Volkswagen 4.2l V8 5V Service Training Download | Manualshive

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Service Training

Self-study programme 341

The 4.2l V8 5V engine

Design and function

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Summary of Contents for 4.2l V8 5V

Page 1: ...Service Training Self study programme 341 The 4 2l V8 5V engine Design and function ...

Page 2: ...er to the customer service literature intended for this purpose The 4 2l V8 5V engine will be launched in two variants In the Touareg with an output of 228kW In the Phaeton with an output of 246kW S341_001 NEW Attention Note Besides their differences in output the two engines will differ primarily as a result of the modifications necessary for the Touareg s off road capability ...

Page 3: ... system 8 Cylinder block 10 Crankshaft drive 11 Cylinder head 12 Camshaft adjustment system 13 Valve gear 16 Lubrication system 18 Cooling circuit 22 Fuel system 23 Exhaust system 24 Secondary air system 25 Engine management system 26 System overview 26 Sensors 28 Actuators 32 Functional diagram 34 Test your knowledge 37 At a glance ...

Page 4: ...m V8 cylinder block Cylinder head with 5 valve technology and roller rocker fingers Inlet camshaft adjustment Two stage variable intake manifold in the Phaeton Three stage variable intake manifold in the Touareg Oil filter module Twin branch intake system Engine management system Bosch Motronic ME 7 1 1 Sequential fuel injection Electronic ignition Two hot film air mass sensors Secondary air syste...

Page 5: ...nt system Bosch ME 7 1 1 Fuel RON 98 RON 95 with reduced output Exhaust gas aftertreatment 4 catalytic converters 4 lambda probes secondary air system Exhaust emission standard EU 4 Torque and output graph 246kW Torque and output graph 228kW Torque Nm Output kW 500 0 50 100 150 200 250 400 450 250 0 25 50 75 100 125 175 200 225 2000 4000 6000 Engine speed rpm 300 350 150 Torque Nm Output kW 500 0 ...

Page 6: ...0mm Phaeton An additional guide roller is required in the Phaeton because the alternator is fitted in a lower position than in the Touareg This is due firstly to the installation space conditions in the Phaeton and secondly to the Touareg s necessary fording capability Belt pulley for air conditioner compressor Belt pulley for vane pump power steering Guide roller Belt pulley for vibration damper ...

Page 7: ...er Crankshaft toothed belt sprocket Hydraulic toothed belt tensioner guide roller S341_091b When renewing or replacing the toothed belt the crankshaft must be set to TDC cylinder No 5 To achieve this the notch on the vibration damper must align with the mark on the toothed belt guard and the locating plates two large bores must face each other inwards ELSA provides information on the detailed proc...

Page 8: ...omprised of four bolted and bonded magnesium components The Touareg is fitted with a three stage variable intake manifold and the Phaeton with a two stage variable intake manifold In comparison with the three stage version the two stage design allows intake tracts with high volume cross sections to be implemented This leads to an increase in engine output In the event of repair the entire intake m...

Page 9: ...he output position to the torque position at 4440 rpm Torque position Long intake ports are used in the torque position This leads to a high flow speed extensive turbulence in the cylinder very good fuel air mixing andrapid combustion In turn this results in the development of high torque Output position Short intake ports with the largest possible cross sections are used in the output position Th...

Page 10: ...th a coating Advantages Low settling behaviour Long service life The aluminium cylinder block has a 90 V angle and is manufactured from an aluminium alloy The pistons run directly on the aluminium alloy s silicon crystals As a result of this no separate cylinder liners are required The gap between cylinders is 90mm S341_080 Coating Metal layers S341_016 ...

Page 11: ...e pattern to the drive plate Connecting rods The connecting rods are machined as complete parts and are finally separated by a tool exerting great force to form the connecting rod and connecting rod bearing cap This process is called cracking Pistons The aluminium pistons are equipped with a valve pocket for the centre intake valve Thanks to the valve pocket the pistons are cylinder bank specific ...

Page 12: ...a result of this there is no direct connection between the cylinder head cover and the cylinder head and engine vibrations are not passed on to the cylinder head cover The cylinder head cover is bolted using what are called decoupling elements ELSA provides information on the detailed procedures for preventing cylinder head cover warping and guaranteeing reliable sealing Cylinder head Inlet camsha...

Page 13: ... on the engine speed with the aid of the inlet camshaft In this case the torque is increased in the lower to medium engine speed range whilst output is raised in the upper engine speed range Camshaft adjustment additionally improves internal exhaust gas recirculation Adjustment equates to a crank angle of 22 in the advance direction S341_033 Hydraulic cylinder with switching piston Chain tensioner...

Page 14: ...se is minimised as a result of this Basic position From idle speed to approx 1000 rpm Torque position From approx 1000 rpm to approx 3600 rpm in the Touareg and approx 5600 rpm in the Phaeton Output position From approx 3600 rpm in the Touareg and approx 5600 rpm in the Phaeton How it works Depending on the manner in which the camshaft adjustment valve is actuated the oil is guided into two differ...

Page 15: ...nd the fuel air mixture follows the movement of the piston Thanks to advanced inlet valve closing the mixture can no longer be pushed back into the intake manifold by the cylinder Output position As of an engine speed of approximately 3600 rpm in the Touareg and 5600 rpm in the Phaeton the system switches to the output position basic position Via port A the oil is conducted to the adjustment pisto...

Page 16: ...t adjustment valve Camshaft roller chain Exhaust camshaft Inlet valves Inlet camshaft Roller rocker finger Exhaust valves Single cam exhaust camshaft Valve actuation The valves are actuated by the camshafts by means of roller rocker fingers The two exhaust valves are actuated via a twin roller rocker finger and the three inlet valves via a triple roller rocker finger Camshaft roller chain Toothed ...

Page 17: ...al Axle shaft for roller rocker fingers Roller rocker fingers Rollers The roller rocker fingers are mounted on an axle shaft The axle shaft is used to simultaneously supply the bearings and the hydraulic valve clearance compensation elements with oil The hydraulic valve clearance compensation elements are located directly in the lever arm above the valves The rollers are each seated between the le...

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