Professional Documents
Culture Documents
6.14
Edition 05.02.2004
List of contents
Subject Page
1 Introduction 4
1.1 Development aims 4
1.2 Technical data 5
1.3 Performance and torque development curve of 2.0 ltr./51 kW SDI engine 6
2 Engine mechanics 7
2.1 "Lightweight crank drive" 7
2.1.1 Crankshaft 7
2.1.2 Pistons 8
2.1.3 Piston pin 8
2.1.4 Conrods 8
2.2 Camshaft 9
2.2.1 Valve seat ring 9
2.3 Intake manifold 10
3 Engine management 11
3.1 Crankshaft seal with integrated engine speed sender wheel 11
3.1.1 Engine speed sender 12
3.1.2 Sender wheel 12
3.2 Hall sender G40 (camshaft) 13
3.2.1 Camshaft sender wheel 13
3.2.2 Signal pattern during normal operation 14
3.2.3 Signal pattern during emergency operation 15
List of contents
Subject Page
3.2.4 Emergency operation 16
3.3 Exhaust gas recirculation 17
3.3.1 Exhaust gas recirculation valve 18
1 Introduction
1.1 Development aims The 2.0 ltr./51 kW SDI engine is offered as an entry-level diesel engine with
emissions standard EU 3 among the range of engines available for the Caddy 2004.
This engine is a further development of the 1.9 ltr./74 kW TDI engine with unit injector
technology.
The greater capacity compared to the 1.9 ltr/74 kW TDI engine is thanks to an increase
in cylinder bore from 79.5 mm to 81.0 mm.
Another version of the engine is the 2.0 ltr./55 kW SDI engine, which is installed in
the passenger vehicle category in the Golf 2004. This engine will fulfil the emissions standard
EU 4.
1.3 Performance and torque development curve of 2.0 ltr./51 kW SDI engine
2 Engine mechanics
2.1 "Lightweight crank The pistons, conrods and also the crankshaft are lighter in weight compared with the
drive" 1.9 ltr./74 kW TDI engine. This was possible due the combustion pressure in the SDI engine
being less than the TDI engine. The SDI engine operates at 90 bar and the TDI engine operates
at 120 bar.
2.2 Camshaft The cam profiles, and thereby also the valve timing, have been modified compared to the 1.9 ltr.
engine. The modified timing ensures the correct quantity of air is drawn in for combustion in the
powerful SDI engine.
Inlet valve opens 21.4° CA bTDC Inlet valve opens 15.8° CA bTDC
Exhaust valves closes 25.4° CA aBDC Exhaust valves closes 25.3° CA aBDC
Exhaust valve opens 43.4° CA bBDC Exhaust valve opens 28.2° CA bBDC
Exhaust valve closes 9.4° CA aTDC Exhaust valve closes 18.7° CA aTDC
2.2.1 Valve seat ring Inline with legal requirements that come into force from 2006, the valve seat rings no longer
contain any cadmium. Molybdenum is added to the material in place of cadmium.
2.3 Intake manifold The intake manifold of the 2.0 ltr./51 kW SDI engine was taken over from the 1.9 ltr./47 kW SDI
engine of the Polo 2002.
To reiterate: The so-called "snail intake manifold" was developed from the overhead intake
manifold from the SDI engine of the Golf 1998. Due to small installation dimensions in the Polo
2002, the intake pipe length of the overhead intake manifold is "wound up" (snail) in the snail
intake manifold.
3 Engine management
3.1 Crankshaft seal with The crankshaft seal on the flywheel side is combined with the engine speed sender wheel. The
integrated engine speed seal in the sealing flange is made of polytetrafluoroethylene (PTFE).
sender wheel
1 Seal
2 Engine speed sender
3 Crankshaft flange
3.1.1 Engine speed sender The engine speed sender is of the Hall sender
type. It is screwed into the housing of the
crankshaft sealing flange.
1 Sender wheel
2 Engine speed sender
3.2 Hall sender G40 The Hall sender G40 is of the so-called static type. It detects a segment or gap as soon as the
(camshaft) ignition is switched "ON".
3.2.1 Camshaft sender wheel The sender wheel on the camshaft is of a new
design. In conjunction with the Hall sender G40
(camshaft), an emergency running feature is
provided, which allows the engine to continue
running in the event of engine speed sender
failure. Restarting of the engine is also
possible.
3.2.2 Signal pattern during Signal pattern of Hall sender G40 (camshaft) and engine speed sender G28 during normal
normal operation operation
3.2.3 Signal pattern during Signal pattern of Hall sender G40 (camshaft) and engine speed sender G28 during
emergency operation emergency operation
Note: To provide clarity, the "missing" or "implausible" signal during emergency operation from
the engine speed sender is also shown in this diagram.
3.3 Exhaust gas On the 2.0 ltr./51 kW SDI engine, exhaust gas recirculation is controlled by the EGR map in the
recirculation engine control unit. There is no control of exhaust gas recirculation by means of an air mass
meter. To fulfil emission standard EU 3, the 2.0 ltr./51 kW SDI engine does not need an air mass
meter.
The EGR rate is determined by the exhaust gas recirculation map based on the quantity of
injection and engine speed. For control of the exhaust gas recirculation volume, the pneumatic
exhaust gas recirculation valve (2 stage) and electric intake manifold flap are actuated by the
engine control unit.
3.4 Exhaust gas recirculation The exhaust gas recirculation valve is monitored by the engine control unit in EOBD (Euro
valve Onboard Diagnosis) when in the "EGR valve open" or "EGR valve closed" positions.
For a predetermined load at a predetermined intake manifold flap position and opened EGR
valve, there is a specified intake manifold pressure stored in a map.
A faulty exhaust gas recirculation valve (EGR valve stuck in "closed" position) is detected if the
actual intake manifold pressure transmitted by the intake manifold pressure sender is not
comparable with the specified intake manifold pressure stored in the map.
• Engine speed
• Quantity of injection
• Surrounding air pressure
• Intake manifold temperature
• Coolant temperature
• Defined intake manifold flap position
• EGR valve in "open" position
• Unit injectors
The flow rate of the unit injectors (5-hole injectors) is fine tuned to the specific engine.
• Preglow system
The 2.0 ltr./55 kW SDI engine features a quick start preglow system made by BERU (GSK 3).
Information about the quick start preglow system can be found in self-study programme no. 316
"The 2.0 ltr. TDI engine".
• Acoustics
The 2.0 ltr./51 kW SDI engine does not feature a special acoustic bonnet with foam elements.