Self-Study Programme 495 3.0L V6 TDI engine 2 generation.pdf

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Service Training

Self-study programme 495

The 3.0 l V6 TDI Engine

(Generation 2)

Design and function

The first generation of the 3.0 l V6 TDI engine entered

series production at Volkswagen in 2005 (it was first

used by Audi in 2003).

The 3.0 l V6 engine developed by Audi has been

used in various VW Group models with great success.

Over 1.6 million V6 TDI engines have now been built.

Now in 2011, Volkswagen is introducing the second

generation of this engine.

This newly developed engine successfully combines

low consumption figures, low emissions and a high

level of power development with reduced engine

weight. The focus was on minimising friction and

achieving a lightweight design.

The new V6 TDI generation comes in two output

versions — a 180 kW version and a 150 kW version.

An optimised piezo common rail injection system with

up to 2,000 bar fuel rail pressure is used.

The V6 TDI engine is already designed for future

developments in terms of output, emissions and fuel

consumption.

S495_002

The self-study programme presents the

design and function of

new developments!

The content will not be updated.

Current testing, setting and repair instructions can

be found in the provided service literature.

Important

note

Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Engine Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Engine Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Test Yourself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Introduction

The 3.0 l V6 150 kW TDI Engine (Generation 2)

with Bosch common rail injection system

Technical features

•

Bosch common rail injection system with piezo

injectors (2,000 bar injection pressure)

Oxidising catalytic converter/diesel particulate

filter

Turbocharger from Honeywell Turbo Technologies

(HTT) GT 2256

Innovative Thermal Management (ITM)

Chain drive, new chain layout

Demand-controlled in-tank fuel pump

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Technical data

Engine code

Type

Displacement

Bore

Stroke

Valves per cylinder

Compression ratio

Max. output

Max. torque

Engine management

CJMA

V6 engine with 90

V angle

2,967 cm

83 mm

91.4 mm

16.8 : 1

Torque (Nm)

Output (kW)

Engine speed (rpm)

S495_005

150 kW at

3,200 to 4,400 rpm

450 Nm at

1,250 at 2,750 rpm

Bosch CRS 3.3

common rail injection sys-

tem

Diesel, according to DIN

EN590

EU5

Torque and output diagram

Fuel

Exhaust emissions standard

The 3.0 l V6 180 kW TDI Engine (Generation 2)