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Service TrainingSelf Study Program 823603VW 3.2 and 3.6 liter FSI Engine

Volkswagen of America, Inc.Volkswagen AcademyPrinted in U.S.A.Printed 10/2006Course Number 823603 2006 Volkswagen of America, Inc.All rights reserved. All information contained in this manual isbased on the latest information available at the time of printingand is subject to the copyright and other intellectual propertyrights of Volkswagen of America, Inc., its affiliated companiesand its licensors. All rights are reserved to make changes atany time without notice. No part of this document may bereproduced, stored in a retrieval system, or transmitted in anyform or by any means, electronic, mechanical, photocopying,recording or otherwise, nor may these materials be modifiedor reposted to other sites without the prior expressed writtenpermission of the publisher.All requests for permission to copy and redistributeinformation should be referred to Volkswagen of America,Inc.Always check Technical Bulletins and the latest electronicrepair information for information that may supersede anyinformation included in this booklet.Trademarks: All brand names and product names used inthis manual are trade names, service marks, trademarks,or registered trademarks; and are the property of theirrespective owners.

ContentsOverview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Engine Mechanics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Engine Management. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Operating Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Knowledge Assessment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67NoteThis Self-Study Program provides informationregarding the design and function of newmodels.This Self-Study Program is not a Repair Manual.Important!This information will not be updated.For maintenance and repair procedures,always refer to the latest electronicservice information.iii

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OverviewThe 3.2L and the 3.6L V6 FSI engines belong tothe VR family of engines. Their reduced V-angle,compared with a traditional V-engine, gives them anextremely compact and space-saving design.The VR engines have a long history at Volkswagen.The VR success began in 1992 with the start ofproduction of the 2.8L VR6 engine. In 2002, theVR6 was converted to four-valve technology. In 2003the capacity of the VR6 was increased to 3.2 liters,resulting in a power increase of up to 250 hp. Then,in 2006, the capacity was increased to 3.6 liters,resulting in a power increase of up to 280 hp.OverviewThis self-study program is designed for use in theVolkswagen Group, and therefore does not addressthe application of the engine in a specific vehicle.If reference is made to a particular vehicle, this isintended only as an example, to describe design,operation or to help better understand this manual.The VR engines are highly suitable for a broad rangeof applications due to their compact design.S360 371

OverviewS360 203The new 3.2L and 3.6L V6 FSI engines are thenewest representatives of the VR engine series.Special Features of both Engines: Compact size FSI direct gasoline injectionThe displacement was increased to 3.2 liters or3.6 liters, combined with the switch to the FSItechnology. This yields a noticeable increase in powerand torque compared with the previous engines.The 3.6L engine has a maximum rated power of280 hp (206 kW) and produces a maximum torque of265 lb.fts (360 Nm). Four-valve technology with roller rocker arms Internal exhaust gas recirculation Single-piece variable-length intake manifold madeof plastic Cast iron crankcase Chain drive located on the transmission side withintegral drive for the high-pressure fuel pump Continuously variable intake and exhaustcamshaftsThe use of FSI direct fuel injection technology makesit possible to meet current Low Emission Vehicle(LEV2) emission standards.

OverviewTechnical Data for the 3.2L V6 EngineConstructionDisplacement6 cylinders VR Engine193.3 cu.in (3168 cm3)Bore3.4 in (86 mm)Stroke3.58 in (90.9 mm)V Angle10.6 Valves per cylinder4Compression ratio12:1Max Output250 hp (184 kW) @ 6250 rpmMax Torque243 lbs.ft (330 Nm) @ 27503750 rpmEngine managementMotronic MED 9.1Exhaust emissioncontrolThree-way catalytic converterswith O2 sensorEmission standardLEV2Torque-power ower in hpTorque in lb.ftTechnical Data for the 3.6L V6 FSI EngineConstructionDisplacement6 cylinders VR Engine219.5 cu.in (3597 cm3)Bore3.5 in (89 mm)Stroke3.8 in (96.4 mm)V Angle10.6 Valves per cylinder4S360 116Torque-power Curve250250200225Compression ratio12:1Max Output280 hp (206 kW) @ 6200 rpm200Max Torque265 lbs.ft (360 Nm) @ 25005000 rpm175Engine managementMotronic MED 9.1Exhaust emissioncontrolThree-way catalytic converterswith O2 sensorEmission standardLEV21501001505012520004000Power in hpTorque in lb.ft6000S360 115

BasicsBasicsThe Variable Intake ManifoldThe variable intake manifold design increases lowrpm torque and high rpm power by taking advantageof the self-charging or “ram effect” that exists atsome engine speeds.By “tuning” the intake manifold air duct length,engineers can produce this ram effect for a given rpmrange. A manifold that has two different lengths of airducts can produce the ram effect over a broader rpmrange.Instead of using high velocity air flow in a longnarrow manifold duct to ram more air into an engineat low rpm and then opening a short, large diameterduct for high rpm, the 3.2 and 3.6-liter V6 enginestake advantage of the pressure wave created bythe pressure differential that exists between thecombustion chamber and the intake manifold.All air enters the intake manifold plenum and torqueport, then is drawn down the long intake ducts tothe cylinders.The 3.2 and 3.6-liter V6 engines use two lengths ofair ducts but not in the same way as the dual pathmanifolds used on other engines.Intake Manifold PlenumTorque PortChange-Over BarrelPerformance PortS360 370Vacuum Motor

BasicsA second plenum called the performance port,which is attached to a set of short manifold ducts,joins the long intake ducts near the cylinder head. Aperformance port valve, similar in design to a throttlevalve, separates the performance port from the shortducts.Note that the performance port does not have anypassage to the intake manifold other than throughthe performance port valve. It does not have accessto the torque port and does not admit any more airPerformance Port Valve OpenTorque Portinto the cylinders than what is already drawn downthe long intake ducts.At engine speeds below 900 rpm the performanceport is open for idling. The performance port valve isactuated. At engine speeds between 900 rpm and4100 rpm, the performance port is closed and theengine produces its maximum low end torque (theperformance port valve is not actuated).At engine speeds above 4100 rpm the performanceport is open (the performance port valve is actuated).Performance Port Valve ClosedPerformance PortS360 353Performance Port Valve OpenS360 352Torque PortPerformance PortS360 354Performance Port Valve CloseS360 351

BasicsPerformance Port Valve ActuationIntake manifold change-over is engine speeddependent. The Motronic Engine Control ModuleJ220 activates the Intake Manifold Change-OverValve N156, which supplies vacuum to the vacuumsolenoid that operates the performance port valve.A vacuum reservoir with non-return valve is usedto store a vacuum supply for the performance valveoperation. This is necessary as manifold vacuummay be insufficient to actuate the vacuum solenoidat high engine speeds.Performance Port Valve (Open)To Performance PortVacuum SolenoidFrom Torque PortTo Intake ValveSignal from MotronicEngine ControlModule J220Intake ManifoldChange-Over ValveN156Non-Return ValveTo Fuel Pressure RegulatorS360 355Vacuum Reservoir

BasicsPrinciples of Variable ResonanceIntake Manifold OperationAfter combustion has taken place in a cylinder,there is a pressure differential between the cylindercombustion chamber and the intake manifold. Whenthe intake valves open, an intake wave forms in theintake manifold. This low pressure wave moves fromthe intake valve ports toward the torque port at thespeed of sound.Performance Port Valve ClosedTorque PortPerformance PortIntake Valve ClosingS360 356The open end of the intake duct at the torque porthas the same effect on the intake wave as a solidwall has on a ball. The wave is reflected back towardthe intake valve ports in the form of a high pressurewave.Reflection PointPerformance Port Valve ClosedIntake Valve ClosingS360 357

BasicsAt an optimal intake manifold length, the maximumpressure reaches the intake valve ports shortlybefore the valves close. By this time the pistonhas started back up the cylinder, compressing theair/fuel mixture.The pressure wave forces more air into the cylinderagainst this rising compression pressure, filling thecylinder with more air/ fuel mixture than would bepossible from just the piston moving downward onthe intake stroke alone. This adds to what is calledself-charging or “ram effect.”Performance Port Valve ClosedIntake Valve ClosingS360 358Pressure WavePerformance Port Valve ClosedAs engine speed increases, the high pressure wavewill have less time to reach the inlet port. Becausethe pressure wave is only able to move at thespeed of sound, it will reach the intake valve portstoo late. The valves will already be closed, and the“ram effect” cannot take place. This problem can besolved by shortening the intake manifold.Intake Valve ClosedS360 359Pressure Wave Closed

BasicsIn the 3.2 and 3.6-liter V6 engines, the performanceport valve turns to the performance position atengine speeds below 900 rpm and above 4100 rpm.This opens up the path to the performance port. Theperformance port is designed so that the intake andpressure waves will have a shorter path back to theintake valve ports.Performance Port Filled with AirPerformance Port Valve OpenIntake Valve ClosedS360 360Performance Port Valve OpenThe performance port is filled with air when theintake valve ports are closed.Intake Valve OpenS360 361Reflection Point for Performance PortWhen the intake valves open, the intake wavemoves up both manifold intake ducts toward thetorque port and the performance port at the samespeed.Because the distance it must travel is shorter, theintake wave reaches the open end of the intake ductat the performance port before it reaches the openend of the intake duct at the torque port.Performance PortValve OpenReflection Pointfor Torque PortS360 362

BasicsThe performance port pressure wave is reflectedback toward the intake valve ports, and that air isforced into the combustion chamber before theintake valves close.Performance Port Valve OpenInput Valve Closingbut Still OpenS360 363Pressure Wave for PerformancePort Charges the Cylinder with AirPressure Wave Fills Performance PortThe pressure wave arriving too late from the torqueport is reflected by the closed intake valves andpushes its air charge up the intake duct, filling theperformance port in preparation for the next cycle.Performance Port Valve OpenIntake Valve ClosedS360 36410