4,longitudinally mounted with the engine code AWA. In February 2003, the 2.0l FSI engine with the codeAXW, identical with the Volkswagen version, was installed transversely in the Audi A3.The following components have been further developed to meet the high demands for engineperformance and economy: An aluminium engine block withcast-iron linersA water-cooled exhaust gas recirculationvalve (EGR)An exhaust system with two starter catalyticconverters fitted close to the engineExhaust gasrecirculation valveS322 051Starter catalytic convertersEngine blockS322 0494
An intake manifold with change-over barrel for switching between the torque and power channelsA new oil filter moduleBosch Motronic MED 9.5.10Four valves per cylinder, operated via roller rocker fingers with upright hydro-elementsAluminium cylinder head with two overhead camshafts and continuous inlet camshaft timingadjustmentDirect fuel injection with demand-regulated high-pressure pumpCamshaftsRoller rocker armValvesS322 073Change-overS322 069Intake manifoldbarrelOil filter moduleS322 047S322 0715
Engine mechanicsThe 2.0l/110kW FSI engine with 4-valve technologyThe 2.0l/110kW FSI engine was used in the Audi A3 in February 2003. Volkswagen used the engine forthe first time in October 2003 in the Touran. It will be available for the Golf from the start of 2004.Technical features Single-piston high-pressure pumpPlastic variable intake manifoldIntake manifold with continuouslyadjustable charge direction flaps/intake manifold flapsWater-cooled exhaust gas recirculation valveRoller rocker finger with hydraulicsupport elementTwo overhead camshafts with continuous inletcamshaft adjustmentBalancer shaft gear assembly in sumpAir-guided combustion methodTechnical dataS322 011Torque and power diagramEngine codeAXWType4-cylinder in-line engineDisplacement [mm³]1984Bore [mm]11020010082.518090Stroke [mm]92.816080Valves per cylinder4Compression ratio11.5:114070Maximum output110kW at 6000rpm12060Maximum torque200Nm at 3500rpm10050Engine managementBosch Motronic MED 9.5.10FuelUnleaded 98 RON8040603040202010(Unleaded 95 RON withreduction in performance)Exhaust gas treatmentTorque [Nm]220Power [kW] NOx storage catalyticconverter and 2 startercatalytic convertersEmissions standardEU 4100030005000Engine speed [rpm]7000S322 0126
Intake manifold with change-over barrelThe two-stage variable intake manifold helps provide the required power and torque characteristics.The pneumatic switching of the change-over barrels from torque to power position is map-controlled.The load, speed and temperature are the relevant variables for this process.Change-over barrelThe change-over barrel in power position.The engine draws in air via the power channeland the torque channel.Power channelS322 065Torque channelThe change-over barrel in torque position. Theengine draws in air only via the torque channel.S322 0677
Engine mechanicsIntake manifold lower partThe lower part of the intake manifold contains four intake manifold flaps that are adjusted by the V157control motor via a common shaft. The G336 potentiometer integrated in the control motor is usedto indicate the flap position to the J220 engine control unit.S322 061The oil filter moduleCrankcase breatherThe new oil filter module was developed as ahighly integrated plastic unit. Its componentsinclude:-An oil pressure shut-off valveA paper filter element to filter the oilAn integrated water-cooled oil coolerA damper chamber on the crankcasebreather for the liquid-vapour separatordamper chamberOil outletWaterinletOil coolerWateroutletOil inletOil pressure shut-off valvePaper filter elementS322 045Oil drainage valve8
The cylinder headThe 2.0l FSI engine with 4-valve technology hasan aluminium cylinder head.The valves are operated by two overheadcamshafts mounted on bearings in a ladderframe to ensure torsional stiffness.The outlet camshaft is driven by toothed belts.The inlet camshaft is driven via the outletcamshaft by a simplex chain.Each intake channel is divided into an upper andlower half by a separating plate. The plates havebeen shaped so that they can only be fitted in thecorrect position.Ladder frameOutlet camshaftInlet camshaftSeparating plateS322 0599
Engine managementSystem overviewG71 Intake manifold pressure senderG42 Intake air temperature senderDiagnosis connectorG299 Intake air temperature sender 2G28 Engine speed senderG40 Hall senderJ338 Throttle valve moduleG187 Throttle valve drive angle sender 1G188 Throttle valve drive angle sender 2J220 Motroniccontrol unitG79 Accelerator pedal position senderG185 Accelerator pedal position sender 2FF47Brake light switchCruise control system brake pedal switchG247 Fuel pressure sender, high pressureKnock sensorKnock sensor 2Communications lineG61G66G62 Coolant temperature senderG83Radiator outlet coolanttemperature senderG336 Intake manifold flap potentiometerCAN driveG410 Fuel pressure sender, low pressureG212 Exhaust gas recirculation potentiometerG39G108G130G131Lambda probeLambda probe IILambda probe after catalytic converterLambda probe II after catalytic converterG235 Exhaust gas temperature senderG295 NOx senderJ583 NOx sensor control unitG294 Brake servo pressure sensorG476 Clutch position sender10J519Onboard supply controlunitJ533 Data bus diagnosticinterface
J538 Fuel pump control unitG6Fuel pumpN30N31N32N33Injector, cylinder 1Injector, cylinder 2Injector, cylinder 3Injector, cylinder 4N70N127N291N292Ignition coil 1 with output stageIgnition coil 2 with output stageIgnition coil 3 with output stageIgnition coil 4 with output stageJ338 Throttle valve moduleG186 Throttle valve driveJ271Motronic current supply relayN276 Fuel pressure regulating valveJ527 Steering columnelectronicscontrol unitJ234 Airbagcontrol unitJ104 ABScontrol unitN80 Activated charcoal filter system solenoid valveN316 Intake manifold flap air flow control valveJ285 Control unit withdisplay indash panel insertN18Exhaust gas recirculation valveZ19Z28Lambda probe heaterLambda probe 2 heaterZ29Z30Lambda probe 1 heater after catalytic converterLambda probe 2 heater after catalytic converterZ44NOx sender heaterN205 Inlet camshaft timing adjustment valveV157 Intake manifold flap motorS322 04211
Engine managementExhaust systemThe front section of the exhaust system is split intodual pipes to increase the torque in the lower revrange. Both exhaust sections are equipped withstarter catalyticconverters.The starter catalytic converters have beenpermanently fixed to the two exhaust manifolds.The two exhaust sections then join together at theNOx storage catalytic converter.In lean mix operation, the storage catalyticconverter temporarily stores nitric oxide (NOx).The NOx sensor monitors the degree ofsaturation and triggers regeneration of thestorage catalytic converter.Two broadband probes monitor the mixturecomposition for the starter catalytic converters.Two step-type Lambda probes come after thestarter catalytic converters (planar Lambdaprobes). These monitor the efficiency of thestarter catalytic converters.Broadband probeStarter catalyticconverterS322 043Step-type LambdaprobeTemperature sensorNOx storage catalyticconverterNOx sensor12
Operating modesThe air-guided combustion method allows use ofhomogenous and stratified charge modes.The engine electronics select the best operatingmode depending on the load and the position ofthe accelerator pedal.There are 4 main modes:- Stratified leanwith exhaust gas recirculation (EGR)- Homogenous lean without EGR- Homogenous with Lambda 1 and EGR- Homogenous with Lambda 1 without EGRMean pressure [bar]HomogenousHomogenous with exhaust gas recirculationHomogenous leanStratifiedleanEngine speed [rpm]S322 040You will find further information in the self-study programme SSP 253 “The petrol direct injectionsystem with Bosch Motronic MED 7”.13
Engine managementStratified charge modeThe fuel injection, the combustion chambergeometry and the flow inside the cylinder needto be fine-tuned to make stratified charge modepossible. The followingrequirements also need to be met:- The engine should be in the appropriateload and rev range.- There cannot be any exhaust gas-relatederrors in the system.- The coolant temperature should be above50 C.- The temperature of the NOx storagecatalytic converter should be between 250 Cand 500 C.- The intake manifold flap should be closed.S322 021Separating plateIntake manifoldflapThe intake manifold flap closes the lower intakeduct according to the engine map. As a result,the increased incoming mass of air has to flowthrough the upper intake duct and starts atumbling charge movement in the cylinder.High-pressureinjectorS322 023The tumbling air flow is enhanced in the cylinderby the air-flow recess in the piston and theupwards movement of the piston.S322 02514
The fuel is injected during the compression strokejust before the ignition point. The fuel is injectedat high pressure (40-110 bar) into the flow of air.The air flow then carries the ignitable mixture tothe spark plug.S322 027As the injection angle is quite flat, the fuel mistvirtually does not come into contact with thethe piston head. This is known as an “air-guided”method.S322 029Upon combustion, there is a layer of insulatingair between the ignited mixture and the cylinderwall. This reduces the amount of heat transferredvia the engine block and thus improvesefficiency.S322 03115
Engine managementHomogenous modeIn homogenous mode, the intake manifold flap ismoved to an intermediate position according tothe engine map.In the combustion chamber, an optimum air flowfor achieving lower fuel consumption andemissions is created.S322 033In homogenous mode, the fuel is injectedduring the intake stroke and not in thecompression phase as with stratified chargemode.S322 03516
As the fuel is injected during the intake stroke,the fuel-air mixture has more time to mixthoroughly before ignition.S322 037Combustion takes place in the whole combustionchamber without an insulating air layer orrecirculated exhaust gases.S322 039The advantages of homogenous mode are brought about by direct injection during the intake stroke.The fuel evaporation removes some of the heat from the incoming air. Cooling the interior reduces theknocking tendency and thus increases the engine compression and efficiency.17
Functional diagramJ519Terminal 30Terminal N316J538J220N70N127N291N292G185G79G410J338G187 G188G186bS322 052FF47GG1G6G28G39G40G42G61G62G66G71G79G83Brake light switchCruise control system brake pedal switchFuel gauge senderFuel gaugeFuel pumpEngine speed senderLambda probeHall senderIntake air temperature senderKnock sensorCoolant temperature senderKnock sensor 2Intake manifold pressure senderAccelerator pedal position senderRadiator outlet coolanttemperature senderG108 Lambda probe IIG130G131G185G186G187G188G212G235G247Lambda probe after catalytic converterLambda probe II after catalytic converterAccelerator pedal position sender 2Throttle valve driveThrottle valve drive angle sender 1Throttle valve drive angle sender 2Exhaust gas recirculation potentiometerExhaust gas temperature senderFuel pressure sender, high pressureColour code/legend input signal output signal positive earth CAN data bus18
J519J533Terminal 30Terminal 15aZ44SSSSF47FG295Z19G39Z28 G130G108Z29Z30 G131J583G476G62J220N18G212G247G42 G71G40G336V157bG235G83G294S322 3N18N30N31N32N33Brake servo pressure sensorNOx senderIntake air temperature sender 2Intake manifold flap potentiometerFuel pressure sender, low pressureClutch position senderMotronic current supply relayThrottle valve moduleOnboard supply control unitData bus diagnostic interfaceFuel pump control unitNOx sensor control unitExhaust gas recirculation valveInjector, cylinder 1Injector, cylinder 2Injector, cylinder 3Injector, cylinder Ignition coil 1 with output stageActivated charcoal filter system solenoid valveIgnition coil 2 with output stageInlet camshaft timing adjustment valveIgnition coil 3 with output stageIgnition coil 4 with output stageFuel pressure regulating valveIntake manifold flap air flow control valveIntake manifold flap motorLambda probe heaterLambda probe 2 heaterLambda probe 1 heater after catalytic converterLambda probe 2 heater after catalytic converterNOx sender heater19
ServiceNew special toolsDesignationToolApplicationT10133FSI special toolcaseFamiliar special tools for repairing FSI engines. Alsofor use with 2.0l FSI engines.S322 063T40057Oil drainageadapterFor draining the engine oil from the oil filter housingS322 053T40001PullerFor removing the camshaft wheelT40001/6Claw attachmentsforpullerT40001/7Claw attachmentsforpullerS322 05520
Notes21
Test yourself1.The engine electronics select the best operating mode depending on the load and the position of theaccelerator pedal. Which 4 main modes are used by the 2.0l FSI engine?a)b)c)d)2.What is meant by the “air-led” method used in stratified charge mode?a) The fuel is injected in the direction of the piston head. The fuel mist is then transported to the spark plugtogether with the tumble-shaped air flow.b) The fuel is injected into the tumble-shaped air flow at a flat angle and transported to the spark plug.c) The fuel directly injected during the intake stroke evaporates in the cylinder and draws part ofheat from the incoming air mass.3.Where is the NOx sensor located in the exhaust system?a) In front of the NOx storage catalytic converter.b) In front of the step-type Lambda probes.c) After the NOx storage catalytic converter.d) In front of the starter catalytic converters.22
23Answers1.) a)b)c)d)Stratified injection with exhaust gas recirculation (EGR)Homogenous lean without EGRHomogenous with Lambda 1 and EGRHomogenous with Lambda 1 without EGR2.) b3.) c
322 VOLKSWAGEN AG, Wolfsburg, VK-36 Service TrainingAll rights and rights to make technical alterations reserved000.2811.43.20 Technical status 10/03 This paper was manufactured from pulp thatwas bleached without the use of chlorine.
5 An intake manifold with change-over barrel for switching between the torque and power channels A new oil filter module Bosch Motronic MED 9.5.10 Four valves per cylinder, operated via roller rocker fingers with upright hydro-elements Aluminium cylinder head with two overhead camshafts and continuous inlet camshaft timing adjustment Direc
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