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Service TrainingSelf Study Program 820433The EA288 Diesel Engine FamilyDesign and Function

Volkswagen Group of America, Inc.Volkswagen AcademyPrinted in U.S.A.Printed 2/2014Course Number SSP 820433 2014 Volkswagen Group of America, Inc.All rights reserved. All information contained in this manual is basedon the latest information available at the time of printing and issubject to the copyright and other intellectual property rights ofVolkswagen Group of America, Inc., its affiliated companies andits licensors. All rights are reserved to make changes at any timewithout notice. No part of this document may be reproduced, storedin a retrieval system, or transmitted in any form or by any means,electronic, mechanical, photocopying, recording or otherwise, normay these materials be modified or reposted to other sites withoutthe prior expressed written permission of the publisher.All requests for permission to copy and redistribute information shouldbe referred to Volkswagen Group of America, Inc.Always check Technical Bulletins and the latest electronic repairinformation for information that may supersede any informationincluded in this booklet.Trademarks: All brand names and product names used in this manualare trade names, service marks, trademarks, or registered trademarks;and are the property of their respective owners.

ContentsIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Engine Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Engine Management System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Knowledge Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71NoteThis Self-Study Program provides information regardingthe design and function of new models.This Self-Study Program is not a Repair Manual. Thisinformation will not be updated.Important!For maintenance and repair procedures,always refer to the latest electronic serviceinformation.i

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IntroductionEA288 Diesel Engine FamilyVolkswagen is introducing a new family of diesel engines in the 2015 Golf. The engine family has the designation EA288 (EA Entwicklungsauftrag [development order]).The design of this new generation of diesel engines was based on the existing EA189 engine family. Displacement, cylinderspacing, stroke and bore ratio are shared between the EA189 and the new EA288 gasoline engines. The new EA288 enginedesign forms the basis for all future inline diesel engines at Volkswagen.Several sub-assemblies were redesigned in the EA 288 family of 4-cylinder diesel engines to satisfy future emission standards.In this Self-Study Program you will learn about the structure and design of the new EA288 TDI engine, and the functions of theindividual engine subsystems.S514 0011

IntroductionModular Diesel Matrix (MDB)The new EA288 diesel engine family is also called a modular diesel matrix, or MDB. The modular diesel system is the basis forall future inline diesel engines in the Volkswagen Group.The modular diesel matrix is a concept that involves dividing the functional engine components into modules. Depending oncapacity, power output, emission standard and the vehicle class, engines can be assembled from modules and components.14253678109S514 104Basic EngineAttachment Parts1 Modular Camshaft Housing7 Exhaust Manifold Module with Turbocharger2 Cylinder Head8 Intake Manifold with Water-Cooled Charge AirCooler3 Cylinder Block4 Switchable Coolant Pump5 Oil/Vacuum Pump9 Exhaust Purification Module10 Exhaust Gas Recirculation Module6 Timing Drive and Accessory DriveThe modular design meets fuel consumption, exhaust emissions and power delivery demands. It also allows the engines toaccept future modular components that meet upcoming country-specific requirements with minimal costs.2

IntroductionTechnical DataEngine CodeCRBCDesignFour-cylinder inline engineEngine Capacity1968 cm3Bore81.0 mmStroke95.5 mmValves per Cylinder4Compression Ratio16.2:1Maximum Output150 hp (110 kW) from 3500 to 4000 rpmMaximum Torque235 lb/ft (320 Nm) from 1750 to 3000 rpmEngine Management SystemBosch EDC 17FuelUltra-Low Sulfur DieselExhaust Gas AftertreatmentExhaust gas recirculation, oxidizing catalyticconverter, diesel particulate filterEmissions StandardBIN 5Torque and Power 451000 2000 3000 4000Engine speed [rpm]Output [hp]Torque [lb/ft]2.0 TDI Engine10S514 1003

Engine MechanicsCylinder BlockThe EA288 cylinder block is grey cast iron, an alloy of cast iron and flake graphite.The cylinder block has deep screw threads for long cylinder head bolts. This distributes combustion forces through the cylinderblock structure, applying equal pressure distribution on the cylinder head gasket.The design of the cooling channels in the cylinder block provides good cooling in the area between the cylinders.Cylinder Block 2.0L TDI EngineThe cylinder block for the 2.0L TDI engine is available forengines with and without balance shafts.S514 0054

Engine MechanicsCrankshaft GroupCrankshaftPiston and ConrodThe EA288 engine uses a forged crankshaft with fivebearings to distribute the high mechancial loads. Instead ofthe usual eight counterweights, this crankshaft only has fourcounterweights to counteract the rotating forces of inertia.The pistons in the EA288 engine have no valve pockets.Instead, the dish design of the piston crown reduces deadspace and improves the swirl formation of the intake air inthe cylinder.This design reduces the load on the crankshaft bearings.Noise emissions, which may be caused by inherentmovement and vibrations in the engine, have also beenreduced.To improve piston ring area cooling, the pistons have a ringshaped cooling channel into which oil is sprayed via pistonspray nozzles.The conrods are cracked trapezoidal conrods.The toothed belt sprocket that drives the oil pump and thesprocket that drives the balance shafts are an interference fitonto the crankshaft.PistonsBalance ShaftConrodGear Sprocketfor BalanceShaft DriveToothed Belt Sprocketfor Oil Pump DriveCamshaft ToothedSprocket for EngineManagement SystemBalance ShaftS514 0065

Engine MechanicsBalance ShaftsOne version of the 2.0L TDI engine has a balance shaftsystem to reduce crankshaft inertial forces inherent in astraight four-cylinder engine. The balance shaft system hastwo countershafts rotating in opposite directions at doublethe speed of the crankshaft.FunctionThe balance shafts are is driven by a gear wheel driveconnected to the crankshaft. An idler gear between thecrankshaft and one of the balance shafts reverses thedirection of the second balance shaft. Both balance shaftsand the idler gear are axially and radially mounted withroller bearings in the cylinder block to reduce friction.S514 007The roller bearings are lubricated by oil mist in the cylinderblock.The components in the balance shaft systemcannot be replaced in the field because theplay between the gears cannot be adjustedusing workshop tools.Rolling BearingBalance ShaftRolling BearingRolling BearingRolling BearingBalance ShaftRolling BearingRolling BearingCrankshaftIdler Gear for Reversing RotationS514 0166

Engine MechanicsToothed Belt DriveThe engine timing components are driven by the crankshaft via a toothed belt. From the crankshaft, the toothed belt is routedto the belt tensioner, over the camshaft drive wheel, to the drive wheel of the high-pressure pump for the common rail injectionsystem, and then to the drive wheel of the coolant pump. Two idler rollers ensure better meshing of the gear wheels and thetoothed belt.Camshaft Drive WheelIdler RollerHigh Pressure Pump Drive GearTensioning RollerCoolant Pump Drive GearIdler RollerCrankshaft SprocketS514 041Accessory Component DriveTensioningRollerAlternatorThe alternator and the air conditioner compressor are drivenby the crankshaft by a pulley with vibration damper and apoly V-belt. The poly V-belt is tensioned by a spring-loadedbelt tensioner.Pulley withVibrationDamperAir ConditionerCompressorS514 0087

Engine MechanicsCylinder HeadThe aluminum alloy cylinder head of the EA288 engine hasa cross-flow design and a unique placement of intake andexhaust valves. The valves are operated by two camshafts.Because of the arrangement of the intake and exhaustports, each camshaft operates intake and exhaust valves.There is not a separate intake or exhaust camshaft.Cylinder HeadThe camshafts are driven by the crankshaft by a toothed beltand the camshaft gear of one of the camshafts. The twocamshafts are joined by a spur gear.Camshaft HousingS514 042Camshaft HousingThe camshafts are integrated into a closed retaining frame by a thermal joining process. They cannot be separated. Thisprocess ensures a very rigid camshaft bearing while keeping the weight low.To reduce friction, a needle bearing is used for the first bearing that receives the highest forces from the toothed belt drive. Asensor wheel for G40 Camshaft Position Sensor is located on one camshaft. The signal from the Hall sensor tells the ECM thecurrent position of the camshafts.Spur Gear TeethNeedle BearingSender WheelRetaining Frame with CamshaftsHall Sensor G40S514 043The camshafts cannot be removed from the camshaft housing. If there is damage to the camshafts or thehousing, the complete assembly must be replaced.8

Engine MechanicsValve LayoutFor future emission standards, the ‘valve star’ has been rotated to the longitudinal axis of the engine. This means the intake andexhaust ports for each cylinder are positioned one behind the other in the direction of flow. As a result, each camshaft actuatesone intake and exhaust valve per cylinder. The valve layout has been designed to allow maximum air delivery with good swirleffects.Intake AirFirst Exhaust Valve, Cylinder 2First Intake Valve, Cylinder 2Second Intake Valve, Cylinder 2Cylinder 1Second Exhaust Valve, Cylinder 2Exhaust GasS514 059Coolant JacketThe cylinder head has an upper and lower coolant jacket.The lower coolant jacket core has a larger volume, toprovide a high level of heat dissipation in the part of thecylinder head close to the combustion chamber. The flowof coolant from the upper and lower parts merge at thespur gear side of the cylinder head where it exits through acombined outlet.Upper Coolant Jacket CoreOutlet to theConnecting PieceTo provide heat when the engine is cold, the coolant ischanneled out of the upper and lower core, through thecoolant hose connecting piece, and towards the heatercore.Connecting Piecesfor Coolant HosesLower CoolantJacket CoreS514 0479

Engine MechanicsCrankcase BreatherThe crankcase breather components are integrated into the cylinder head cover, with the oil filler neck and the pressureaccumulator for the engine vacuum system.Blow-by gases are returned to the intake side through the crankcase breather.Crankcase venting takes place in several stages for efficient separation. First, the blow-by gases travel from the crankshaft andcamshaft chamber into the “settling volume” area of the cylinder head cover. This is where larger oil drops collect on the wallsand drip down into the cylinder head. Then the oily gases are separated from gas fumes in a cyclone separator. The pressurecontrol valve regulates the transfer of purified gases to the intake manifold, where they enter the combustion chamber.To prevent the passages from freezing in cold climate countries, a heater element is used in the crankcase breather.Heater Element for Crankcase BreatherPressure Regulating ValveVacuum ReservoirFine Oil Separation (Cyclone)Oil Return from Fine Oil SeparatorSettling VolumeGravity Valve for Oil ReturnS514 01110