Self-Study Programme 467 4.2L V8 TDI engine with common rail fuel injection system.pdf

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Service Training
Self-study Programme 467
The 4.2 l V8 TDI engine with
common rail fuel injection system
Design and Function
Following the introduction of the 3.0 l V6 TDI engine
in the Phaeton and Touareg in 2005, the engine
range is now being expanded to include the 4.2 l V8
TDI engine.
Thanks to this range-topping diesel engine,
Volkswagen now has a power plant that boasts
excellent figures and thus superior performance with
250 kw max. at 4,000 rpm and 800 Nm as early as
1,750 rpm.
This high-torque engine, which was developed by
Audi and has featured in the A8 and Q7, has been
adapted for use in the new Touareg. It has been
possible to reach the high emissions goals for the EU5
emissions standard and, at the same time, achieve a
consumption of 9.4 l/100 km with 239 g/km CO
2
.
This engine sets standards in terms of dynamics,
driving fun, consumption and reliability while
improving comfort and reducing noise.
S467_002
The self-study programme portrays 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.
Important
Note
2
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Test Yourself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3
Introduction
The 4.2 l V8 TDI engine with common rail injection system
Technical features
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Bosch common rail injection system with piezo
injectors max. 2,000 bar injection pressure
Diesel particulate filter/oxidising catalytic
converter
Turbochargers with speed sensors
Innovative thermal management (ITM)
Low-temperature exhaust gas recirculation
Volumetric flow-controlled oil pump
Demand-regulated fuel delivery unit
Oil level/oil temperature sender with ultrasonic
measurement principle
S467_040
Technical data
Output and torque graph
Engine code
Type
Displacement
Bore
Stroke
Valves per cylinder
Compression ratio
Max. output in kW
Maximum torque
Engine management
Fuel
Exhaust gas treatment
CKDA
8-cylinder V engine
4,134 cm
3
83.0 mm
95.5 mm
4
16.4 : 1
250 at 4,000 rpm
800 Nm at 1,750 rpm
to 2,750 rpm
Bosch EDC 17
Diesel fuel complying with
DIN EN590
Exhaust gas recirculation,
oxidising catalytic converter,
diesel particulate filter
EURO 5
239 g/km
Engine speed (rpm)
S467_026
Torque (Nm)
Output (kW)
Emissions standard
CO
2
emission
4
Engine Components
Crankshaft drive
The crankcase with a gap of 90 mm between the cylinders (90°V) is made from grey cast iron.
The crankshaft is forged and mounted in 5 bearings. The big end bearing journals are roller burnished for strength.
Roller burnishing is a non-cutting process that uses rolling tools to smoothen and strengthen material surfaces.
The cast aluminium pistons with combustion cavity have a diameter of 83 mm. They are equipped with a ring
carrier cooling duct for cooling the piston. Oil spray nozzles constantly spray oil onto the underside of the piston
crown.
Crankcase
Main oil duct
Bearing frame
Crankshaft
Oil sump
S467_044
5

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