Audi 4.2-liter V8 FSI Service Training Download Page 1

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Self-Study Program 921603

Audi of America, Inc.
3800 Hamlin Road
Auburn Hills, Michigan 48326

Audi 4.2-liter V8 FSI Engine

Service Training

Leading through Technology

www.audiusa.com

Summary of Contents for 4.2-liter V8 FSI

Page 1: ...Self Study Program 921603 Audi 4 2 liter V8 FSI Engine Service Training...

Page 2: ...ored 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 t...

Page 3: ...All values given are intended as a guideline only and refer to the software version valid at the time of publication of the SSP For maintenance and repair work always refer to the current technical li...

Page 4: ...ii...

Page 5: ...een the cylinder banks and the 90 mm spacing between the cylinders The 4 2 liter V8 FSI engine is also a member of this family It is available in two versions a comfort oriented version used for the f...

Page 6: ...5 lb ft out of 4 2 liters Reduction of fuel consumption by approximately 5 at 2000 rpm and 2 bar Short and compact design Modular engine concept based on the V6 FSI engine for V8 and V10 FSI High idli...

Page 7: ...le flap not fitted in RS4 Drive by wire throttle control For compliance with exhaust emission standards LEV II The main technical differences between the base engine and the high revving engine lie in...

Page 8: ...BNS Type of Engine V8 90 V angle 4V FSI Displacement in cm3 4163 Maximum Power Output in bhp 350 6800 rpm 420 7800 rpm Maximum Torque in lbft 325 3500 rpm 317 5500 rpm Valves per Cylinder 4 Bore in mm...

Page 9: ...ypoeutectic or hypereutectic depending on their silicon content Alusil has a hypereutectic silicon content of 16 to 18 so that primary silicon is precipitated on solidification of the molten metal A m...

Page 10: ...h 18 5 mm Big end bearing diameter 54 mm Big end bearing width 15 25 mm Modifications to High revving Engine At very high engine speeds axial vibration occurs due to the unbalance in the single mass d...

Page 11: ...de Length of bushing 0 20 mm diameter rolled Connecting rod length 154 mm Cracking During the cracking process the connecting rod is split at a predetermined breaking point using a special tool The re...

Page 12: ...to the intake manifold downstream of the throttle valve This inlet point is integrated in the coolant circulation system and heated This prevents the crankcase breather from freezing up Note Modificat...

Page 13: ...d but the remainder is optimally treated by the cyclones The separated oil is collected in an oil reservoir beneath the cyclones The oil cannot drain out of the reservoir until the oil drain valve is...

Page 14: ...gear concept is identical in all Audi V engine series There are four chain drives arranged in two layers Layer 1 Chain drive A drives the camshafts idler gears from the crankshaft Layer 2 Top drives B...

Page 15: ...ng pump and the compressor are driven by chain drive D The chain is driven directly by the crankshaft deflected by an idler gear and drives the chain sprocket seated on the gear module 377_013 Air Con...

Page 16: ...Engine To match the higher engine power output and RPM the following cylinder head components were modified Intake ports are charge optimized based on larger cross sections Intake valves are chrome pl...

Page 17: ...chanical 13 377_015 377_080 Crankcase Breather Valve Cover Hall Sensor High pressure Fuel Pump with Fuel Metering Valve Camshaft Assemblies Intake Camshaft Adjuster Exhaust Camshaft Adjuster with Retu...

Page 18: ...l economy The baffle plate is designed such that it not only prevents the crankshaft from churning the oil in the sump but also strengthens the main bearing walls In the basic engine the oil is cooled...

Page 19: ...de Oil Filter Module The oil filter module is designed as a full flow filter For easy maintenance it is located in the inner V of the engine The filter element can be easily replaced without the need...

Page 20: ...e arranged inside a housing Each of the flaps opens toward the inside of the intake end of the oil pump Function When the vehicle is cornering the oil flows inside the sump toward the outside of the c...

Page 21: ...Oil Circulation System 17 Oil Circulation System 377_059 Pressurized Oil Downstream of Filter Pressurized Oil Upstream of Filter...

Page 22: ...the basic engine When operating at full throttle the coolant temperature is reduced to 90 C via an electrically heated thermostat to avoid increasing the tendency of the engine to knock When operating...

Page 23: ...ter shutting off the hot engine the coolant run on pump is activated a preset period of time after the engine is shut off The pump run on time and the need for additional activation of both radiator f...

Page 24: ...manifold flaps in both engine variants are controlled according to a characteristic map In both engines the intake manifold flaps are activated in the lower engine load and RPM ranges They are brough...

Page 25: ...d closed by a vacuum actuator which is map controlled by the ECM via the Intake Air Switch Over Valve N335 The sand cast aluminum intake manifold was designed specifically to match the sporty characte...

Page 26: ...e intake manifold Secondary Air Injection AIR Pump Motor V101 Air Filter Filter Housing Flap Combination Valve Vacuum Unit Activated Charcoal Canister Evaporative Emission EVAP Canister Purge Regulato...

Page 27: ...ng up the throttle valve is wide open In this case the vacuum produced by the suction jet pump is not enough to sufficiently evacuate the brake servo The Brake Booster Pressure Sensor G294 is connecte...

Page 28: ...Pump Brake System Vacuum Pump V192 Suction Jet Pump entrainment pump with Non return Valve Combination Valve A A Brake Servo Brake Booster Pressure Sensor G294 Brake Booster Relay J569 Engine Control...

Page 29: ...ote The illustrations show the vacuum hoses The fitting locations may deviate from those shown here Always refer to the latest Electronic Service Information Secondary Air Injection AIR Pump Relay J29...

Page 30: ...Transmissions The main difference with this system is that it uses two high pressure pumps Fuel Metering Valve 2 N402 High pressure Fuel Pump 2 High pressure Fuel Pump 1 Low Fuel Pressure Sensor G410...

Page 31: ...njectors N30 N33 cylinders 1 4 To Fuel Injectors N83 N86 cylinders 5 8 Pressure Limiting Valve 136 bar Fuel Filter Integrated in Tank Fuel Tank Transfer Fuel Pump FP G6 Fuel Pump FP Control Module J53...

Page 32: ...ower output and torque The front and rear silencers are connected by separate pipes Again the rear silencer is a common component of both exhaust pipes On the inside of the rear silencer however the l...

Page 33: ...low engine RPM Function The exhaust flaps are switched by a vacuum actuator Both vacuum units are switched by an electrically activated solenoid valve The exhaust flaps are switched according to a ch...

Page 34: ...dissipated during this process heats the catalytic converter to operating temperature within approximately 30 seconds after engine start Operating Mode in the Audi Q7 During the warm up phase the Eng...

Page 35: ...e N112 via the ECM The basic engine in the Audi Q7 and the high revving engine in the RS4 have different fitting locations for the secondary air system In the Audi Q7 the secondary air system is fitte...

Page 36: ...G410 Engine Coolant Temperature ECT Sensor G62 Throttle Valve Control Module J338 Throttle Drive Angle Sensors 1 2 for Electronic Power Control EPC G187 G188 Heated Oxygen Sensor HO2S G39 Heated Oxyge...

Page 37: ...Metering Valve 2 N402 Secondary Air Injection AIR Pump Relay J299 Secondary Air Injection AIR Pump Motor V101 Camshaft Adjustment Valves 1 2 N205 N208 Camshaft Adjustment Valves 1 2 exhaust N318 N319...

Page 38: ...or G410 Intake Manifold Runner Position Sensor G336 Heated Oxygen Sensor HO2S G39 Oxygen Sensor O2S Behind Three Way Catalytic Converter TWC G130 Brake Booster Pressure Sensor G294 Brake Light Switch...

Page 39: ...lant Pump V51 Oxygen Sensor O2S Heater Z19 Oxygen Sensor O2S 1 behind Three Way Catalytic Converter TWC Heater Z29 Intake Air Switch Over Valve N335 Secondary Air Injection AIR Pump Relay J299 Seconda...

Page 40: ...odule used in the Audi Q7 is the largest in the range with a diameter of 82 mm The Pierburg system was selected because the air intake system in the RS4 has a diameter of 90 mm However both systems wo...

Page 41: ...ol the signals for the actuators of cylinder bank 2 are transmitted via private bus The slave control module acts as the misfire detector for each of the eight cylinders It also processes the signal f...

Page 42: ...n Brake pedal switch CCS switch positions CCS set speed SET ACTUAL idle speed Throttle valve angle Intake air temperature Drive by wire throttle lamp OBD2 lamp Hot warning lamp Power reduction or A C...

Page 43: ...lant temperature Brake light switch information CCS status Throttle valve angle Intake air temperature OBD2 lamp Hot warning lamp A C compressor OFF or power reduction Starter control automatic start...

Page 44: ...30 15a 50 30 87 15 31 M 30 87 15 31 S J623 J624 S Legend B Starter D Ignition Switch F36 Clutch Pedal Switch F194 Clutch Pedal Starter Interlock Switch G28 Engine Speed RPM Sensor J53 Starter Realy J6...

Page 45: ...the requested engine torque is higher than in normal operation in the same accelerator pedal position In addition the comfort oriented soft engine torque curve is suppressed As a result the engine res...

Page 46: ......

Page 47: ...s Self Study Program The Knowledge Assessment may or may not be required for Certification You can find this Knowledge Assessment at www accessaudi com For assistance please call Audi Academy Learning...

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