SSP 420 Audi 2.0-litre TDI Engine with Common Rail Injection System en.pdf

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Service Training
Audi 2.0-litre TDI Engine with
Common Rail Injection System
Self-Study Programme 420
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The 105 kW (143 hp) 2.0-litre TDI engine featuring
common rail (CR) injection technology marks the
birth of a new generation of dynamic and efficient
diesel engines. It reinterprets the qualities of the TDI
concept while addressing the future challenges facing
environmental protection in particular.
The 2.0-litre TDI CR engine is based on the successful
2.0-litre pump injector TDI engine, whereby the
combination of the 2.0-litre TDI unit with common rail
technology sets new standards.
The new 2.0-litre TDI CR engine built at Audi Hungaria
Motor in Györ already meets the high standards of the
Euro 5 exhaust emission standard due to come into
effect in 2010.
Thanks to the use of common rail technology, the
2.0-litre TDI CR engine has major advantages with
regard to exhaust emissions, acoustics, weight and
overall build height.
The TDI engines deliver high torque at low revs.
The goal for the development of the 2.0-litre TDI
CR engine was to enhance this character.
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Contents
Introduction
2.0-litre 105 kW TDI engine with common rail injection system . . . . . . . . . . . . . . 4
Engine mechanicals
Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Crank mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Camshaft drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-valve technology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Intake manifold with swirl flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Oil circulation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Crankcase ventilation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Coolant system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Exhaust gas recirculation cooling system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Common rail injection system
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Auxiliary fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Fuel preheating valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Common rail injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Engine management
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Engine management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Service
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
The Self-Study Programme teaches the design and function of new vehicle models, new automotive
components or new technologies.
Reference
Note
The Self-Study Programme is not a Repair Manual.
Values specified herein are intended for easier understanding only and refer
to the software version valid at the time of preparation of the SSP.
For information about maintenance and repair work, always refer to the current technical literature.
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Introduction
2.0-litre 105 kW TDI engine
with common rail injection
system
The 2.0-litre TDI engine with common rail injection
system is based on the 1.9-litre/2.0-litre TDI engine
with pump injection system.
The predecessor engine (base engine) is one of the
world's biggest-selling diesel engines.
To meet the higher demands with regard to
acoustics, fuel economy and exhaust emissions, a
large number of engine components have been
revised.
A major change was the adoption of the common
rail technology for the injection system.
Equipped with a diesel particulate filter, the engine
meets current Euro 4 emission standards.
In several markets the engine is also available
without a diesel particulate filter. These engines
meet the Euro 3 exhaust emission standard.
420_009
4
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2.0-litre TDI common rail engine
Technical features
–
Common rail injection system with piezoelectric
injectors
–
Diesel particulate filter with upstream oxidising
catalytic converter
–
Intake manifold with swirl flap adjustment
–
Electrical EGR valve
–
Adjustable exhaust gas turbocharger with flow-
path feedback
–
Low-temperature EGR cooling system
420_078
Torque/power curve
Max. torque in Nm
Max. power in kW
Engine speed in rpm
Specifications
Engine code
CAGA
Type of engine
4-cylinder inline engine
Displacement in cm 3
1968
Max. power in kW (bhp)
105 (143) at 4200 rpm
Max. torque in Nm
320 at 1750 to 2500 RPM
No. of valves per cylinder
4
Bore in mm
81
Stroke in mm
95.5
Compression ratio
16,5 : 1
Engine management
Bosch EDC 17
Exhaust emission control
Oxidising catalytic converter, water-cooled exhaust gas
recirculation, maintenance-free diesel particulate filter
Exhaust emission standard
Euro 4
5
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