2.0t.pdf

The 2.0L FSI Turbocharged Engine

Design and Function

Self-Study Program

Course Number 821503

Volkswagen of America, Inc.

Volkswagen Academy

Printed in U.S.A.

Printed 08/2005

Course Number 821503

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 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 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.

Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2.0L/200 HP 4-Cylinder Turbo FSI Engine with 4-Valves per

Cylinder

Engine Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Crankshaft, Engine Block, Pistons, Engine Balance Shaft, Final

Drive Sprocket, Toothed Belt Drive, Cylinder Head, Crankcase

Ventilation, Exhaust Turbocharger/Manifold Module, Charge

Air Ducting and Boost Pressure Control, Boost Pressure

Overrun, Cooling System, Tumble Flaps

Fuel System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Demand-Controlled Fuel System, Low Pressure System, High

Pressure System

Fuel System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Fuel Pump Control Module J538, Transfer Fuel Pump G6,

High Pressure Fuel Pump with Fuel Pressure Regulator Valve

N276, High Pressure Fuel Pump, High Pressure Fuel Pump

Operation, Low Fuel Pressure Sensor G410, Fuel Pressure

Sensor G247, Cylinder Fuel Injectors N30–N33, Fuel Injector

Operation, Pressure Limiting Valve, Connector Fitting with

Restrictor

Engine Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Modes of Operation, Actuators and Sensor Diagram,

Functional Diagram

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Special Tools

New!

Knowledge Assessment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Important/Note!

This Self-Study Program covers the design and function of the

2.0L FSI Turbo.

This Self-Study Program is not a Repair Manual. This

information will not be updated.

For testing, adjustment and repair procedures, always refer

to the latest electronic service information.

Introduction

2.0L/200 HP 4-Cylinder Turbo FSI

Engine with 4-Valves per Cylinder

Special Features

• Exhaust system with two catalytic

converters

• Hitatchi ethanol-resistant high-pressure

fuel pump

• Returnless fuel system

• Homogeneous fuel injection

• Decoupled ﬁnal drive sprocket in the

balance shaft drive gear

• Elliptical secondary drive wheel on the

crankshaft

The 2.0L turbocharged FSI engine is ﬁrst

being introduced to the North American

market in the 2005 Jetta and the 2006

Passat.

S339_046

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