VW_Common_Rail_TDI_2.0l_SSP 826803.pdf

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Service Training
Self Study Program 826803
2.0 Liter TDI Common Rail
BIN5 ULEV Engine
Cover art fi le number tbd
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Volkswagen of America, Inc.
Volkswagen Academy
Printed in U.S.A.
Printed 4/2008
Course Number 826803
©2008 Volkswagen of America, Inc.
All rights reserved. All information contained in this manual is
based on the latest information available at the time of printing
and is subject to the copyright and other intellectual property
rights of Volkswagen of America, Inc., its affi liated companies
and its licensors. All rights are reserved to make changes at
any time without notice. No part of this document may be
reproduced, stored in a retrieval system, or transmitted in any
form or by any means, electronic, mechanical, photocopying,
recording or otherwise, nor may these materials be modifi ed
or reposted to other sites without the prior expressed written
permission of the publisher.
All requests for permission to copy and redistribute
information should be referred to Volkswagen of America,
Inc.
Always check Technical Bulletins and the latest electronic
repair information for information that may supersede any
information included in this booklet.
Trademarks: All brand names and product names used in
this manual are trade names, service marks, trademarks,
or registered trademarks; and are the property of their
respective owners.
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine Management System. . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Knowledge Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Important!
Note
This information will not be updated.
For maintenance and repair procedures,
always refer to the latest electronic
service information.
This Self-Study Program provides information
regarding the design and function of new
models.
This Self-Study Program is not a Repair Manual.
iii
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Introduction
Introduction
A New Generation of Diesel
Engines from Volkswagen
The 2.0 Liter TDI engine with common rail injection
system is the fi rst of a new generation of dynamic
and effi cient diesel engines from Volkswagen.
By combining the successful and proven 2.0 Liter TDI
engine with common rail technology, Volkswagen is
setting new standards in terms of such characteristic
TDI attributes as dynamics, driving enjoyment,
economy, and reliability. The superior qualities of
the 2.0 Liter TDI engine with common rail injection
system are oriented towards future challenges in
acoustics, comfort, and exhaust gas after-treatment.
The lead taken on by Volkswagen in 1993 with the
introduction of the fi rst turbocharged direct injection
(TDI) diesel engine in a passenger car continues with
the 2.0 Liter TDI engine, confi rming Volkswagen’s role
as a pioneer in diesel technology.
The engine offers the potential for future
improvements in exhaust gas standards and the
associated technologies.
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