Self-Study Programme 485 1.2L TFSI engine.pdf

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Self Study Programme 485
Audi
1.2l TFSI engine
Audi
Service Training
Following on from the A3 with its 92 kW 1.4l TFSI engine which
paved the way for small petrol engines with superior torque and
high fuel economy by combining turbocharging with direct fuel
injection, Audi presents the 1.2l TFSI - yet another engine with
TFSI technology for the entry-level segment. Economy and pulling
power are still the key success factors, especially in the light of the
on-going heated debate on CO
2
emissions.
For this reason, Audi has systematically extended its
TFSI*
strat-
egy, and with the new 63 and 77 kW 1.2l TFSI engines it continues
its successful efforts in
downsizing*
the volume engines for the A1
and A3. Audi has further improved the engine technology of the
small but powerful EA 111 engine series by maintaining a sharp
focus on optimising friction and lightweight design. Featuring a
new weight-optimised aluminium cylinder block and an entirely
new combustion process, this engine offers an ideal combination
of performance, fuel economy and cost for entry-level Audi
models.
The radically redesigned 1.2l TFSI engine, which in the A3 delivers
a specific power output of 87.7 HP from a displacement of
1197 cm
3
, utilises the same technology as its renowned siblings
with displacements of 1.8 and 2.0 litres. Turbocharging and direct
petrol injection make a perfect combination in the A3 too, and
together they provide a high compression ratio of 10.0 : 1 which
not only benefits thermodynamic efficiency but also enhances
performance and economy.
Typically of a turbo, the small four cylinder operates at low speeds.
In the A3 the engine delivers an impressive 175 Nm of torque
between 1550 and 4100 rpm and a maximum power output of
77 kW (105 hp) at 5000 rpm. This allows the engine to run
smoothly and efficiently. The three-door Audi A3 with 1.2l TFSI
engine accelerates in 11.1 seconds from zero to 100 kph
(A3 Sportback 11.3 seconds). The A3 and the A3 Sportback
consume on average only 5.5 litres of fuel per 100 km. At the same
time, the engine produces CO
2
emissions of only 127 g/km. Fuel
consumption is reduced by 1 litre per 100 km compared to the
75 kW (102 HP) predecessor engine (1.6l MPI).
485_046
Learning objectives of this Self Study Programme are:
In this Self Study Programme you will learn the technology of the
1.2l TFSI engine.
When you have worked your way through this Self Study Pro-
gramme you will be able to answer the following questions:
• How is the basic engine designed?
• What are the differences between the 1.2l TFSI engine and the
TFSI engines previously used by Audi?
• Which modifications have been made to the fuel system?
• What are the special features of the engine management
system?
• What must be observed when servicing the vehicle?
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Contents
Introduction
Specifications ________________________________________________________________________________________________________________________________________________ 5
Engine mechanicals
Weight reduction measures ________________________________________________________________________________________________________________________________ 6
Cylinder block _______________________________________________________________________________________________________________________________________________ 6
Cranktrain ____________________________________________________________________________________________________________________________________________________ 7
Chain drive ___________________________________________________________________________________________________________________________________________________ 8
Cylinder head ________________________________________________________________________________________________________________________________________________ 9
Positive crankcase ventilation ____________________________________________________________________________________________________________________________ 13
Vacuum supply _____________________________________________________________________________________________________________________________________________ 15
Oil supply
Oil circuit ____________________________________________________________________________________________________________________________________________________ 16
Oil filter _____________________________________________________________________________________________________________________________________________________ 17
Air supply
Overview ____________________________________________________________________________________________________________________________________________________ 18
Charge air circuit ___________________________________________________________________________________________________________________________________________ 18
Charge pressure actuator V465 with charge pressure actuator position sensor G581 _____________________________________________________________ 19
Charge pressure control function _________________________________________________________________________________________________________________________ 20
Cooling system
Overview ____________________________________________________________________________________________________________________________________________________ 22
Charge air cooling system _________________________________________________________________________________________________________________________________ 22
Engine cooling system _____________________________________________________________________________________________________________________________________ 23
Thermal management _____________________________________________________________________________________________________________________________________ 27
Active coolant pump _______________________________________________________________________________________________________________________________________ 27
Fuel system
System overview ___________________________________________________________________________________________________________________________________________ 29
Injectors N30 – N33 _______________________________________________________________________________________________________________________________________ 29
Engine management
Overview of the Simos 10 system on the Audi A3 ______________________________________________________________________________________________________ 30
Engine control unit J623 __________________________________________________________________________________________________________________________________ 32
Operating modes ___________________________________________________________________________________________________________________________________________ 32
Ignition system _____________________________________________________________________________________________________________________________________________ 33
Service
Special tools ________________________________________________________________________________________________________________________________________________ 35
Scope of maintenance _____________________________________________________________________________________________________________________________________ 36
Annex
Glossary _____________________________________________________________________________________________________________________________________________________ 37
Test your knowledge _______________________________________________________________________________________________________________________________________ 38
Summary ____________________________________________________________________________________________________________________________________________________ 39
Self Study Programmes ___________________________________________________________________________________________________________________________________ 39
• The Self Study Programme explains the basics of the design and function of new models, new automotive
components or new technologies.
It is not a Repair Manual! Figures given are for explanatory purposes only and refer to the software version
valid at the time of preparation of the SSP.
For maintenance and repair work, always refer to the current technical literature.
Terms shown in italics and marked by an asterisk (*) are explained in the glossary at the back of this Self
Study Programme.
!
Note
Reference
3
Introduction
Brief technical description
• Newly developed aluminium cylinder block with innovative cast
iron cylinder liners
• Two-valve cylinder head with inclined overhead valves
• Steel crankshaft with reduced conrod and main bearing
diameters of 42 mm
• Low-friction lightweight crank drive
• Positive crankcase ventilation system with oil separator inte-
grated in the cylinder block and cylinder head
• Active coolant pump
• Easy-to-service split lightweight timing case with plastic and
magnesium alloy covers
• Exhaust turbocharger module with electrical charge pressure
actuator
• Ignition transformer
• Single-chamber exhaust system with close-coupled pre-catalyst
• Combustion process: Homogeneous direct injection
485_014
Reference
You can find basic information about the TFSI technology in Self Study Programmes 432 "Audi 1.4l TFSI engine" and 384
"Audi chain-driven 1.8l 4V TFSI engine".
4
Specifications
Torque/power curves
1.2l TFSI engine CBZA
Power in kW
Torque in Nm
1.2l TFSI engine CBZB
Power in kW
Torque in Nm
Engine speed [rpm]
485_019
Engine code
Type
Displacement
in cm
3
Stroke
in mm
Bore
in mm
Number of valves per cylinder
Firing order
Compression ratio
Power output
in kW at rpm
Torque
in Nm at rpm
Fuel
Engine weight
in kg
Engine management
Emissions standard
CO
2
emission
in g/km
Exhaust gas aftertreatment
Vehicle use
1)
CBZA
4-cylinder inline engine
1197
75.6
71
2
1-3-4-2
10:1
63/5000
160/1500 – 3500
Prem. unleaded 95 RON
1)
89.5
Continental Simos 10
EU 5
118
3-way catalytic conv. with lambda control
A1
CBZB
4-cylinder inline engine
1197
75.6
71
2
1-3-4-2
10:1
77/5000
175/1550 – 4100
Premium unleaded 95 RON
1)
89.5
Continental Simos 10
EU 5
127
3-way catalytic converter with lambda control
A3
Unleaded regular 91 RON petrol can also be used, but will result in slight loss of power.
5

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