VW Engine Technology 2006

VW Golf GT TDI

200 HP GTI engine now available in the Jetta

March 16, 2006 7:52 PM
Filed Under: German, Volkswagen

Press Release

In brief

Power train offensive: Maximum power with minimum consumption

Volkswagen continues its power train offensive. First: the new Golf GT with 125 kW / 170 PS strong TSI takes off this spring. Second: parallel to that, Volkswagen will be launching an also 170 PS strong TDI for the Golf GT and the Touran. Third: the Touran will also be available with a double charged TSI engine which in this case achieves 103 kW / 140 PS. Fourth: if you are looking for an alternative to gasoline and diesel, Touran is an option as well. Because in the future, Volkswagen will cut fuel costs in half with its natural gas powered Touran EcoFuel. Fifth: the new Jetta T-FSI presents itself absolutely economical but also very sporty. With the 147 kW / 200 PS strong turbo FSI from the Golf GTI it reaches a maximum speed of 235 km/h.

TDI, FSI, T-FSI and TSI: Victory march of direct fuel injection

Efficiency is fun: All new engines are extremely efficient, economical and sporty. Especially the double-charged TSI engines ring in a new power train era. Characteristics: maximum power with minimum consumption. And this with a system: TSI, FSI and Turbo FSI have long become synonyms for torque strong and economical Volkswagen engines. Whether its diesel or gasoline, they are all connected through a central technology: direct injection. This type of fuel supply carried out in different forms depending on the engine type started its career at Volkswagen in a turbo diesel. It is not a coincidence that TDI sounds like GTI – these sporty diesel were born 1993. After that Volkswagen expanded their spectrum of direct fuel injection to the gasoline engines with the fuel stratified injection. The first FSI engine debuted in 2000. In 2004 the Golf GTI followed and was the first turbo to be charged by gasoline direct injection which we have come to know as the turbo FSI. Now, two years later, the double charged direct fuel injection starts off again on a grand scale under the label TSI.

Torque strong twincharger (TSI) for Golf and Touran

Golf GT / 125 kW: worldwide the Golf GT is the first automobile with TSI on board. This “little brother” of the Golf GTI brings 125 kW / 170 PS power and 240 newton meters torque which is achieved with an average consumption of 7,2 liters. Starting from 0, the sporty Golf flies past the 100 km/h mark in only 7,9 seconds. And the maximum speed is reached at 220 km/h. The Golf GT is fueled with Super Plus (98 ROZ) whereas the TSI version can also be driven with unleaded Super (95 ROZ).

Touran TSI / 103 kW: Now Volkswagen introduces the Touran with a TSI feauring a higher comfort level. Its new aggregate is based on the Golf GT engine and in the most successful German van it turns out 103 kW / 140 PS (at 5,600 rpm). This engine also packs a punch. Because TSI stands for a new way of downsizing, for less cubic capacity, less fuel consumption, less emissions – but more power, more torque and more driving fun. The new TSI develops 220 newton meters torque at 1,500 rpm. It accelerates the Touran in 9,8 seconds to 100 km/h. This Volkswagen keeps up with today’s quick pace by reaching a maximum speed of 200 km/h. But with 7,4 liters average consumption the van’s engine which has a noticeably larger front surface than a Golf is very cost-effective. In the 103 kW strong Touran the TSI is generally satisfied with 95 ROZ (Super unleaded).

Strong turbo gasoline engine (T-FSI) for the Jetta

Jetta T-FSI / 147 kW: In its youngest generation, the Jetta has completely emancipated itself from the Golf. In the USA, the limousine is the best selling car of European manufacturers. In Europe the new Jetta convinces more than ever with an independent and exclusive design, an outstanding 527-liters trunk volume, a high-grade interior and a large engine spectrum. Powered by the 147 kW / 200 PS strong T-FSI, the Jetta turns out to be a true sports limousine. Starting from 0, the front-wheel drive blazes through the 100-km/h mark in only 7,5 seconds and reaches a maximum speed of 235 km/h. In contrast to that is an average consumption of merely 8,0 liters Super Plus every 100 kilometers. Ex factory, the Jetta 2,0 FSI with turbocharger segments its power via a manual six gear transmission. Optionally available: the DSG which works with a double transmission.

Strong Turbo diesel (TDI) for Golf and Touran

Golf GT TDI / 125 kW: As the strongest TDI power train of the series Golf, Touran and Passat, Volkswagen offers a completely newly developed 2.0 TDI with 125 kW / 170 PS (at 4,200 rpm). This four-valve TDI with piezo elements and standard diesel particle filter develops a maximum torque of 350 newton meters between 1,750 and 2,500 rpm. The strongest turbo diesel ever used in a Golf accelerates the best selling car in Europe in only 8,2 seconds to 100 km/h. The Golf GT TDI reaches its maximum speed at 220 km/h. The average consumption is extremely low: according to the norm 99/100/EG, 5.9 liters are a peak value for such an agile car. This GT is shifted via a manual six-gear transmission. Just like for the Golf GT TSI, the automatic double-clutch transmission DSG will be available optionally starting this summer.

Touran TDI / 125 kW: it turns the Golf GT into a sports car, the Touran into a “sports” van: the 125 kW / 170 PS strong 2,0 liters TDI with piezo technology. In the Touran as well the new TDI is the strongest diesel since the inception of the series. With this engine, the van storms to 100 km/h in only 9,0 seconds. With a maximum speed of 214 km/h it belongs to one of the fastest large capacity limousines on the market. But at the same time its economy also marks an optimum value: 6,5 liters in combined operation.

Economical natural gas power (EcoFuel) for the Touran

Touran EcoFuel: for the first time this summer, the Touran will be available as a natural gas vehicle. Its name: Touran EcoFuel. Performance 80 kW / 109 PS (at 4,500 rpm). The 180 km/h fast multi-talent can also be driven with gasoline. Laid out as a “quasi monovalent” natural gaas vehicle, the gasoline power serves primarily as a reserve and standby. Developed by Volkswagen Individual, the range of the Touran EcoFuel is approximately 310 kilometers when driven with natural gas – after that it’s on to gasoline or off to one of the roughly 650 German natural gas stations. Consumption of the Touran EcoFuel: just 5,8 kg for every 100 kilometers. In Germany a “natural gas kilometer” currently costs about half of a “gasoline kilometer”, in addition many power suppliers in Germany financially support the purchase of natural gas vehicles.


TSI Engines in Golf GT and Touran

Maximum strength, minimum consumption

In 2006, Volkswagen rings in a new era with its double-charged TSI engines. Characteristics: maximum strength with minimum consumption. And this with a system: TSI, FSI and Turbo FSI have long become synonyms for torque strong and economical VW engines. Whether its diesel or gasoline, they are all connected through a central technology: the direct injection. This type of fuel supply, carried out in different forms depending on the engines type, started its career at Volkswagen in a turbo diesel. It is not a coincidence that TDI sounds like GTI – these sporty VW diesel were born 1993 and with them the diesel engine advanced in Europe to a fast as well as economical automobile view of life. After that, Volkswagen expanded their spectrum of direct injection systems to the gasoline engines by way of the fuel stratified injection. The first FSI engine debuted in 2000. Following in 2004, the Golf GTI had the first turbocharged, gasoline direct injection engine, the turbo FSI. Now two years later and starting on a grand scale the double-charged gasoline direct injection: the TSI with turbo charger plus compressor.


TSI IN GOLF AND TOURAN

Golf GT TSI, the first twincharger: the Golf GT is the first automobile worldwide with a twincharged stratified injection on board. This “little brother” of the Golf GTI brings 125 kW / 170 PS power and 240 newton meters torque while the comsumption average is only 7,2 liters. Starting at 0 the sporty Golf f lies past the 100 km/h mark in only 7,9 seconds. And the maximum speed is reached at 220 km/h. The Golf GT comes standard with a six-gear transmission. On request this Volkswagen also comes with the technically unique double-gear shift transmission DSG. To bring out its full strength, the Golf GT is fueled with Super Plus (98 ROZ) but the TSI version can also be driven with Super unleaded (95 ROZ).

The technical base frame for this TSI is a 1,390 cm3 large four-cylinder, whose dynamic, thanks to twincharger technology, equals a 2,5 liters normally aspirated engine. As early as 1,750 rpm the TSI develops its maximum torque which consistently lies at 4,500 rpm. The gently starting and over many rotations consistent thrust – ignited by the compressor and then powered via turbo – is currently not offered in this form by any other automobile manufacturer.

Touran TSI, the comfortable twincharger: on its next TSI level, Volkswagen now introduces the Touran. The fundamental layout of its new TSI is based on the Golf GT engine; in the most successful German van it turns out 103 kW / 140 PS (at 5,600 rpm). This engine also packs a punch. Because TSI stands for a new way of downsizing, for less cubic capacity, less fuel consumption, less emissions – but more power, more torque and more driving fun.

Starting at 1,500 rpm, the new TSI develops 225 newton meters and holds this rate consitently up to 4,000 rpm. It accelerates the Touran TSI in 9,8 seconds to 100 km/h. The maximum speed is at 200 km/h. But with 7,4 liters average fuel consumption the engine in the van – its front surface noticeably larger than a Golf – is very cost effective. In the Touran, the TSI is generally satisfied with 95 ROZ, Super unleaded.

Ergo, with the second “twincharger”, Volkswagen consistently continued to further develop the gasoline direct injection in the directions of driving fun and effectiveness. Compared to the fast Golf GT, however, the main focus here was more towards a comfortable rather than sporty design. In this case this also means that the vehement engine power at low rotations allows for a “shift-lazy” driving style. Fact is that, looking at the technical data, the twincharger of the Touran exceeds the performance and torque characteristic of a 2.0 liters normally aspirated engine with clearly better values. And that, as mentioned, with significantly lower consumption.


TSI TECHNOLOGY

The baseline is the FSI, the conceptional role model is the TDI

103-kW and 125-kW-TSI are technical twins: the most effective way of consumption reduction is the so called “downsizing”. Due to the reduction of the cubic capacity and thus less friction loss a lower specific consumption is reached and therefore a better effectiveness. The way of the future is in the combination of compressor and turbo charger. The compressor compensates the acceleration weakness in lower speed ranges. Typical for turbo gasoline engines the turbo charger on the other hand fires up in higher rotation numbers. The combination of both chargers in full production series engines is unique in the world. The only option for the injection technique was the FSI technology which Volkswagen has already used in numerous model series. Through the experience with the injection technique the engine developers have gathered in the past years it became clear that FSI augments the two charging techniques ideally and enables an unexpected efficiency improvement.

The base power train is called EA 111: the decision for the base power train fell on the FSI from the engine series EA 111. The 1,4 liters engine is a four-valve four-cylinder with 1,390 cm3 cubic capacity, a cylinder distance of 82 millimeters and a bore/stroke ratio of 76,5 to 75,6 millimeters. main focus in the development of the TSI was on the construction of a new, highly resilient cylinder crankcase made of gray cast iron to permanently manage the top pressures of up to 130 bar. Above that, the order of the charge aggregates as well as the compressor power train were at the constructive center of the development.

Modified injection technique: with the TSI motors a multi-hole high-pressure injection valve with six fuel exit openings are being used for the first time. Just like the FSI normally aspirated engine, the injector is located on the entry side between entry canal and cylinder head gasket level. The amount of the fuel to be injected – over the spectrum from idle speed to high rotation numbers, while giving off the maximum performance – requires a high spread in the f low through amount of the injectors. To display this large area in the flow through amount, the maximum injection pressure was increased to 150 bar. Furthermore, it was only possible through FSI technology to achieve a compression ration of 10:1, which is high for charged motors.

The compressor applies pressure from the bottom: to increase the torque at low rotation numbers, the engine developers chose a compressor powered mechanically via a belt. It is a compressor based on the Roots principle. A specialty of the compressor used is an internal translation level which is pre switched to the synchronizations gear wheel couple and which allows high compressor performance also at low engine speed.

The turbo charger switches on via the top: at heightened engine speed an additional emission turbo charger (with wastegate regulation) comes on. Thereby compressor and emission turbo charger are switched in sequence. The compressor is activated via a magnetic clutch, which is integrated in a module in the water pump. A regulation flap ensures that the, fresh air necessary for the operations point necessary, fresh air reaches the emission turbo charger or the compressor. In pure emission turbo charger operation the regulation flap is open. After that the air then takes the way familiar from the conventional turbo enginess via the front intercooler and the choke f lap in the controlled intake manifold.

In the frame of development a particular challenge was the best possible layout of the interplay of both of the chargers lined up in a row. Because, only if the compressor and the emission turbo charger augment each other optimally the power train will achieve the desired smooth torque course. And this over a very wide range of speed and in combination with a never before realized efficiency improvement.

It’s the combination of compressor and Turbo: the maximum boost pressure of the twincharger is ca. 2,5 bar at 1,500 rpm. To keep the required boost pressure, the compressor is only needed up to 2,400 rpm. The emission turbo charger is laid out for an optimal efficiency in the upper performance level and also provides sufficient super charge pressure at medium revs. In dynamic drive operation at lower revs, this is not sufficient for the required elasticity goals. The TSI solves this problem as the worldwide only engine by switching on the compressor. Result: a spontaneous boost pressure. Through the reciprocal augmentation of both systems, the turbo hole is considered suspended. No later than at a number of revolutions of 3,500 rpm, the compressor is no longer needed and the emission turbo charger always provides the desired boost pressure, even dynamically when transitioning from thrust to fully loaded operation.


T-FSI in the Jetta

In its youngest generation, the Jetta has completely emancipated itself from the Golf. In the USA the limousine is the most sold car by European manufacturers. In Europe the new Jetta convinces more than ever with an independent and exclusive design, outstanding 527-liters trunk volume, a high end interior and large engine spectrum. New in the Jetta program: the 147 kW / 200 PS strong T-FSI. This engine was used for the first time in the current Golf GTI. Then it debuted with the Passat. This engine now drives the Jetta which has been sold more than 6,6 million times, to highest performances.

T-FSI WITH 147 KW IN THE JETTA

With the engine of the Golf GTI, the Jetta becomes a 235 km/h fast sports limousine

Powered by the gasoline T-FSI, the Jetta turns out to be a veritable sports limousine. Starting from 0, the front wheel drive blazes through the 100-km/h mark, in only 7,5 seconds and reaches a maximum speed of 235 km/h. In contrast to that there is an average fuel consumption of merely 8,0 liters Super Plus every 100 kilometers. The with 10.3:1 compressed four-cylinder thereby combines the advantages of a homogenous direct injection with the powerful advantages of the turbo charge Result: an outstanding torque course, excellent responsiveness and a lot of driving fun. From the factory, the Jetta 2.0 FSI with turbocharger segments its power via a manual six-gear transmission. The DSG, which works with a double transmission, is available optionally.

T-FSI-TECHNOLOGY

The Turbo-FSI belongs to the engine series EA-113. In this version free of extra charge, the four-cylinder direct injection produces 110 kW / 150 PS

Base engine of the Jetta T-FSI: constructively, the strongest Jetta engine goes back to the 110 kW / 150 PS strong 2.0 FSI (model series EA-113, 88 millimeter cylinder distance). The main goal in developing the charged FSI with homogeneous combustion process was a significant increase in performance with consistently low consumption and emission rates. Thanks to the core technologies direct injection, emission turbo charger, continuous inlet camshaft adjustment and variable synthetics controlled intake manifold as well as other inner engine measures a very high efficiency could be realized. Like all Jetta engines, this T-FSI also complies with the EU4-Norm.


TDI Engines in Golf GT and Touran

As the strongest TDI power train of the series Golf, Touran and Passat, Volkswagen offers a completely newly developed 2.0 TDI with 125 kW / 170 PS (at 4,200 rpm). This four-valve TDI with piezo technologie elements and standard diesel particulate filter, develops a maximum torque of 350 newton meters between 1,750 and 2,500 rpm.


TDI WITH 125 KW IN GOLF AND TOURAN

Golf GT TDI with 125 kW: the strongest turbo diesel ever fitted in a Golf accelerates the best selling car in Europe in only 8,2 seconds to 100 km/h. The Golf GT TDI reaches a maximum speed at 220 km/h. The average consumption is extremely low. According to the norm 99/100/EG, 5,9 liters are a top rate for such an agile car. If you put economy in the forefront of your driving style you can also reach rates under 5,0 liters. This GT is shifted via a manual six-gear transmission. Just like for the Golf GT TSI, the automatic double-clutch transmission DSG will be available optionally.

Touran TDI with 125 kW: it turns the Golf GT into a sports car, the Touran into a sports van: the 125 kW / 170 PS strong 2.0-liters TDI with piezo technology. In the Touran as well, the new TDI is the strongest diesel since the inception of the series. With this engine, the van storms to 100 km/h in only 9,0 seconds. With a maximum speed of 214 km/h it is one of the fastest large capacity limousines on the market. But at the same time its efficiency also marks an optimum rate: 6,5 liters in combined operation.


TDI TECHNOLOGY

Higher performance, more comfort and lower consumption through newly developed piezo elements

High specific performance: other technical data: an injection pressure of up to 2,200 bar. With 62,5 kW/1 the specific performance of the 2.0 TDI marks a top rate. Even though the new TDI shows performance and comfort characteristics that come close to the level of a five- or six-cylinder turbo diesel, the consumption and emission rates are in the low four-cylinder range.

Piezo-Technology: the direct injection reaches high performance and comfort rates while at the same time keeping consumption low – this is owed to the newly developed piezo elements. They enable a chain of positive characteristics. First: a very high injection pressure and therefore low emissions and an optimum specific performance. Second: an ideal hyrdraulic efficiency as the result of a very small high-pressure volume. Third: an ideal course of the injection rate. Fourth: pre injection is very precise only requiring a small amount and operating on a low pressure level. Fifth: f lexibly steerable pre- and post-injection amounts as well as intervals. Sixth: low injection noise.


EcoFuel in the Touran - Natural gas

For the first time this summer the new EcoFuel Version will be available as a natural gas vehicle. It’s name: Touran EcoFuel. Performance: 80 kW / 109 PS (at 4,500 rpm). The multi-talent can also be driven with gasoline. Laid out as a “quasi monovalent” natural gas vehicle, the gasoline power serves primarily as a reserve and standby. In natural gas only operation the range of the Touran EcoFuel is approximately 310 kilometres, after that it’s on to gasoline or off to one of the roughly 650 German natural gas stations. Touran EcoFuel’s consumption is a mere 5,8 kg for every 100 kilometers. In Germany a “natural gas kilometer” currently costs about half of a “gasoline kilometer”; in addition, many power suppliers and communities financially support the purchase of natural gas vehicles.

No restrictions in the use of space: the Touran EcoFuel was developed by Volkswagen Individual. The four natural gas tanks are integrated as space-saving under f loor solutions (18 kg) and therefore do not impede the variability or the interior and loading volume respectively. So the option of equipping the Touran with seven seats is left untouched. With this interesting vehicle concept as well as with the parallel developed Caddy EcoFuel, Volkswagen is reacting to the clearly increased demand for vehicles with this environmentally friendly and economical power technology.

Clearly less emissions: in gasoline mode, the 13,5:1 compressed engine of the new Touran EcoFuel develops a maximum torque of 160 newton meters (at 3,500 rpm). The 1,984 cm3 large four-cylinder enables a maximum speed of 180 km/h. After 13,5 seconds 100 km/h are reached. As opposed to the comparable Otto engine, the use of the EcoFuel power train in natural gas mode produces 80 percent less carbon monoxide, also 80 percent less nitrogen oxide, 73 percent less methan containing hydrocarbons and 23 percent less carbon dioxide.


ECOFUEL-TECHNOLOGY

Natural gas-powered vehicles like the new Touran EcoFuel are just as safe as automobiles with pure diesel and gasoline

Highest safety: the steel tanks of the Touran EcoFuel were tested in intensive crash test programs. When in gasoline mode, electronic lock valves automatically interrupt the fuel supply in case the motor stops running as well as during a crash. Apart from the electro-mechanical lock valves, the bottle valves also have an integrated thermal security as well as a f low through limiter which prevents an uncontrolled drop in pressure in case of pipe damage. The first of the four underfloor gas bottles also has an integrated non-return valve preventing the ref lux of the gases from the bottle. So there is no safety relevant difference to a pure diesel or gasoline vehicle.

Free choice: The natural gas power Touran is not connected to any equipment version. So EcoFuel is available in combination with the versions Conceptline, Trendline and Highline. Even the special model Goal can be ordered as Touran EcoFuel.