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Self Study Program 820433

The EA288 Diesel Engine Family

Design and Function

Volkswagen Group of America, Inc. Volkswagen Academy Printed in U.S.A. Printed 2/2014

Course Number SSP 820433

?2014 Volkswagen Group 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 copyright and other intellectual property rights of Volkswagen Group 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 otherwise, nor may these materials be modified or reposted 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 Group 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 product names used in this manual are trade names, service marks, trademarks, or registered trademarks; and are the property of their respective owners.

Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Engine Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine Management System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Knowledge Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Note

Important!

This Self-Study Program provides information regarding the design and function of new models. This Self-Study Program is not a Repair Manual. This information will not be updated.

For maintenance and repair procedures, always refer to the latest electronic service information.

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Introduction

EA288 Diesel Engine Family

Volkswagen is introducing a new family of diesel engines in the 2015 Golf. The engine family has the designation EA288 (EA = Entwicklungsauftrag [development order]). The design of this new generation of diesel engines was based on the existing EA189 engine family. Displacement, cylinder spacing, stroke and bore ratio are shared between the EA189 and the new EA288 gasoline engines. The new EA288 engine design forms the basis for all future inline diesel engines at Volkswagen. Several sub-assemblies were redesigned in the EA 288 family of 4-cylinder diesel engines to satisfy future emission standards. In this Self-Study Program you will learn about the structure and design of the new EA288 TDI engine, and the functions of the individual engine subsystems.

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Introduction

Modular Diesel Matrix (MDB)

The new EA288 diesel engine family is also called a modular diesel matrix, or MDB. The modular diesel system is the basis for all future inline diesel engines in the Volkswagen Group.

The modular diesel matrix is a concept that involves dividing the functional engine components into modules. Depending on capacity, power output, emission standard and the vehicle class, engines can be assembled from modules and components.

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4

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5

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6

7

8

9

10

Basic Engine 1 Modular Camshaft Housing 2 Cylinder Head 3 Cylinder Block 4 Switchable Coolant Pump 5 Oil/Vacuum Pump 6 Timing Drive and Accessory Drive

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Attachment Parts 7 Exhaust Manifold Module with Turbocharger 8 Intake Manifold with Water-Cooled Charge Air Cooler 9 Exhaust Purification Module

10 Exhaust Gas Recirculation Module

The modular design meets fuel consumption, exhaust emissions and power delivery demands. It also allows the engines to accept future modular components that meet upcoming country-specific requirements with minimal costs.

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Introduction

Technical Data

Engine Code Design Engine Capacity Bore Stroke Valves per Cylinder Compression Ratio Maximum Output Maximum Torque Engine Management System Fuel Exhaust Gas Aftertreatment

Emissions Standard

CRBC Four-cylinder inline engine 1968 cm3 81.0 mm 95.5 mm 4 16.2:1 150 hp (110 kW) from 3500 to 4000 rpm 235 lb/ft (320 Nm) from 1750 to 3000 rpm Bosch EDC 17 Ultra-Low Sulfur Diesel Exhaust gas recirculation, oxidizing catalytic converter, diesel particulate filter BIN 5

Torque and Power Diagram

Torque [lb/ft] Output [hp]

2.0 TDI Engine

280

150

250

130

220

125

190

100

160

80

130

60

100

40

75

25

45

10

1000 2000 3000 4000

Engine speed [rpm]

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Engine Mechanics

Cylinder Block

The EA288 cylinder block is grey cast iron, an alloy of cast iron and flake graphite. The cylinder block has deep screw threads for long cylinder head bolts. This distributes combustion forces through the cylinderblock structure, applying equal pressure distribution on the cylinder head gasket. The design of the cooling channels in the cylinder block provides good cooling in the area between the cylinders.

Cylinder Block 2.0L TDI Engine The cylinder block for the 2.0L TDI engine is available for engines with and without balance shafts.

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