W Engine Concept
W Engine Concept
W Engine Concept
The constantly rising demands regarding The W engines set exacting demands on design.
performance, running comfort and fuel economy Large numbers of cylinders were adapted to the
have led to the advancement of existing drive extremely compact dimensions of the engine.
units and the development of new drive units. In the process, more attention was paid to
lightweight design.
The new W8 as well as the W12 engine by This Self-Study Programme will familiarise you
VOLKSWAGEN are representatives of a new with the engine mechanicals of the W engine
engine generation - the W engines. family.
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New Important
Note
This Self-Study Programme explains the design Please always refer to the relevant Service Literature for cur-
and function of new developments. rent inspection, adjustment and repair instructions.
The contents will not be updated!
2
At a glance
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Engine mechanicals . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Sealing concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3
Introduction
72°
15° 15°
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4
The W principle
To illustrate the principle of the W engine cylinder arrangement, we will first show you conventional
engine types.
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The V engine
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5
Introduction
VR engines
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W engines
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15
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6
The modular design principle of the W engines
Numerous components of the VR and W series
Proven, serial-produced components from the are identical, e.g.:
modules of the VR engine family were integrated
into the new W engine concept. The principle is - valves, valve springs and valve seat inserts
very simple. - roller rocker fingers
Two compact VR engines from the VR series are - valve clearance compensating elements
combined to produce a W engine. The result is a
series of compact petrol engines ranging from This allows us to manufacture many parts in
the W8 to the W16. series and achieve high volumes.
6 cylinder 6 cylinder
V engine VR engine
W16 2xW8
2xVR6
W12
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With regard to the evolution of the 6-cylinder A W16 engine is obtained by joining two
engine, the VR6 engine stands out due to its cylinders to each cylinder bank of a W12 engine.
compactness. It is much shorter than the Splitting the W16 in the middle leaves two
comparable inline engine, and narrower than W8 engines. A W10 engine consisting of two
the V engine. Combining two VR6 engines with a VR5 engines is also a possibility. This covers the
cylinder angle of 72° produces a W12 engine. complete range of W engines.
7
Introduction
A comparison
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W8 crankshaft V8 crankshaft
8
Comparing the 12-cylinder crankshaft of a Depending on the number of cylinders, the W
conventional V12 engine with that of a 12- principle therefore saves material, and hence
cylinder W engine emphasises the constructional also weight.
advantage.
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W12 crankshaft V12 crankshaft
9
Engine mechanicals
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10
Torque and power output
[Nm] [kW]
500 200
400 150
300 100
200 50
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100
2000 4000 6000
rpm
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Torque curve
Output curve
11
Engine mechanicals
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12
Torque and power output
[Nm] [kW]
800 400
700 350
600 300
500 250
400 200
300 150
200 100
100 50
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Engine mechanicals
Offset Offset
12.5 mm left 12.5 mm right
W10 engine
720° crankshaft : 10 cylinder = 72° bank angle W12 engine
W8 engine 21.833°
720° : 8-cylinder = 90° spark gap
72° bank angle - 90° spark gap = 7 6
1 12
Splitpin -18° 12°
W12 engine
720° : 12 cylinder = 60° spark gap
72° bank angle - 60° spark gap =
Splitpin +12°
8
2
3
11
5 9
4
10
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The engine in detail
To familiarise you thoroughly with the mechanical construction of the W8 and W12 engines, we will
now describe the main modules of both engines in succession.
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15
Engine mechanicals
The crankcase
The crankcase comprises two components: the crankcase upper section and the crankcase lower section.
The upper section contains, among other things, the cylinders and the upper bearing cover halves of the
crankshaft. The crankcase lower section is designed as a bearing support and carries the lower bearing
cover halves.
W12
W8
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The "aluminium" crankcase upper section is Use of this alloy eliminates the need for
made of a hypereutectic aluminium-silicon alloy additional cylinder liners or a plasma coating for
(AlSi17CuMg). the purposes of cooling and lubricating the
cylinder surfaces as the material already has
Hypereutectic means that pure silicon crystals sufficient natural strength and thermal stability.
initially precipitate out of the aluminium-silicon
melt while it cools before aluminium/silicon
crystals form. Due to the presence of these silicon
crystals within the metal microstructure, the
cooled melt is harder than a eutectic Al-Si alloy.
16
The crankcase lower section
The crankcase lower section is a bearing support with integral bearing seats
Bearing cover
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Cast element in
bearing support
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W8 bearing support
The bearing support is also made of aluminium. They are located on the pressure side of the
It serves as a frame structure for the lower crankshaft and give the crankshaft bearing the
crankshaft bearing covers. These bearing covers strength it requires.
are made of grey cast iron and are also The bearing support is attached to the crankcase
embedded when the bearing support is cast. upper section by 4 bolts per bearing cover.
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Engine mechanicals
The crankshaft
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Journals for driving the oil pump Gears for the double-
Main bearing Conrod journal
and the balancing shaft chains of the chain drive
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Crankshaft journal
Toothed belt pulley
Balancing shafts
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bearing
Crankshaft of the
W engine family
with corner radii
Vibration absorber
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Gear S248_045
Oil pump
The drive gear of the oil pump, together with the The conrod journals are arranged in pairs and in
toothed belt pulley for the balancing shafts (on accordance with the crankshaft throw.
the W8 engine only), is pressed against the outer When the conrods are installed, the bearing
main bearing and fixed in place by the vibration cups must not contact the radii or the edge
absorber. between the two conrod faces (use tool).
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Conrods and pistons
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Engine mechanicals
Installation S248_055
openings
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There is a groove at the gear wheel end of the
balancing shaft. The lock plate engages into this Gears of the Marking
groove, locating the balancing shafts axially. balancing shafts
During installation, the balancing shafts must be
aligned with regard to the TDC position of the 1st
cylinder.
The balancing shafts must be rotated so that the
markings on the balancing shafts are opposite
each other.
Position of balancing
shafts at TDC of 1st
cylinder
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Lock plate
Balancing shaft I
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The balancing shaft drive is protected on the belt On the clutch side, the openings for inserting the
drive side by a plastic housing cover. balancing shafts, together with the chain drive,
are sealed by an aluminium cover.
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Engine mechanicals
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Two-mass flywheel
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A spring damper system within the two-mass
flywheel separates the primary inertia mass from
the secondary inertia mass so that the torsional
vibration produced by the engine is not
transmitted to the gearbox.
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The two-mass flywheel also serves as a sender wheel. Its job is to determine the engine speed and
recognise cylinder No. 1 together with the Hall senders of the camshafts. It has a larger tooth gap which
serves as a marker point. This point is registered by the engine speed sender located in the gearbox
housing during each revolution of the two-mass flywheel.
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Engine mechanicals
The W engines have two aluminium cylinder heads with two overhead camshafts apiece.
The injectors are inserted into the cylinder heads.
Camshaft bearing -
exhaust
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Each of the cylinder heads in the two W engines has an intake camshaft and an exhaust camshaft with
camshaft adjusters attached to their end faces.
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Camshaft
Valve
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Engine mechanicals
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Intake valve
Intake ports
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Exhaust valve
Exhaust ports
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The secondary air ducting system
Beside the coolant and oil ducts, the secondary From here the secondary air is guided back into
air is guided via ducts and bores into the exhaust the cylinder head via grooves in the exhaust
ducts near the exhaust valves. The secondary air flange. The secondary air then flows via ducts
flows into a duct in the cylinder head via a and bores to the exhaust valves.
secondary air inlet valve.
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inlet valve
Exhaust valves
(external)
Secondary air duct
Exhaust valves
(internal)
Coolant
Oil ducts S248_174
Secondary air
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Engine mechanicals
The chain drive is mounted at the flywheel end of the engine. Engine power is transmitted by a gear on
the crankshaft to the gears of the central intermediate shaft by means of a double-chain.
At this point, each of the camshafts of the two cylinder heads is driven by means of a single chain. Three
hydraulic chain tensioners ensure that an optimal chain tension is maintained.
Camshaft adjuster Tensioning rail Chain tensioner Slide rail Inlet camshaft
Single chain
(sleeve type chain) Single chain
Left bank (sleeve type chain)
Right bank
Slide rail
Chain tensioner
Double chain
(roller chain)
Tensioning rail
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Gear on crankshaft Chain tensioner with
tensioning rail
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The camshaft timing control
Like the W12 engine, the W8 engine has The camshaft is adjusted by hydraulic
continuous camshaft engine timing control. camshaft positioners bolted to the end face of
each camshaft. The exhaust camshaft of the W8
In this case, "continuous" means that the inlet engine is an exception. It can only be adjusted to
camshaft can be advanced/retarded relative to the "advance" or "retard" position within a
its neutral position at any angle within a range of range of 22°. The engine control unit regulates
52°. the oil supply to the camshaft positioners via the
solenoid valves.
Timing case
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Vane adjuster
Exhaust camshaft
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29
Engine mechanicals
System design
Neutral position
When the solenoid valve moves the adjusting piston into a central position, this causes both oil ducts
(a+b) - and hence the chambers (A+B) on either side of the inner rotor - to fill with oil. The inner rotor,
together with the camshaft which it is rigidly coupled to, now adopts a position in the middle of the
adjustment range.
Chamber (A)
Outer rotor
(coupled to timing chain)
Annular ducts
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Bank I
Stop
Advance adjuster
Chamber (A)
Inner rotor
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Retard adjustment
The solenoid valve guides the oil into the oil duct (b). The oil flows from channel (b) through the annular
groove and camshaft and via the bores (bb) to the chambers (B) of the camshaft adjuster. When the oil
enters the chambers (B), the inner rotor is rotated against the direction of rotation of the drive, thus
adjusting the camshaft in the retard direction. The oil is forced out of the chambers (A) through the bores
(aa). It flows back into the cylinder head via the camshaft and duct (a).
Chamber (A)
Inner rotor
Chamber (B)
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Outer rotor
Advance adjustment
To rotate the inner rotor forwards, the adjusting piston housed within the solenoid valve adjusts itself so
that the oil duct (a) is put under oil pressure. As a result, the oil flows in the chamber (A), thus advancing
the inner rotor. Chamber B is simultaneously bled via the solenoid valve so as to ensure a quick response.
Bank I
Intake Exhaust
Camshaft
camshaft camshaft
Advance stop
Chamber (A)
Inner rotor
Chamber (B)
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Outer rotor
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Engine mechanicals
The following units and devices are driven The poly-V-ribbed belt is tensioned by a hydrau-
by the belt drive: lic tensioning and deflection pulley. 2 deflection
pulleys ensure that all units to be driven can be
- the coolant pump reached.
- the alternator
- the power steering pump
- the air conditioner compressor
Water pump
Hydraulic
belt tensioner with
deflection pulley
Deflection pulley
Air conditioner
compressor
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In the W12 engine, the hydraulic belt tensioner and deflection pulley are fixed to the air conditioner
compressor bracket.
Coolant pump
Deflection pulley
Deflection pulley
Hydraulic
belt tensioner
Air conditioner
compressor
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Engine mechanicals
The oil is drawn out of the oil pan by the oil The oil also flows to the intermediate shaft, to the
pump and flows to the central oil passage via the entire engine timing gear and to the chain
external tensioner.
oil filter/cooler module.
In the cylinder heads, the oil flows along ducts to
The main crankshaft bearings are supplied with the camshaft adjusters and the camshaft
pressurised oil via the central oil passage; the bearings.
central oil duct is supplied with pressurised oil via
a riser. The return lines guide the oil back into the oil
sump.
The oil from flows from the central oil duct to the
spray jets for piston cooling, and then from there
to the cylinder heads via risers fitted with non-
return restrictors.
Riser
Central oil duct
Crankshaft bearing
Spray jets for
piston cooling
Return ducts
Oil sump upper section
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Oil pump drive gear Central oil passage Oil sump lower section
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Schematic diagram of the oil circuit of the W engines
Solenoid valve
3 chain tensioners
with chain oil spray
Spray jet
Return line
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35
Engine mechanicals
The W8 and W12 engine for VW models have a wet-sump lubrication system. The W12 engine for Audi
models has a dry-sump lubrication system.
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Oil filter and cooler module Single-stage oil pump
In the case of the wet-sump lubrication system, In contrast to the dry-sump, the job of the oil
the entire oil supply is retained in the oil sump. sump with wet sump is to retain the entire oil
The single-stage oil pump draws the oil out of the supply. As a result, it has a larger volume which
wet sump via the intake line and immediately affects the overall height of the engine.
returns it to the engine after it has cooled down
and has been filtered.
36
The oil circuit based on the dry-sump principle
Reservoir
Three-stage oil
pump
Filter
Cooler
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In the case of the dry-sump lubrication system, The third stage (discharge stage) returns the oil
the entire oil supply is retained in an additional, from the reservoir to the engine via the oil cooler
external reservoir, and not in the oil sump. and the oil filter. The oil sump can be kept small
and flat due to its lower oil volume, with the
To facilitate this, the oil pump is of three-stage result that the engine has a smaller overall
design. Two stages draw the oil out of the oil height.
sump at various points and pump it into the
reservoir. This requires a slightly more complex design.
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Engine mechanicals
Baffles
(swash plates) Oil level sender
Drive
Intake line
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The oil is extracted from the sump by the oil The single-stage oil pump is driven by the
pump via the intake line, and pumped into the oil crankshaft by means of a separate chain in the
circuit. crankcase.
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The oil pump is mounted from below and bolted to the bearing support.
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Oil filter/cooler module of the W8
39
Engine mechanicals
The oil in the oil circuit has a lubricating and cooling function. The W engines are filled with
type 0W30 3.5 engine oil.
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Bearing support
Oil supply
Groove on the back
of the bearing cups
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Lubrication of the conrod bearings
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Groove in crankcase
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Transitional pockets Inflow to main bea-
ring
The oil flows from the outer circumferential groove into the inner groove of the upper bearing cup
through five bores. The bore ensures that an even oil film forms.
Integrated pockets at the transition to the lower bearing cup ensure a steady supply of oil to the conrod
bearings via bores in the crankshaft.
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Engine mechanicals
The coolant circuit is filled with VW G12 coolant. The coolant circuit is subdivided into a small
The coolant is channelled out of the central circuit, in which the coolant is only ducted within
coolant duct in the crankcase upper section and the engine block. An outer circuit is located
into the cylinder heads. Baffles ensure that all above the radiator.
cylinders are swept evenly. At the same time, the
coolant flow is redirected from the exhaust side
of the combustion chambers towards the intake
side.
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Oil cooler Alternator
Coolant
temperature
sender at
radiator outlet
Small cooling circuit
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Coolant circuit of W12 engine
Cyclical valve
Coolant tempe-
rature sender Auxiliary
Radiator Radiator
Thermostat
valve
Coolant
pump
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Gearbox oil cooler Alternator
Coolant
Engine oil cooler temperature
sender at
radiator outlet
Small cooling circuit
Large cooling circuit
Equalising vessel
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Engine mechanicals
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Coolant flows into the cylinder heads
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Coolant flows through the cylinder heads from the exhaust side to the intake side. This results in very
good temperature equalisation as well as effective cooling of the outlet webs and spark plugs.
44
In both W engines, the coolant pump is located
in the cylinder block at the face end. It is
mounted directly upstream of the central coolant
duct and is driven by the ribbed V-belt.
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Coolant pump with pump gear
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Heating resistor
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Engine mechanicals
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W12 engine
The intake manifold used in the W 12 engine is
Intake manifold upper section made of magnesium alloy. Unlike the W8
engine, each of the manifolds is coupled to a
throttle valve control unit.
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Engine mechanicals
The diaphragm valve limits the vacuum in the crankcase irrespective of the intake pipe vacuum, allowing
the cleaned crankcase exhaust gases (blow-by) to be abducted continuously into the intake manifold and
burnt in the engine. No oil is entrained in the process. The oil separator segregates the oil particles from
the blow-by gas. The separated oil is then returned to the oil sump.
W8 engine
Diaphragm valve
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Oil separator
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W12 engine
Diaphragm valve,
left
Oil separator
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Diaphragm valve,
right
Oil separator
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As the W12 engine has a double flow intake manifold, each bank has a side diaphragm valve
and an oil separator.
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Engine mechanicals
The W8 engine has an exhaust manifold with a The exhaust system has primary silencer and a
permanently assigned catalytic converter for rear silencer for each bank, as well as a common
each cylinder head. A total of four lambda central silencer.
probes are therefore required for emission
control.
Catalytic converter
Tailpipes
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Lambda probe
Lambda probe after before catalytic-
Primary silencer catalytic converter converter Manifold
Primary catalytic
Rear silencer Central silencer Main catalytic converters converter
51
Service
Sealing concept
Each of the cylinder heads is sealed off from the The gasket between the bearing support and the
valve covers by a rubber gasket, from the oil sump upper section is also designed as a
contact faces of the intake manifold by an single layer embossed metal gasket.
elastomer gasket, from the exhaust manifolds by
a two layer embossed metal gasket and from the The oil pan upper section and lower section as
crankcase by a multilayer embossed metal well as the crankcase upper section and the bea-
gasket. ring support are sealed by means of a liquid gas-
ket.
52
Liquid gaskets
Application of the liquid gasket sealant is CNC- When enough liquid sealant has been injected,
controlled in order to ensure a constant sealant the excess sealant is discharged from the
supply. The liquid gasket between the lower openings on the end of the timing case cover.
timing case cover and the upper timing case The screw nipples remain in the housing after
cover is applied according to a different injecting the sealant. However, they have to be
principle. In this case, the parts are first bolted, replaced when repairing the gasket.
then the sealant is injected into the groove in the
upper timing case cover via screw nipples
(Sealing Injection System).
Screw nipple
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Groove for
sealant
Upper timing
case cover
(covering part)
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Lower timing
case cover
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(sealing flange)
Outlet
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Service
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Put copper coloured Put copper coloured
chain link on arrow chain link on arrow
of bank II of bank II
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Bank II
Position the marker on the vibration Insert the mandrel for fixing the
damper on the housing joint: crankshaft into the threaded hole in the
housing:
piston in 1st cylinder at top dead centre. piston in 1st cylinder at top dead centre.
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54
Insert camshaft rule for aligning the
camshafts.
Bank I
55
Service
Special tools
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56
Notes
57
Test your knowledge
1. The cylinders in the W engine are arranged according to the follow principle:
2. The W engine has left and right cylinder banks. They are aligned at an angle of:
a. 15°
b. 60°
c. 72°
d. 120°
3. The maximum possible number of cylinders in an engine based on the W engine principle is:
a. W18.
b. W16.
c. W12.
d. W10.
e. W8.
c. The centre of the crankshaft (fulcrum) is located below the point of intersection of the
intersecting centres of the cylinders.
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5. Why does the W8 engine have a balancing shaft?
1.) __________________________________________________________________________
2.) __________________________________________________________________________
3.) __________________________________________________________________________
a. pneumatically
b. hydraulically
c. mechanically
59
Test your knowledge
9. The adjustment ranges of the camshaft adjuster between the inlet camshaft and the
exhaust camshaft are different. The exhaust camshaft of the W8 engine can
a. be adjusted continuously!
b. the alternator
12. Characteristic maps which allow the desired engine temperature to be reached in accor
dance with theengine's operating requirements are stored in the engine control unit.
Which of the following statements is applicable?
a. There is only one temperature sensor in the cooling circuit, and it is located at the radiator outlet.
c. there is only one temperature sensor in the cooling circuit, and it is located at the engine
block outlet.
60
13. Which of the following statements is true?
a. The coolant flows through the cylinder heads from the exhaust end to the intake end.
This ensures very good temperature equalisation as well as effective cooling of the outlet webs
and spark plugs.
b. Coolant flows through the cylinder heads from the intake side to the exhaust side.
This ensures very good temperature equalisation as well as effective cooling of the outlet webs
andspark plugs.
14. A new liquid sealing method is used to seal the upper timing case cover.
The liquid gasket is injected through screw nipples.
61
Notes
62
63
Solutions
1.) c
2.) c
3.) b, c, d, e
4.) b
5.) c
6.) b
7.) 1 Oil ducts
2 Coolant ducts
3 Secondary air ducts
8.) b
9.) b
10.) a, b, d, e
11.) a, c
12.) b
13.) a
14.) a
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