Self-Study Programme 508 1.0L 44kw 55kW MPI engine.pdf

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Service Training
Self-study programme 508
The 1.0 l 44/55 kW MPI Engine
Design and function
The 1.0 l 44/55 kW MPI engine, featuring the same intake manifold injection as in the up!, is the first example of a
completely newly developed generation of engines which are now being installed in diverse models across the
Volkswagen Group. For the market launch of the up! there are two power versions, one with 44 kW and one with
55 kW. At a later point in time there will also be an up! EcoFuel with 50 kW.
When an engine is newly developed, or improved, there are always a multitude of specifications which must be
met. Along with fuel consumption and therefore the CO
2
emissions, weight, costs and compliance with existing and
future exhaust emission standards, attention must also be paid to the most compact design possible.
The new series of engines have allowed all these targets to be achieved.
As the new generation of engines presently stands, there are the following capacity and power versions available:
-
-
-
-
1.0 l 44 kW to 55 kW
1.2 l 63 kW to 77 kW
1.4 l 66 kW to 110 kW
1.6 l- 77 kW to 88 kW
with intake manifold injection
with direct injection
with intake manifold injection or direct injection
with intake manifold injection
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On the following pages, we will be introducing you to the design and function of the new 1.0 l 44/55 kW MPI
engine with intake manifold injection.
The self-study programme presents the
design and function of
new developments!
The content will not be updated.
Current testing, setting and repair instructions can
be found in the provided service literature.
Important
note
2
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Technical features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Crankshaft drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Crankcase breather and ventilation system . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Intake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
24
26
27
31
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Test Your Knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3
Introduction
The 1.0 l 44/55 kW MPI Engine
The 1.0 l 44/55 kW MPI engine is a completely new design, and is the first in a new generation of engines.
The engine mechanics are the same for both power variants. The differences in power are achieved by the
software.
Technical features
•
•
•
•
•
•
Camshafts driven by a toothed belt
Camshaft housing features a modular design
Cylinder head with integrated exhaust manifold
Coolant pump integrated into the thermostat
housing
Coolant pump driven by a toothed belt from the
exhaust camshaft
Inlet camshaft adjustment
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Technical data
Engine code
Design
Displacement
Bore
Stroke
Valves per cylinder
Compression ratio
Max. output
Max. torque
Engine Management
Fuel
44 kW at
5500 rpm
CHYA
CHYB
Torque and performance diagram
[Nm]
110
100
90
80
70
60
50
1000
3000
5000
[kW]
60
50
40
30
20
10
0
7000
[rpm]
3-cylinder inline engine
999 cm
3
74.5 mm
76.4 mm
4
10.5:1
55 kW at
6200 rpm
95 Nm at
3000-4300 rpm
Bosch Motronic ME 17.5.20
Super unleaded RON 95
(normal unleaded RON 91 with
a slight reduction in
performance)
Three-way catalytic converter
with one step-type lambda
probe upstream and one
downstream of the catalytic
converter
EU5
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44 kW:
55 kW:
Exhaust gas treatment
Emissions standard
4
Engine Mechanics
Poly V-belt drive
There are two basic types of poly V-belt drive, one with and one without an air conditioner compressor.
Both are driven by a six-rib poly V-belt. The belt pulley on the crankshaft is equipped with a vibration damper to
ensure the engine runs quietly.
Poly V-belt drive without A/C compressor:
Without the air conditioner compressor, only the
alternator is driven.
The poly V-belt (Optibelt) is flexible and elastic.
The combination of this, and low mechanical stresses,
means a tensioning roller is not required.
Belt pulley
alternator
Poly V-belt
(Optibelt)
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Belt pulley
alternator
Poly-V-belt
Crankshaft pulley with
vibration damper
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Tensioning roller
Belt pulley air
conditioner
compressor
Crankshaft pulley
with vibration damper
Poly V-belt drive with A/C compressor:
If an air conditioner compressor has been installed,
then a standard poly V-belt is used.
This version tensions the poly V-belt using a fixed
tensioning roller.
An automatic tensioning roller and an alternator with a coasting function are installed in all vehicles
which feature BlueMotion technology, regardless of whether an air conditioner compressor has been
installed.
They reduce friction and fuel consumption.
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