大眾奧迪W12 6.0L發(fā)動機(jī)技術(shù)培訓(xùn)課件.ppt

1、,1,12,2,3,5,8,10,6,7,11,4,9,Seminar content Engine design Technical data W configuration Crank drive and cylinder heads Engine lubrication Engine cooling system Engine control Alternator Intake and exhaust systems Secondary air system and EGR Exhaust system,Practical operations Engine assembly Servi

2、ce concept Oil level check Generating readiness code Final control diagnosis,Technical data,Engine code:AZCConfiguration: W-engine with aV-angle of 15 and abank angle of 72Cubic capacity:5998 cm3Max. output:309 kW (420 PS)at 6000 rpmSpec. output:51.5 kW/l70.0 PS/lMax. torque:550 Nmat 3500-4750 rpmSp

3、ec. torque:91.7 Nm/lBore:84.0 mmStroke:90.268 mmCompression:10.75 : 1,Fuel: unleaded Euro Super 95 RON unleaded Super Plus 98 RON*Ignition sequence: 1-12-5-8-3-10-6-7-2-11-4-9Ignition interval:60 crankshaftEngine management:Motronic ME 7.1.1Emission standard:EU 4Service interval:LongLifemax. 30,000

4、km ormax. 2 years,Output kW,Engine speed rpm,Torque Nm,Audi A8 L 6.0 quattro,Permissible total weight (kg)2530 Permissible front axle load (kg)1380 Curb weight (kg) approx. 2050 Permissible rear axle load (kg)1190 Wheel base (mm)3010 Luggage compartment (litres)525 Power transmissionquattro, five-st

5、age automatic Acceleration (s)0-80 km/h4.3 0-100 km/h5.8 Maximum speed (km/h)250 Fuel tank (litres.)approx. 92 Windscreen washer reservoir (litres.)approx. 4 with headlight washer systemapprox. 7.0 Engine oil Change quantity with filter change10.5,Features of the W12-6.0 l. are: - 12 cylinder petrol

6、 engine in W configuration - engine block and cylinder heads made from aluminium - oil supply by means of dry-sump lubrication - double overhead camshafts with 4 valves per cylinder, actuated by means of roller rocker fingers - infinitely variable camshaft timing control for inlet and exhaust camsha

7、fts - 6 catalytic converters - 8 lambda probes for monitoring catalytic converters and control of mixture formation,Engine mechanical components,Cylinder block / crankcase,Two Vs equal: With a length of 513mm and a width of 710mm, the dimensions of the W12 engine are as compact as those of a V8 engi

8、ne. This forms the basis for a superior drive concept with respect to performance, smooth running and 4-wheel drive.,In-line engine,V-engine,VR-engine(V-engine with narrow V-angle),VR-engine,VR-engine,W-engine,A- Split intake manifold (right intake pipes for left cylinder bank and vice versa) B- Cyl

9、inder head cover C- Aluminium cylinder head with camshafts, CS adjusters and valves D- Aluminium cylinder block without additional cylinder liners,E- Bearing cross piece with cast-in bearing blocks made from cast iron F- Upper section of sump G- Upper section of sump with oil pump and distribution d

10、ucts, oil filter and oil cooler outlet,Cylinder block / crankcase,Cylinder bank 1,Cylinder bank 2,Bearing cross piece,In order to fulfil the stringent acoustic requirements, it is necessary to achieve constant bearing clearance throughout the entire operating temperature range. Thus, the main bearin

11、g blocks of nodular cast iron are cast into the rigidly constructed aluminium bearing cross piece, to form a positive fit. Each of the main bearings (17 mm in width) is secured by 4 stretch bolts with M8 thread.,Bearing cross piece (aluminium),Main bearing web (cast iron),Connecting web,The fanned a

12、rrangement of the cylinder bores in conjunction with the V-angle of 15 and the cylinder bank angle of 72, results in an extremely compact and torsionally rigid cylinder block.,The cylinder axes are offset with respect to the axis of rotation of the crankshaft in order to prevent overlap near the BDC

13、 position. The offset arrangement of the cylinders makes constructional demands on the - crank drive - pistons - valve gear The offset dimensions are: - uneven cylinders 1-3-5-7-9-11 - 12.5mm - even cylinders 2-4-6-8-10-12 + 12.5mm,Engine mechanical components,The compact, short crankshaft design fe

14、atures seven main bearings. Two conrods are mounted between each adjacent pair of main bearing shells. The V-angle of 15 and the cylinder bank angle of 72 result in an extremely compact design. The width of the conrods (13 mm) and the associated bearings (12 mm) is extremely low.,Crank drive,Pistons

15、 two for each cylinder head. These are connected to two catalytic converters (on each side) with front pipes. For monitoring purposes, one pre and one post-catalytic converter probe are fitted for each catalytic converter. In order to remove the primary and main catalytic converters and the intermed

16、iate pipes, the engine must first be removed. The exhaust system, up to the main catalytic converters, is pre-installed before engine installation and is aligned in the removed condition by means of numerous measurements. See Workshop Manual. The controlled exhaust flap is located in the front part

17、of the right tailpipe.,Primary catalytic converter,cylinders 7-9,Primary catalytic converter,cylinders 10-12,X-pipe connection,Rear silencer,Exhaust flap,Noise-optimisedtwin-scroll tailpipe,Centre silencer,Main catalytic converters (3-way),Primary catalytic converter,cylinders 4-6,Primary catalyic c

18、onverter, cylinders 1-3,The purpose of the exhaust flap, which is installed in the right tailpipe of the rear silencer, is to permit conformance to statutory noise legislation during idling and in the lower engine speed range. If a vacuum is present at the vacuum unit, the exhaust flap is closed. In

19、 the absence of vacuum, the exhaust flap is held open by spring pressure. This method of actuation has been chosen to protect the rear silencer against possible overheating in the event of a system failure. The exhaust flap valve N321 is located on the left side of the luggage compartment, below the

20、 CD changer and is activated by engine control unit 1.,Exhaust flap,Diaphragm valves for oil reservoir venting,Cylinder bank 2,Cylinder head vent pipe,Crankcase and oil pump vent pipe,Oil reservoir,Oil dipstick,Baffle separator,Oil reservoir vent hose,Cylinder bank 1,Engine ventingSystem overview,Oi

21、l reservoir vent pipe,Oil return to reservoir,Vent pipe,*3 Slave makes CAN data available to master *2 Master makes CAN data available to slave ECU *1 Additional information in master / slave message,Engine control unit 1(master control unit) Intake air temperature Brake light switch1 Brake pedal sw

22、itch Throttle valve angle Electronic throttle warning lamp info. Driver-specified torque Fault status1 Accelerator pedal position1 CCS switch position CCS specified speed Altitude information Switch off compressor Compressor ON/OFF (feedback from bi-directional interface) Fuel consumption Coolant te

23、mperature1 Idling recognition Engine shut-off position2 Engine speed ACTUAL engine torques Emergency operation programmes (information via self- diagnosis) Oil temperature protection from GOB Vmax limitation active2 Immobiliser,Engine control unit 2(slave control unit) Request fault lamp EPC3 Reques

24、t fault lamp OBD3 Misfire detection3 Fault status3 Oil temperature (from GOB)3 Immobiliser3,Gearbox control unit - Torque gradient limitation (converter/gearbox protection)- Release adaption idle-charge compensation- Switch off compressor- Specified idle speed- Current gear / target gear- SPECIFIED

25、engine torque- Emergency operation programmes (information via self-diagnosis)- Gear change active/not active- Selector lever postion- Converter clutch status,ESP / ABS control unit- TCS requirement- SPECIFIED TCS engaging torque- Brake pedal status- EPS engaging- OTL requirement- OTL engaging torqu

26、e,Dash panel insert- Self diagnosis information- Driving speed- Coolant temperature- Immobiliser (from master and slave control units),Steering angle sensor- Steering angle (is used for pre-control of the idle control and for torque calculation based on power requirement of power steering),Can drive

27、 High,Can drive Low,Service schedules Telematics: Renew emergency backup battery,Service schedule - 48 months In accordance with additional work, the emergency backup battery must be changed every 48 months. Important: Activate the service mode of the telematics control unit before disconnecting the

28、 battery. Handset entry: *#4610# To quit service mode: Press Navi button once Following connection, the basic setting described in the Owners Manual must be performed.,Observe preconditions Ignition ON Address word 11 ECU II 020504060 DKADP OK06 Address word 01 ECU I 02 05 04 060 DKADP OK Start engi

29、ne, run engine to operating temperature. Generate readiness code. Address word 01 04 Insert VAG 1788/10 2000 rpm030 Probe status (control active) Field 1 and 3111 Field 2 and 4110,Lambda probe ageing, pre-cat.2000 rpm 034Bank 1cyl. 1, 2, 3system OK 035Bank 2cyl. 4, 5, 6system OK Lambda control diagn

30、osis2000 rpm 037Bank 1cyl. 1, 2, 3system OK 038Bank 2cyl. 4, 5, 6system OK Lambda probes exchanged, post-cat.2000 rpm 039system OK Lambda probe ageing, post-cat.2000 rpm 043Bank 1cyl. 1, 2, 3system OK 044Bank 2cyl. 4, 5, 6system OK Catalytic converter diagnosis2000 rpm 046Bank 1cyl. 1, 2, 3cat. B1 O

31、K 047Bank 2cyl. 4, 5, 6cat. B1 OK Tank breather valve diagnosisidling 070TBV OK Secondary air system diagnosisidling 077system OK,Address word 011 04 Insert VAG 1788/10 2000 rpm030 Probe status (control active) Field 1 and 3111 Field 2 and 4110 Generate readiness code,Lambda probe ageing, pre-cat.20

32、00 rpm 034Bank 1cyl. 1, 2, 3system OK 035Bank 2cyl. 4, 5, 6system OK Lambda control diagnosis2000 rpm 037Bank 1cyl. 1, 2, 3system OK 038Bank 2cyl. 4, 5, 6system OK Lambda probes exchanged, post-cat.2000 rpm 039system OK Lambda probe ageing, post-cat.2000 rpm 043Bank 1cyl. 1, 2, 3system OK 044Bank 2c

33、yl. 4, 5, 6system OK Catalytic converter diagnosis2000 rpm 046Bank 1cyl. 1, 2, 3cat. B1 OK 047Bank 2cyl. 4, 5, 6cat. B1 OK Tank breather valve diagnosisidling 070TBV OK Secondary air system diagnosisrev engine 077system OK,Service schedules Delivery ServiceLongLife Service,ELSAELSA Audi A8 as of cha

34、ssis number 4DYN 00181 Maintenance tableMaintenance table LongLife engine oil specification VW 50301 Petrol / turbo petrol engines (6.0l - W12 engine) Emergency: 0.5l top-up quantity VW 500 00 / 501 01 / 502 00,Service schedules Delivery form,ItemWork schedule Page,Service schedules Delivery form,Se

35、rvice schedules Delivery form,See CD ROM: A00.5181.04.00 A00.5181.05.00 A00.5181.06.00,Service schedules Delivery form,Service schedules LongLife form,ItemWork schedule Page,Service schedules LongLife form,Service schedules LongLife form,Service schedules LongLife form,Service schedules LongLife for

36、m,Service schedules Reset service interval display - LongLife Service,VAS 5051 Sequence: 1Address word 17dash panel insert 2Press arrow key 3Select adaption 10 4Enter 02 at number block 5Position indicator on display to left until 0 is displayed 6Save key 7Transfer key 8End of output with skip key,V

37、AS 5051Vehicle Diagnosis, Testing and Information SystemVersion -D- /V05.00 02/04/98,Service schedules Check oil grade coding,VAS 5051 Sequence: 1Address word 17dash panel insert 2Press arrow key 3Select adaption 10 4Enter adaption channel 45 oil grade 5Move position indicator to adaption value 2 6P

38、ress save key 7Press display transfer key,Service schedules Reset time until next service,VAS 5051 Sequence: 8Press display arrow key 9Select adaption (10) 10Enter adaption channel 44 (time) 11Confirm with Q key 12Move position indicator to adaption value 730 13Press save key 14Press display transfe

39、r key 15Press display arrow key,Service schedules Maximum mileage until next service,VAS 5051 Sequence: 16Select adaption (10) 17Enter adaption channel 43 (mileage) 18Confirm with Q key 19Move position indicator to adaption value 30 20Press save key 21Press display transfer key 22Press display arrow

40、 key,Service schedules Maximum mileage until next service,VAS 5051 Sequence: 23Select adaption (10) 24Enter adaption channel 42 (mileage) 25Confirm with Q key 26Move position indicator to adaption value 15 27Press save key 28Press display transfer key 29Press display skip key 30Press display end key

41、,Service schedules Replace spark plugs,Tightening torque ComponentNm Spark plugs30 Intake pipe, side part22 Connector bracket8 Special tool 3122 B,Service schedules Replace spark plugs,Note: When removing the side part of the intake pipe, it must be ensured that the threaded sleeve for bolt 1 is secured against falling out.,Service schedules Oil change,Dry-sump lubrication The oil must be changed via drain plugs 1 / 2 / 3 and cannot be extracted by suction. Tightening torqueNm Oil filter cover25 Oil drain plug on oil filter housing10 Oil drain plug on engine55 Oil drain plu