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

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

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or otherwise, nor may these materials be

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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.

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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.

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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.

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Introduction

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.

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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

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Engine Mechanics

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

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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

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Engine Mechanics

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

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