Self-Study Programme 412 2.0L 125 kW TDI engine with pump injection system.pdf

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Service Training
Audi 2.0l 125 kW TDI Engine
with Pump Injection System
Self-Study Programme 412
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In this booklet we explain to you the design and function of the 2.0 l 125 kW four-valve TDI engine, focussing on the
differences between it and the 103 kW version.
412_009
Reference
For information about the 2.0 l 103 kW four-
valve TDI engine, please refer to SSP 316
"The 2.0 l TDI Engine".
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Contents
Introduction
2.0l 125 kW TDI engine with pump injection system . . . . . . . . . . . . . . . . . . . . . . . 4
Engine mechanicals
Crank train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Valve train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Exhaust system
Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Exhaust gas turbocharger with positional feedback . . . . . . . . . . . . . . . . . . . . . 21
Diesel particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine management
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Service
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
The Self-Study Programme explains 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!
Please note that all data and values given are for purposes of easier comprehension only
and refer to the software version valid at the time of publication of the SSP.
For information about maintenance and repair work, always refer to the current technical literature.
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Introduction
2.0l 125 kW TDI engine with
pump injection system
The 2.0 l 125 kW TDI engine is based on the
2.0l 103 kW TDI engine. In terms of power output,
the 125 kW TDI engine is the market leader in the
2-litre diesel engine class.
This gain in power was accomplished whilst
reducing fuel consumption and pollutant e xhaust
emissions through systematic development of
proven TDI technology.
412_002
4
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2.0l TDI
Technical features
–
New pump-injector unit with piezo valve and
injection pressures up to 2200 bar
–
Balancer shaft module*
–
Pistons without valve pockets
–
Ceramic or steel glow plugs (depending on
engine code)
–
CTC toothed belt sprocket on the crankshaft
–
Improved oil separation
–
Exhaust gas turbocharger with positional
feedback
–
Maintenance-free diesel particulate filter
* for longitudinally mounted engines
412_001
135
500
Torque/power curve
125
450
400
115
Max. torque in Nm
350
105
Max. power in kW
95
300
75
250
200
65
Nm
kW
100
45
35
50
0
0
1000
2000
3000
4000
5000
0
Engine speed rpm
Specifications
Engine codes
BMN, BRE, BRD
Type of engine
In-line four-cylinder diesel with VTG exhaust gas
turbocharger, DOHC, TDI direct injection
Displacement in cm 3
1968
Max. power output in kW (bhp)
125 (170) at 4200 rpm
Max. torque in Nm
350 from 1750 to 2500 rpm
Bore in mm
81
Stroke in mm
95.5
Compression ratio
18 : 1
Cylinder spacing in mm
88
Firing order
1 - 3 - 4 - 2
Engine management
Bosch EDC 16
Exhaust emission control
Coated oxidising catalytic converter integrated
in the diesel particulate filter
Exhaust emission standard
EU 4
5
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