Self-Study Programme 403 2.0L TDI Engine with common rail.pdf

Service Training

Self-study Programme 403

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2.0l TDI Engine with

Common Rail Fuel Injection System

Design and Function

The 2.0l TDI engine with common rail injection system

is the first in a new generation of dynamic and

efficient diesel engines from Volkswagen.

By combining the successful and proven 2.0l TDI

engine with common rail technology, Volkswagen

is setting new standards with regards to the

characteristic TDI features of dynamics, driving fun,

economy and reliability. These outstanding TDI

qualities in the 2.0l TDI engine with common rail

injection system are aimed at future challenges in

terms of acoustics, comfort and exhaust gas

treatment.

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The leading role of Volkswagen, which began in 1993

with the introduction of the first turbocharged direct-

injection diesel engine to be used in a car, successfully

continues with the 2.0l TDI engine. This confirms

Volkswagen’s position as a pioneer in diesel

technology.

The engine already fulfils the requirements of the

Euro 5 emissions standard that will come into force

at the end of 2009 and offers potential for future

emissions standards and the associated technologies.

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NEW

Warning

Note

The self-study programme shows the design and

function of new developments.

The contents will not be updated.

For current testing, adjustment and repair

instructions, refer to the relevant

service literature.

Contents

In Brief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Engine Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Engine Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Test Yourself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

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In Brief

Introduction

The 2.0l TDI engine with common rail injection system is based on the 2.0l TDI engine with unit injector system. The

predecessor engine is one the most frequently built diesel engines. It is also the engine with the widest range of

applications at Volkswagen Group from cars to the Transporter.

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A multitude of engine components have been re-engineered to meet the increased acoustics, consumption and

emissions requirements. Switching the injection system to common rail fuel injection technology is a particularly

important factor in this regard.

Equipped with a diesel particulate filter, the engine meets the current EU 5 emissions standard that is planned for

the end of 2009. Since the legal requirements for registration conditions for the EU 5 exhaust standard have not yet

been agreed, the engine is approved with the EU 4 emissions standard.

In some markets, the engine is also available without diesel particulate filter. These engines meet the EU 3

emissions standard.

Technical features

Common rail injection system with piezo injectors

●

Diesel particulate filter with upstream oxidation

catalytic converter

●

Intake manifold with swirl flap adjustment

●

Electric exhaust gas recirculation valve

●

Adjustable turbocharger with travel feedback

●

Low-temperature exhaust gas recirculation cooling

●

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Technical data

Power and torque development graph

Engine code

CBAB

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Type

4-cylinder in-line engine

Valves per cylinder

1968 cm 3

Displacement

Stroke

95.5 mm

Bore

81 mm

Maximum output

103 kW at 4200 rpm

Maximum torque

320 Nm at

1750 to 2500 rpm

Compression ratio

16.5:1

Engine management

Bosch EDC 17

(common rail fuel injection

system)

Engine speed rpm

Fuel

Diesel, in accordance with

DIN EN 590

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Exhaust gas cleaning

Exhaust gas recirculation,

diesel particulate filter

Emissions standard

EU 4

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