SSP_368_The_2_0l_-_125_kW-TDI_Engine_with_4-valve_technology.pdf

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Service Training
Self-study Programme 368
The 2.0l 125 kW TDI Engine
with 4-valve technology
Design and function
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Following the 2.0l 103 kW TDI engine with 4-valve technology, the 2.0l TDI engine with 125 kW is now being
launched onto the market.
In this document, we will introduce you to the design and function of the 2.0l 125 kW TDI engine with 4-valve
technology, whereby we will concentrate extensively on the differences versus the 103kW variant.
The 2.0l 125 kW TDI engine with 4-valve technology will initially be fitted in the Passat.
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S368_009
Information on the 2.0l 103 kW TDI engine with 4-valve technology can be found in
self-study programme 316 "The 2.0l TDI Engine".
NEW
Important
Note
The self-study programme shows the design and
function of new developments.
The contents will not be updated.
For current testing, adjustment and repair
instructions, refer to the relevant service literature.
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Contents
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Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Crankshaft drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Cylinder head gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Turbocharger with travel feedback. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Diesel particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Functional diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Test yourself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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Introduction
The 2.0l 125 kW TDI engine with 4-valve technology
The 2.0l 125 kW TDI engine is based on the 2.0l TDI engine with 103 kW. With its output, the 125 kW TDI engine is
the market leader amongst 2-litre diesel engines. This increased output has been achieved by consistently
re-developing the tried-and-tested technology whilst simultaneously reducing consumption and pollutant emissions.
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S368_002
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Technical features
New unit injector with piezo-electric valve and an
injection pressure of up to 2200 bar
●
Balancer shaft module *
●
Pistons without valve pockets
●
New ceramic glow plugs
●
CTC toothed belt sprocket on the crankshaft
●
Improved oil separation
●
Turbocharger with travel feedback
●
Maintenance-free diesel particulate filter
●
* In the Passat and with longitudinal mounting only
S368_001
Technical data
Torque and output diagram
500
135
Engine codes
BMR, BMN
450
125
Type
4-cylinder in-line engine
1968cm 3
Displacement
400
115
Bore
81mm
105
350
Stroke
95.5mm
Valves per cylinder
4
95
300
Compression ratio
18.5 : 1
75
250
Maximum output
125kW at 4200 rpm
Maximum torque
350 Nm at 1800 rpm to
2500 rpm
65
200
150
55
Engine management
Simos PPD 1
Fuel
Diesel, at least 51CN
45
100
Exhaust gas treatment
Exhaust gas recirculation
and diesel particulate filter
50
35
Emissions standard
EU4
1000
2000 3000
4000
5000
Engine speed (rpm)
S368_082
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