Self-Study ProgramCourse Number 89N303
The Touareg V10-TDI Engine
Design and Function
ProCarManuals.com
Page 1: ...Self Study Program Course Number 89N303 TheTouareg V10 TDI Engine Design and Function ProCarManuals com...
Page 2: ...a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise nor may these materials be modified or reposted to other sites without the prior...
Page 3: ...s and Connecting Rods Balancing Auxilary Drive and Components Oil Circulation Coolant Circulation Fuel System Exhaust System Overview of Engine Management Service 40 Service Tools The Self Study Progr...
Page 4: ...ii ProCarManuals com...
Page 5: ...estone With the V10 TDI engine Volkswagen once again sets new standards in diesel technology Due to a multitude of innovative techniques the highest demands in terms of performance torque and emission...
Page 6: ...o i t c u r t s n o C 0 9 s r e d n i l y C 0 1 0 e l g n A V t n e m e c a l p s i D c c 1 2 9 4 s e h c n I c i b u C 0 0 3 e r o B m m 1 8 n I 9 1 3 e k o r t S m m 5 5 9 n I 6 7 3 r e d n i l y C...
Page 7: ...atic controlled exhaust gas recirculation with electric motor operated intake manifold flaps Oxygen sensors for controlling exhaust gas recirculation A detailed description of the engine management sy...
Page 8: ...he assembly a rigid platform Plasma Sprayed Cylinder Walls For the first time in diesel engines a plasma sprayed running film is applied to the cylinder walls As a result the use of cylinder liners in...
Page 9: ...trong and rigid structure to contain the high combustion forces of the diesel engine The cylinder block will be damaged or deformed by loosening the bolts connecting the cylinder block with the upper...
Page 10: ...d thus good cylinder filling The intake ports are located in the V space of the engine while the exhaust ports are on the engine exterior Connecting Bolt Principle To prevent tension in the cylinder b...
Page 11: ...mplete revolutions of the crankshaft 720 To attain uniform ignition the ignition angle for a 10 cylinder engine must be 72 A 10 cylinder V engine must therefore have a V angle of 72 Since the V10 TDI...
Page 12: ...metal To separate the cap from the rod a procedure called Cracking is required Piston Pin Axis Offset The piston pin axis is offset to prevent noise from the tilting of the piston at top dead center E...
Page 13: ...serves as a driveshaft for the oil pump The counterweights are made of a tungsten alloy As tungsten has a high density the weights be small in size which saves space Vibration Damper The vibration da...
Page 14: ...of a gear drive over a toothed belt is that larger forces can be transferred while the size of the gears remains the same as the sprockets used for toothed belt In addition a toothed belt will stretc...
Page 15: ...11 Engine Mechanics Alternator Camshaft Drive Drive Module Crankshaft 303_016 ProCarManuals com...
Page 16: ...n Gear Coolant Pump Drive Gear Alternator Drive Gear Camshaft Drive Gear Cylinder Bank 2 Crankshaft Power Steering Pump and Air Conditioning System Compressor Drive Gear Oil Pump Balance Shaft Drive G...
Page 17: ...expansion through the entire temperature operating range of the engine The drive module is connected by three bolts to the bearing tunnel formed by the upper and lower cast iron end brackets The gear...
Page 18: ...block throughout the entire operating temperature of the engine How itWorks When subjected to heat the spacing between the camshaft to the drive module changes The compensation wheel in the shackle j...
Page 19: ...he balance piston is bolted into the cylinder head Using a full floating axle it tensions the two shackle joints this prevents dangling movements of the shackle joint Camshaft Gear Shackles Drive Gear...
Page 20: ...ransmission shaft the alternator speed increases by a factor of 3 6 compared to the engine speed This provides an increased alternator performance that can cover high power demands of the vehicle elec...
Page 21: ...eering pump The overload protection of the air conditioning system compressor is implemented by a reinforced rubber element The Gates drive consists of two metal drive couplings with lugs that fit int...
Page 22: ...ffle Oil Return Baffle 303_053 The Oil Pressure ControlValves control the oil pressure of the engine They open as soon as the oil pressure reaches the maximum permitted value The Oil Return Baffles pr...
Page 23: ...neck and the oil cooler are integrated in the oil filter module Drive Module Oil Supply Main Channel in Cylinder Head Oil Line Oil Supply from Cylinder Block Drive Module Drive Module Oil Channel Oil...
Page 24: ...avenge pumps that return oil from the turbocharger oil returns to the oil sump ensuring that there is a sufficient amount of oil in the sump in every operating state The oil pump is gear driven by the...
Page 25: ...d to calm the oil in the oil sump The Touareg has a deep lower part of the oil pan so it can hold a large amount of oil In addition the lower part of the oil pan of the Touareg has elastic flap traps...
Page 26: ...p of the oil pan while the rest flows from the returns of the turbocharger and auxiliary drive into the rear area of the oil pan There the oil is suctioned off by oil scavenge pumps and returned to th...
Page 27: ...il is then routed to the oil separator The oil separator removes air from the oil The air free oil drains into the sump ensuring ample oil supply to the oil pressure pumps Oil Scavenge System Downhill...
Page 28: ...5 8 9 7 13 14 11 12 4 14 10 3 16 5 6 1 2 Coolant Circulation System System Overview 303_039 Warm Engine Coolant Circulation Cold Coolant Circulation for Alternator and Fuel Cooling Touareg Only Warm C...
Page 29: ...cording to a characteristic map 9 Fuel Cooler 10 Compensator Reservoir 11 Recirculation Pump V55 12 Heater Core for Heater 13 Auxiliary Water Heater Auxiliary Heater 14 Cooler for Exhaust Return Phaet...
Page 30: ...wo coolant drain plugs are located on the engine face in the cylinder block When the cylinder heads or another component in the V space of the engine is removed the coolant drain plugs can be used to...
Page 31: ...racteristic maps that contain the nominal value temperature depending on the engine load are stored in the ECM The advantage of characteristic map controlled engine cooling is that the coolant tempera...
Page 32: ...he coolant is transported out of the cylinder heads through the two large connections to the coolant controller housing The topmost small connections are used for ventilation Coolant Connection Oil Fi...
Page 33: ...space of the engine to be removed and installed the two large connections in the coolant connection housing can be pushed in pulled apart Coolant Connection Installed Position Coolant Connection Assem...
Page 34: ...e fuel filter unit and transport it at high pressure into the preliminary run of the fuel rails The fuel not required for fuel injection is returned to the tank through the return fuel rails fuel filt...
Page 35: ...ngine Mechanics In the Touareg the fuel is cooled by a fuel to coolant cooler Fuel Manifold Fuel Cooler Connection Nozzle Fuel Return Pressure Relief Valve Vacuum Pump Fuel Pump 303_051 ProCarManuals...
Page 36: ...nary run to approximately 8 5 bar The Pressure ReliefValves limit the fuel pressure in the fuel return flow to approximately 1 bar As a result the pressure conditions in the fuel system are balanced T...
Page 37: ...33 Engine Mechanics Electric Fuel Pump Fuel Manifold Fuel Manifold Return Preliminary Run Low pressure Preliminary Run High pressure Coolant Fuel Cooler Pump Injector Unit 303_088 ProCarManuals com...
Page 38: ...er unit when the outside temperature is low this guides the fuel in the return flow from the engine back into the filter In the Touareg a coolant fuel cooler is integrated into the fuel filter unit It...
Page 39: ...ported via filter inserts and the flapper valve to the fuel pumps Cold FuelTemperature At a fuel temperature below 50 F 10 C the elastic element contracts so that the spring force of the piston closes...
Page 40: ...urface pressure is low In addition the engine oil can collect in the ball socket thus ensuring good lubrication between the adjusting screw and the stud In the partial load range the injection pressur...
Page 41: ...ytic converters The preliminary catalytic converters are located near the engine so operating temperature can be quickly attained ensuring a high degree of pollutant reduction The oxygen sensors locat...
Page 42: ...8 Mass Airflow MAF 2 G246 Sensor Additional Input Signals and functions of engine management can be found in Self Study Program 89P303 Touareg Electronic Diesel Control EDC 16 Brake Light Switch F63 B...
Page 43: ...5 Q19 Valve for Pump Injector N240 N244 Fuel Pump FP Relay J17 Fuel Pump FP G6 Transfer Fuel Pump FP G23 EGR Vacuum Regulator Solenoid Valve N18 Motor for Intake Flap V157 MAP Controlled Engine Coolin...
Page 44: ...303_056 303_057 303_058 303_059 To fasten the camshaft cylinder bank 2 when setting the control times Removal and installation of the oil filter module To fasten the camshaft cylinder bank 1 when set...
Page 45: ...Cartridge XZN16 303_061 303_061 303_062 303_063 To fasten the crankshaft when setting the control times To install the PTFE crankshaft gasket on the flywheel side For removal and installation of vario...
Page 46: ...mshaft gears to remove and install the camshaft gears For removal and installation of the belt drive module For removal and installation of the bearing tunnel For removal and installation of the fuel...
Page 47: ...ent T10210 Caliper Figure not available at time of printing To align the pump injector units To install the PTFE crankshaft gasket on the alternator shaft To install the PTFE crankshaft gasket on the...
Page 48: ..._________ _____________________________________________________________________________________ _____________________________________________________________________________________ __________________...
Page 49: ...ment at www vwwebsource com From the vwwebsource com Homepage do the following Click on the Certification tab Type the course number in the Search box Click Go and wait until the screen refreshes Clic...
Page 50: ...Volkswagen of America Inc 3800 Hamlin Road Auburn Hills MI 48326 Printed in U S A March 2003 TheTouareg V10 TDI Engine ProCarManuals com...
