SSP 350 – The 3.0l V6 TDI Engine - VolksPage
Service TrainingSelf-study programme 350The 3.0l V6 TDI engineDesign and function
The range of engines fitted in the Phaetonand Touareg is being extended by a hightech turbodiesel engine.The 3.0l V6 TDI engine has beendeveloped by Audi and is equippedwith a piezo-controlled common railfuel injection system.This unifies power and smoothness ina compact engine.The engine is combined with a dieselparticulate filter and meets the EU 4exhaust emission standard.S350 001NEWThe self-study programme portrays the designand function of new developments!The contents will not be updated.2For current testing, adjustment and repairinstructions, please refer to the customerservice literature intended for this purpose.AttentionNote
At a glanceIn brief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Engine mechanical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Engine management system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Test your knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
In briefThe 3.0l V6 TDI engineThe 3.0l V6 TDI engine is a new diesel engine developed from the Audi V engine family.This engine family's special characteristic is its extremely short and compact design, which is achieved by means ofa chain drive. The engine additionally combines high output and ample torque with smooth running characteristicsand low exhaust emissions. A piezo-controlled common rail fuel injection system ensures high injection pressureand a flexible injection process. The engine is installed in the Volkswagen Phaeton and Touareg.S350 003(View of the Phaeton engine)Technical engine features: 4High-strength, compacted graphite iron cylinderblock4-valve technologyIntake manifolds with swirl flapsChain drive for valve control system, balancer shaftand oil pump Common rail fuel injection systemPiezo-controlled injectors (piezo injectors)Diesel particulate filter
Technical dataEngine codeBMK (Phaeton)Design typeBKS (Touareg)6-cylinder V engine (90 V angle)2967 cm3DisplacementBore83 mmStroke91.4 mmCompression ratio17 : 1Valves per cylinder4Firing sequence1-4-3-6-2-5Max. output165 kW at 4000 rpmMax. torque450 Nm at 1400 to 3250 rpmEngine management system500 Nm at 1750 to 2750 rpmBosch EDC 16 C common rail fuel injection systemFuelDiesel, at least 51 CNExhaust gas cleaningOxidising catalytic converter, exhaust gas recirculation, diesel particulate filterExhaust emission standardEU 4Output (kW)Torque (Nm)Torque and output graphIn the Phaeton, the 3.0l V6 TDI engine achieves itsmaximum torque of 450 Nm as of an engine speed of1600 rpm; this is available over a wide speed range,up to 3250 rpm.In the Touareg, the engine offers maximum torque of500 Nm in the engine speed range from 1750 to2750 rpm.Its maximum output of 165 kW is achieved at4000 rpm in both vehicles.PhaetonEngine speed (rpm)TouaregS350 0405
Engine mechanical systemCylinder blockThe cylinder block has a 90 V angle and ismanufactured from compacted graphite iron(CGI-450).The cylinder liners are finished using the newUV photon honing process. This reduces frictionand improves running-in behaviour.S350 006Compacted graphite ironCast iron with vermicular graphite is commonlynamed as such due to its worm-like graphitestructure (worm-shaped vermicular, Latin).In professional circles, this material is calledcompacted graphite iron (CGI).Compacted graphite iron is a high-strength materialwhich enables a thin-walled, cast iron construction.This results in a weight saving of 5 – 10 % incomparison with a grey cast iron design.S350 002Cast iron withvermicular graphiteUV photon honingCast iron withnodular graphiteWith UV photon honingThe cylinder contact surface is honed in theconventional manner and is then processed usingUV photon honing.During this process, a laser beam melts the surface ofthe cylinder contact surface, and nitrogen penetratesit. This smoothes and hardens the cylinder surface.S350 056Without UV photon honing6
Bearing frameA grey cast iron bearing frame is bolted into thecrankcase. This contains the support for the crankshaftand additionally stiffens the cylinder block.S350 007Crankshaft and balancer shaftThe crankshaft, which is forged from tempered steel,is supported at four points in the bearing frame.Due to the 90 V angle, the crank pins are offsetby 30 . This is necessary to achieve an even firinginterval.To ensure low-vibration engine operation, a balancershaft is located in the V of the cylinder block tocompensate the moments of inertia which occur. Thebalancer shaft is driven by the crankshaft via a chain.This rotates at engine speed counter to the direction inwhich the engine is running.S350 008PistonsThe aluminium pistons are designed without valvepockets.The swirl is influenced by the ports in the cylinderhead and the position of the swirl flaps in the intakemodule, and ensures optimum mixture formation.To cool the piston ring zone, the pistons are equippedwith an annular cooling duct, into which oil is sprayedvia piston spray nozzles.S350 0097
Engine mechanical systemCylinder headThe 3.0l V6 TDI engine has two cylinder headsmanufactured from aluminium alloy. Two intakeand two exhaust valves per cylinder are arrangedaccording to the principle of cross-flow.Each cylinder head is fitted with one camshaft forthe intake valves and one camshaft for the exhaustvalves. The intake and exhaust camshafts are linkedvia spur gear toothing with integrated backlashcompansation. The bearing frame for the camshaftsis bolted to the cylinder head.The valves are actuated via low-friction roller rockerfingers with hydraulic valve clearance compensationelements.InjectorsBearing frameIntake camshaftS350 010Exhaust camshaftHydraulic valve clearancecompensationFor the structure and function of thehydraulic valve clearance compensationelements, refer to self-study programmeNo. 183 "The 2.5l V6 TDI 4V engine".InjectorThe injectors are secured in the cylinder head with theaid of clamping pieces. They can be removed viasmall covers in the cylinder head cover.S350 027Clamping piece8
4-valve technologyExhaust camshaftInjectorTwo intake and two exhaust valves per cylinder arearranged vertically in the cylinder head.Intake camshaftThe vertically positioned, centrally located injectionvalve is positioned directly over the central pistonrecess. This design leads to good mixture formation,resulting in low fuel consumption and low exhaustemissions.Intake valvesExhaust valvesPiston recessS350 044The shape, size and layout of the intake and exhaustports ensure good volumetric efficiency and afavourable gas cycle in the combustion chamber.Spiral portThe intake ports are designed as spiral and tangentialports.Thanks to the tangential port, the inflowing airgenerates the desired, high degree of in-cylinder flow.Particularly at high speeds, the spiral port leads togood combustion chamber filling.Tangential portExhaust portS350 0159
Engine mechanical systemAir intake systemIntake manifolds with swirl flapsIntake manifoldtop sectionIntake manifoldbottom sectionThe intake manifolds of both cylinder banks are fittedwith continuously variable swirl flaps. Due to theposition of the swirl flaps, the intaken air's swirl isadjusted depending on the engine speed and load.Intake manifoldflap motorV157, V275Intaken airSwirl flapsS350 016Intake manifold flap motorV157, V275The swirl flaps are moved by the intake manifold flapmotor via a push rod. To do this, the positioning motoris actuated by the engine control unit. An integratedsensor serves to feed back the current position of theswirl flaps.The intake manifold flap motors must onlybe renewed completely together with theintake manifold lower section. Pleaseobserve the notes in the workshopmanual!10Swirl flapS350 049Push rod
Swirl flap closedFunction of the swirl flapsLow engine speedsThe swirl flaps are closed when the engine is idlingand at low engine speeds. This causes a high levelof swirling, which leads to good mixture formation.The swirl flaps are open when the engine is started,in limp-home mode and at full throttle.S350 017Swirl flap openHigh engine speedsAs of an engine speed of approx. 1250 rpm, the swirlflaps are open continuously. Good combustionchamber filling is achieved thanks to the increasedair throughput.As of an engine speed of approx. 2750 rpm, the swirlflaps are opened completely.S350 01811
Engine mechanical systemBacklash compensationThe intake and exhaust camshafts are linked via spur gear toothing with integrated backlash compansation.In this case, the exhaust camshaft's spur gear is driven by the intake camshaft's spur gear. Backlash compensationensures that the camshafts are driven with little noise.Left cylinder headIntake camshaftSpur gearsIntermediate diskS350 011S350 012Exhaust camshaftCamshaftRetaining ringDiaphragm springFixedspur gearStructureMoveablespur gearThe exhaust camshaft spur gear is split into two partsin the left-hand cylinder head. (The intake camshaftspur gear is split into two parts in the right-handcylinder head.)The broader part of the spur gear (fixed spur gear)is positively connected to the camshaft.Three lugs are located on the front face.The narrower part of the spur gear (moveable spurgear) can be moved radially and axially. Recesses forthe three lugs are located on its rear side.Lugs12S350 019
How it works:Both spur gear parts are pushed axially togethervia the force exerted by a diaphragm spring. Whilstthis occurs, they are simultaneously caused to rotatevia the lugs.S350 020Diaphragm springBacklash compensationTooth offsetThis rotational movement offsets the teeth of bothspur gear parts and therefore leads to backlashcompensation between the intake and exhaustcamshafts' gear wheels.S350 02113
Engine mechanical systemChain driveThe camshafts, the balancer shaft and the oil pump are driven by the crankshaft via a chain drive.This is located on the engine's gearbox side.The chain drive makes the engine's compact design possible.Camshaft drive bank 2 – drive BCamshaft drive bank 1 – drive CCentral chain drive – drive AIntermediate gearIntermediate gearBalancer shaft driveS350 013CrankshaftOil pump driveSecond chain drive – drive D14
The chain drive is comprised of: A central chain from the crankshaft tothe intermediate gears (drive A),The camshaft chain sprockets have the same diameteras the crankshaft sprocket.The necessary camshaft: crankshaft ratio of 2 : 1 isachieved by means of the intermediate gears. A chain from each of the intermediate gears tothe intake camshafts (drives B and C),The chains are tensioned by sprung, hydraulic chaintensioners; this system is maintenance-free. A chain from the crankshaft to the oil pump driveand to the balancershaft.Ancillary component driveThe coolant pump, the power steering pump, the airconditioner compressor and the alternator are drivenby the crankshaft via a poly V-belt.Coolant pumpPower steering pumpAlternatorPoly V-beltAir conditionercompressorHydraulic tensionerS350 02215
Engine mechanical systemLubrication systemOverview of the systemOil filter moduleVacuum pumpOil coolerTurbochargerOil returnS350 023Oil spray nozzles(piston cooling)Pressure relief valveOil pressureregulating valveOil panOil pumpOil level and oil temperaturesender G266Oil without pressureOil under pressure16
Oil filter moduleOil spray nozzlesThe oil filter module contains an oil non-return valveand the short-circuit valve. The oil non-return valveprevents oil from flowing back into the oil pan fromthe oil filter housing when the engine is switched off.The short-circuit valve is a bypass valve, which openswhen the oil filter or oil cooler is blocked and therebyensures that the engine is supplied with oil.It opens at 2.5 bar.Oil is sprayed into the pistons' cooling ducts via the oilspray nozzles. This cools the pistons.Pressure relief valveThis is a safety valve in the oil pump. It protects thelubrication system from excessive pressure on coldstarting.It opens at 11 bar.Oil pressure regulating valveThe oil pressure regulating valve is integrated into theoil pump and regulates the engine's oil pressure.17
Engine mechanical systemOil panThe oil pan is comprised of two components; a cast aluminium upper oil pan section and a sheet steel lower oil pansection.The design of the oil pan differs in the Phaeton and the Touareg. This is the result of installation space conditionsand off-road capability requirements. The oil pump's oil intake system has accordingly been adapted to thedifferent design forms.Oil pan top sectionPhaeton oil panDue to the limited installation space, the oil pan fittedin the Phaeton flattens and broadens at the bottom.Oil pan lower sectionS350 014Oil pan top sectionTouareg oil panThe design of the oil pan fitted in the Touareg isnarrow and deep. Due to the low oil intake point and,in comparison with the Phaeton, lower oil level,guaranteed oil intake with little oil foaming isachieved on gradients.S350 026Oil pan lower section18
Oil pumpThe oil pump is a crescent pump. It operatesaccording to the duocentric principle and is drivenby chain drive D via a stub shaft.The length of the intake fitting has been adapted tothe different oil pan designs.PhaetonIntake fittingTouaregS350 024Oil filter moduleOil filterCyclonic oil separator withpressure control valveThe oil filter module is located in the V of the engine.The oil filter, the oil cooler and the cyclonic oilseparator with pressure control valve for thecrankcase breather system are integrated intothe oil filter module.The oil cooler is connected to the engine's coolantcircuit.S350 025Oil cooler19
Engine mechanical systemCrankcase breather systemPressure control valveCyclonic oil separatorIn combustion engines, pressure differences betweenthe combustion chamber and crankcase lead to airflows between the piston rings and cylinder contactsurface; these are called blow-by gases.To prevent environmental pollution, these gases,which contain oil, are fed back to the intake area viathe crankcase breather system.A cyclonic oil separator separates the oil contained inthe gases from the air. This oil is returned to the oilpan via a port in the crankcase.S350 029Functional principleTurbochargerCharge air coolerPressure control valveBlow-by gasesCyclonic oil separatorS350 06620
Function of the cyclonic oil separatorTo the intake portPressure control valveThe blow-by gases are fed to the cyclonic oilseparator via a port inside the engine.Cyclonic oil separatorThe cyclonic oil separator causes the air to rotate. Dueto the centrifugal force which occurs, the oil spray isspun onto the wall of the separator.Oil droplets form there, and these flow off into the oilpan via a port in the crankcase. The air, from whichthe oil spray has been removed, is fed back into theintake port via the pressure control valve.S350 030From the crankcasePressure control valve openTo the intake portFunction of the pressure control valveDiaphragmsThe pressure control valve is located in the cover ofthe cyclonic oil separator. It is comprised of amembrane and a pressure spring, and regulates thepressure for venting the crankcase.CompressionspringWhen the blow-by gases are introduced, the pressurecontrol valve limits the vacuum in the crankcase, asengine gaskets may become damaged if there is anexcessive vacuum.From the crankcaseIf the vacuum in the intake port is high, the pressurecontrol valve closes. In the case of a low vacuum inthe intake port, it opens by means of the pressurespring's force.S350 050Pressure control valve closedS350 03421
Engine mechanical systemCoolant circuit234Overview of the system17161018111191412151399208Engine coolant circuit1234567227Coolant circuit for fuel cooling(Touareg only)HotHotColdColdCooler for engine coolant circuitGearbox oil coolerAlternatorContinued coolant circulation pump V51(with towing attachment only)Air reservoirHeat exchangerExpansion tank8910111213Additional heaterChokeOil coolerCooler for exhaust gas recirculationExhaust gas recirculation flapThermostat (opens as of a coolanttemperature of 87 C)
Coolant circuit for fuel cooling(Touareg only)5In the Touareg, the 3.0l V6 TDI engine is equippedwith a separate coolant circuit for the fuel cooler.This is necessary because the temperature of thecoolant is too high, when the engine is at operatingtemperature, to cool the returning fuel.6Water pump V36 (Touareg only)21The water pump V36 is an electric circulation pump. Itis initialised as required by the engine control unit,and ensures that the coolant is circulated in thecoolant circuit in order to cool the fuel.Continued coolant circulation pump V51(vehicles with towing attachment only)The continued coolant circulation pump V51 is anelectrically driven pump. It is initialised according to aperformance map by the engine control unit, andtherefore ensures that the coolant is circulated forcooling purposes when the engine is "off".6S350 0281415161718192021Coolant pumpCoolant temperature sender G62Radiator outlet coolant temperature sender G83Water pump V36Cooler for fuel coolingFuel coolerNon-return valveHeating23
Engine mechanical systemCommon rail fuel injectionsystemThe common rail fuel injection system is a highpressure accumulator fuel injection system for dieselengines.The main features of this fuel injection system are:The term "common rail" means that all of one cylinderbank's injectors have a common, high-pressure fuelaccumulator. The injection pressure can be selected almostinfinitely within the performance map.The availability of high injection pressure enablesoptimal mixture formation.A flexible pilot, primary and secondary injectionprocess is achieved.In this system, pressure generation and fuel injectionare separate. The high pressure required for injectionis generated by a separate high-pressure pump. Thisfuel pressure is stored in a high-pressure accumulator(rail) and is made available to the injectors via shortinjector pipes.High-pressure accumulator (rail), cylinder bank 1with injectors N30, N31, N32Fuel pressure regulating valve N276Distributor between the railsHigh-pressure accumulator (rail),cylinder bank 2Fuel pressuresender G247High-pressure pumpS350 031A detailed description of the common railfuel injection system can be found in selfstudy programme No. 351 "The commonrail fuel injection system".24Piezo injectorsN33, N83, N84
Injectors (piezo injectors)The 3.0l V6 TDI engine is fitted with piezo-controlled injectors. In comparison with solenoid valve-controlledinjectors, piezo technology has approximately 75 % less moved mass at the injector needle.This weight reduction offers the following advantages: Very short switching timesSeveral injections per working cycle are possiblePrecisely apportionable injection quantitiesThe injection process, with a total of up to five partial injections per working cycle, has up to two pilot injections inthe lower engine speed range and two secondary injections. This enables low emissions and smooth combustion.Piezo effect(Piezo [Greek] pressure)The piezo-electric effect was discovered byPierre Curie in 1880.If a crystalline lattice (turmaline, quartz) comprised ofions is deformed under pressure, electrical voltage isgenerated.The piezo-electric effect can also be reversed byapplying an electric voltage. In this case, the crystalexpands. This effect is used to control the injectors.Piezo actuatorConnecting pistonValve pistonSwitching valveCaution! The piezo-controlled injectorsare actuated with a voltage of110 – 148 V. Observe the safetyinstructions in the workshop manual!Injector needleS350 03225
Engine mechanical systemFuel systemOverview of the
Oil spray nozzles Oil is sprayed into the pistons' cooling ducts via the oil spray nozzles. This cools the pistons. Pressure relief valve This is a safety valve in the oil pump. It protects the lubrication system from excessive pressure on cold-starting. It opens at 11 bar. Oil filter module The oil filter module contains an oil non-return valve
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