Service.
Self-Study Programme 303
The V10-TDI engine
with pump-jet fuel injection system
Design and function
, ... Easy to recognise, 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,
you can see here the world’s top performer!
A milestone...
... in statuary! ... in engine development!
303_U2
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 made of a diesel motor 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.
NEW Caution
Note
The Self-Study Programme describes the Please always refer to the relevant service
design and function of new developments! literature for up-to-date inspection, adjustment
The contents are not updated. and repair instructions.
2
,At a glance
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Oil circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Coolant circulation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fuel system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Check your knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3
, Introduction
The V10-TDI engine
The V10-TDI engine is a newly developed
diesel engine in which innovative light-weight
construction and enormous power are united
within compact dimensions.
It has a cylinder block made of aluminium, where
the two rows of cylinders are arranged at an
angle of 90o to one another.
The control and ancillary unit is driven by
gearwheels The tried-and-tested pump-jet fuel
injection system ensures a high performance yield
at low exhaust emissions.
The V10-TDI engine is used as a high-performance
engine in the Volkswagen Touareg and Phaeton.
303_001
Engine mechanics technical features Engine management technical features
– Cylinder block made of aluminium with an – Two motor controllers
end bracket made of cast-iron – Charged by two adjustable turbochargers
– Joining of cylinder head and cylinder block – Exhaust gas recirculation effected with
via tie-rod screw connection pneumatically controlled exhaust gas
– Contol and ancillary unit driven by recirculation valves with electrically-operated
gearwheels intake manifold flaps
– Balancer shaft for reducing vibrations – Lambda probes for controlling exhaust gas
recirculation
A detailed description of the engine management system for the V10-TDI engine can be
found in Self-Study Programme No. 304 ”Electronic Diesel Control EDC 16”.
4
Self-Study Programme 303
The V10-TDI engine
with pump-jet fuel injection system
Design and function
, ... Easy to recognise, 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,
you can see here the world’s top performer!
A milestone...
... in statuary! ... in engine development!
303_U2
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 made of a diesel motor 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.
NEW Caution
Note
The Self-Study Programme describes the Please always refer to the relevant service
design and function of new developments! literature for up-to-date inspection, adjustment
The contents are not updated. and repair instructions.
2
,At a glance
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Oil circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Coolant circulation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fuel system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Check your knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3
, Introduction
The V10-TDI engine
The V10-TDI engine is a newly developed
diesel engine in which innovative light-weight
construction and enormous power are united
within compact dimensions.
It has a cylinder block made of aluminium, where
the two rows of cylinders are arranged at an
angle of 90o to one another.
The control and ancillary unit is driven by
gearwheels The tried-and-tested pump-jet fuel
injection system ensures a high performance yield
at low exhaust emissions.
The V10-TDI engine is used as a high-performance
engine in the Volkswagen Touareg and Phaeton.
303_001
Engine mechanics technical features Engine management technical features
– Cylinder block made of aluminium with an – Two motor controllers
end bracket made of cast-iron – Charged by two adjustable turbochargers
– Joining of cylinder head and cylinder block – Exhaust gas recirculation effected with
via tie-rod screw connection pneumatically controlled exhaust gas
– Contol and ancillary unit driven by recirculation valves with electrically-operated
gearwheels intake manifold flaps
– Balancer shaft for reducing vibrations – Lambda probes for controlling exhaust gas
recirculation
A detailed description of the engine management system for the V10-TDI engine can be
found in Self-Study Programme No. 304 ”Electronic Diesel Control EDC 16”.
4
