SSP 401 1.8 tsfi eng.pdf

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SERVICE TRAINING
Self Study Programme 401
1.8 l TFSI 16v 118kW engine
Architecture and Operation
A new family of engines has been developed, the EA 888
family, which will progressively replace the EA 113 fam-
ily engines and the direct petrol injection engines
(MPI).
This new generation of engines (EA888) starts with an
overboosted direct petrol injection and 1800 c.c. capac-
ity engine.
This engine has been designed taking into account the
constant evolution of technology in order to achieve
maximum performance and at the same time to make
the most out of each and every single drop of fuel.
During the process of design and development of the
engine the following issues were set as priorities:
- To achieve a reasonable price for the customer by
reducing the unitary cost of manufacturing,
- To provide for both longitudinal and transversal
assembly of the engine into the different models of
the Group,
- To comply with legal requirements such as pedes-
trian protection or reduction of the footwell area
deformation zone in front collisions,
- To comply with the environmental standards regard-
ing noise and exhaust gases,
- To obtain a good mechanical and thermodynamics
performance in a compact structure,
- To contribute to ease of repair and maintenance at
the Aftersales Service.
S401_001
The Self-Study Programme includes basics regarding the design and operation of new
engines, new engine components and new technologies.
The Self-Study Programme is NOT a repair manual. For maintenance and repair jobs it
is absolutely necessary to refer to the updated technical literature of each of the Brands.
Additional
information
Note
2
Summary of contents
Mechanicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air passage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Synoptic chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Sensors and actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Variable Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Functions wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Check your knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3
Mechanicals
Technical features
The 1.8l TFSI engine with 4 cylinders inline and 4
valves per cylinder has been designed to run always on
homogeneous mix. The engine works in a very similar
way to the 2.0l TFSI engine. However, design and posi-
tion of most of the engine components have been modi-
fied in order to achieve a more compact engine and to
reduce maintenance.
S401_002
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It is ready for complying with the EU 5 emissions
standard. However, in the meantime, until it
becomes mandatory, the engines marketed will
comply with the EU 4 emissions standard.
The camshafts, balance shafts and oil pump are
driven by means of three chains.
The counter-rotating balance shafts are integrated
in the engine block, above the crankshaft.
It is fitted with variable timing in the intake camshaft
The inlet manifold is equipped with the guided
intake system.
Fuel supply system made up by lo pressure circuit
and a high pressure circuit, with no return passage
and with multiple drills injectors.
The turbocharger, integrated in the exhaust mani-
fold, if fitted with overboost pressure regulation and
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air recirculation when decelerating.
Exhaust system with precatalyst close to the engine,
and only one lambda probe.
New coolant pump module, driven by a belt.
Oil filter position on the top of the engine, screwed
onto the auxiliary elements support bracket.
It incorporates an oil and fuel vapours elimination
(blow-by) vapours system
For further information about the engine components and operation consult the infor-
mation in each of the Brands the for the 2.0l TFSI engine.
4
300
280
260
240
220
200
190
170
150
130
120
110
100
90
80
70
60
50
40
30
20
10
1000
2000
3000
4000
5000
6000
Torque
130
110
90
70
50
Power
rpm
S401_003
Technical data
This engine’s designation letters are BYT. However,
because of its evolution, this engine will be subject to
some changes that will imply having to change the des-
ignation letters to BZB.
The 1.8l TFSI engine delivers high power at high revs,
with a maximum power output of 160 bhp from 5000
rpm and practically up to the injection cut-off moment.
It also delivers high and constant engine torque along a
wide range of revs. This is so mainly because of using an
intake variable timing system which provides complete
combustion chamber fill-up, thus reaching a maxim
torque of 250 Nm from 1500 to 4200 rpm.
Other achievements are an economical consumption
rate, engine spontaneity and elasticity plus driving com-
fort.
Engine designation
letters
Capacity [cm
3
]
Bore [mm]
Stroke [mm]
Compression ratio
Maximum power
Maximum torque
Engine management
system
Firing order
Fuel
BYT - BZB
1,798
82.5
84.2
9.6:1
118 kW at 5,000 - 6,200 rpm
250 Nm at 1,500-4,200 rpm
Bosch Motronic MED 17.5
1-3-4-2
Unleaded 98 - 95 octane (it is
possible to use 91 octane rat-
ing, however accepting a loss of
power output).
EU 4
Emission standards
For the sake of understanding the document better, all explanations are based on the BYT engine and any mod-
ifications worth mentioning which affect the BZB engine will be indicated.
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