SSP 920113 The 6.3L W12 FSI.pdf

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Self-Study Program 920113
The 6.3L W12 FSI Engine
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Audi of America, LLC
Service Training
Printed in U.S.A.
Printed 6/2011
Course Number 920113
©2011 Audi of America, LLC
All rights reserved. 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 Audi of America, LLC., its affi liated 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 modifi ed 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 Audi of America, LLC.
Always check Technical Bulletins and the latest electronic
service repair literature for information that may supersede any
information included in this booklet.
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6.3L W12 FSI Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Specifi cations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cylinder Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pistons and Connecting Rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Chain Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Crankcase Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fine Oil Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Oil Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Intake Air Flow System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Secondary Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Vacuum Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Coolant Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fuel Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
High Pressure Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Engine Management. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Exhaust Flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Knowledge Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . .39
i
The Self-Study Program provides introductory information regarding the design
and function of new models, automotive components, or technologies.
The Self-Study Program is not a Repair Manual!
All values given are intended as a guideline only.
For maintenance and repair work, always refer to current technical literature.
Reference
Note
!
ii
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Introduction
A 12-cylinder engine is the pinnacle of engine
design and a hallmark of luxury class vehicles.
Twelve-cylinder engines have been used in the
Audi A8 model line since 2001.
Over time, Audi’s engineers have thoroughly
revised the W12, increasing its displacement
to 6.3 liters and equipping it with direct fuel
injection for greater power and effi ciency.
The 6.3L W12 FSI engine gives the 2011 A8L
sports car performance: zero to 60 in just under
4.9 seconds and an electronically limited top
speed of 155 mph (250 km/h).
The engine is exceptionally smooth running,
and only at high engine loads and speeds do
the car’s occupants sense any of this supreme
power at work.
The high fuel economy of the 6.3L W12 FSI
engine, when compared with its competitors,
is mainly the result of technologies from Audi’s
modular effi ciency platform, which is used
throughout the A8 model line.
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