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Audi 4.2-liter V8 FSI Service Training
Summary of 4.2-liter V8 FSI
Page 1
Self-study program 921603 all rights reserved. Technical specifications subject to change without notice. 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.
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Audi of america, inc. Service training printed in u.S.A. Printed 07/2006 course number 921603 ©2006 audi of america, inc. All rights reserved. All information contained in this manual is based on the latest information available at the time of printing and is subject to the copyright and other intel...
Page 3: Table Of Contents
Table of contents i the self-study program provides introductory information regarding the design and function of new models, automotive components or technologies. The self-study program is not a repair manual! All values given are intended as a guideline only and refer to the software version vali...
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Page 5: Introduction
Introduction 1 the first member of the current audi v family of engines was the 3.2-liter v6 fsi engine. Special features of the audi v-engine family are the 90-degree angle between the cylinder banks and the 90 mm spacing between the cylinders. The 4.2-liter v8 fsi engine is also a member of this f...
Page 6: Introduction
Introduction 2 the 4.2-liter v8 fsi engine is supplied in the new audi q7 and rs4. In the future, the engine will be used in the audi a6 and a8. The following main objectives were set for the development of the audi q7 engine: high specific engine power: 350 bhp out of 4.2 liters (15 bhp more than m...
Page 7: Introduction
Introduction 3 technical features fuel straight injection roller cam rocker arms with hydraulic lifters chain drives for camshafts and accessories variable camshaft adjustment for intake and exhaust camshafts two-stage magnesium variable inlet manifold with integrated tumble flap (not fitted in rs4)...
Page 8: Introduction
Introduction 4 215 268 322 375 429 107 hp lb ft 340 221 280 310 2000 0 5000 7000 9000 torque/power curve maximum torque in lb ft v8 fsi basic engine in audi q7 v8 fsi high-revving engine in rs4 maximum power output in horsepower (hp) v8 fsi basic engine in audi q7 v8 fsi high-revving engine in rs4 e...
Page 9: Engine Mechanical
Engine mechanical 5 cylinder block the cylinder crankcase has a closed-deck design, which is stronger than the open-deck design. In an open-deck cylinder block, the water jacket for cooling the cylinders is open at the top. The cylinder crankcase is made of a low-pressure gravity diecast aluminum-si...
Page 10: Engine Mechanical
Engine mechanical 6 crankshaft/connecting rods/ pistons crankshaft the crankshaft runs on five bearings and is made of high- alloy tempered steel (42crmos4). It is 90° cranked and has no connecting rod journal offset. The vibration damper is a vulcanized single-mass damper with unbalance. Main beari...
Page 11: Engine Mechanical
Engine mechanical 7 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 revv...
Page 12: Engine Mechanical
Engine mechanical 8 crankcase ventilation the crankcase is ventilated through both cylinder heads. The valve covers incorporate a large settling space. This space acts as a gravity-type oil separator. A fine oil separator is connected to the valve covers by means of plastic hoses. A control piston, ...
Page 13: Engine Mechanical
Engine mechanical 9 fine oil separator blow-by gas volume is dependent on engine load and rpm. The fine oil (“oil spray”) is separated by means of a cyclone separator. Cyclone separators have a high separation efficiency over only a small volumetric range. For that reason, one, two, or three cyclone...
Page 14: Engine Mechanical
Engine mechanical 10 chain drives audi q7 the camshafts in the basic engine are driven by 3/8” simplex roller chains. Due to their acoustic advantages, the chains were developed to meet the high comfort requirements. In this case, the idler gears have 40 and 24 teeth. The camshaft sprockets have 30 ...
Page 15: Engine Mechanical
Engine mechanical 11 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. 377_013 air conditioner compressor co...
Page 16: Engine Mechanical
Engine mechanical 12 cylinder heads the cylinder heads are similar in design to the audi v6 four-valve fsi cylinder heads. Specifications aluminum cylinder head fsi intake ports with horizontal divisions to produce a tumble effect four-valve technology with centralized layout of the spark plugs inle...
Page 17: Engine Mechanical
Engine mechanical 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 return spring.
Page 18: Oil Circulation System
Oil circulation system 14 design the oil supply in the basic engine, and likewise in the high-revving engine, is based on a traditional wet sump concept. The focal point of development was on significant reduction of the oil flow rate. As a result, the oil remains in the sump longer and is better ab...
Page 19: Oil Circulation System
Oil circulation system 15 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. Oil filter module the...
Page 20: Oil Circulation System
Oil circulation system 16 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. T...
Page 21: Oil Circulation System
Oil circulation system 17 oil circulation system 377_059 pressurized oil downstream of filter pressurized oil upstream of filter.
Page 22: Cooling System
Cooling system 18 audi q7 4 .2l v8 fsi cooling system the cooling system in the new v8 engines was configured as a longitudinal-flow cooling system. The cooling water flows in on the outlet side and through the cylinder head gasket into the cylinder head, where it flows out longitudinally through th...
Page 23: Cooling System
Cooling system 19 audi rs4 4 .2l v8 fsi cooling system 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 ...
Page 24: Air Circulation System
Air circulation system 20 air intake the intake path of the audi q7 is double-chambered and discharges into a variable inlet manifold made of gravity die cast aluminum. A bosch throttle valve module with a diameter of 82 mm is located upstream of the variable inlet manifold. The variable intake mani...
Page 25: Air Circulation System
Air circulation system 21 the intake system of the rs4 engine was designed with emphasis on maximum flow control. Pressure loss is minimized by a large cross-sectional areas in the mass air flow (maf) sensor g70 and air intake pipe in combination with a 90 mm diameter throttle valve. To ensure a suf...
Page 26: Air Circulation System
Air circulation system 22 audi rs4 vacuum hoses the conventional method of supplying vacuum to the brake servo and the engine components is problematic in the case of fsi engines. This means that connecting a vacuum line downstream of the throttle valve would not supply the needed vacuum. This is du...
Page 27: Air Circulation System
Air circulation system 23 for this reason, in both engine versions, the required vacuum is produced by a suction jet pump and, if necessary, additionally by an electrical vacuum pump. The suction jet pump is connected in parallel with the throttle valve part upstream and downstream of the throttle v...
Page 28: Air Circulation System
Air circulation system 24 audi q7 vacuum hoses secondary air 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 module (ecm) j623 air filter evaporat...
Page 29: Air Circulation System
Air circulation system 25 377_068 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.
Page 30: Fuel System
Fuel system 26 audi q7/rs4 fuel 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. Fuel metering valve 2 n402 high-pressure fuel pump 2 hig...
Page 31: Fuel System
Fuel system 27 377_036 fuel (rail) 2 fuel (rail) 1 fuel pressure sensor g247 fuel injectors 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 j538 r...
Page 32: Exhaust System
Exhaust system 28 exhaust system during the development of the exhaust system, special emphasis was placed on optimizing flow resistance. Audi q7 each cylinder bank has its own exhaust pipe. The air-gap insulated exhaust manifolds are flanged onto the cylinder heads. They offer the advantage of low ...
Page 33: Exhaust System
Exhaust system 29 audi rs4 exhaust flap control 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. Low-frequency droning noise at low engine rpm is prevented. At high engine rpm and...
Page 34: Exhaust System
Exhaust system 30 secondary air system the secondary air system ensures that the catalytic converter heats up more quickly and is available sooner after a cold start. Principle due to the richer air-fuel mixture in the cold start and warm-up phases, a higher concentration of unburned hydrocarbons oc...
Page 35: Exhaust System
Exhaust system 31 operating mode in the rs4 the secondary air system operates in much the same way as that in the audi q7 engine. The difference here lies in the way the combination valves open and close. The air path from the secondary air pump to the secondary air duct in the cylinder head is open...
Page 36: Engine Management
Engine management 32 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 powertrain can data bus engine control module (ecm) j623 throttle position (tp) sensor g79 accelerator pedal position se...
Page 37: Engine Management
Engine management 33 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 m...
Page 38: Engine Management
Engine management 34 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 engine speed (rpm) sensor g28 knock sensors (ks) 1+2 g61, g66 fuel pressure senso...
Page 39: Engine Management
Engine management 35 377_032 actuators fuel pump control module j538 transfer fuel pump (fp) g6 diagnostic connection 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 engin...
Page 40: Engine Management
Engine management 36 engine management in the new 4.2l v8 fsi is by two versions of the bosch med 9.1.1. A single control module is used in the audi q7 engine. There are two control modules for the rs4 engine. A master-slave concept is required here due to the requisite processing power at engine sp...
Page 41: Engine Management
Engine management 37 control module communications in the rs4 the engine control module j623 (ecm, master) computes and controls the signals from the actuators for cylinder bank 1. Most sensors are connected to the ecm (refer to system overview, pages 34/35). Both control modules are connected to th...
Page 42: Engine Management
Engine management 38 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...
Page 43: Engine Management
Engine management 39 can data bus interfaces (powertrain can data bus) in the audi rs4 engine control module 2 j624 (slave) utilizes the signals from can 1 (powertrain can bus) and can 2 (private can) to calculate the activation of the actuators of cylinder bank 2 (left bank) (refer to system overvi...
Page 44: Engine Management
Engine management 40 audi rs4 function diagram 377_076 f194 f36 j53 g28 b d j695 s 5v + - s 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 j623 eng...
Page 45: Engine Management
Engine management 41 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: more direct accelerator pedal response more sporty...
Page 47: Knowledge Assessment
Knowledge assessment 43 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 ...
Page 48: Service Training
Self-study program 911403 all rights reserved. Technical specifications subject to change without notice. Audi of america, inc. 3800 hamlin road auburn hills, michigan 48326 diagnosis with vas scan tools service training vorsprung durch technik www.Audiusa.Com vehicle self- diagnosis vas 5052 help p...