Audi 2.0 Liter Chain-driven TFSI Engine

Online PDF Audi 2.0 Liter Chain-driven TFSI Engine

The chain drive sprocket is mounted to the crankshaft face and driven by a spur gear forged in the crankshaft. The other end of the chain sprocket also has a spur gear surface which drives the vibration damper.

This method of joining allows high torque to be transmitted to the chain sprocket and vibration damper while keeping the diameter of the components small. This allows better sealing by the radial shaft seal at the vibration damper hub. On the transmission side of the engine, a dual mass flywheel or torque converter (depending on transmission) is mounted to the crankshaft with eight bolts.

Cylinder Block
The cylinder block has a closed-deck configuration and is made of cast iron. It houses the five-bearing crankshaft assembly and the two balancer shafts. The housing for mounting the chain drives is integrated in the block. The cylinder liners are finished in a three-stage fluid jet honing process.

The undersides of the pistons are cooled by engine oil supplied by spray jets mounted on the cylinder block. The cylinder block is sealed on the transmission side by a sealing flange and gasket.

Oil Pan
The oil pan consists of two sections. The upper section is made of an aluminum alloy (AlSi12Cu) and reinforces the crankcase through a bedplate effect. It also houses the oil pump.
The upper section is bolted to the crankcase and sealed with a liquid sealant.

The bottom section is made of sheet steel (deep drawn, punched, and catalytically coated). It houses Oil Level Sensor G12 and the drain plug. The bottom section is bolted to the upper section and sealed with a liquid sealant. The oil pan has an integral honeycomb insert made of polyamide to prevent oil churning when the vehicle is driven aggressively.

The five main bearing crankshaft is made of forged steel and induction hardened. Optimal balancing is achieved by using eight counterweights. To additionally reinforce the crankshaft assembly, the three inner main bearing covers are cross-bolted to the cylinder block.

The crankshaft main bearings are a two component type. Axial play of the crankshaft is controlled by thrust washers at the middle support bearing. Bronze bushings are press-fit into the small trapezoidal upper end of the connecting rods. The lower end of the connecting rods are cracked to ensure a precision fit and reduce movement of the bearing cap under load.

The upper and lower bearing shells of the connecting rod are not identical in composition. The upper bearing shell is a two-component composite bearing while the lower shell is a three-component composite bearing.

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