Self-Study Programme 252 1.4L 77kw with petrol direct injection in the Lupo FSI.pdf

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Service.
Self-Study Programme 252
1.4 l 77 kW Engine with
Petrol Direct Injection System in the Lupo FSI
Design and Function
Volkswagen is fitting a direct-injection petrol
engine for the first time in the Lupo FSI.
The engine in question is a 1.4-litre unit
developing 77kW (105 bhp).
The abbreviation
FSI
stands for
Fuel Stratified
Injection.
This describes the type of injection used
in the fuel-saving operating mode.
By virtue of the petrol-direct injection system in
particular, fuel consumption is reduced by as
much as 15% compared with a similar engine
equipped with an intake manifold injection
system.
However, the engine mechanicals were also
modified in order to reduce fuel consumption
even further.
For more detailed information on the petrol-
direct injection system, please refer to Self-Study
Programme 253 which describes the engine
management system of the 1.4-litre 77kW engine.
252_110
New
Important
Note
This Self-Study Programme explains the design and
function of new developments.
The contents are not updated.
Please always refer to the relevant Service Literature for current inspection,
adjustment and repair instructions.
2
Table of contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine mechanicals . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Intake manifold with intake manifold-lower section . . .7
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Camshafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Camshaft timing control . . . . . . . . . . . . . . . . . . . . . . . . 10
Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Crankcase breather . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine management. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Intake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Cooling system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Function diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Test your knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3
Introduction
The 1.4-litre 77kW engine with petrol-direct injection
is a further development of the 1.4-litre 74kW engine
used in the model year 2000 for the Polo.
252_077
The parts of the engine mechanicals adopted from the 1.4-litre 74kW engine used in the Polo are shown
below. For a more detailed description, please refer to Self-Study Programme No. 196.
Valve gear
The valve gear comprises the
valves, the roller rocker arms
and the support elements.
Sealing flange with integrated sender wheel
A sealing flange with
integrated sender wheel
for engine speed sender
G28 is used on the clutch
side.
252_047
Conrod
Cracked conrods are
used.
252_004
Crankshaft
252_010
The crankshaft runs in five bearings. The bearing covers
must not be detached.
252_009
Oil pump
A Duo-Centric
oil pump is used.
Oil cooler
252_011
Adopted from the 1.6-litre 92 kW engine, the oil cooler is
integrated in the cooling system on account of the
increased amount of heat dissipation to the engine oil.
252_045
4
Specifications
The 1.4-litre 77kW engine
[kW]
[Nm]
Maximum power output is 77kW at 6200 rpm.
Maximum torque is 130 Nm at an engine speed
of 4500 rpm.
The Lupo FSI, like the Lupo 3L, has an ECO
mode. In this mode, average fuel consumption is
4.9 l per 100 km in accordance with the MVEG
standard.
Engine speed is limited to 4000 rpm and full
throttle injection quantity is reduced. Maximum
power output is 51 kW and maximum torque is
125 Nm at 4000 rpm.
The power output and torque figures at engine
speeds up to 4000 rpm are approximately 3 %
below those shown in the adjacent diagram.
Differences compared with the Lupo 3L
- The Lupo FSI does not have a stop/start func-
tion. During stationary phases, therefore, the
engine continues to run. This prevents the
catalytic converters cooling down to below
their working temperature.
[rpm]
252_037
- In overrun phases, the clutch is not
disengaged. Consequently, overrun shut-off
remains active for as long as possible.
Engine code
Type
Valves per cylinder
Displacement in cm³
Bore / stroke in mm
Compression ratio
Engine management
Fuel
Exhaust gas aftertreatment
Exhaust emission standard
ARR
4-cylinder inline engine
4
1390
76.5 / 75.6
11.5 : 1
Bosch Motronic MED 7.5.10
Premium unleaded with RON 98
Lambda control, three-way catalytic converter, NOx storage catalytic
converter
EU 4
In the event of a loss of power and torque as well as increased fuel consumption, the engine runs on premium
unleaded RON 95. The increased fuel consumption is the result of the higher sulphur content in the fuel, which is
detrimental to petrol-direct injection engines in particular.
5

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