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1、Technical platformLike the Audi A3 and the Skoda Octavia, the new Golf is based on the A-platform.The platform components are therefore almost identical from a technical aspect.EnginesRunning gearBraking systemElectrical systemHeating/air-conditioning sys- tem22EnginesEngine-gearbox combinationsGear
2、boxEngine5-speed manual gearbox02K02J4-speed automatic gearbox01M1.4-ltr. 4V 55 kW1.6-ltr. 74 kW1.8-ltr. 5V 92 kW1.8-ltr. 5VTurbo 110 kW2.3-ltr. V5 110 kW1.9-ltr. SDI 50 kW1.9-ltr. TDI 66 kW1.9-ltr. TDI 81 kW231.4-ltr. 4V engine (55 kW)German emissions standard25In Germany, a new emissions standard
3、has been in force since July 1997. This standard, referred to as Emission Stage D3, specifies lower emis- sion limits.Customers driving a vehicle which meets this emissions standard are eligible for government tax benefits.The table below shows the relationships between the engines and the D3 emissi
4、ons standard as well as EU II.EngineEngine codeGearboxEmission StageMeasuresEngine managementD3EU II1.4-ltr. 55kWAHWmanualxMagneti Marelli 4AVAKQmanualxPrimary catalytic converter1.6-ltr. 74kWAEHmanualxSoftware updateSimos 2automaticxAKLautomaticxTwo primary catalytic converters1.8-ltr. 92kWAGNmanua
5、lxSoftware updateBosch Motronic 3.8.5automaticx1.8-ltr. 110kWAGUmanualxSoftware updateTrimetallic catalytic converterBosch Motronic 3.8.3automatic2.3-ltr. 110kWAGZmanualxSecondary air injectionBosch Motronic 3.8.3automatic1.9-ltr. SDI 50kWAGPmanualxBosch Electronic Diesel Control1.9-ltr. TDI 66kWALH
6、manualxVariable turbine geometryEnlarged oxidation catalytic converterCooler for exhaust gas recir- culation (auto gearbox only)Bosch Electronic Diesel ControlautomaticAGRmanualxautomatic1.9-ltr. TDI 81kWAHFmanualxBosch Electronic Diesel ControlautomaticThe 1.4-ltr. 4V engine is a new development an
7、d has the following special features: Aluminium engine block Static high-voltage distributorSSP 200/054You can find more ed informa- tion on this engine in Self-Study Programme No. 196.Output kWTorque Nm8020070180160504012010080600040100020003000400050006000Engine speed rpmDisplacement: Compression
8、ratio: Output:Torque:Engine management: Fuel:1390 cm310.5 : 155 kW at 5000 rpm128 Nm at 3300 rpm Magneti Marelli 4AV Premium unleaded (95 RON)SSP 200/053The engine may also be run on regular unleaded fuel (91 RON), but with reduced max. power.1.6-ltr. engine (74 kW)SSP 200/045The 1.6-ltr. 4-cylinder
9、 in-line engine has the fol- lowing special features: Aluminium engine block with internal vent pipe Press-fitted cast iron cylinders Plastic twin-path intake manifold Static high-voltage distributor Pressure switch for power steering Clutch pedal switchOutput kWTorque Nm962208420060481250020004000E
10、ngine speed rpm6000Displacement: Compression ratio: Output:Torque:Engine management: Fuel:1595 cm310.2 : 174 kW at 5600 rpm145 Nm at 3800 rpmSimos 2Premium unleaded (95 RON)SSP 200/046The engine may also be run on regular unleaded fuel (91 RON), but with reduced max. power.1.8-ltr. 5V engine (92 kW)
11、SSP 200/061The 1.8-ltr. 4-cylinder in-line engine with five valves per cylinder has the following special features: Variable valve Plastic twin-path intake manifold Static high-voltage distributorHot film air mass meter with reverse flow detection Pressure switch for power steeringClutch pedal switc
12、h27Output kWTorque Nm962208420060481250020004000Engine speed rpm6000Displacement: Compression ratio: Output:Torque:Engine management: Fuel:1781 cm310.3 : 192 kW at 6000 rpm170 Nm at 4200 rpmMotronic 3.8.5Premium unleaded (95 RON)SSP 200/055The engine may also be run on regular unleaded fuel (91 RON)
13、, but with reduced max. power.1.8-ltr. 5V turbo engine (110 kW)The 1.8-ltr. 4-cylinder in-line engine with five valves per cylinder and turbocharger has the fol- lowing special features:SSP 200/062 Static high-voltage distributor with individual ignition coils Pressure switch for power steering Clut
14、ch pedal switchOutput kWTorque Nm160220200120100150801256040205000020004000Engine speed rpm6000Displacement: Compression ratio: Output:Torque:Engine management: Fuel:1781 cm39.5 : 1110 kW at 5700 rpm210 Nm at 1750 rpmMotronic 3.8.3Premium unleaded (95 RON)SSP 200/063The engine may also be run on reg
15、ular unleaded fuel (91 RON), but with reduced max. power.2.3-ltr. V5 engine (110 kW)SSP 200/050The 2.3-ltr. 5-cylinder V-engine is a derivative of the VR6 engine in terms of its design. It has the following special features: Twin-path intake manifold Hot film air mass meter with reverse flow detecti
16、on Static high-voltage distributor with 5 individual ignition coils Pressure switch for power steering Clutch pedal switchThe construction and function of this engine are described in Self-Study Programme No. 195.29Output kWTorque Nm16022014020012010016080140604020060500150025003500450055006500Engin
17、e speed rpmDisplacement: Compression ratio: Output:Torque:Engine management: Fuel:2326 cm310.0 : 1110 kW at 6000 rpm205 Nm at 3200 rpmMotronic 3.8.3Premium unleaded (95 RON)The engine may also be run on regular unleaded fuel (91 RON), but with reduced max. power.SSP 200/0521.9-ltr. SDI engine (50 kW
18、)SSP 200/065The 1.9-ltr. 4-cylinder in-line engine is a naturally aspirated diesel with direct injection. It has the following special features: Two-stage EGR valve Electrically controlled intake manifold flap Preset injection pump with adjustable rib belt wheel Vertical oil filterOutput kWTorque Nm
19、8070160150504013012011010000010003000Engine speed rpm5000Displacement: Compression ratio: Output:Torque:Mixture preparationFuel:1896 cm319.5 : 150 kW at 4000 rpm130 Nm at 2200 rpm Direct injection with electronically controlled distributor injection pump45 CN dieselThe engine may also be run on biod
20、iesel.SSP 200/0591.9-ltr. TDI engine (66 kW)The 1.9-ltr. turbocharged diesel engine with intercooler has the following special features:31SSP 200/051 Preset injection pump with adjustable rib belt wheel Lightweight valve gear Vertical oil filter with replaceable paper insert Intake manifold flapOutp
21、ut kWTorque Nm8030070275602505022540200302010010003000Engine speed rpm5000Displacement: Compression ratio: Output:Torque:Mixture preparationFuel:1896 cm319.5 : 166 kW at 3750 rpm210 Nm at 1900 rpm Direct injection with electronically controlled distributor injection pump45 CN dieselThe engine may al
22、so be run on biodiesel.SSP 200/0571.9-ltr. TDI Engine (81 kW)SSP 200/051This 1.9-ltr. TDI engine has a higher power output than the 1.9-ltr. TDI engine develo66 kW because of its variable turbine geometry.Output kWTorque Nm90300802757025060225502004030201010003000Engine speed rpm5000Displacement: Co
23、mpression ratio: Output:Torque:Mixture preparationFuel:1896 cm319.5 : 181 kW at 4150 rpm235 Nm at 1900 rpm Direct injection with electronically controlled distributor injection pump45 CN dieselThe engine may also be run on biodiesel.SSP 200/058The intake manifold flapIn the 1.9-ltr. TDI engine, a fl
24、ap is integrated in the intake manifold. This flap stops engine vibrations when it is turned off.SSP 200/11337Diesel engines have a high compression ratio. They tend to vibrate when turned off due to the high compression pressure of the intake air.The intake manifold flap shuts off the air supply wh
25、en the engine is switched off. This minimises the quty of air compressed and ensures the engine runs out smoothly.This is how it works:When the engine turned off, the engine control unids a signal to the intake manifold flap change-over valve. The change-over valve then switches the partial pressure
26、 for the vacuum box, and the vacuum box s the intake man- ifold flap.Intake manifold flapIntake manifoldIntake airIgnition lockEngine control unitVacuum boxIntake manifold flap change-over valveSSP 200/114The hot-film air mass meter with reverse flow detectionAir mass meterIntake airReverse flowInta
27、ke manifoldSome engines have a hot-film air mass meter with reverse flow detection. An optimal mixture composition is essential for low exhaust emis- sions and high engine power output, both of which aeavily dependent on metering the intake air mass accurately.The opening and closing action of the v
28、alves produces a reverse flow in the intake air mass inside the intake manifold. The hot-film air mass meter with reverse flow detection detectsthe returning air mass. It then generates a signal and sends it to the engine control unit. This ensures highly accurate air mass metering.SSP 200/098Housin
29、gHousing coverMetering ductElectric circuitSensor element Partial air flowThe designThe electric circuit and the sensor element of the air mass meter are accommodated in a compact plastic housing.Located at the bottom end of the housing is a metering duct into which the sensor element protrudes. The
30、 metering duct extracts part of the intake and return air flows and routes this partial flow past the sensor element. The signal which the sensor element generates is processed by the electric circuit and sent to the engine control unit.SSP 200/099You can find ed information in Self- Study Programme
31、 No. 195.The clutch pedal switchis located at the foot controls. It s the “Clutch operated” signal to the engine control unit.Signal utilisation when clutch is operated: In vehicles equipped with a TDI or SDI engine, the quty of fuel injected is reduced. This prevengine vibrations when a gearshift i
32、s performed. In vehicles with a cruise control system, the cruise control function is disabled.In petrol-engined vehicles (upwards of 74 kW), the throttle clo- sing damper function is disabled.This is how it works:SSP 200/096The clutch pedal switch informs the engine con- trol unit when the clutch i
33、s operated. The engine control unit then disables the throttle closing damper function.The throttle valve s more quickly and this prevents a short-term increase in revs caused by excess air.Engine control unitClutch pedal switchThrottle valve control unitSSP200/115Pressure switch for power steeringT
34、his is located on the vane pump. It informs the engine control unit when the vane pump is under a heavy load.The vane pump is driven by the engine by the rib- bed V-belt.At full steering lock the vane pump is requiredto produce a high pressure. A greater load is also placed on the engine, and idling
35、 speed may drop sharply. Using the signal sent by the pressure switch, the engine control unit is able to recog- nise the engine load state in good time and adjust the engine idling speed accordingly.This is how it works:SSP 200/095The pressure switch for the power steering informs the engine contro
36、l unit when there is a high pressure inside the vane pump.The engine control unit activates the throttle valve positioner which opens the throttle valve by a certain angle. Engine idling speed is maintained.Engine control unitThrottle valve con- trol unitPressure switch for power steeringSSP 200/118
37、Cruise control systemThis controls the road speed according to the drivers wishes without the driver actually hav- ing to operate the accelerator pedal. The cruise control system (CCS) was previously controlled by an independent control unit and the throttle valve wauated by a vacuum box.The cruise
38、control system is now controlled by the engine control unit. The throttle valve is actuated by the throttle valve control unit.Signals to engine control unitEngine speed signal Road speedBrake operated Clutch operatedCruise control switchON/OFF signalOperation of throttle valve positionerFeedback of
39、throttle valve positionEngine control unitThrottle valve control unitSSP 200/097This is how it works:Switching the cruise control system ON tells the engine control unit to maintain the current road speed. The engine control unit then activates the electric motor of the throttle valve gear and actuates the throttle valve according tothe vehicles current speed.T
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