Transmision fsi

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 ©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 copyrightand 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 other wise, nor may these materials be modified orreposted 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 productnames 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 FuelSystem, 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 Knowledge Assessment. . . . . . . . . . . . . . . . .. . . . . . . . . . . . .40

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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.

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Introduction
2.0L/200 HP 4-Cylinder Turbo FSI Enginewith 4-Valves per Cylinder
The 2.0L turbocharged FSI engine is first being introduced to the North American market in the 2005 Jetta and the 2006 Passat. 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 • Ellipticalsecondary drive wheel on the crankshaft

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Introduction
Technical Data
Type Displacement Bore Stroke Valves per cylinder Compression ratio Maximum power Maximum torque 4 cylinder, inline 121 cu. in. (1984 cc) 3.2 in. (82.5mm) 3.7 in. (92.8mm) 4

Torque and Power
243 330 221 300 199 270 177 240 224 165 204 150 184 135 163 120 143 105 109 90 102 75 82 60 61 45 41 30 20 15...