Self-Study Programme 405 1.4L 90kW TSI engine with turbocharger.pdf

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Service Training
Self-study Programme 405
1.4l 90kW TSI Engine with
Turbocharger
Design and Function
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The 1.4l 90kW TSI engine replaces the 1.6l 85kW FSI
engine. Compared with the FSI engine, fuel
consumption and CO2 emissions have been reduced
considerably and performance has improved
significantly.
The difference from the two TSI engines with dual-
charging is the omission of the supercharger and a
new charge-air cooling system.
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Over the following pages, we will introduce you to the differences in the design and function between the new
1.4l 90kW TSI engine and the engines with dual-charging.
You will find further information on this engine in self-study programme no. 359 “1.4l TSI Engine with Dual-
charging”.
NEW
Important
Note
The self-study programme shows the design and
function of new developments.
The contents will not be updated.
For current testing, adjustment and repair
instructions, refer to the relevant service literature.
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Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Technical features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Intake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Single-charging with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cooling systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Charge-air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Demand-regulated fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Bosch Motronic MED 17.5.20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Functional diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Test Yourself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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Introduction
Technical features
Unlike the two previous TSI engines, the 1.4l 90kW TSI
engine is only charged with a turbocharger. It is
specially configured to deliver high torque in the
frequently used low rev ranges. The maximum torque
of 200Nm is reached between 1500rpm and
4000rpm.
Another special feature is that the air-to-liquid
intercooler is integrated into the intake manifold.
Furthermore changes to the design of the intake ports
in the cylinder head and the pistons mean there is no
need for intake manifold flap change-over.
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Technical features
Bosch Motronic MED 17.5.20
Continuous inlet camshaft timing adjustment
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Homogenous mode (Lambda 1)
Grey cast iron cylinder block
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Stratified high-pressure start
Steel crankshaft
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Double injection catalytic converter heating
Duo-centric oil pump
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Turbocharger with waste gate
Dual-circuit cooling system
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Air-to-liquid charge-air cooling
Fuel system regulated according to requirements
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Maintenance-free timing chain
High-pressure fuel pump with integrated pressure
limiting valve
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Plastic intake manifold with integrated intercooler
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Technical data
Torque and power diagram
1.4l 90kW TSI engine
Nm
kW
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rpm
Technical data
Engine code
CAXA
Type
4-cylinder in-line engine
Displacement in cm 3
1390
Bore in mm
76.5
Stroke in mm
75.6
Valves per cylinder
4
Compression ratio
10:1
Maximum output
90kW at 5000–5500rpm
Maximum torque
200Nm at 1500–4000rpm
Engine management
Bosch Motronic MED 17.5.20
Fuel
Super unleaded RON 95
Exhaust gas treatment
Main catalytic converter, Lambda control
Emissions standard
EU 4
You will find detailed information on the four-letter engine code in self-study programme
no. 400 “The Golf Estate”.
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