Beruflich Dokumente
Kultur Dokumente
o . 203
36
ME N
32
28
24
RAM
OG
P (kW)
20
PR
DY
16
TU
-S
12
LF
SE
4
1000 2000 3000
n (1/min)
In the Lupo, VW will be extending its range of petrol engines
with a new 1.0-ltr. engine with aluminium block with camshaft in
block (ohv).
It conforms to the exhaust emission standards EU III and D3.
203/24
Specifications .............................................................. 4
Engine data
Engine overview
Sensors ......................................................................... 14
Engine speed sender G28 and TDC recognition
Intake manifold pressure sender G71 and intake air temperature sender
G41
Knock sensor G61
Self-diagnosis ............................................................. 20
New Important
Note
3
Specifications
Engine data
Type: 4-cylinder 36
in-line engine 32
Displacement: 997 cm3 28
Bore: 72 mm
24
Stroke: 61.2 mm
P (kW)
Compression ratio: 10 : 1 20 90
Rated output: 37 kW at 16 80
5000 rpm 12 70
M (Nm)
Max. torque: 84 Nm at
8 60
3250 rpm
Mixture preparation: Simos 2P multipoint 4 50
1000 2000 3000 4000 5000 6000
injection system
n (1/min)
Fuel: 95 RON unleaded.
The vehicle can alter- 203/1
natively be operated
on 91 RON fuel via
the knock control with
a slight reduction in
torque and performance.
203/23
4
Engine overview
Twin roller
chain
Camshaft
5
Engine mechanicals
Crankshaft
Centre main bearing
Mounted in 3 bearings
Cylinder liner
Cylinder block
Copper
The pretensioned cylinder liner is sealed off from sealing disc
the cylinder head by means of the cylinder head
gasket. Cylinder block 203/11
6
Timing gears
203/14
Oil pump
The oil pump drive and the oil pump are located
below the timing gear cover. The oil pump is a gear Timing gear cover
type pump.
The oil pump is driven via the camshaft. Oil pump gears
203/33
7
Engine mechanicals
Tappet with
hydraulic
valve lifters
203/3.3
Camshaft
The tappet and the hydraulic valve lifters function in Tappet Push rod
the same way as conventional bucket tappets. (For
a description of the bucket tappet, please refer to
Tappet piston
SSP 105).
Oil inlet
High-pres. chamber
Oil supply
Camshaft
Non-return valve
8
Drives for auxiliary units
Coolant pump
Coolant
203/10
9
System overview
G28
Legend
G6 Fuel pump
G39 Lambda probe
G28 Engine speed sender
G42 Intake air temperature sender
G61 Knock sensor
G62 Coolant temperature sender
G71 Intake manifold pressure sender
J 17 Fuel pump relay
J361 Simos 2P control unit
J338 Throttle valve control unit
N30 Injector
N80 Solenoid valve for act. charcoal filter
N152 Ignition transformer For a description of the throttle valve
P Spark plug socket control unit, please refer to SSP 173.
Q Spark plugs
Z19 Lambda probe heater
10
C
B
J338
A
N80
D
G71 G42
J17
J361
SIMOS 2P
E G6
203/6
= Exhaust gas
11
System overview
Sensors
Lambda probe
G39
12
Actuators
13
Sensors
203/8
14
Intake manifold pressure sender G71
and intake air temperature sender G42
Signal utilisation
Self-diagnosis
15
Sensors
The knock sensor is attached to the rear wall of the Knock sensor G61
crankcase between cylinders 2 and 3.
Signal output
Signal utilisation
203/31
The ignition advance angle of the cylinder in
question is shifted towards "retard" in steps
of 0.5 to 2o until the tendency to knock diminishes.
Substitute function
Screening
If a signal is missing, the ignition advance angle of
all 4 cylinders is reduced by 15o.
This leads to a reduction in engine performance.
Self-diagnosis
The fault Sensor signal too weak is detected. G61 Knock sensor
J361 Control unit for Simos
16
Injection system
Injection
Activation
M G6
31
J361
203/16
17
Functional diagram
M +
V60
G88
Auxiliary signals F60 G69 -
A Engine speed G28
J338
B Air conditioner compressor (in - out)
C A/C ready (in) M G6
Air conditioner switch activation
D Air conditioner PWM (in)
Check signal, e.g. for Air
conditioner load
E K-wire (for diagnosis)
31
F Road speed signal
G Terminal 50 Code codes/Legend
= Input signal
= Output signal
18
30
15
S S S S
A B C D E F G
N80
49 14 9
J361
41
N152
G71 G42 G61 F88 G62
I IV II III
Q
P
31
203/5
19
Self-diagnosis
C
B
N152
P/Q J338
A
N30
N80
G39 D
Z19
G71 G42
G62 G61 J17
J361
SIMOS 2P
G28
E G6
203/25
C 0 Q
The fault is saved to the fault memory.
In addition, measured values are displayed in the
read measured value block function for troubles-
hooting purposes.
20
21
1. C; 2. B; 3. a chain, count the chain pins;
4. flywheel, engine speed sender, an additional tooth, 1 and 4, 2 ad 3;
5. A, C; 6. C; 7. A, B, C; 8. B; 9. A, C
Solutions
203/22
Test your knowledge
Test your knowledge
?
203/22
1. Valves are controlled
A. The valve clearance must be adjusted every 15,000 km or during the annual inspection.
B. As hydraulic valve tappets are used, there is no need for mechanical adjustment
during inspections.
C. The basic adjustment must be repeated after a mileage of 1,000 km.
This makes it possible for the control unit to distinguish whether the signal belongs
to cylinders ..... and ..... or ..... and ..... .
22
5. The intake module carries the fuel rail together with the injectors.
?
6. The injection system operates semi-sequentially.
Semi-sequentially means:
23
Service. 203