SSP_318_d2.pdf

The advantages of the 4-valve technology

Larger inlet and exhaust cross-sections of the

valves provide improved volumetric efficiency,

as well as higher power output and torque.

Wastage on load change is also reduced.

The symmetrical layout of the valves and the

vertical, centrally located unit injectors allow for

good mixture formation. This leads to lower fuel

consumption and exhaust gas emissions

are reduced as a result.

Roller rocker arm

for unit injector

Vertically installed,

centrally located

unit injector

Inlet camshaft

Exhaust camshaft

Roller rocker finger

for valves

Stub shafts

Inlet port

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Exhaust port

Vertically installed valves

Power units

The crankshaft sealing flange with integrated engine speed sender wheel

A crankshaft sealing flange with an integrated

engine speed sender wheel will be used in the

diesel engines. This system has already been

tried and tested in several petrol engines.

The engine speed sender wheel is the only new

feature. The crankshaft sealing flange seals off

the cylinder block on the flywheel end. The oil

seal is made of heat-resistant and nonwearing

polytetrafluoroethylene (PTFE) plastic.

Crankshaft sealing flange

The engine speed sender is actually a Hall

sender. It is mounted in the crankshaft sealing

flange housing.

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Engine speed sender

wheel

The engine speed sender wheel consists of a

steel ring coated with a rubber compound.

This rubber compound contains a large number

of metal chips which are alternately magnetised

to become north and south pole regions.

The diesel engines have two large north poles

(60-2-2) and the petrol engines have one large

north pole (60-2) on the sender wheel; they

serve as reference marks for the engine speed

sender. The sender wheel is press-fitted onto the

crankshaft flange and exactly positioned.

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North pole

South pole

The pedal cluster

The pedal assembly in the 2004 Golf comprises

separately pre-assembled accelerator, brake

and clutch control modules.

Accelerator

pedal

module

The brake pedal module is made of aluminium

and sheet steel.

Clutch pedal

module

The accelerator pedal and the clutch pedal

module are made of plastic.

Pedal position recognition is by

contactless senders.

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Brake pedal module

Clutch position sender G476

Accelerator pedal position sender G79 and

G185

Master cylinder

Clutch pedal

Accelerator pedal position sender G79 and G185

Metal plate

Accelerator

pedal

Clutch position sender G476

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The clutch position sender is a Hall sensor, which

signals to the engine control unit that the clutch

pedal has been operated. The cruise control

system will then be deactivated and the injection

quantity in the engines will briefly be reduced in

order to prevent engine shudder during the gear

change.

The two accelerator position senders G79 and

G185 are integrated in the upright accelerator

pedal module. They are inductive senders, which

indicate the exact position of the accelerator

pedal the engine control unit. From this data, the

engine control unit computes the required

injection quantity.

For further information on the design and function of the contactless senders, please refer to

SSP 316 "2.0l TDI engine with 4-valve Technology" and SSP 321 "The 2004 Golf Running Gear".

Power transmission

The 6-speed direct shift gearbox 02E

The 6-speed Direct Shift Gearbox (DSG)

combines the advantages of a manual gearbox:

DSG also provides pure driving enjoyment for

manual gearbox drivers by allowing the driver to

actively influence the choice of gears and

gearshifts and with its lightning-fast, jolt-free

gearshifts. At the same time, it surpasses manual

gearboxes in terms of fuel economy.

● high efficiency,

● as well as robustness and sportiness

with those of an automatic gearbox:

The gearbox is distinguished by:

● a high level of comfort, particularly when

changing gears.

- Six forward gears and one reverse gear

- Normal gearbox program "D",

Sport gearbox program "S" as well as

Tiptronic selector lever and steering wheel

switches,

- Mechatronics: electronic and hydraulic control

units form a single unit and are accommodated

in the gearbox,

- Oil cooler and compressed air filter on the

gearbox

- Maximum torque 350 Nm.

DSG meets the high standards of comfort

expected by automatic gearbox drivers thanks to

its design, which comprises two multi-plate

clutches and various automatic shift programs.

Compressed air filter

Oil cooler

Mechatronics

Multi-plate clutches

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Design of the gearbox

The direct shift gearbox basically consists of two

independent part-gearboxes. Each part-gearbox

is built to function like a manual gearbox. Each

part-gearbox has a dedicated multi-plate clutch.

Both multi-plate clutches run in DSG oil and are

controlled, opened and closed by the

mechatronics, depending on the gear

to be selected.

Gears 1, 3, 5 and reverse are selected via

multi-plate clutch K1.

Gears 2, 4 and 6 are selected via

multi-plate clutch K2.

The figure below shows the principle of the direct

shift gearbox.

Part-gearbox 2

Multi-plate clutch K2

Differential

Engine torque

Output gear

Multi-plate clutch K1

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Part-gearbox 1

Both part-gearboxes transmit the engine's torque to a common output gear,

which in turn transfers the torque to the differential.

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