Audi CAYC Specifications
| Engine Model: Audi CAYC |
| Engine Type: 4-cycle 4-cylinder DOHC 16-valve turbocharged liquid-cooled diesel |
| Total Displacement: 97.5 cu.in (1.59 L) |
| Rated Engine Power: 104 Hp (77 kW) at 4400 rpm |
| Fuel System Type: Common rail direct injection |
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The Audi CAYC is a 1.6-liter, 4-cylinder common rail
diesel engine from the EA189 family. Produced roughly between 2009 and 2015, it
replaced the older 1.9 TDI "Pumpe Duse" engines and is widely recognized for its
high fuel efficiency and Euro 5 emissions compliance. This power unit represents
a shift towards high-pressure direct injection with piezoelectric injectors,
optimizing combustion for reduced particulate matter and CO2 output.
The engine’s compact architecture and lightweight aluminum construction
contribute to improved vehicle dynamics and lower front-end weight. Its design
integrates a variable geometry turbocharger (VTG) to deliver a broad torque
plateau, ensuring drivability across a wide rpm range.
The CAYC is fundamentally engineered for longevity, though its sophisticated
emissions control systems, including a diesel particulate filter (DPF) and
high-pressure exhaust gas recirculation, require strict adherence to low-ash
engine oil specifications. This engine became a cornerstone of the Volkswagen
Group’s diesel lineup during its production run, powering a wide array of
compact and subcompact models.
Engine Code: CAYC
Displacement: 1598 cc (97.5 cu.in)
Configuration: Inline 4-cylinder
Valvetrain: DOHC, 4 valves per cylinder (16 total)
Bore x Stroke: 79.5 mm x 80.5 mm (3.13 in x 3.17 in)
Compression Ratio: 16.5:1
Induction: Turbocharger with VTG (Variable Turbo Geometry) and Intercooler
Fuel System: Common Rail Direct Injection
Camshaft Drive: Timing Belt (Toothed Belt)
Max Power Output: 77 kW (105 PS / 104 hp) at 4,400 rpm
Max Torque: 250 Nm (184 lb-ft) at 1,500-2,500 rpm
Acceleration (0-100 km/h): 10.7-11.4 seconds (model dependent)
Top Speed: 194 km/h (121 mph)
Emission Standard: Euro 5
Engine Oil Capacity: 4.3 liters (4.5 US qt) service fill
Oil Specification: VW 507 00 (5W-30 fully synthetic) mandatory due to DPF
Fuel Requirement: Diesel
Timing Belt Interval: Official: 210,000 km (130,000 miles). Replacement every 5
years or 100,000-120,000 miles to prevent unexpected failure.
The cylinder block is constructed from gray cast iron,
a material chosen for its acoustic damping properties and structural rigidity
under high combustion pressures inherent to diesel operation. The open-deck
design facilitates efficient cooling around the upper cylinder region. The block
houses the crankshaft in five main bearings, each supported by robust bearing
caps.
Deep-skirt walls extend below the crankshaft centerline, enhancing overall block
stiffness and reducing vibration. Cylinder bores are finished with a plateau
honing process to optimize oil retention for the piston rings, promoting
effective sealing from the outset of the engine’s service life. The block
incorporates integrated oil galleries that supply pressurized oil to the
crankshaft, connecting rods, and the vacuum pump mounted on the rear.
The cylinder head is manufactured from aluminum alloy
to reduce overall engine weight and improve thermal conductivity. It utilizes a
DOHC (Dual Overhead Camshaft) configuration, with the camshafts driven by a
toothed timing belt. Each of the four cylinders features four valves - two
intake and two exhaust - arranged in a cross-flow pattern to optimize volumetric
efficiency. The valves are actuated via low-friction roller finger followers.
Hydraulic valve lifters are integrated to maintain zero valve clearance
throughout the engine’s operating life, eliminating the need for manual
adjustments. The exhaust valves are sodium-filled to enhance heat dissipation, a
critical feature given the high exhaust gas temperatures generated by the
turbocharged diesel cycle. The cylinder head gasket is a multi-layer steel (MLS)
design, providing a durable seal against the cast iron block.
The fuel system is a common rail direct injection setup
operating at pressures up to 1,600 bar (23,206 psi). A high-pressure fuel pump,
driven by a triple-lobe cam on the vacuum pump assembly, draws fuel from the
tank and delivers it to the common rail accumulator. The system’s defining
feature is the use of piezoelectric injectors. These injectors offer
exceptionally fast response times and precise control over multiple injection
events per combustion cycle - such as pilot, main, and post-injections.
This precision enables quieter engine operation, reduced emissions, and
optimized fuel consumption. The post-injection phases are particularly crucial
for elevating exhaust gas temperatures to initiate DPF regeneration. The fuel
system is highly sensitive to contamination; strict adherence to fuel filtration
and the use of high-quality diesel are essential for injector longevity.
The lubrication system employs a regulated oil pump
that adjusts output based on engine demand, reducing parasitic power loss and
improving fuel economy. A full-flow oil filter with a bypass valve ensures
continuous lubrication even if the filter becomes restricted. The system is
designed for use exclusively with low-SAPS (Sulfated Ash, Phosphorus, Sulfur)
engine oil meeting VW 507 00 specification.
This oil chemistry is mandatory to prevent ash clogging of the DPF and to
protect the high-pressure fuel pump and injectors from premature wear. An
oil-to-water heat exchanger, mounted on the oil filter housing, rapidly brings
the oil up to operating temperature and maintains thermal stability under high
load. The oil pan is a two-part steel construction, with the upper section
contributing to engine rigidity.
The cooling system operates under pressure with a
thermostatically controlled circuit. A cross-flow radiator, complemented by an
electric cooling fan, manages heat rejection. The system is divided into two
primary circuits: the engine cooling circuit and a separate EGR cooler circuit.
The EGR cooler reduces the temperature of recirculated exhaust gases, lowering
NOx emissions and improving volumetric efficiency.
A coolant pump, driven by the toothed timing belt, circulates the mixture of
water and glycol. An additional electric auxiliary coolant pump supports the
main pump, providing continued circulation after engine shutdown to prevent
localized hot spots, particularly around the turbocharger and DPF. The system
uses G12++ or G13 coolant, characterized by its long-life silicate-free organic
acid technology.
Exhaust System: Features a close-coupled diesel
oxidation catalyst (DOC) and a diesel particulate filter (DPF) integrated into a
single unit. The DPF uses passive and active regeneration cycles to burn off
accumulated soot. Post-injection of fuel is the primary method for initiating
active regeneration.
Turbocharger: Equipped with variable turbine geometry (VTG). Electronic
actuators adjust the vanes to optimize exhaust gas flow across the turbine
wheel, effectively controlling boost pressure across a broad rpm range,
minimizing lag, and acting as an exhaust brake.
Exhaust Gas Recirculation (EGR): A high-pressure EGR system diverts exhaust gas
from upstream of the turbocharger to the intake manifold via a dedicated cooler
and electrically actuated valve. This reduces peak combustion temperatures to
limit NOx formation.
Engine Management: Controlled by a Bosch EDC17 (Electronic Diesel Control)
engine control unit (ECU). The ECU manages injection timing, boost pressure, EGR
rate, and DPF regeneration through a network of sensors, including a mass air
flow (MAF) sensor, manifold absolute pressure (MAP) sensor, and multiple
temperature sensors.
Overall Length: 637 mm (25.1 in)
Overall Width: 642 mm (25.3 in)
Overall Height: 650 mm (25.6 in)
Engine Weight (dry): 140 kg (309 lb)
Engine Oil: VW 507 00 approved 5W-30 or 5W-40 fully
synthetic. Capacity with filter change: 4.3 liters (4.5 US qt). Oil Change
Interval: Flexible service up to 30,000 km (18,600 miles) or fixed service every
15,000 km (9,300 miles), depending on driving conditions.
Timing Belt Replacement: Critical maintenance item. Interval is 210,000 km
(130,000 miles). Due to age-related degradation, a replacement interval of 5
years is widely advised. Fuel Filter: Replacement recommended every 60,000 km
(37,000 miles) or every 2 years to protect the high-pressure fuel system.
Air Filter: Replacement recommended every 60,000 km (37,000 miles) or earlier in
dusty conditions. Coolant: G12++ or G13. Replacement interval is generally every
5 years or 200,000 km (124,000 miles). Valve Clearance: Hydraulic lifters
provide automatic adjustment; no periodic checking is required.
Cylinder Head Bolts (M11 x 2.0): Stage 1: 40 Nm (30
lb-ft).
Cylinder Head Bolts (M11 x 2.0): Stage 2: 90 Nm (66 lb-ft).
Main Bearing Cap Bolts (M10 x 1.25): 40 Nm (30 lb-ft).
Connecting Rod Cap Bolts (M9 x 1.25): 30 Nm (22 lb-ft).
Camshaft Bearing Cap (M8 x 1.25): 23 Nm (17 lb-ft).
Flywheel/Dual Mass Flywheel Bolts (M10 x 1.25): 60 Nm (44 lb-ft) + additional
90°.
Crankshaft Pulley Bolt (M18 x 1.5): 150 Nm (111 lb-ft) + additional 180°.
High-Pressure Pump Drive Sprocket: 25 Nm (18 lb-ft).
Intake Manifold Bolts: 20 Nm (15 lb-ft).
Exhaust Manifold Nuts: 25 Nm (18 lb-ft).
Engine Mount to Block: 40 Nm (30 lb-ft) + additional 90°.
Audi A1 (8X): 2010-2014.
Audi A3 (8P): 2009-2013.
Volkswagen Golf (5K and 5M): 2009-2014.
Volkswagen Jetta (5C): 2010-2015.
Volkswagen Touran (1T): 2010-2015.
Volkswagen Tiguan (5N): 2010-2015.
SEAT Leon (1P): 2009-2013
SEAT Altea (5P): 2010-2015.
Skoda Octavia (1Z): 2009-2013.
Skoda Yeti (5L): 2009-2015.
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