1. Manuals
  2. Brands
  3. Audi Manuals
  4. Engine
  5. 4.2-liter V8 FSI
  6. Service training

Audi 4.2-liter V8 FSI Service Training

Hide thumbs
Table of Contents

Advertisement

Quick Links

Service Training
Audi 4.2-liter V8 FSI Engine
Self-Study Program 921603

Advertisement

Table of Contents
loading

Related Manuals for Audi 4.2-liter V8 FSI

Summary of Contents for Audi 4.2-liter V8 FSI

  • Page 1 Service Training Audi 4.2-liter V8 FSI Engine Self-Study Program 921603...
  • Page 2 Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.

  • Page 3: Table Of Contents

    Table of Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Engine Mechanical .

  • Page 5: Introduction

    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 first time in the Audi Q7) and a sporty high-revving version for the new RS4. A 5.2L V10 FSI will also be available in the near future.
  • Page 6 Introduction The 4.2-liter V8 FSI engine is supplied in the new Audi Q7 The following main objectives were set for the and RS4. In the future, the engine will be used in the Audi development of the Audi Q7 engine: A6 and A8.

  • Page 7: Technical Features

    Introduction Technical Features The main technical differences between the base engine – Fuel Straight Injection and the high-revving engine lie in the following: – Roller cam rocker arms with hydraulic lifters – Chain drives for camshafts and accessories – Crankshaft/connecting rods/pistons –...

  • Page 8: Specifications

    Introduction Torque/Power Curve Maximum Torque in lb ft V8 FSI Basic Engine in Audi Q7 V8 FSI High-revving Engine in RS4 lb ft Maximum Power Output in Horsepower (HP) V8 FSI Basic Engine in Audi Q7 V8 FSI High-revving Engine in RS4...

  • Page 9: Engine Mechanical

    Engine Mechanical Cylinder Block *Aluminum alloys are classed as hypoeutectic or The cylinder crankcase has a closed-deck design, which is hypereutectic, depending on their silicon content. stronger than the open-deck design. “Alusil” has a hypereutectic silicon content of 16 to 18 % In an open-deck cylinder block, the water jacket for so that primary silicon is precipitated on solidification of cooling the cylinders is open at the top.
  • Page 10 Engine Mechanical Crankshaft/Connecting Rods/ Pistons Modifications to High-revving Engine Crankshaft At very high engine speeds, axial vibration occurs due to The crankshaft runs on five bearings and is made of high- alloy tempered steel (42CrMoS4). It is 90° cranked and the unbalance in the single-mass damper.

  • Page 11: Connecting Rod

    Engine Mechanical Connecting Rod Cracked connecting rods made of 36MnVS4 are used in the basic engine, while the conventionally split connecting rods in the RS4 engine are made of 34CrNiMo8, for strength. In addition, the geometry and tolerances of the connecting rods were reduced on the high revving version of the 4.2L V8 FSI engine.

  • Page 12: Crankcase Ventilation

    V, adjacent the crankcase breather (no longer through the chain housing). In the Audi Q7 engine, the crankcase is vented through a single chamber, i.e., via bank 2 only. Better icing protection is achieved in this way.
  • Page 13 Engine Mechanical Fine Oil Separator 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 opened. The oil drain valve Blow-by gas volume is dependent on engine load and is closed as long as the pressure in the crankcase, i.e., RPM.
  • Page 14 Chain Drive C Chain Drive D 377_012 Audi Q7 The timing gear concept is identical in all Audi V-engine series. The camshafts in the basic engine are driven by 3/8” There are four chain drives arranged in two layers. simplex roller chains.
  • Page 15 Engine Mechanical Accessory Drive The oil pump, water pump, power steering 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.

  • Page 16: Cylinder Heads

    Engine Mechanical Cylinder Heads The cylinder heads are similar in design to the Audi V6 four-valve FSI cylinder heads. Different Features of the Specifications High-revving Engine – Aluminum cylinder head To match the higher engine power output and RPM, the –...
  • Page 17 Engine Mechanical Crankcase Breather Valve Cover Hall Sensor High-pressure Fuel Pump with Fuel Metering Valve 377_015 Camshaft Assemblies Intake Camshaft Adjuster Exhaust Camshaft Adjuster with Return Spring 377_080...

  • Page 18: Oil Circulation System

    This has helped to minimize oil pump drive power and thus improve fuel economy. Oil Filter Module Chain Tensioner Cylinder Bank 1 Cylinder Bank 2 Hydraulic Camshaft Adjustment Oil Cooler (coolant) Oil Pressure Regulator Oil Pump (gear) Components Thermostat Exclusive to the Audi RS4 377_028 Oil Cooler (air)

  • Page 19: Oil Pump

    Oil Circulation System Oil Pump The oil pump is located above the oil pan. The oil is drawn in through the filter in the bottom of the sump and simultaneously through the engine return duct while driving. All engine lubrication points are swept from the pressurized oil side.
  • Page 20 Oil Circulation System Audi RS4 Sump A reliable supply of oil in all driving situations is critical, especially in a sports car such as the RS4. The oil supply system in the high-revving engine was designed for racing applications in which it is subjected to lateral acceleration of up to 1.4 g.
  • Page 21 Oil Circulation System Oil Circulation System 377_059 Pressurized Oil Downstream of Filter Pressurized Oil Upstream of Filter...

  • Page 22: Cooling System

    Cooling System Audi Q7 4 .2L V8 FSI Cooling System Heater Core Expansion Tank Coolant Temperature Sensor t° Generator Coolant Pump Radiator Oil Cooler Thermostat 377_030 The cooling system in the new V8 engines was configured A map-controlled coolant thermostat is used in the basic as a longitudinal-flow cooling system.
  • Page 23 Coolant Pump and Thermostat The 4.2L V8 FSI engine in the RS4 does not use the map- controlled thermostat as found in the Audi Q7 engine. To achieve more effective cooling, two additional coolers are used. Coolant flows continuously through one of the additional coolers.

  • Page 24: Air Circulation System

    377_023 Intake Manifold Flaps As with the variable intake manifold, the intake manifold In the basic engine in the Audi Q7 the intake manifold flaps in both engine variants are controlled according to flaps are activated via an electrical actuator.
  • Page 25 5000 RPM and at road speeds higher the intake manifold changeover valve would be switched than 200 kph. to the short path for higher power output. Audi RS4 Intake System Air Intake Mass Air Flow (MAF) Sensor G70...
  • Page 26 Air Circulation System Audi RS4 Vacuum Hoses The conventional method of supplying vacuum to the This means that connecting a vacuum line downstream brake servo and the engine components is problematic in of the throttle valve would not supply the needed the case of FSI engines.
  • Page 27 Air Circulation System For this reason, in both engine versions, the required In this case, the vacuum produced by the suction jet vacuum is produced by a suction jet pump and, if pump is not enough to sufficiently evacuate the brake necessary, additionally by an electrical vacuum pump.
  • Page 28 Air Circulation System Audi Q7 Vacuum Hoses Secondary Air Pump Air Filter Evaporator Casing Extraction Valve Brake System Vacuum Pump V192 Suction Jet Pump (entrainment pump) with Non-return Valve Combination Valve Brake Booster Pressure Brake Booster Brake Servo Sensor G294...
  • Page 29 Air Circulation System Note: 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 J299 Evaporator Casing From Fuel Tank 377_068...

  • Page 30: Fuel System

    Leakage Line Audi Q7 Low-pressure System Reference: For a description of the system’s operating mode, refer to SSP 992403 – The 2005 Audi A6 Engines and Transmissions. The main difference with this system is that it uses two high-pressure pumps.
  • Page 31 Fuel System Fuel Pressure Sensor G247 Fuel (rail) 2 To Fuel Injectors N83 - N86 (cylinders 5-8) Pressure Limiting Valve (136 bar) Fuel (rail) 1 Fuel Injectors N30 - N33 (cylinders 1-4) 377_033 Fuel Filter Integrated in Tank Fuel Pump (FP) Control Module J538 Transfer Fuel Pump (FP) G6...

  • Page 32: Exhaust System

    Again, the rear silencer is a common component of both exhaust pipes. On the inside of the rear silencer, however, the left and right exhaust pipes are clearly separated. Audi Q7 Exhaust System Exhaust Manifold Primary Catalytic Converter Decoupling Element...
  • Page 33 Exhaust System Audi RS4 Exhaust Flap Control Function A further difference is the layout; one exhaust flap is located downstream of each of the rear silencers. The exhaust flaps are fitted to give the engine a sporty sound. The exhaust flaps are switched by a vacuum actuator.

  • Page 34: Secondary Air System

    Exhaust System Secondary Air System Operating Mode in the Audi Q7 The secondary air system ensures that the catalytic converter heats up more quickly and is available sooner after a cold start. During the warm-up phase, the Engine Control Module...
  • Page 35 The secondary air system operates in much the same way system is fitted at the engine front end on the input side as that in the Audi Q7 engine. The difference here lies in of the ribbed V-belt, while in the RS4 it is fitted at the the way the combination valves open and close.

  • Page 36: Engine Management

    Engine Management System Overview – Audi Q7 (Boxch MED 9 .1 .1) Sensors Mass Air Flow (MAF) Sensor G70 Mass Air Flow (MAF) Sensor 2 G246 Intake Air Temperature (IAT) Sensor G42 Throttle Position (TP) Sensor G79 Accelerator Pedal Position Sensor 2 G185...
  • Page 37 Engine Management Actuators Starter Relay J53, Starter Relay 2 J695 Motronic Engine Control Module Power Supply Relay J271 Engine Component Power Supply Relay J757 Fuel Pump (FP) Control Module J538 Transfer Fuel Pump (FP) G6 Fuel Injectors, Cylinders 1-8 N30-N33, N83-N86 Throttle Valve Control Module J338 Throttle Drive (for Electronic Power Control (EPC)) G186 Ignition Coils 1-8 with Power Output Stage...
  • Page 38 Engine Management System Overview – Audi RS4 (Boxch MED 9 .1) Sensors Mass Air Flow (MAF) Sensor G70 Intake Air Temperature (IAT) Sensor G42 Throttle Position (TP) Sensor G79 Accelerator Pedal Position Sensor 2 G185 PowerTrain CAN Data Bus Engine Speed (RPM) Sensor G28...
  • Page 39 Engine Management Actuators Fuel Pump Control Module J538 Transfer Fuel Pump (FP) G6 Ignition Coils 1-4 with Power Output Stage N70, N127, N291, N292 Fuel Metering Valve N290 Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 Right Electro-Hydraulic Engine Mount Solenoid Valve N145 Intake Manifold Runner Control (IMRC) Valve N316 Starter Relay J53, Starter Relay 2 J695 Exhaust Flap Valve 1 N321...
  • Page 40 Engine Speed Sensor G28 An inductive sender is used in the Audi Q7 engine. A Hall effect sensor is used in the RS4 engine with master/slave concept.
  • Page 41 Engine Management Control Module Communications in the RS4 The slave control module acts as the misfire detector for The Engine Control Module J623 (ECM, master) computes each of the eight cylinders. It also processes the signal and controls the signals from the actuators for cylinder from the Engine Speed (RPM) Sensor G28.
  • Page 42 Engine Management CAN Data Bus Interfaces (Powertrain CAN Data Bus) in the Audi Q7 The messages listed here are transmitted from the control modules to the powertrain CAN data bus. However, only a few of the important messages are listed. In reality, there are many more. Of course, these messages are subject to change due to software updates.
  • Page 43 Engine Management CAN Data Bus Interfaces (Powertrain CAN Data Bus) in the Audi RS4 Engine Control Module J623 (master) ABS Control Module J104 Instrument Cluster Control Module J285 Idle information TCS request Rear light Accelerator pedal angle EBC request Steering Column Electronic...
  • Page 44 Engine Management Audi RS4 Function Diagram F194 J623 J624 J695 377_076 Legend Starter Ignition Switch Clutch Pedal Switch F194 Clutch Pedal Starter Interlock Switch Engine Speed (RPM) Sensor Starter Realy J623 Engine Control Module (master) J624 Engine Control Module 2 (slave)
  • Page 45 Engine Management Audi RS4 Sport Mode To accentuate the sporty character of the RS4, the driver can switch Sport mode “on” or “off” using a special switch. When the Sport program button is pressed the following in-vehicle functions are activated: –...

  • Page 47: Knowledge Assessment

    An on-line Knowledge Assessment (exam) is available for this 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 Management Center Headquarters 1-877-AUDI-LMC (283-4562) (8:00 a.m. to 8:00 p.m. EST)
  • Page 48 Vorsprung durch Technik www.audiusa.com All rights reserved. Technical specifications subject to change without notice. Audi of America, Inc. 3800 Hamlin Road Auburn Hills, Michigan 48326...

Table of Contents