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2.0-litre Engine
233_024
New Important
Note
The Self-Study Programme Please always refer to the relevant Service Literature
is not a Workshop Manual! for all inspection, adjustment and repair instructions.
Service Literature.
2
Table of contents
Crankcase breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Function diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Flying camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3
2.0-litre/85 kW engine AQY/ATU
Specifications
Differences/common features
233_012 233_013
113 series – engine AQY 827 series – engine ATU
Bore 82.5 mm
Stroke 92.8 mm
4
Technical features
Differences/common features
AQY ATU
Engine management Motronic 5.9.2
Exhaust gas Secondary air system without Secondary air system with
treatment secondary air injection valve secondary air injection valve
AQY
ATU
AQY
ATU
233_002 233_001
Comparison of performance curves Comparison of torque curves
5
2.0-litre/85 kW engine AQY/ATU
Engine overview
Differences/common features
233_003 233_004
– The crankshaft is mounted on 5 bearings. – The oil pump used in the AQY engine is an
– The cylinder block is manufactured from gray internal gear pump. It is driven by the
cast iron. crankshaft by means of a chain. The oil pump
– The crankcase is ventilated via the cylinder used in the ATU engine is driven via the
head cover. intermediate shaft.
– Lighter pistons reduce moving masses in the – Spray jets for piston cooling: the ATU engine
engine. does not have a piston cooling system.
– The cylinder head is made of aluminium. – The reference marks and engine speed are
– The oil sump used in the AQY engine is made registered by senders mounted on the
of aluminium and has 3 mounting points crankshaft.
facing towards the gearbox. – Phase recognition by Hall sender. Mounted
on the camshaft in the AQY engine and on
the distributor in the ATU engine.
6
233_019 233_005
The crossflow cylinder head is based on tried The stainless steel exhaust manifold is a
and tested structural design details. double-flow manifold. Each cylinder has its own
exhaust pipe; these pipes are then paired up.
It is also used in the 1.6-litre engine with twin-
path intake manifold. The lightweight valve gear is used:
7
Crankcase breather
Heating resistor
233_027
Task
The heating resistor operates continuously when J17 Fuel pump relay
the ignition is "on". N79 Heating resistor
(crankcase breather)
8
Fuel injection
Fuel rail
Injector
233_029
Air pipe
Fuel feed
A single injector is assigned to each cylinder.
The four injectors are inserted into the fuel rail at
the top and into the engine intake manifold at
the bottom.
Fuel flows through these injectors from top to
bottom according to the so-called “top-feed”
principle. Air supply from
air pipe
The injectors have an additional air shroud
which improves mixture preparation.
An air pipe is connected to the intake pipe.
Each injector is, in turn, connected to the air
pipe.
The vacuum in the intake manifold draws air out
of the intake pipe. This air is then fed to each
individual injector along the air pipe.
The fuel and air molecules interact in such a way Air shroud
that the fuel is finely atomised.
The air shroud is mainly effective in the part-
throttle mode of the engine.
233_030
Advantages:
Combustion is improved.
Pollutant emissions in the exhaust gas are
reduced.
9
Piston
Piston design
Piston cooling
10
Sensors
Valve timing
Hall sender G40 gear
Signal utilisation
Hall sender
Substitute function and self-diagnosis
Important
The ATU engine has a rotating
ignition distributor which is driven
by means of the intermediate
shaft.
11
PTFE oil seal
12
Secondary air system
5
p
6
p
t°
1 3
233_008
During the cold starting phase of an engine, the The secondary air pump -2- blows additional air
pollutant emissions (non-combusted from the air filter -1- directly behind the exhaust
hydrocarbons) are relatively high on account of valves when the engine is started.
the fact that the catalytic converter has not yet
reached its operating temperature. The system works on the basis of interaction
between the following system components:
The secondary air system helps to reduce the
pollutant emission during this phase. – Engine control unit -3-
The exhaust gas is enriched with oxygen through – Secondary air pump relay -4-
the injection of additional (secondary) air. The – Secondary air pump -2-
non-combusted exhaust gas constituents (carbon – Secondary air control valve -5-
monoxide (CO) and hydrocarbons (HC)) are now – Combination valve -6-
thermally combusted.
Secondly, the catalytic converter reaches its Input variables for the engine control unit are
operating temperature more quickly through the the coolant temperature -to- and the lambda
heat generated by secondary combustion. control -λ-.
13
Secondary air system
6
p
t°
1 3
de-energised 233_009
Functional description The secondary air pump receives its voltage via
the secondary air pump relay. The engine control
The secondary air system is active in two unit also activates the secondary air inlet valve
operating states and for a limited period of time via which the combination valve is actuated by
only: means of partial pressure "p“.
The secondary air pump injects air downstream
– cold start of the exhaust valves into the exhaust gas stream
– in idling mode after warm start, for self-dia- for a short period of time.
gnosis
When the secondary air pump is inactive, the hot
The secondary air system is activated by the exhaust gases are also present at the
engine control unit according to the prevailing combination valve. The combination valve seals
operating conditions. the exhaust gases off from the secondary air
pump.
State Coolant Period
temperature activated During the activation procedure, the self-
diagnosis checks the system.
The lambda control must be active during the
Cold start +5 to 33oC 100s self-diagnosis procedure because the increased
oxygen content in the exhaust gas reduces the
Warm start up to 10s probe voltage.
Idling max. 96˚C
When the secondary air system is intact, the
lambda probes must register an extremely lean
mixture.
14
Emission control
Catalytic converter
233_039
Lambda probe G130 after
catalytic converter
The position of the lambda probes in the exhaust However, the more stringent exhaust emission
system is very important for emission control as regulations require quick and precise lambda
they are subjected to heavy soiling in the exhaust control.
gas.
A second lambda probe (with heating) therefore
A probe located downstream of the catalytic was installed in the exhaust system downstream
converter is less prone to soiling. of the catalytic converter (G130) in addition to
the probe upstream of the catalytic converter
A lambda control system with only one probe (G39).
downstream of the catalytic converter would be This probe serves to check for proper functioning
too slow because of the longer gas flow times. of the catalytic converter. The probe upstream of
catalytic converter (G39) is also adapted.
15
Emission control
J220
233_040
The signals for air mass and engine speed are The 2nd probe simultaneously checks the degree
the basis for the injection signal (Uv). of conversion (a measure of cleaning efficiency)
of the catalytic converter.
The engine control unit calculates the additional
injection time correction factor (increase/ The engine control unit compares the probe
decrease) for lambda control from the signal voltage UG39/probe upstream of the catalytic
supplied by the lambda probe. converter and UG130/probe downstream of the
catalytic converter.
The lambda factor is regulated on the basis of
continuous data interchange. If the ratio deviates from the setpoint, this is
registered as a catalytic converter malfunction
The lambda map is still stored in the control unit and stored as a fault.
memory. This map specifies the various engine
operating states. The voltage curves of both probes can be
checked in the self-diagnosis.
Using a second closed control loop, the shift in
the voltage curve corrected within a defined Effects of malfunction
window (adaption) ensuring long-term stability
of the mixture composition. The probe If the probe upstream of catalytic converter fails,
downstream of the catalytic converter has lambda control is not performed. The adaption
priority over the probe upstream of catalytic function is disabled.
converter. Emergency operation via a map-based open
control loop.
If the probe downstream of the catalytic
converter fails, lambda control is still performed.
The function of the catalytic converter cannot be
checked.
16
ODB II exhaust emission monitoring system
Electrical circuit
The warning lamp is integrated in the dash panel – Lamp flashing: 3 4 100
120
140
1/min x 1000 5 80 km/h 160
insert, directly connected to the engine control There is a fault which can damage 2 60 180
6 40 200
1 20 220
7
240
unit and registered by the fault memory. the catalytic converter in this vehicle
operating state. The vehicle may still 233_007
Like all warning lamps, the exhaust gas warning be operated, but only using less
lamp lights up for several seconds when the power.
ignition is turned on.
– Lamp lit continuously:
If it does not go out after starting the engine or There is a fault which adversely
lights up or flashes while travelling, there is a affects emission levels.
fault in the engine electronics or certain exhaust
emissions are too high.
17
J220
233_041
17
System overview
Motronic 5.9.2
The new Motronic 5.9.2 implements technical It meets the requirements of OBD II.
improvements for starting of the engine, lower Pollutant emissions are checked continuously.
fuel consumption and exhaust emission control. Diagnoses relevant to exhaust emissions are
displayed using the readiness code.
Hot film
air mass meter G70 and
intake air temperature sender G42
CAN-Bus L
Auxiliary signals:
air conditioner compressor On
A/C ready
18 Road speed signal
In the Motronic 5.9.2 systems used See also table with heading
the both engines, several "Differences and Common Features“
components are different.
Differences:
* AQY only
** ATU only
Engine AQY
J17
4
D 5 6
ST ST
λ λ
14
A J220
+
M K83
V60
CAN - BUS H
CAN - BUS L
M G6
31
20
D/+30
D/+15 +30
E45
31
F47 F
J299 V101 N79
2
M
4
F36
1 2 3 4
N152
G66 G61 G62
I IV II III
Q
P
31
in out
233_011
21
Function diagram
Engine ATU
30
15
S J17
12
D 5 6
ST ST
λ λ
14
A J220
M K83
V60
CAN - BUS H
CAN - BUS L
G6 M
31
E45
31
F47 F
J299 V101 N79
N112
M
4
F36
1 2 3 4
G66 G62 G40 N152 N157
Q
P
31
233_015
in out
23