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Design and Function TDIClub
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Volkswagen Group of America Inc, Volkswagen Academy. Printed in U S A, Printed 2 2014, Course Number SSP 820433. 2014 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 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, 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, Introduction 1. Engine Mechanics 4, Engine Management System 40, Service 67. Knowledge Assessment 71, Note Important, This Self Study Program provides information regarding For maintenance and repair procedures. the design and function of new models always refer to the latest electronic service. This Self Study Program is not a Repair Manual This information. information will not be updated, Page intentionally left blank. Introduction, EA288 Diesel Engine Family, Volkswagen 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 standards. In 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 subsystems, Introduction, Modular Diesel Matrix MDB. The new EA288 diesel engine family is also called a modular diesel matrix or MDB The modular diesel system is the basis for. all future inline diesel engines in the Volkswagen Group. The 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 components. Basic Engine Attachment Parts, 1 Modular Camshaft Housing 7 Exhaust Manifold Module with Turbocharger. 2 Cylinder Head 8 Intake Manifold with Water Cooled Charge Air. 3 Cylinder Block, 9 Exhaust Purification Module, 4 Switchable Coolant Pump. 10 Exhaust Gas Recirculation Module, 5 Oil Vacuum Pump.
6 Timing Drive and Accessory Drive, The 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 costs. Introduction, Technical Data, Engine Code CRBC, Design Four cylinder inline engine. Engine Capacity 1968 cm3, Bore 81 0 mm, Stroke 95 5 mm. Valves per Cylinder 4, Compression Ratio 16 2 1, Maximum Output 150 hp 110 kW from 3500 to 4000 rpm. Maximum Torque 235 lb ft 320 Nm from 1750 to 3000 rpm. Engine Management System Bosch EDC 17, Fuel Ultra Low Sulfur Diesel.
Exhaust Gas Aftertreatment Exhaust gas recirculation oxidizing catalytic. converter diesel particulate filter, Emissions Standard BIN 5. Torque and Power Diagram, 2 0 TDI Engine, Torque lb ft. 1000 2000 3000 4000, Engine speed rpm, Engine Mechanics. Cylinder Block, The EA288 cylinder block is grey cast iron an alloy of cast iron and flake graphite. The 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 cylinders. Cylinder Block 2 0L TDI Engine, The cylinder block for the 2 0L TDI engine is available for.
engines with and without balance shafts, Engine Mechanics. Crankshaft Group, Crankshaft Piston and Conrod, The EA288 engine uses a forged crankshaft with five The pistons in the EA288 engine have no valve pockets. bearings to distribute the high mechancial loads Instead of Instead the dish design of the piston crown reduces dead. the usual eight counterweights this crankshaft only has four space and improves the swirl formation of the intake air in. counterweights to counteract the rotating forces of inertia the cylinder. This design reduces the load on the crankshaft bearings To improve piston ring area cooling the pistons have a ring. Noise emissions which may be caused by inherent shaped cooling channel into which oil is sprayed via piston. movement and vibrations in the engine have also been spray nozzles. The conrods are cracked trapezoidal conrods, The toothed belt sprocket that drives the oil pump and the. sprocket that drives the balance shafts are an interference fit. onto the crankshaft, Balance Shaft, Gear Sprocket, for Balance. Shaft Drive, Toothed Belt Sprocket, for Oil Pump Drive.
Camshaft Toothed, Sprocket for Engine, Management System. Balance Shaft, Engine Mechanics, Balance Shafts, One version of the 2 0L TDI engine has a balance shaft. system to reduce crankshaft inertial forces inherent in a. straight four cylinder engine The balance shaft system has. two countershafts rotating in opposite directions at double. the speed of the crankshaft, The balance shafts are is driven by a gear wheel drive. connected to the crankshaft An idler gear between the S514 007. crankshaft and one of the balance shafts reverses the The roller bearings are lubricated by oil mist in the cylinder. direction of the second balance shaft Both balance shafts block. and the idler gear are axially and radially mounted with. roller bearings in the cylinder block to reduce friction. The components in the balance shaft system, cannot be replaced in the field because the. play between the gears cannot be adjusted, using workshop tools.
Rolling Bearing, Balance Shaft, Rolling Bearing, Rolling Bearing Rolling Bearing. Balance Shaft, Rolling Bearing, Rolling Bearing, Crankshaft. Idler Gear for Reversing Rotation, Engine Mechanics. Toothed Belt Drive, The 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 Two idler rollers ensure better meshing of the gear wheels and the. toothed belt, Camshaft Drive Wheel, Idler Roller, High Pressure Pump Drive Gear.
Tensioning Roller, Coolant Pump Drive Gear, Idler Roller. Crankshaft Sprocket, Accessory Component Drive Tensioning Alternator. The 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 tensioner, Pulley with, Vibration Air Conditioner. Damper Compressor, Engine Mechanics, Cylinder Head. The 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 camshaft. Cylinder Head, The 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 gear, Camshaft Housing. Camshaft Housing, The camshafts are integrated into a closed retaining frame by a thermal joining process 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, Spur Gear Teeth. Needle Bearing, Sender Wheel, Retaining Frame with Camshafts. Hall Sensor G40, The camshafts cannot be removed from the camshaft housing If there is damage to the camshafts or the.
housing the complete assembly must be replaced, Engine Mechanics. Valve Layout, For 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 The valve layout has been designed to allow maximum air delivery with good swirl. Intake Air, First Exhaust Valve Cylinder 2, First Intake Valve Cylinder 2. Second Intake Valve Cylinder 2, Cylinder 1, Second Exhaust Valve Cylinder 2. Exhaust Gas, Coolant Jacket Upper Coolant Jacket Core.
The cylinder head has an upper and lower coolant jacket. The lower coolant jacket core has a larger volume to Outlet to the. Connecting Piece, 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 outlet, To 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. Lower Coolant, Jacket Core, Connecting Pieces, for Coolant Hoses. Engine Mechanics, Crankcase Breather, The crankcase breather components are integrated into the cylinder head cover with the oil filler neck and the pressure. accumulator for the engine vacuum system, Blow by gases are returned to the intake side through the crankcase breather.
Crankcase venting takes place in several stages for efficient separation 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 chamber. To prevent the passages from freezing in cold climate countries a heater element is used in the crankcase breather. Heater Element for Crankcase Breather, Pressure Regulating Valve. Vacuum Reservoir, Fine Oil Separation Cyclone, Oil Return from Fine Oil Separator Settling Volume. Gravity Valve for Oil Return, Engine Mechanics, Oil Circuit. Engine 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 requirements, Camshaft Oil Gallery. Oil Filter Module, Compensation, Element Oil, Oil Supply for.
Turbocharger, F1 Oil Pressure Switch, Crankshaft Oil. F378 Reduced Oil Pressure, Spray Jets for, Piston Cooling Two Stage. the design and function of new models This Self Study Program is not a Repair Manual This information will not be updated For maintenance and repair procedures always refer to the latest electronic service information Note Important

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