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The 105 kW 143 hp 2.0 litre TDI engine featuring common rail CR injection technology marks the birth of a new generation of dynamic and efficient diesel engines. It reinterprets the qualities of the TDI concept while addressing the future challenges facing environmental protection in particular. The 2.0 litre TDI CR engine is based on the successful 2.0 litre pump injector TDI engine, whereby the combination of the 2.0 litre TDI unit with common rail technology sets new standards. The new 2.0 litre TDI CR engine built at Audi Hungaria Motor in Györ already meets the high standards of the Euro 5 exhaust emission standard due to come into effect in 2010. Thanks to the use of common rail technology, the 2.0 litre TDI CR engine has major advantages with regard to exhaust emissions, acoustics, weight and overall build height. The TDI engines deliver high torque at low revs. The goal for the development of the 2.0 litre TDI CR engine was to enhance this character. Contents Introduction 2.0 litre 105 kW TDI engine with common rail injection system . .4 Engine mechanicals Cylinder block . 7 Crank mechanism 7 Balancer shaft module 9 Cylinder head . 10 Camshaft drive .11 4 valve technology . .12 Toothed belt drive . .13 Intake manifold with swirl flaps . .14 Oil circulation system .16 Crankcase ventilation system . .18 Coolant system .22 Exhaust gas recirculation cooling system . .24 Common rail injection system Introduction .25 Fuel system . .26 Auxiliary fuel pump 28 Fuel preheating valve .29 Common rail injection system 30 Engine management System overview .42 Engine management . .44 Service Special tools . 62 The Self Study Programme teaches the design and function of new vehicle models, new automotive components or new technologies. Reference Note The Self Study Programme is not a Repair Manual. Values specified herein are intended for easier understandin