Audi V6 TSFI Engine 925803

Service Training
ProCarManuals.com
Audi 3.0 V6 TFSI engine

with Roots blower
Self-Study Program 925803
Audi of America, LLC.
Service Training
Printed in U.S.A.
Printed 12/2008
Course Number 925803
©2008 Audi of America, LLC.
All rights reserved. All information contained in this manual is

based on the latest information available at the time of printing
and is subject to the copyright and other intellectual property
rights of Audi of America, Inc., its affiliated companies, and its
licensors. All rights are reserved to make changes at any time
without notice. No part of this document may be reproduced,
ProCarManuals.com
stored in a retrieval system, or transmitted in any form or by

any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to
other sites without the prior expressed written permission of the
publisher.
All requests for permission to copy and redistribute information

should be referred to Audi of America, LLC.
Always check Technical Bulletins and the latest electronic repair

literature for information that may supersede any information
included in this booklet.
Trademarks: All brand names and product names used in this

manual are trade names, service marks, trademarks, or registered
trademarks and are the property of their respective owners.
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 2
Engine Mechanical . . . . . . . . . . . . . . . . . . . . . 6
Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cooling System . . . . . . . . . . . . . . . . . . . . . . . 32
Exhaust Emission Treatment . . . . . . . . . . . . . . 38

ProCarManuals.com
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 42
Engine Management . . . . . . . . . . . . . . . . . . . . 44
Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . 50
The Self-Study Program teaches the design and function of new vehicle models, Reference Note
automotive components and technologies.
The Self-Study Program is not a Repair Manual!

The values given are only intended as a guideline. Refer to
the software version valid at the time of publication of the SSP.
For maintenance and repair work, always refer to the current technical literature.
i
191651 Audi 3.0L Supercharged.indd Sec1:i 2/16/2009 11:12:30 AM

Notes
ProCarManuals.com
ii
191651 Audi 3.0L Supercharged.indd Sec1:ii 2/16/2009 11:12:31 AM

For the first time, Audi has brought to market a mechanically supercharged powerplant: the 3.0l V6 TFSI. This Roots
blower supercharged engine is based on the 3.2l V6 naturally aspirated engine from the current Audi V-engine family.
By embracing new technology, in combination with the FSI combustion process, Audi has developed an engine
concept that has impressive compact design, acoustics, responsiveness and fuel efficiency.
The engine has a broad range of characteristics from comfort-oriented to ultra-sporty. The sporty version of the engine
specifically targets US clientele. The car’s so-called take-off behavior plays a key role to achieve the greatest possible
acceleration between traffic lights in urban traffic.
With its enormous power the 3.0l V6 TFSI engine is also well suited to comfort-oriented driving. A wide range of
uses have been envisioned for it within the Audi product portfolio. In Europe, China and the USA, it will be available
beginning in the Fall of 2008 in the Audi A6.
Historically, mechanical supercharging using Roots blowers is nothing new to cars bearing the four-ring badge. In fact,
Roots blowers were once used on the engines of the legendary AUTO UNION racing cars (“Silver Arrows”), which were
powered by huge V engines with up to 16 cylinders supercharged by up to two Roots blowers. Between 1934 and 1939,
the legendary AUTO UNION drivers spearheaded by Hans Stuck and Bernd Rosemeyer racked up numerous Grand Prix
wins, not to mention setting a string of world speed records.
ProCarManuals.com
437 _ 003
191651 Audi 3.0L Supercharged.indd Sec2:1 2/16/2009 11:12:32 AM

Introduction
Technical description
Main changes from the 3.2l V6 FSI engine:
The 3.0l V6 TFSI engine will be used for the first time in
the 2009 Audi A6. – Heat treated cylinder crankcase
– Crankshaft drive
– Supercharger module with integrated intercooling
Main technical features: system
– Six-cylinder V engine with mechanical supercharging – Coolant pipes in the car’s low-temperature circuit
(technical basis: 3.2l V6 FSI engine) – Belt drive for the supercharger module
– Fuel supply, activated carbon filter system, exhaust – Engine management system with “Simos 8” control
system (manifold for selective lambda control) and – Secondary air system for compliance with the EU V and
engine cooling system are identical to those of the 3.2l ULEV II exhaust emission standards
V6 FSI engine in terms of their geometry and position.
Adaptations from the 3.2L FSI engine:
– Vacuum system with mechanical vacuum pump
(identical to that of the 3.2l V6 FSI engine) – Intake system
– Camshafts
– Valves and valve springs
– Flange for the tumble flaps
Deletions from the 3.2L FSI engine:

ProCarManuals.com
– Audi valvelift system

– Exhaust camshaft adjustment
Coolant tube
Supercharger module
Additional charge-air cooler
2nd belt drive

pulley
437 _ 005
Adapted crank mechanism
2

Introduction
Torque/power curve
355 280
Max. torque in lb-ft
295 230
Max. power in horsepower
Nm kW
175 120
120 70
0 1000 2000 3000 4000 5000 6000 7000 8000

Engine speed [rpm]
ProCarManuals.com
Engine code CAJA/CCAA
Engine type Six-cylinder V-engine

3
Displacement in cm 2995
Max. power in hp (kW) 285 (213) at 4850 – 7000 rpm
Max. torque in lb-ft 310 at 2500 – 4850 rpm
Valves per cylinder 4
Bore in mm 84.5
Stroke in mm 89
Compression ratio 10.5 : 1
Firing order 1–4–3–6–2–5
Engine weight 418 lbs (190 kg)
Engine management Simos 8

Fuel grade Premium unleaded
Mixture formation Direct injection FSI (homogeneous)

High-pressure fuel pump HDP 3
Exhaust emission standard EU V, ULEV II
Exhaust aftertreatment Cylinder-selective lambda control with one broadband pre-cat

sensor per cylinder bank, two ceramic catalytic converters
with post-cat oxygen sensor (nonlinear sensor)
CO2 emissions in g/km 228

Introduction
Characterization
Although the 3.0l V6 TFSI engine does not have the The same goes for economy, i.e. fuel consumption
largest displacement of the Audi V6 engine family, it sets and exhaust emissions. In the figure, you are shown
the benchmark for power output. a comparison of the full-throttle curves of the V6 FSI
engines installed on the Audi A6.
This is also reflected in its performance, where the engine
outstrips the equivalent naturally aspirated 3.2l V6 FSI
unit.
Torque/power curves of the V6 FSI engine

ProCarManuals.com
355 280
325 255
295 230
265 200
Power output (hp)

Torque (lb-ft)
235 175
205 150
175 120
150 95
120 70
0 1000 2000 3000 4000 5000 6000 7000 8000

Engine speed RPM)
3.0 TFSI engine
3.2 FSI engine

Introduction
Specifications of the V6 engines on the Audi A6
Parameter 3.2l FSI 3.0l TFSI
Displacement in cm3 3123 2995
Stroke in mm 92.8 89
Bore in mm 84.5 84.5
Stroke/bore 1.10 1.05
Compression ratio 12.5 : 1 10.5 : 1
Cylinder spacing in mm 90 90
Cyl. bank offset in mm 18.5 18.5
Main bearing diameter 65 65

in mm
Big-end bearing diameter 56 56

in mm
Con-rod length in mm 154 153

ProCarManuals.com
Engine block height in mm 228 228
Max. power 250 at 6500 285 at 4800 – 7000

in hp at rpm
Max. torque in lb-ft at rpm 245 at 3250 310 at 2500 – 4850
Fuel in Octane 87/91 1) 87/91 1)
1) with reduced power output
Comparison of performance data: 3.2l V6 FSI engine and 3.0l V6 TFSI engine on the Audi A6
Audi A6 Audi A6
3.2l FSI 3.0l TFSI
250 hp/245 lb-ft 285 hp/310 lb-ft
tiptronic quattro tiptronic quattro
Model year 2008 Model year 2009
Parameter Units
0 – 62 mph (100 kph) S 7.1 6.3
Elasticity in speed D mph (kph) 50 - 75 (80 – 120) 50 - 75 (80 – 120)
S 6.0 5.3
Max. speed mph (kph) 155 (250) 2) 155 (250) 2)
rpm / gear 6350 / 5 4500 / 6
Average consumption (overall) mpg (l/100 km) 21.6 (10.9) 24.5 (9.6)
CO2 emissions g/km 259 228
2) governed

Engine Mechanical
Cylinder block
The cylinder block is identical to that of the 3.2l V6 FSI To ensure high stability, the bearing seats undergo a
engine. However, the load on the engine is higher due to special heat treatment process during manufacturing.
the increased mean peak pressure (combustion pressure). Also, higher strength main bearing bolts are used.
Cylinder block
ProCarManuals.com
Cylinder crankcase
bottom section (bedplate)
Oil pan top section
Oil pan bottom section

437 _ 007

Engine Mechanical
Crankshaft drive
Crankshaft
The crankshaft has been adapted for a stroke of 89 mm.

Like the 3.2l V6 FSI engine, the crankshaft has a split-pin
configuration* (see glossary).
The newly developed, cracked con-rods* are 153 mm

long and optimised for strength. All bearing bushings are
lead-free 3-component composite bearing bushings.
ProCarManuals.com
437_008
Cast piston
Pistons
Unlike the 3.2l V6 FSI engine, the pistons are rated for a
compression ratio of 10.5:1.
The piston skirts have a wear resistant Ferrostan plating.
The special piston ring combination provides:
– High power output

– Low blow-by gas flow rates
– Low oil consumption
– Minimum friction and wear
Ring carrier
1.2 mm asymmetric
steel ring
1.5 mm
taper-face ring
2.0 mm oil scraper ring

(two piece
437_009

Engine Mechanical
Crankcase ventilation
The crankcase is ventilated in the same way as the 3.2L V6 The treated crankcase ventilation gases follow the
FSI engine. shortest possible route from the V chamber.
Connection to cylinder head cover, left

(with integrated labyrinth oil separator PCV line with non-
return valve
Connection to
supercharger module
ProCarManuals.com
Oil separator module
Connection to cylinder head cover, right

(with integrated labyrinth oil separator
437_070
Adaptor
Connection to supercharger module
The blow-by gases* are introduced into the supercharger

module from below. An adaptor seals the feeder line
off from the supercharger module. The opening in the
supercharger module is tapered to aid inserting the
adaptor. The adaptor has a lug which can be used to
position it exactly at the PCV outlet.
8 437_050

Engine Mechanical
Cylinder head
The four-valve cylinder heads have very few changes from The exhaust camshaft adjuster has also been removed.
the 3.2l V6 FSI engine. The Audi valvelift system is not However, an internal exhaust gas recirculation system has
used in this engine. been implemented to assume the responsibilities of the
exhaust camshaft adjuster.
Changes from the Intake camshaft

3.2l V6 FSI engine adjustment valve N205
Cylinder head cover
High-pressure fuel pump

ProCarManuals.com
Valve springs
(different alloy, different tensile strength
Exhaust valves
(chrome plated, sodium filled hollow-stem
valve, steel plated at valve seat)
Cylinder head
437_071
Chain drive
The chain drive is identical design to that of the 3.2l FSI

engine. Differences are the modified valve timing* and
the absence of exhaust camshaft adjusters.
437_072
9

Engine Mechanical
Driving the ancillary units/components
The engine has two separate belt drives for driving the ancillary units/components. The serpentine belt drives the
alternator, the air conditioning compressor and the power steering hydraulic pump. The Roots blower is driven by a
separate belt drive.
Roots blower isolator (SSI)
Crankshaft drive
ProCarManuals.com
Ancillary units drive
437_010
Belt drive for the Roots blower
Roots blower
Layout of units Coolant pump
Pulley
Servo pump
Tensioning device
Belt drive 2
Air conditioner
Alternator
compressor
Crankshaft
Tensioning device 437_055

Belt drive 1
10

Oil Supply
Oil circulation system
The oil circulation system of the 3.0l V6 TFSI engine was adopted from the 3.2l V6 FSI engine
However, there are the following differences:
– There are no spray nozzles for the cam followers in the – There is no drive module for the exhaust camshaft
valve gear (they are only needed in an engine with Audi adjuster
valvelift system, since the narrower rollers require better
lubrication)
Upright oil filter module

ProCarManuals.com
Oil pressure regulation

valve N428
Oil cooler
Unfiltered oil port

Clean oil port
Self-regulating oil pump
437_073
11

Air Supply
Air circulation system
The central component of the air supply system is the supercharger module, which sits inside the V shaped area
between the cylinder banks. It consists of the Roots blower, the bypass control module and the intercooler.
Air filter
Supercharger module
Intercooler
ProCarManuals.com
Intake manifold
flaps
437_025
Given Audi's extensive experience with exhaust The following criteria played a key role:
turbocharging, you may ask yourself why a mechanical
– High standard of comfort
supercharging system has been chosen for the 3.0l V6
TFSI engine. – Good starting performance, coupled with a broad range
of characteristics between comfort-oriented and ultra-
After carefully weighing the pros and cons on the basis of sporty
numerous tests conducted during the conceptual design – Because of this, the engine is suitable for use in
and development phase, the decision fell in favor of the multiple models
mechanical supercharging system. – Compliance with all current and upcoming exhaust
emission standards (EU V and ULEV II)
12

Air Supply
Pros and cons of a mechanical supercharging system with Roots

blower compared to an exhaust turbocharging system
Pros:
– Charge pressure is immediately available whenever it is required
– Charge pressure is continuously supplied and rises with increasing rpm
– The charge air does not have to be cooled as much as turbocharged air
– Long life and maintenance-friendly operation
– Compact design (to save space, the supercharger can be installed in place of the intake manifold inside the V shaped
area between the cylinder banks)
– High fuel efficiency
– Quick and dynamic torque response; peak torque is available at low rpm, providing good starting performance
– The compressed air paths to the cylinders are very short, resulting in a very low air volume and extremely quick
response
– Enhanced exhaust emission characteristics (reason: the catalytic converter reaches its operating temperature faster).
In an exhaust turbocharged engine, a portion of the heat energy is wasted in driving the turbocharger
Cons:
– It is very difficult to produce because very close manufacturing tolerances have to be maintained (rotor to housing
and rotor to rotor)
ProCarManuals.com
– Higher susceptibility to ingress of foreign matter into the filtered air tract
– Relatively high weight
– Extensive soundproofing is needed
– Some engine power is lost in driving the blower
Exhaust turbocharger Roots blower
437_044
437_053
13

Air Supply
General information on Roots blowers
With their mechanical supercharging technology, Roots blowers are presently staging a comeback at Audi.
In this section you will find general information about the design and development of this technology.
Basic principle
Air inlet
Housing
Rotor 2
ProCarManuals.com
Rotor 1
Air outlet 437_014
What are Roots blowers? In design terms, Root blowers From a design standpoint, it is very important that the
are rotary piston compressors. They work without inner rotors are sealed off against each another and against
compression according to the displacement principle. the housing. The difficulty here is that no friction must be
allowed to develop.
The fresh air blower consists of a housing in which two
shafts (rotors) rotate. Both rotors are driven mechanically, When the blower is operating (i.e. the rotors are rotating),
e.g. by the crankshaft. Both rotors are coupled by a air is conveyed between the vanes and the outer wall of
gearing outside the housing so that they counter-rotate the housing from the air inlet (on the intake side) to the
synchronously. That is how they interact. air outlet (on the pressure side).
Types
437_015 437_016
The historic blowers of the past were equipped Today's modern versions usually have three vanes and
with twin-vane rotors. are screw shaped to provide a higher pressure (for better
efficiency).
14

Air Supply
Historical evolution
The system is named after brothers Philander and Francis The difference between the AUTO UNION racing car and
Roots, who had the principle patented as long ago as the 3.0l V6 TFSI engine is that, on the former, the air-fuel
1860. mixture was formed upstream of the Roots blower.
At that time Roots blowers were principally used as wind This configuration was chosen because the partial
generators for blast furnaces, but also found uses in vacuum needed to draw fuel out of the carburetor was
other branches of industry. only available upstream of the Roots blower. The Roots
blower compressed the the air-fuel mixture.
A Roots blower was used in an automobile for the first
time by Gottlieb Daimler in 1900. In the 1920s and 1930s,
Roots blowers were introduced into motorsport.
A special feature of these engines is that they can be Housing

easily identified by their typical “compressor squeal”
Rotors
sound.
The illustration to the right shows a Roots blower from

the 1936 AUTO UNION Type C grand prix racing car.
With the development of highly temperature-resistant

materials, the Roots blower was superseded by the
ProCarManuals.com
exhaust turbocharger. Today, Roots blowers are mainly

used on sporty vehicles.
Upper
bearing cover
437_051
Carburetor Roots blower 16-cylinder engine
437_026
Fuel pump
15

Air Supply
Supercharger module
Modern Roots blowers of the type used on Audi models have two identical four-vane rotors. Each vane of the two
rotors is set at an angle of 160° relative to the longitudinal axis to provide a more continuous air flow with less
pulsation.
The Roots blower for the 3.0l V6 TFSI engine is manufactured by EATON. This company already has many years of
experience in the manufacture of Roots blowers.
Design
Throttle valve control module J338
The entire supercharger module sits inside the V shaped

area between the cylinder banks, so the engine is flat and
meets pedestrian safety regulations. The total weight of
the module is 39 lb (18 kg) (excluding coolant).
The power consumption of the supercharger module is

between 2 and 50 hp, depending on engine speed.
Adaptor (main throttle valve)
Snap-in coupling for design cover

ProCarManuals.com
Damping plate
Charge air pressure sensor G31

Intake air temperature sender G72
Lifting lug
Housing
Rear rotor bearing
Rotors
Belt pulley
16

Air Supply
Bypass bend
Adaptor (bypass valve)
Control valve control module J808
Intercooler
ProCarManuals.com
Side seal, intercooler
Intake air temperature sensor G42

Bearing cover
Manifold absolute pressure sensor G71
Charge air pressure sensor 2 G447

Intake air temperature
sensor 2 G430
Front rotor bearing

Synchronizer gears
Single Spring Isolator (SSI)
Input shaft with bearing

437_037
Drive housing
17

Air Supply
Housing
The Roots blower, an electrically activated bypass valve The air outlets to the individual cylinders can be found on
and one intercooler per cylinder bank are integrated in a the underside of the housing. The lifting lugs bolted to
cast mono-block housing. the supercharger module are for suspending the engine
during removal and installation.
Snap-in coupling
Lifting lug
for design cover
Damping plate
ProCarManuals.com
437_038
Housing

Intake manifold pressure sender G42
Intercooler
Intercooler
PCV intake
Air outlets
Drive shaft
437_034
18 Direction of travel

Air Supply
Drive
The Roots blower is driven by the crankshaft via the The result is better resonance damping at low engine
second pulley of the belt drive. speeds and full throttle.
Drive is permanent, and is not engaged or disengaged by Because of this the load on the belt is significantly lower.
a magnetic coupling. The crankshaft-to-supercharger drive ratio is 1:2.5.
Each belt drive is insulated against crankshaft vibration

by a rubber buffer in a shared torsion vibration damper.
Supercharger module
ProCarManuals.com
2nd belt drive

pulley
437_039
The Roots blower is coupled by means of a Single Spring It ensures very smooth running (optimized acoustics) and
Isolator (SSI) integrated in the drive housing of the extends the life of the drive belt.
supercharger module.
The ribbed V-belt which drives the Roots blower has a
The SSI is designed to optimize force transmission under replacement interval of 75,000 miles (120,000 km).
load reversal.
Bearing cover
Drive housing
Belt pulley
Synchronizer
Front rotor bearing
gears
Single Spring Isolator (SSI)
Input shaft with bearing

437_040
19

Air Supply
Function
A spring element is built into the drive housing of the Further along the drive-line, the second rotor is driven
Roots blower. It consists of a torsion spring guided by an through a pair of gears so that the two rotors counter-
input bushing and an output bushing and transmits drive rotate absolutely synchronously. The gears are press
torque from the belt pulley to the gearing. fitted onto the rotor shafts by the manufacturer using
special gauges.
The input and output bushings limit the movement of the
spring, both into and counter to the direction of rotation A perfect fit must be ensured, as the rotor vanes would
of the Roots blower. otherwise come into contact with one another.
The spring element is rated "soft" enough to effectively For this reason, the gears must not be removed from
isolate the blower, yet also firm enough to prevent the shafts during servicing. The drive head is filled with
harshness during dynamic operation (under load special-grade oil.
reversal), which can cause unwanted noise.
Drive housing
Rotors
ProCarManuals.com
Belt pulley
Input shaft
with bearing
437_041
Input bushing Synchroniser gears

Torsion spring
Output bushing
Rear rotor bearing
Rotors
The two four-vane rotors are set at an angle of 160° and

run on maintenance-free roller bearings. To minimize
wear during the run-in phase, the rotors have a special
graphite-based coating.
This coating also guards against air leakage (rotor to

rotor, rotor to rotor bore) providing better performance.
437_042
Rotor
20

Air Supply
Control of air flow and charge pressure
The Roots blower is permanently driven. Without a charge In the 3.0l V6 TFSI engine, the control valve control
pressure control system, the Roots blower would always module J808 is used to regulate the charge pressure. It
deliver the maximum air flow rate for each engine speed is integrated in the supercharger module and connects
and therefore generate the maximum charge pressure. the pressure side to the intake side. By opening a bypass
valve, a portion of the air flow is recirculated through the
However, charged air is not required in all operating open bypass to the intake side of the Roots blower.
states, so there would be an excessive build-up of air on
the pressure side of the blower. This would, in turn, lead The bypass valve works in much the same way as a
to an unnecessary loss of engine power. Therefore, it is wastegate on an exhaust turbocharged gasoline engine.
necessary to regulate charge pressure.
Tasks of the control valve control module J808:
– Regulation of the charge pressure defined by the

engine control module
– Limitation of maximum charge pressure to 1.9 bar
(absolute)
Function
Full-throttle operation (bypass valve closed)
When the engine is running at wide open throttle, air flows through the throttle valve, Roots blower and intercooler to
ProCarManuals.com
the engine.
Bypass valve
Damping plate
Charge air pressure sensor 2 G447

Intake manifold temperature
sender G430

437_044
Part-throttle mode (bypass valve open)
When the engine is running at part throttle, at idle and when coasting, a portion of the airflow is recirculated through
the open bypass valve to the intake side.
Main throttle valve
Intercooler
437_043
Rotor
21

Air Supply
Use of the control valve control module J808 eliminates the need for a complex and expensive belt drive shut-off in the
form of a magnetic coupling.
Angle sender
Bypass valve
Control flap adjustment

motor V380
ProCarManuals.com
437_036
Signal characteristic of the control flap potentiometer G584
100
1 Lower mechanical
stop
2 Upper mechanical 80
stop
Sensor output [%]
60
40
20
1 Sensor travel 2
22

Air Supply
Legend:
G584 Control valve position sensor

J808 Control valve control module
V380 Control flap adjustment motor (type: DC motor)
1 Sensor voltage ground
2 Control signal
3 Positive sensor voltage
4 Motor supply voltage
5 Motor supply voltage
437_052
ProCarManuals.com
Control flap position sensor G584 Effects of signal failure
This component senses the current position of the The flap is de-energized and moves into its wide open
control flap and is integrated in the actuator housing position under spring load. The fault is irreversible for
cover. the duration of one driving cycle In this case, no charge
pressure is built up.
Its output voltage range is between 0.5 and 4.5
V. The potentiometer operates on the magneto- Neither the full engine power output nor the full engine
resistive measurement principle and is immune to torque is available.
electromagnetic radiation (EMC*).
This component is subject to OBD; i.e. if it fails, the
malfunction indicator lamp K83 (MIL) is activated.
Signal utilization
The flap position feedback signal is utilized to determine

the control input variable. It is also used to determine the
adaptation values
23

Air Supply
Sensors for the measurement of

air mass and charge pressure
Air mass and charge pressure are two factors used

for engine load management. For this purpose, there
are three sensors with absolutely identical functions.
They measure the intake air temperature and the intake
manifold pressure. The first sender unit is located
upstream of the throttle valve control module J338 and
contains the following senders:
– Intake air temperature sensor G42

– Manifold absolute pressure sensor G71
437_028
The other identical senders are integrated in the

supercharger module. They measure the pressure and
ProCarManuals.com
temperature of the air in each individual cylinder bank.

It is important that the measuring point be located
downstream of the intercoolers. The values measured
here correspond to the actual air mass in the cylinder
banks. The senders are as follows:
– Charge air sensor G31 (cylinder bank 1)

– Intake air temperature sensor G72 (cylinder
bank 1)
437_029
– Charge air pressure sensor 2 G447 (cylinder bank 2)
– Intake air temperature sensor 2 G430 (cylinder bank 2)
Circuit diagram
The intake air temperature sensor G42 is a temperature

sensor with a negative temperature coefficient (NTC). Its
output is a voltage signal to the engine control module.
Legend:
G42 Intake air temperature sensor

G71 Manifold absolute pressure sensor
15 Terminal 15
31 Terminal 31
– Voltage signal for intake manifold pressure

– Resistance signal for intake air temperature
437_018
24

Air Supply
Signal characteristic of the intake manifold pressure sender
Characteristic curve of supply voltage U

Signal output voltage U
ProCarManuals.com
Absolute pressure p
Signal Utilization Effects of signal failure
The signal generated by the manifold absolute pressure In case of signal failure, the malfunction indicator lamp
sensor G71 upstream of the throttle valve control module K83 (MIL) is activated. Failure of the manifold absolute
is used to determine the nominal position of the bypass pressure sensor G71 will result in less precise adjustment
valve. of the charge pressure, which may result in uneven
acceleration.
This information is required to set the required charge
pressure. This nominal position of the bypass valve If charge air sensors G31 and G447, fail this will result in
depends largely on the pressure level upstream of the an incorrect air-fuel mixture throughout the load/speed
supercharger module. range because of an incorrect air mass calculation.
Charge pressure sensors G31 and G447 have two This will in turn cause an incorrect quantity of fuel to be
purposes. First, they are used to adjust the charge injected, resulting in higher exhaust emissions and loss
pressure to the required nominal value. Second, the air of power (and even misfiring). In charging mode, a fault in
mass is calculated from their output signal during each this sender can result in wrong charge pressures, causing
working cycle. This air mass is a key input variable of irreparable damage to the engine.
the torque-based engine management system, which
determines the injection rate, injection timing and For this reason, all senders are validated after the ignition
ignition advance angle. is turned on. If irregularities are detected, an entry will
be made in the fault memory and the system switches
over to an equivalent sensor or the backup sender. This
allows the system to operate normally from the driver's
viewpoint and consequential damage will be avoided.
25

Air Supply
Circuit diagram
Legend:
G31 Charge air sensor (cylinder bank 1)
G72 Intake air temperature sensor (cylinder bank 1)
G430 Intake air temperature sensor cylinder bank 2
G447 Charge air pressure sensor 2 (cylinder bank 2)
J623 Engine control module
Vs Supply voltage (5 volts)
Positive
Ground
ProCarManuals.com
Sensor signal
437_020
26

Air Supply
Load management
The control valve control module J808 operates in During part-throttle and naturally aspirated operation,
conjunction with the throttle valve control module J388. the bypass valve is wide open and the engine throttle
valve takes care of load management. In charge pressure
The control system was designed to maximize throttle mode, the bypass valve regulates the engine load and the
free operation and power delivery. engine throttle valve is wide open.
The diagram below shows the function of both flaps.
Load section at 3000 rpm
1800
Intake manifold pressure [mbar]

160 2 1600
1400
1 3
140 1200
ProCarManuals.com
1000
120 800
600
Opening angle [degrees]
100 400
200
80
60
40
20
0
1000 2000 3000 4000 5000 6000
Engine speed [rpm]
Intake manifold pressure 1 Naturally aspirated mode
Bypass valve 2 Ambient pressure
Throttle valve 3 Charging mode
27

Air Supply
Intake manifold flaps
Intake manifold flaps are used on the 3.0l V6 TFSI

engine to improve internal mixture formation. They
are housed in an adaptor element between the Note
supercharger module and the cylinder head
When installing the intake manifold flap
module, the intake manifold flaps must
be moved into the "power" position
(intake port open).
Intake manifold flap module, left cylinder

bank
Actuation of the shaft for opening/

closing the intake manifold flaps
ProCarManuals.com
437_027
Intake manifold flaps
Intake manifold runner

Vacuum cell
position sensorG336
Intake manifold runner control valve N316
The intake manifold valves are mounted on a common

shaft and actuated by a vacuum cell. The partial vacuum
required for actuation is supplied by the intake manifold
flap valve N316. The engine control module activates the
intake manifold runner control valve N316 on the basis of
a characteristic map.
Effects of failure
If N316 is not activated or faulty, no partial vacuum

will be supplied. In this condition, the intake manifold
flaps close the "power" port in the cylinder
head under the spring pressure produced by the
vacuum cell, reducing engine output. 437_049
28

Air Supply
Intake manifold runner position

sensor
Two sensors monitor the positions of the intake manifold

flaps: Vacuum cell
– Cylinder bank 1: Intake manifold runner position sensor

G336
– Cylinder bank 2: Intake manifold runner position sensor
2 G512
The sensors are integrated directly in the vacuum cell

flange. They are contactless incremental encoders and
work on the Hall sender* principle. The sensor electronics
generate a voltage signal, which is evaluated by the
engine control module.
Intake manifold runner

ProCarManuals.com
Signal utilization position sensor G336 437_030
The signal is used to monitor the position of the intake

manifold flap and for diagnostic purposes (e.g. to check
for wear etc.).
Effects of signal failure
The position of the intake manifold flap will no longer

be correctly sensed. No diagnosis will be possible.
This component is subject to OBD; i.e. if it fails, the
malfunction indicator lamp K83 (MIL) is activated. Loss of
power can occur.
Signal characteristic of the intake manifold flap potentiometer
4,5
3,5
Voltage signal [V]
2,5
1,5
0,5
0
-30 -20 -10 0 10 20 30 40
Angle of rotation [degrees]
29

Air Supply
Soundproofing
One of the development goals was to keep the Noise is also reduced by modifications to the intake (see
characteristic sound of the Roots blower to a minimum. figure). Insulating mats positioned around and below the
This was achieved by modifying the design of the supercharger module provide additional soundproofing.
housing. A multilayer damping plate reduces noise at the
gas outlet on the Roots blower.
Unfiltered air intake Filtered air intake with

broadband damper
Helmholtz resonator*
ProCarManuals.com
Multilayer damping plate
Air filter with foam mat
437_047
Supercharger module
Air outlet
30

Air Supply
Insulating mats
Multiple insulating mats are positioned between the

supercharger module and the cylinder head and block.
They direct the noise produced by the Roots blower

downward. Two small insulating inserts are located
on the back of the supercharger module (see adjacent
figure).
437_031
Additional insulating mats are located below the

ProCarManuals.com
supercharger module inside the V shaped area between

the cylinder banks.
A larger mat is positioned between the two intake

manifolds, and there are two narrower insulating mats at
the sides between the intake manifolds and the cylinder
heads.
437_032
The adjacent figure shows the insulating mats installed

between the supercharger module and the cylinder head
or block.
437_033
31

Cooling System
Cooling circuit
There are two different types of cooling circuits for the

Audi A6 with the 3.0l V6 TFSI engine (they are market
dependent).
The adjacent figure shows a version with preheater and

after run coolant pump V51 (for super-hot climates, PR Note
No.: 8z9).
Please refer to the instructions for
filling and venting the coolant system
Another electrically driven coolant pump is the charge air
in the relevant service literature.
cooling pump V188, which is used in the low temperature
circuit of the intercooler.
However, both circuits are interconnected and share a

common coolant expansion tank.
ProCarManuals.com
Cooling circuit without preheater
437_013
32

Cooling System
Cooling circuit with preheater

ProCarManuals.com
437_012
Legend:
A Vent line N ATF cooler

B Expansion tank N175 Left heat regulating valve
C Heat exchanger N176 Right heat regulating valve
D Pump/valve unit (N175/N176 and V50) O Recirculation pump
E Vent screw P Pre-heater
F Coolant circulation pump V50 Q Heater coolant shut-off valve N279
G Engine oil cooler R Auxiliary cooler, front
H Coolant pump S Vent screw
I Coolant run-on pump (hot climates only) T Intercooler, right
J Coolant thermostat U Vent screw
K Radiator V Intercooler, left
L Non-return valve WI Intercooling pump V188
M Coolant temperature sender G62
33

Cooling System
Charge air cooling (intercooling)

Vent screws
The supercharger module has one intercooler per cylinder
bank. Coolant flows through the intercoolers, which
are integrated in the intercooling circuit in a parallel Intercooler, right
configuration.
Supercharger module
Intercooler, left
ProCarManuals.com
Side seal of intercooler
Intercooler sealing kit
437_045
437_045
Note
The intercooler must be installed and removed with great care.

Follow the instructions given in the Electronic Service Information.
34

Cooling System
Intercooling circuit
The intercooling circuit is a cooling circuit which is The temperature level within the intercooling circuit is
separate from the main cooling circuit. However, both usually lower than within the primary circuit.
circuits are interconnected and share a common coolant
expansion tank.
Vent screw
Intercooler, left
Coolant return line

from right intercooler
ProCarManuals.com
Supercharger module
437_046
Coolant supply
Coolant return line
Charge air cooling pump V188

Intercooling radiator
35

Cooling System
Charge air cooling pump V188
The charge air cooling pump V188 is an electrically

driven coolant pump. It pumps the heated coolant Pressure connection
from the intercooler inside the supercharger module
to the low-temperature cooler. The lower-temperature
cooler is integrated in the cooling unit at the front end
of the vehicle (in the direction of travel upstream of the
radiator).
The pump is close coupled to the oil cooler at the front

left of the engine compartment.
The pump is configured as a centrifugal pump. A Electrical connection

centrifugal pump is not self-priming, and must not be
allowed to run dry or the pump bearings could overheat.
The following subassemblies are integrated in the pump

module:
– Centrifugal pump
– Electric motor
– Electronic control module 437_057
ProCarManuals.com
The electrical connection of the pump has three pins:
– Battery voltage from the motronic engine control

module J271 Intake port
– PWM signal*
– Terminal 31
How the pump control unit works Effects of failure
The pump is activated according to the temperature and If the pump electronics detect a fault, the PWM signal will
pressure downstream of the intercooler, both of which be altered. The modified signal is evaluated by the engine
are read from a map stored in the engine control module. control module, which initiates a response corresponding
The pump begins to run at a pressure of 1300 mbar or a to the nature of the fault.
coolant temperature of 122 °F (50 °C).
If a fault is found, the fault is stored in the fault memory
The pump is activated by a PWM signal generated by the of the engine control module.
engine control module. The pump electronics calculate
the required pump speed from this signal and will The loss of power due to failure of the pump will only
activate the electric motor. be noticeable when the throttle is wide open. Exhaust
emissions are not affected, and no warning lamp is
If the pump is operating correctly, the pump electronics activated.
feed the current pump speed back to the engine control
module. This process repeats itself cyclically throughout If the pump fails, no substitute response is initiated
the duration of pump operation. in the engine control module. However, the charge air
temperature is monitored. In the event of excessively high
charge air temperature, engine output will be reduced.
If the signal line to the pump is broken or if a short circuit

to positive occurs in the signal line, the pump will enter
an emergency mode delivering 100 % output. If a short
circuit to ground occurs on the signal line, the pump will
stop.
36

Cooling System
Fault identification
If faults are found, the system will attempt to protect the Possibilities for diagnosis during servicing
pump either by reducing its speed or shutting it off.
The following possibilities for diagnosis are available:
– Read out fault memory in engine control module

– Guided Fault Finding function (test plan)
– Measuring value block 109 (Audi A6)
– Actuator test
During the actuator test, various pump speeds are

activated and evaluated by the engine control module.
The actuator test must not be interrupted.
The table below shows possible faults and their effects.

ProCarManuals.com
Faults detected by the pump Effects
Dry-running due to low coolant level Speed reduction to 80 %

(speed higher than expected) (max. 15 min)
Low coolant level >15 min Pump is shut down
Overtemperature Speed is reduced in two steps, first to 80 %

and then to 50 %
Undertemperature (excessively cold coolant and Speed is reduced in two steps, first to 80 %
high viscosity* increase current draw) and then to 50 %
Overvoltage If the voltage is > 20 V, the pump will be shut

down as long as overvoltage is present.
Rotor lockup The pump is shut down.

It attempts to work itself free.
Temperature of the pump electronics > 160 °C The pump is shut down as long as
the overtemperature is present.
37

Exhaust Emission Treatment
Secondary air system
A secondary air system is used to ensure compliance with The unburned hydrocarbons and carbon monoxide
the EU V and ULEV II exhaust emission standards. contained in the exhaust gas or accumulated in the
catalytic converter will then react with the oxygen in the
It facilitates rapid heating of the catalytic converters air. Due to the heat released in this process, the catalytic
and reduces exhaust emissions by injecting air into the converter reaches its light-off temperature*
exhaust line downstream of the exhaust valves for a more quickly.
defined period of time after the engine is cold-started.
Secondary air injection valve 1+2
Combination valve 1
Combination valve 2
ProCarManuals.com
437_069
Secondary air injection pump motor V101
Differences to previously used systems:
– The system uses two electrical changeover valves

to comply with the EU V exhaust emission standard.
Previously, both combination valves were activated by a
secondary air injection solenoid valve N112
– The system that is used to comply with the ULEV II

exhaust emission standard also has a pressure sensor -
the G609. It is integrated at the branch in the secondary
air line to the cylinder banks.
38

Secondary air injection valves Data bus
The two secondary air injection valves for activating the If the system malfunctions, the exhaust emission limits
two combination valves are located on the back of the can be exceeded very quickly. The limit value stipulated by
motor. the exhaust emission standard must not be exceeded by
more than a factor of 1.5:1. For this reason, the system is
They are activated electrically by the engine control subject to mandatory inspection
module to turn the vacuum on and off. A partial vacuum
is supplied by the mechanically driven vacuum pump.
Secondary air injection solenoid valve N112 Secondary air injection solenoid valve 2 N320
ProCarManuals.com
437_048
Combination valve 1 Combination valve 2
Note
The connectors and hoses of the
secondary air injection valves must not
be interchanged or faults can occur in the
system.
Testing the system on engines compliant with Measurement phase:

the EU V exhaust emission standard
The secondary air pump is activated and the secondary
Oxygen sensor based secondary air diagnostics air valves (combination valves) are opened. The engine
control module evaluates the signals generated by the
This function is used for testing systems on engines oxygen sensors and compares them with the threshold
classified as compliant with the EU IV exhaust emission values. If the threshold values are not achieved, a
standard. diagnostic trouble code is set.
The secondary air mass is computed by the engine Offset phase:

control module on the basis of the changing oxygen
content during the secondary air injection phase. After the secondary air pump is shut off, the quality of
However, this diagnosis is not made during normal the pilot air-fuel mixture is evaluated. If the determined
secondary air operation as the oxygen sensors reach their value deviates excessively from the nominal value, the
operating temperature too late. The system is activated secondary air diagnosis will be rejected. A faulty drive
separately for diagnostic purposes and checked in several cycle would be assumed.
phases. 39

Testing the system on engines compliant with

the ULEV exhaust emission standard (North
America)
The California Air Resource Board (CARB) requires that the In this system, the signal from G609 is evaluated in
secondary air system be tested during the heat-up phase the engine control module. The injected air quantity is
of the catalytic converter. However, the oxygen sensors determined from the pressure level. Restricted flow,
do not reach their operating temperature fast enough for e.g. ingress of dirt into the system downstream of the
this purpose. This is why a pressure sensor (secondary pressure sensor, causes the pressure level to increase.
air injection sensor -1 G609) is used for making the Restricted flow upstream of the pressure sensor or a leak
diagnosis. The "pressure based secondary air diagnostics" in the system will cause the pressure level to decrease.
function is used.
The pressure based secondary air diagnosis process
Phase 0
ProCarManuals.com
The control unit is initialized at "ignition On". The signal from the secondary air injection sensor -1 G609 is saved and
compared with the signals generated by the ambient pressure sensor and the intake manifold pressure sensor.
Phase 1
When the secondary air mass is injected, the pressure in the secondary air system also increases (to approx. 90 mbar).
The rise in pressure is determined by secondary air injection sensor -1 G609. The analog signal generated by G609
is evaluated by the engine control module. If it exceeds the set limit value (ex. due to a blockage in the system or a
leak), a fault will be generated. If a fault repeats itself, the engine electronics warning lamp will be activated. If no fault
occurs during phase 1, the diagnostic process is continued.
Phases 2.1 and 2.2

During these two phases, a secondary air valve (combination valve) is opened and the other valve closed alternately for
a short period of time. The values are compared with the value saved in phase 0. Blockages or leaks can be determined
for each cylinder bank. Even leaks downstream of the combination valves can be identified from the pressure
amplitudes.
Phase 2
During this phase, both combination valves are closed and checked for leaks. This allows evaluation of the secondary
air injection sensor -1 G609 value.
Phase 3
The secondary air pump is shut off and both combination valves are closed. The difference between the actual
measured pressure and the stored value determined in phase 0 is evaluated. A faulty secondary air pump (does not
shut off) or faulty secondary air injection sensor -1- G609 can be detected.
40

Phases of the secondary air diagnosis process
1 3
Pressure difference
Cylinder bank 1
Cylinder bank 2
4
2
ProCarManuals.com
Time
Phase 0 1 2.1 2.2 2 3
1 Blockage (restricted flow) 5 Faulty pressure sensor
2 Reduced pumping capacity or a 6 Secondary air pump running

blockage upstream of secondary
air pressure sender -1 G609
7 Combination valve 1 open
3 Secondary air pump running

8 Combination valve 2 open
(does not shut off)
4 Faulty pressure sensor
41

Fuel System
Overview
Like the 3.2l V6 FSI engine with Audi valvelift system, the 3.0l V6 TFSI engine uses a supply-on-demand fuel system.
Fuel pressure
Low fuel pressure sensor G247
sensor G410
Injectors
2, 4, 6
N31, N33, N84
Fuel metering valve

N290
Injectors
ProCarManuals.com
1, 3, 5
N30, N32, N83
Depressurized
Fuel filter
High pressure
Low pressure
Fuel pump G6
To engine
Battery Ground
control module
(positive) 437_058
Fuel pump control
module J538
High-pressure fuel pump
A 3rd generation pump is used as the fuel pump. The

high-pressure fuel pump is manufactured by Hitachi.
437_059
42

Fuel System
Injectors
The injectors developed in conjunction with Continental This allows the injection time window to be configured
(formerly Siemens VDO) have been modofied for use in so that the injection timing is neither very early (fuel
this engine. deposition on piston) nor very late (short mixture
formation time until ignition).
The six-hole nozzles were designed to ensure optimal
homogenization of the fuel-air mixture in any operating The new injectors are a key factor for:
state of the engine.
– Reduction of hydrocarbon emissions
The flow rate has also been significantly increased to
– Increased rate of combustion
reduce the duration of the injection cycle (less than 4
milliseconds at full throttle). – Reduced tendency to knock
ProCarManuals.com
437_024
43

Engine Management
System overview (Audi A6 of model year 2009)

Sensors
Charge air pressure sensor G31, G447
Intake air temperature sensor G72, G430

Secondary air injection sensor -1 G609

(for ULEV vehicles only)
Engine speed sensor G28

Throttle drive angle sensor G188, G187

Control valve position sensor G584
Camshaft position sensor G40 (intake, bank 1)

Camshaft position sensor 2 G163 (intake, bank 2)
Camshaft position sensor 3 G300 (exhaust, bank 1)
Camshaft position sensor 4 G301 (exhaust, bank 2)
ProCarManuals.com
Throttle position sensor G79

Powertrain CAN data bus
Accelerator pedal position sensor 2 G185
Clutch position sensor G476
Brake light switch F
Fuel pressure sensor G247 Engine control module J623

Low fuel pressure sensor G410
Knock sensor G61 (bank 1)

Knock sensor G66 (bank 2)
Fuel gauge sensor G

Fuel level sensor -2- G169
Oil pressure switch F22
Reduced oil pressure switch F378
Engine coolant temperature sensor G62
Intake manifold runner position sensor G336 (bank 1)

Intake manifold runner position sensor 2 G512 (bank 2)
Heated oxygen sensor G39

G108 (bank 2)
Oxygen sensor behind three-way catalytic converter G130
G131 (bank 2)
Auxiliary signals:
J393 Comfort system central control module
E45 Cruise control switch
Outp
J364 Auxiliary heater control module Engin
J695 Starter relay 2 trans
J53 Starter relay J217
J518 Access/start authorization control module
(vehi
gearb
44

Engine Management
Actuators
Fuel pump control module J538
Transfer fuel pump (FP) G6
Fuel Injectors for cylinders 1 – 6

N30 – 33 and N83, N84
Ignition coils for cylinders 1 – 6

N70, N127, N291, N292, N323, N324

Throttle drive (for electronic power control) G186

Control flap adjustment motor V380
Intensive washer pump relay J75

ProCarManuals.com
Motronic engine control module (ECM)

power supply relay J271
Evaporative Emission (EVAP) Canister Purge

Regulator Valve N80
Oil pressure regulation valve N428
Fuel metering valve N290
Intake manifold runner control

(IMCR) valve N316
Camshaft adjustment valve 1+2

N205 (intake, bank 1), N208 (intake, bank 2
Change air cooling pump V188
Secondary air injection pump relay J299

Secondary air injection pump motor V101
Secondary air injection solenoid valve 1+2 N112, N320
Data Link
Connector Coolant fan control (FC) control module J293
Coolant fan V7
Coolant fan 2 V177
Electro/hydraulic engine mount solenoid valves N144, N145
Oxygen sensor heater Z19, Z28, Z29, Z30
Auxiliary engine coolant pump relay J496

After run coolant pump V51
Output signals: Leak detection pump (LDP) V144

Engine speed to automatic (vehicles with fuel system diagnostic pump)
transmission control module
J217
(vehicles with automatic
gearbox 01J only)
437_035 45

Engine Management
Engine control module
The Simos 8 engine control module, jointly developed

with Audi and Continental (formerly Siemens VDO) is used
with this engine.
Operating modes
The FSI injection process is configured for homogeneous

mixture formation.
The complete fuel charge is injected into the combustion

chamber during the intake phase.
This does not include the engine start and warm-up

phases, during which the following operating modes are
used.
ProCarManuals.com
437_056
1. Engine start 2. Cold start/warm-up phase
During starting, a high-pressure stratified start mode is During this phase, a dual injection or homogeneous split
used. (HOSP) mode is used.
For this purpose, the fuel pressure is increased to The total quantity of fuel to be injected is divided into
45 – 100 bar. The fuel pressure level is dependent on two partial quantities and injected into the combustion
the engine temperature. At low temperatures, the fuel chamber at different times. The injection time window
pressure is higher. is before and after the bottom dead center position of
the piston. By the second injection, the intake valves are
High-pressure stratified starting takes place at coolant already closed.
temperatures between -11°F (-24 °C) and at operating
temperature 194° F (90 °C). HOSP mode is used in two applications:
At coolant temperatures below -11°F (-24 °C), starting – The first application is the “cold start” and is always
takes place at low pressure to protect the components. used. It serves to heat up the catalytic converters and
The pressure is identical to the pressure in the electrical takes place at coolant temperatures between 19°F (-7 °C)
fuel pump in the fuel tank. and 113°F (45 °C).
During the development process, special emphasis was – The second application is the “warm-up”, which is only
placed on throttle-free load regulation (refer to “Load used under heavy engine load when the driver requests a
regulation”). high engine output. It serves to optimize engine load and
speed, but also to reduce soot emission. The temperature
range for this application is between -4°F (-20 °C) and
113°F (45 °C). In this case, the second injection is later
than in the cold start phase.
46

Engine Management
Maintenance work
Maintenance work Interval
Engine oil replacement interval : Fixed interval of 10,000 miles

(15,000 km) or 12 months
(whichever comes first)
Engine oil specifications: Engine oil to VW standard 502 00 or 504 00
Engine oil filter replacement interval: at every oil change
Engine oil change quantity (incl. filter): 6.5 liters (6.9 quarts)
Engine oil extraction/drainage: both are possible

ProCarManuals.com
Air filter replacement interval: 55,000 miles (90,000 km)
Fuel filter replacement interval: Lifetime
Spark plug replacement interval: 55,000 miles (90,000 km) or 6 years

(whichever comes first)
Timing gear and ancillary units drive
Replacement interval of the ribbed V-belt for Lifetime

all ancillary units except Roots blower:
Replacement interval of the ribbed V-belt for Roots 75,000 miles (120,000 km)
blower:
Tensioning systems of both ribbed V-belts: Lifetime
Timing gear chain replacement interval: Lifetime
Timing gear chain tensioning system: Lifetime
47

Service
Special tools
The tools below are for the 3.0l V6 TFSI engine with Roots blower
ProCarManuals.com
437_063
437_075
T40206/1 Gearbox support plate T40206/2 Mount for supercharger module
48

Glossary
Glossary
This glossary explains to you all terms written in italics or indicated by an asterisk (*) in this Self-Study
Program
Blow-by gases Light-off temperature
Blow-by gases are also known as leakage gases. The temperature at which the conversion rate of the
When the engine running, blow-by gases flow from catalytic converter is 50 %. The light-off temperature is
the combustion chamber and past the piston into the highly relevant to future and current US exhaust emission
crankcase. This is due to the high pressure inside the standards, as they require low emissions even when the
combustion chamber and the absolutely normal leakage engine is cold.
that occurs around the piston rings. Blow-by gases are
extracted from the crankcase by the PCV system and
re-introduced into the combustion chamber.
Cracked con-rod PWM signal

The abbreviation PWM stands for Pulse Width Modulated
This name derives from the manufacturing process. In signal. A PWM signal is a digital signal where one variable
this process the con-rod shaft and the big end bearing (e.g. electrical current) alternates between two values.
ProCarManuals.com
cover are separated from one another by breaking

(cracking) them at a pre-determined point. The advantage The length of the interval between this change-over varies
of this process is that the finished parts fit one another depending on activation level. In this way, it is possible to
perfectly. transmit digital signals.
EMC Split-pin design
This abbreviation stands for Electromagnetic Depending on engine type, the crank pin has an offset
Compatibility. It is defined as the ability of electrical (also referred to as split pin) due to the V angle or cylinder
and electronic equipment to operate effectively in close bank angle. This configuration is necessary to achieve a
proximity without causing mutual interference through uniform firing interval.
unwanted electrical or electromagnetic effects.
Hall sender Valve timing
The Hall sender (also known as Hall sensor or Hall probe) The term "valve timing" is used to describe the periods
utilises the Hall effect to measure magnetic fields and during which the valves of an engine are opened or
currents, and for position sensing. If a Hall sensor is closed. If the angular ranges of the valves are transferred
energised with electrical current and placed into a to a pie chart, the result will be the timing diagram of an
vertical magnetic field, it will supply an output voltage engine.
proportional to the product of the magnetic field strength
and the electrical current.
Helmholtz resonator Viscosity
A Helmholtz resonator is an acoustic resonator designed An important physical property of liquids is their viscosity.
to reduce intake noise. It consists of an air space with a Viscosity is temperature dependent and is a measure
narrow opening to the exterior. The Helmholtz resonator of how "thick" a liquid is at different temperatures. The
was named after the German physicist Hermann von viscosity of oils is specified as a viscosity index.
Helmholtz.
This index describes the flow behavior of an oil at
different temperatures.
49

Summary
From the glorious 1930s tradition of motor sport dominated by cars bearing the four-ring badge, the Roots blower is
now staging a comeback. The new 3.0l TFSI engine is powerful, extremely quick and ultra-efficient. It is also the new
top version in Audi's V6 engine range, and sets impressive benchmarks for fuel economy and clean emissions. The
engine is notable for its sporty throttle response, exceptional agility and "bite". It revs up to its 6,500 rpm maximum
with playful ease, achieving its rated output of 285 hp at just under 5,000 rpm.
All this has been achieved thanks to an array of refined high-tech features. The crankcase has been adapted to the
higher prevailing pressures, and all components have been systematically optimized for minimal friction. Both intake
camshafts can be adjusted through 42° of crankshaft angle. In the intake ports, tumble flaps induce a tumbling
movement in the incoming air to optimize mixture formation.
The improved fuel system with its new six-hole nozzles have a capability of up to three injections per stroke for future
applications. The engine's high compression ratio of 10.5:1 is also a major factor in enhancing efficiency. The direct
injection principle is once again the key, because the intensively swirled fuel cools the combustion chamber, reducing
the tendency to knock. Inside the Roots blower, two four-vane rotary pistons counter-rotate at a speed of up to 23,000
rpm, delivering 2204 lbs (1,000 kg) of air per hour and forcing it into the combustion chambers at a boost pressure of
up to 0.8 bar. Two water-to-air intercoolers integrated in the supercharger module enhance efficiency still further, and
much work went in to reducing the noise transmitted by the roots blower.
The new 3.0l TFSI engine will achieve an average fuel consumption of well under 23 MPG in virtually all Audi models
with longitudinal engines for which it has been earmarked. As with all Audi innovations, the engine fully embraces the
principle of "Vorsprung durch Technik".
ProCarManuals.com
50

Notes
ProCarManuals.com
51

Notes
ProCarManuals.com
52

Knowledge Assessment
An on-line Knowledge Assessment (exam) is available for this Self-Study Program.

The Knowledge Assessment may or may not be required for Certification.
You can find this Knowledge Assessment at:
www.accessaudi.com
From the accessaudi.com Homepage:

– Click on the “ACADEMY” Tab.
– Click on the “Academy Site” Link.
– Click on the “CRC Certification” Link.
ProCarManuals.com
For Assistance, please call:
Audi Academy
Certification Resource Center (CRC)
1-877-283-4562
(8:00 a.m. to 8:00 p.m. EST)
925803
ProCarManuals.com
All rights reserved.

Technical specifications
subject to change without
notice.
Audi of America, LLC

2200 Ferdinand Porsche Drive
Herndon, VA 20171

Audi V6 TSFI Engine 925803

Uploaded by

Copyright:

Available Formats

Audi V6 TSFI Engine 925803

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Audi V6 TSFI Engine 925803

Uploaded by

Copyright:

Available Formats

Service Training

Audi 3.0 V6 TFSI engine

Course Number 925803

©2008 Audi of America, LLC.

All rights reserved. All information contained in this manual is

stored in a retrieval system, or transmitted in any form or by

All requests for permission to copy and redistribute information

Always check Technical Bulletins and the latest electronic repair

Trademarks: All brand names and product names used in this

Exhaust Emission Treatment . . . . . . . . . . . . . . 38

The Self-Study Program is not a Repair Manual!

191651 Audi 3.0L Supercharged.indd Sec1:i 2/16/2009 11:12:30 AM

191651 Audi 3.0L Supercharged.indd Sec1:ii 2/16/2009 11:12:31 AM

191651 Audi 3.0L Supercharged.indd Sec2:1 2/16/2009 11:12:32 AM

Deletions from the 3.2L FSI engine:

– Audi valvelift system

Additional charge-air cooler

2nd belt drive

191651 Audi 3.0L Supercharged.indd Sec2:2 2/16/2009 11:12:33 AM

0 1000 2000 3000 4000 5000 6000 7000 8000

Engine code CAJA/CCAA

Engine type Six-cylinder V-engine

Max. power in hp (kW) 285 (213) at 4850 – 7000 rpm

Max. torque in lb-ft 310 at 2500 – 4850 rpm

Valves per cylinder 4

Compression ratio 10.5 : 1

Firing order 1–4–3–6–2–5

Engine weight 418 lbs (190 kg)

Engine management Simos 8

Mixture formation Direct injection FSI (homogeneous)

Exhaust emission standard EU V, ULEV II

Exhaust aftertreatment Cylinder-selective lambda control with one broadband pre-cat

CO2 emissions in g/km 228

191651 Audi 3.0L Supercharged.indd Sec2:3 2/16/2009 11:12:33 AM

Torque/power curves of the V6 FSI engine

Power output (hp)

0 1000 2000 3000 4000 5000 6000 7000 8000

3.0 TFSI engine

3.2 FSI engine

191651 Audi 3.0L Supercharged.indd Sec2:4 2/16/2009 11:12:33 AM

Speciﬁcations of the V6 engines on the Audi A6

Parameter 3.2l FSI 3.0l TFSI

Displacement in cm3 3123 2995

Bore in mm 84.5 84.5

Stroke/bore 1.10 1.05

Compression ratio 12.5 : 1 10.5 : 1

Cyl. bank offset in mm 18.5 18.5

Main bearing diameter 65 65

Big-end bearing diameter 56 56

Con-rod length in mm 154 153

Engine block height in mm 228 228

Max. power 250 at 6500 285 at 4800 – 7000

Max. torque in lb-ft at rpm 245 at 3250 310 at 2500 – 4850

Fuel in Octane 87/91 1) 87/91 1)

1) with reduced power output

0 – 62 mph (100 kph) S 7.1 6.3

Elasticity in speed D mph (kph) 50 - 75 (80 – 120) 50 - 75 (80 – 120)

Max. speed mph (kph) 155 (250) 2) 155 (250) 2)

rpm / gear 6350 / 5 4500 / 6

CO2 emissions g/km 259 228