Volkswagen 4.2l V8 5V Manual
Service Training
Self-study programme 341
The 4.2l V8 5V engine
Design and function
2
The self-study programme portrays the design and
function of new developments!
The contents will not be updated.
For current testing, adjustment and repair
instructions, please refer to the customer service
literature intended for this purpose.
The 4.2l V8 5V engine will be launched in two
variants:
- In the Touareg, with an output of 228kW
- In the Phaeton, with an output of 246kW
S341_001
NEW Attention
Note
Besides their differences in output, the two engines
will differ primarily as a result of the modifications
necessary for the Touareg's off-road capability.
3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Technical features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine mechanical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Ancillary unit drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Intake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Crankshaft drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Camshaft adjustment system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Cooling circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Engine management system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Functional diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Test your knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
At a glance
4
Introduction
Technical features
Development of the two V8 engines focussed
primarily on the following development objectives:
- Compliance with future emission regulations
- Reducing fuel consumption
- Increasing torque and output
- Reducing the weight of the engine
- Improving operating comfort
- Off-road capability in the case of the Touareg
Engine mechanical system
- V8 cylinder block
- Cylinder head with 5-valve technology and
roller rocker fingers
- Inlet camshaft adjustment
- Two-stage variable intake manifold in the Phaeton
- Three-stage variable intake manifold in the
Touareg
- Oil filter module
- Twin-branch intake system
Engine management system
- Bosch Motronic ME 7.1.1
- Sequential fuel injection
- Electronic ignition
- Two hot film air mass sensors
- Secondary air system
- One knock sensor per cylinder bank
- Two primary catalytic converter broadband
lambda probes
- Two transient lambda probes after the catalytic
converter
S341_011
5
Technical data
Engine code AXQ (Touareg) BGH (Phaeton)
Design type 8-cylinder V engine with a
90° V angle
Displacement [cm3]4172
Bore [mm] 84.5
Stroke [mm] 93
Valves per cylinder 5
Compression ratio 11:1
Maximum output 228kW at
6200 rpm
246kW at
6500 rpm
Maximum torque 410Nm at
3000 to 4000 rpm
430Nm at
3500 rpm
Engine management system Bosch ME 7.1.1
Fuel RON 98, RON 95 with reduced output
Exhaust gas aftertreatment 4 catalytic converters, 4 lambda probes
secondary air system
Exhaust emission standard EU 4
Torque and output graph 246kWTorque and output graph 228kW
To rq u e [ Nm ]
Output [kW]
500
0
50
100
150
200
250
400
450
250
0
25
50
75
100
125
175
200
225
2000 4000 6000
Engine speed [rpm]
300
350
150
Tor que [ Nm ]
Output [kW]
500
0
50
100
150
200
250
400
450
250
0
25
50
75
100
125
175
200
225
2000 4000 6000
Engine speed [rpm]
S341_012
300
350
150
S341_010
6
Engine mechanical system
Ancillary unit drive
The ancillary units are driven by means of a 7-groove poly-V belt. The ancillary unit drive fitted in the Phaeton
differs from that in the Touareg due to an additional guide roller and the different layout of certain ancillary units.
Touareg
In the Touareg, the alternator and air conditioning compressor are installed in a higher location than in the
Phaeton. As a result of this, the Touareg is capable of fording water up to a depth of 500mm.
Phaeton
An additional guide roller is required in the
Phaeton because the alternator is fitted in a lower
position than in the Touareg. This is due firstly to
the installation space conditions in the Phaeton
and secondly to the Touareg's necessary fording
capability.
Belt pulley for
air conditioner compressor
Belt pulley for
vane pump/power steering
Guide roller
Belt pulley for
vibration damper
Poly V-belt
7-groove
Belt pulley for
alternator
Tensioning element
with
belt tensioner
S341_087
S341_088
Guide roller
Toothed belt guard
S341_089
Notch on vibration damper
and mark on toothed belt
guard
Belt pulley for
vane pump/power steering
Belt pulley for
air conditioner compressor
7
Toothed belt drive
Both exhaust camshafts and the coolant pump are driven by the crankshaft in the toothed belt drive. The toothed
belt is tensioned via a belt tensioner and a hydraulic tensioning element.
Exhaust camshaft sprocket
cylinder bank 2
Exhaust camshaft sprocket
cylinder bank 1
Coolant pump
driving gear
Belt tensioner
Crankshaft
toothed belt
sprocket
Hydraulic toothed belt tensioner
guide roller
S341_091b
When renewing or replacing the toothed belt, the crankshaft must be set to TDC cylinder No. 5. To
achieve this, the notch on the vibration damper must align with the mark on the toothed belt guard, and
the locating plates' two large bores must face each other inwards. ELSA provides information on the
detailed procedures for removing and installing the toothed belt.
Locating plates with bores
S341_091a
S341_090
Hydraulic
toothed belt tensioner
8
Engine mechanical system
Intake system
The fresh air intake system has a twin-branch design to reduce pressure losses. Both intake tracts are brought
together at the intake manifold upstream of the throttle valve module.
A hot film air mass meter per intake tract and an intake air temperature sender in the air mass meter G70 are used
to determine the intaken quantity of fresh air.
Intake manifold
The intake manifold is comprised of four bolted and
bonded magnesium components.
The Touareg is fitted with a three-stage variable
intake manifold and the Phaeton with a two-stage
variable intake manifold. In comparison with the
three-stage version, the two-stage design allows
intake tracts with high-volume cross-sections to be
implemented. This leads to an increase in engine
output.
In the event of repair, the entire intake
manifold has to be renewed, as the
bonded surfaces can no longer be sealed.
S341_097
Air mass meter G70
Intake air temperature sender G42
cylinder bank 1
Throttle valve module J336
Air mass meter 2 G246
cylinder bank 2
S341_098
9
Variable intake manifold
The figure shows the two-stage variable intake
manifold fitted in the Phaeton.
It is comprised of the variable intake manifold
change-over valve, two vacuum units with adjusting
levers, a non-return valve, the hoses and the vacuum
reservoir in the front area of the vehicle.
Change-over
- From the torque position (long intake tract) to the
output position (short intake tract) at 4600 rpm.
- From the output position to the torque position at
4440 rpm.
Torque position
Long intake ports are used in the torque position. This
leads to a high flow speed, extensive turbulence in the
cylinder, very good fuel/air mixing andrapid
combustion. In turn, this results in the development of
high torque.
Output position
Short intake ports with the largest possible cross-
sections are used in the output position. This results in
high air throughput with good charging. In turn, this
leads to high power output.
S341_015
S341_013
S341_014
Variable intake manifold
change-over valve N156
Vac uum u ni ts
Adjusting levers
Non-return valve
10
Engine mechanical system
Cylinder block
Cylinder head gasket
The cylinder head gasket is a triple-layer metal
gasket, whose outer layers are covered with a
coating.
Advantages:
- Low settling behaviour
-Longservicelife
The aluminium cylinder block has a 90° V
angle and is manufactured from an
aluminium alloy. The pistons run directly on
the aluminium alloy's silicon crystals. As a
result of this, no separate cylinder liners are
required. The gap between cylinders is
90mm.
S341_080
Coating
Metal layers S341_016
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