Volkswagen CAVD Specifications
| Engine Model: Volkswagen CAVD (Audi 1.4L TSI) |
| Engine Type: 4-cycle 4-cylinder DOHC 16-valve dual-charged liquid-cooled gasoline |
| Total Displacement: 84.8 cu.in (1.39 L) |
| Rated Engine Power: 158 Hp (118 kW) at 5800 rpm |
| Fuel System Type: Direct fuel injection (Fuel Stratified Injection-TSI) |
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The 1.4-liter TSI twin-charged engine is a
groundbreaking and technically sophisticated powerplant from Volkswagen.
By combining a mechanical supercharger (Roots-type) for low-end response
with a conventional exhaust-driven turbocharger for high-end power, it
effectively eliminated turbo lag and delivered a remarkably wide, flat
torque curve from very low engine speeds.
This Twincharger system, paired with direct fuel injection (TSI),
allowed a small-displacement engine to achieve performance figures
rivaling larger naturally aspirated units, with superior fuel efficiency
under part-throttle conditions. Found in performance-oriented models
like the Polo GTI, Golf, Scirocco, and Audi A1, it offered a unique
blend of drivability and power. However, its complexity led to
characteristic reliability concerns, including issues with high-pressure
fuel pumps, supercharger clutches, and carbon buildup, making precise
maintenance paramount.
Engine Type: Inline-4 cylinder, liquid-cooled, dual-charged
(supercharger + turbocharger) with intercooler, gasoline direct
injection (TSI).
Displacement: 1390 cc. 1.390 liters or 84.8 cubic inches.
Bore x Stroke: 76.5 x 75.6 mm or 3.01 x 2.98 inches.
Compression Ratio: 10.0:1. Firing Order: 1-3-4-2.
Direction of Rotation: Clockwise (viewed from the front/flywheel end).
Maximum Power Output: 118 kW at 5800 rpm (rpm). 160 PS or 158 Hp at 5800
rpm.
Maximum Torque Output: 240 Nm from 1500-4500 rpm (continuous band) or
177 lb-ft from 1500-4500 rpm. Fuel Requirement: Premium unleaded
gasoline, minimum 98 RON (93 AKI) required for optimal performance and
to prevent abnormal combustion.
Emission Standards Compliance: Originally designed to meet Euro 5
emission standards.
Material: Cast iron. This robust material was chosen to handle the high
cylinder pressures generated by the twin-charging system.
Construction: Closed-deck design for maximum strength under high boost
pressures. The crankshaft is supported by four main bearings integrated
into a rigid lower crankcase.
Crankshaft: Forged steel, a necessity for the high mechanical loads.
Main bearing journal diameter: 54.0 mm or 2.126 inches. Crankpin journal
diameter: 45.0 mm or 1.772 inches.
Pistons: aluminum alloy with a specially shaped, deep-crowned combustion
bowl optimized for direct injection and high turbulence. Piston cooling
jets spray oil onto the undersides to manage thermal load.
Connecting Rods: High-strength forged steel with fracture-split big end
caps.
Material: aluminum alloy.
Head Construction: Dual overhead camshaft (DOHC), 16-valve design. The
camshafts are driven by a maintenance-free timing chain.
Valve Arrangement: 4 valves per cylinder. Valves are actuated by
roller-finger followers with hydraulic lash adjusters for
zero-maintenance valve clearance.
Variable Valve Timing: Volkswagen's intake camshaft adjustment system
(VVT) is used to optimize valve timing for power and emissions.
Valve Diameters: Intake: 29.0 mm or 1.142 inches. Exhaust: 25.0 mm or
0.984 inches.
| Fuel System and Charging System |
Injection Type: Direct fuel injection (Fuel Stratified Injection-TSI).
High-pressure fuel is injected directly into the combustion chamber.
Fuel Pump: A camshaft-driven, high-pressure mechanical fuel pump
(single-piston) mounted on the cylinder head supplies the fuel rail. An
in-tank electric lift pump provides supply.
Fuel Rail and Injectors: Common rail design with solenoid-controlled,
side-mounted injectors. Operating pressure ranges from 40 to 150 bar.
Charging System-Supercharger: Eaton TVS roots-type supercharger,
mechanically driven by the crankshaft via a magnetic powder clutch
(bypass clutch). This clutch engages the supercharger primarily at low
to medium engine speeds (up to 2400-3000 rpm, depending on load) to
provide immediate boost and eliminate turbo lag.
Charging System -Turbocharger: A conventional exhaust-driven
turbocharger (e.g., BorgWarner K03) takes over as the primary boost
source at higher engine speeds and loads. An electronically controlled
bypass valve (dump valve) manages boost pressure.
Intercooler: A single, air-to-air intercooler cools the compressed air
from both charging devices.
Throttle Body: Electronically controlled (drive-by-wire).
Type: Pressure-fed, full-flow filtration with a conventional gear-type
oil pump.
Oil Pump: Driven directly by the crankshaft, located in the oil pan.
Oil Filter: Cartridge-type, mounted on the top front of the engine.
Oil Capacity (including filter): 3.6 liters or 3.80 US quarts.
Recommended Oil Grade: High-performance full synthetic engine oil
meeting VW standard 504 00 / 507 00 (low-SAPS for longevity of emission
components). Viscosity: 5W-30 or 5W-40.
Operating Oil Pressure: 2.0 bar at hot idle, rising to 3.5-4.5 bar at
higher rpm or 29 psi (idle), 51-65 psi (load).
Type: Pressurized, dual-circuit system. Separate cooling circuits for
the engine block/head and the turbocharger. Water Pump: Belt-driven
(timing belt) centrifugal pump.
Thermostat: Electronically controlled map thermostat for precise
temperature management, opening around 95-105°C (203-221°F) under load.
Coolant Capacity: 5.5 liters (entire system) or 5.81 US quarts.
Coolant Type: Specific pink/purple G12++ or G13 antifreeze mixture.
Electrical System: 12-volt negative ground. High-output alternator
(140A).
Ignition System: Coil-on-plug (COP) individual ignition coils with
iridium spark plugs.
Engine Management: Advanced Bosch MED 17 or similar ECU, coordinating
the complex interaction between supercharger clutch, turbocharger
wastegate, direct injection, and variable valve timing.
Crankcase Ventilation: An oil separation system integrated into the
valve cover. Prone to clogging, which can lead to oil consumption and
pressure issues.
Length: 500 mm or 19.7 inches.
Width: 650 mm or 25.6 inches.
Height: 600 mm or 23.6 inches.
Dry Weight: 115-125 kg or 254-276 lbs.
Engine Oil Change Interval: Strictly every 15,000 km or 12 months under
fixed servicing, but highly recommended at 10,000 km (6,200 miles) or
annually due to high stress.
Oil Filter Change: Every oil change. Air Filter Change: Every 60,000 km
or as inspected or 37,300 miles. Fuel Filter: Integrated with the
in-tank pump; service as needed or at high mileage (e.g., 120,000 km).
Timing Belt: Drives the water pump and high-pressure fuel pump.
Replacement critical at 120,000 km or 5 years (75,000 miles / 5 years).
Includes belt, tensioner, and rollers.
Timing Chain: Drives the camshafts. Officially "lifetime" but should be
inspected for stretch and tensioner wear every 100,000 km (62,000
miles). Spark Plug Replacement: Every 60,000 km (37,300 miles). Use
specified iridium plugs. Carbon Cleaning: Mandatory high-mileage
service. Walnut blasting of intake valves required every 80,000-100,000
km (50,000-62,000 miles) due to direct injection. Supercharger Clutch
and Belt: Inspect the electromagnetic clutch function and the dedicated
serpentine belt driving the supercharger regularly. Belt replacement
interval is 60,000-80,000 km.
Always refer to the official service manual. Many fasteners are
torque-to-yield (TTY) and single-use.
Cylinder Head Bolts: TTY. Tighten in a specific multi-stage angular
sequence. Example: Step 1: 40 Nm, Step 2: +90°, Step 3: +90°.
Main Bearing Cap Bolts: 60 Nm + 90° turn (TTY).
Connecting Rod Cap Bolts: 30 Nm + 90° turn (TTY, always replace).
Spark Plugs: 30 Nm or 22 lb-ft.
Oil Drain Plug: 30 Nm or 22 lb-ft.
Supercharger Drive Pulley Bolt: 50 Nm + 90° turn or 37 lb-ft + 90°.
Wheel Bolts: 120 Nm or 89 lb-ft.
Volkswagen Polo Mk5 (6R): Polo GTI (160 PS).
Volkswagen Golf Mk6: Golf 1.4 TSI 160 PS (GT model).
Volkswagen Scirocco Mk3: Scirocco 1.4 TSI 160 PS.
SEAT Ibiza Mk4: Ibiza FR / Cupra (180 PS version exists with different
engine code).
Audi A1 (8X): Audi A1 1.4 TFSI 185 PS (higher-output variant, engine
code CTHE).
The engine code CAVD/CAVE denotes the 160 PS variant. The later CTHE
code addressed some reliability issues in the 185 PS version for the
Audi A1 and Beetle.
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