Volkswagen V10-TDI Bedienungsanleitung
Self-Study Program
Course Number 89N303
TheTouareg
V10-TDI Engine
Design and Function
ProCarManuals.com
Volkswagen of America, Inc.
Service Training
Printed in U.S.A.
Printed 03/2004
Course Number 89N303
©2004 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
affiliated 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
modified 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
Volkswagen Worldwide Repair Information
System 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.
ProCarManuals.com
i
Contents
New! Caution/Note
Introduction .............................................................................................................. 1
The V10-TDI, Specifications, Power/Torque Diagram
Engine Mechanics..................................................................................................... 4
Cylinder Block,Endbracket, Cylinder Head, Connecting Bolt Principal, Crankshaft,
Crank Pin Offset, Pistons 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 Program provides you with
information regarding designs and functions.
The Self-Study Program is not a Repair Manual.
For maintenance and repair work, always refer
to the current technical literature.
ProCarManuals.com
ii
ProCarManuals.com
1
Introduction
“...Easy to recognize, the beauty of the classical lines,
the calm but predominantly powerful charisma
of intelligent and sensible engine activity, simple and elegant -
in short, ladies and gentlemen, the world’s top performer!
A milestone...”
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 emissions of a diesel engine are fulfilled for the luxury
vehicle class.
The V10-TDI engine crowns 25 years of diesel engine development at Volkswagen.
It is the most powerful series passenger-vehicle diesel engine in the world.
ProCarManuals.com
Introduction
2
The V10-TDI Engine
The V10-TDI engine is a newly developed diesel
engine in which innovative lightweight
construction and enormous power are united
within compact dimensions.
It has a 900aluminum cylinder block with 5
cylinders in each bank of the block. The control
and auxiliary drive are gear-driven. The fuel
injection system uses solenoid controlled unit
injectors to ensure a high performance yield at
low exhaust emissions.
303_001
edoCenignEWKB
noitcurtsnoC09,srednilyC01
0
elgnA-V
tnemecalpsiD)cc1294(sehcnIcibuC003
eroB)mm18(.nI91.3
ekortS)mm5.59(.nI67.3
rednilyC-rep-sevlaV2
oitaRn
oisserpmoC1:81
rewopesroHMPR0573@)Wk032(ph803
euqroT tfbl355
MPR0522@)mN057(
tnemeganaMenignE61CDEhcsoB
stneme
riuqeRleuFmuminimZC94leseiD
tnemtaerTtsuahxE dnanoitalucricersagtsuahxE
retrevnoccitylatacnoitadixo
redrOg
niriF9-4-8-3-7-2-01-5-6-1
ProCarManuals.com
3
Introduction
Engine MechanicsTechnical Features
• Cylinder block made of aluminum with an
end bracket made of cast-iron
• Joining of cylinder head and cylinder block
with tie-rod bolt connection
• Control and auxiliary drive unit are gear-driven
• Balancer shaft to reduce vibrations
Engine ManagementTechnical Features
• EDC 16
• Two Engine Control Modules
• Pneumatic 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 system can be found in Self-Study Program No.
89P303 “Touareg Electronic Diesel Control EDC 16”, design and function.
100
120
140
160
180
200
220
240
1000 2000 3000 4000 5000
800
600
400
200
Power Output / Torque
5.0 I - V10 - TDI - 308 hp (230 kW) @ 3750 RPM
533 lb ft (750 Nm) @ 2250 RPM
= Power Output
= Torque
Engine (RPM)
Power Output
(kW)
Torque
(Nm)
2,250
3,750
ProCarManuals.com
Engine Mechanics
4
Cylinder Block
The cylinder block assembly consists of three
components; an aluminum cylinder block, upper
and a lower end brackets. The aluminum
cylinder block provides a significant weight
reduction for the 90° cylinder banks. The high
tensile cast iron end brackets give the 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
the aluminium cylinder block is no longer
necessary. This reduces the weight of the
engine and permits compact dimensions due to
a short distance between the cylinder bores.
Top Portion of
Cylinder Block
End Brackets
Plasma Jet
Plasma Burner
Cylinder Wall
303_031
303_069
ProCarManuals.com
5
Engine Mechanics
End Bracket
The upper and lower end brackets are manufactured from high tensile cast iron. The upper and
lower portions of the end brackets use a press fit; and 4 bolts per main journal to provide the
crankshaft with a strong 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 portion of the end bracket .
End Bracket,
Upper Portion
End Bracket,
Lower Portion
End Bracket ,
Lower Portion
Crankshaft Bracket
Upper Portion
Press Fit
Bolted Connection
Balancer Shaft Thrust Bearing
303_077
303_087
303_022
ProCarManuals.com
Engine Mechanics
6
Cylinder Head
The V10-TDI engine has two aluminium-alloy
cylinder heads. The intake and exhaust ports are
arranged according to the crossflow principle;
that is, the intake and exhaust ports are located
on opposite sides of the cylinder head. This
arrangement provides good gas exchange and
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 block, the
cylinder heads, cylinder block, and upper portion
of the end bracket are bolted to each other
using connecting bolts.
Exhaust Port
Intake Port
Connecting Bolts
Cylinder Head
Balancer Shaft Bearing
End Bracket,
Lower Portion
End Bracket,
Upper Portion
Cylinder Block
303_025
303_049
ProCarManuals.com
Inhaltsverzeichnis
Andere Volkswagen Motor Handbücher
Volkswagen
Volkswagen Volkswagen 2.8L VR6 6-Cylinder Golf, GTI,... Bedienungsanleitung
Volkswagen
Volkswagen 1.9-Liter TDI Bedienungsanleitung
Volkswagen
Volkswagen FOX 2004 Gebrauchsanweisung
Volkswagen
Volkswagen SDI 1.9L Series Bedienungsanleitung
Volkswagen
Volkswagen CJDA Gebrauchsanweisung
Volkswagen
Volkswagen CC 2014 Bedienungsanleitung
Volkswagen
Volkswagen 4.2l V8 5V Handbuch
Volkswagen
Volkswagen Taro 1989 Gebrauchsanweisung
Volkswagen
Volkswagen NEW BEETLE - Bedienungsanleitung
Volkswagen
Volkswagen TDI 350-8 Bedienungsanleitung
