SSP 436 Modifications to the 2.0 TFSI engine.pdf

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Service Training
Modifications to the chain-driven
4-cylinder TFSI engine
Self-Study Programme 436
The 1.8-litre chain-driven 4V TFSI engine was the first engine of its kind when it was launched in 2006. This new 4-cylinder
engine generation (EA888) is gradually replacing the timing belt-driven 4-cylinder engine generation, now being phased out.
The engine first appeared on the Audi A3 as a transverse unit. This so-called "Stage 0" engine was developed with emphasis
on the following development goals:
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Enhanced fuel economy
Reduced exhaust emissions and compliance with future exhaust emission standards
Extended performance range
Longitudinal installation of the engine
For a detailed technical description of the "Stage 0" engine, please refer to Self-Study Programme 384, "Audi 1.8-litre chain-
driven 4V TFSI engine". Stage 2 has now been implemented. A table summarising the various modifications is included in
this Self-Study Programme. The modifications relevant to service centres are described below.
A key milestone for Audi was the launch of the engine on the North American market, where the world's most stringent
exhaust emission standards (ULEV II and SULEV) apply. To meet these limits, further technical modifications were called for.
You will also find a description of these modifications in this Self-Study Programme.
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Illustrations on page 1
Large picture: longitudinal 1.8l TFSI engine
Small picture: longitudinal cylinder head of the 2.0l TFSI engine
Transverse 2.0l TFSI engine
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The learning objectives of this Self-Study Programme:
In this Self-Study Programme, you will learn about the key modifications to the chain-driven 4-cylinder TFSI engine.
Once you have worked your way through this Self-Study Programme, you will be able to answer the following questions:
How do you differentiate between the various development stages of the longitudinal and tr ansverse engines?
What are the main technical modifications, and why were they introduced?
Which modifications were made to the crankcase ventilation system?
What are the points to observe when testing the oil pressure when a self-regulating oil pump is installed?
What are the special features of the Audi valvelift system in the 4-cylinder TFSI engine compared to the system on
the V6 FSI engine?
– What were the measures implemented to meet the ULEV II and SULEV exhaust emission standards, and how does
this technology work?
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Contents
Introduction
Overview of the development stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Technical features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine mechanicals
Audi valvelift system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Crankcase ventilation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Oil circulation system
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Self-regulating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Oil pressure monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.0l TFSI engine for SULEV
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Modifications compared to engines for the European market . . . . . . . . . . . . . . 33
Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Exhaust turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Catalytic converter system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Automatic starter control in the Audi A3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Compliance with statutory limits (PremAir
®
). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Service
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Annex
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Test yourself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Summary
Self-Study Programmes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Reference
Terms shown in italics and marked by an asterisk (*) are explained in the glossary at the end of
this Self-Study Programme.
The Self-Study Programme teaches the design and function of new vehicle models,
new automotive components or new technologies.
The Self Study Programme is not a Repair Manual.
All values given are intended for reference purposes only and refer to the software version valid at the time
of preparation of the SSP
.
For information about maintenance and repair work, always refer to the current technical literature.
Reference
Note

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