SSP 337 - Der 2.0l-FSI-Motor mit Turboaufladung - eng.pdf

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The 2.0L FSI Turbocharged Engine
Design and Function
Self-Study Program
Course Number 821503
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Volkswagen of America, Inc.
Volkswagen Academy
Printed in U.S.A.
Printed 08/2005
Course Number 821503
©2005 Volkswagen of America, Inc.
All rights reserved. All 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 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.
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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.
i
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ii
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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
1
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