TDI is a range of diesel turbocharged engines with direct fuel injection produced by the Volkswagen Group. They debuted on the Audi 100 C3 in 1989. Nowadays, almost all models of Volkswagen, Seat, Audi, and Škoda are equipped with these engines. They are also installed on some models of Ford, Volvo, Mitsubishi, Chrysler, and other makes.
Features
TDI engines have aluminium or cast iron cylinder blocks. The cylinder heads are made of aluminium. A belt is usually used in the valve timing mechanism, but there are also versions that use a chain or gears. Depending on the engine version, the fuel system features a high-pressure pump, unit injectors, or a fuel rail. A variable-geometry turbocharger is installed on many cars instead of a regular one. There are also twin-turbo versions, some of which are called BiTDI.
Popular TDI engines
Engine series | Engine capacity, L | Engine code | Number of cylinders | Number of valves | Max output, hp | Max torque, N·m | Fuel injection type | Production start | Model applications |
EA381 | 2.5 | 1T | in-line 5 | 10 | 120 | 265 | Direct injection | 1989 | Audi 100 C3 |
EA153 | 2.5 | BAC | in-line 5 | 10 | 174 | 400 | Unit injectors | 2003 | Volkswagen Touareg 1 |
5.0 | AJS | V10 | 20 | 313 | 750 | Unit injectors | 2002 | Volkswagen Phaeton 1 | |
EA180 | 1.9 | AFN | in-line 4 | 8 | 110 | 235 | Direct injection | 1996 | Volkswagen Golf 3; SEAT Cordoba 1; Volkswagen Vento 1; Audi A6 C5; Volkswagen Passat B4; Volkswagen Passat B5; SEAT Ibiza 2; Volkswagen Polo 3; SEAT Toledo 1; Volkswagen Sharan 1; Audi A4 B5 |
EA188 | 1.9 | AWX | in-line 4 | 8 | 130 | 285 | Unit injectors | 2000 | Audi A4 B6; Audi A6 C6; Škoda Superb 1; Volkswagen Passat B5 |
2.0 | BMM | in-line 4 | 8 | 140 | 320 | Unit injectors | 2004 | Audi A3 8P; Škoda Octavia 2; Volkswagen Caddy 3; SEAT Altea 1; Volkswagen Golf 5; Volkswagen Jetta 5; SEAT Leon 2; Volkswagen Touran 1 | |
EA189 | 1.6 | CAYC | in-line 4 | 16 | 105 | 250 | Common rail | 2009 | Škoda Rapid 1; Audi A3 8P; SEAT Ibiza 4; Volkswagen Passat B7; Škoda Octavia 2; SEAT Leon 2; Škoda Yeti; Volkswagen Golf 6; Škoda Superb 2; Volkswagen Jetta 5 |
1.9 | CAAC | in-line 4 | 16 | 140 | 340 | Common rail | 2009 | Volkswagen Multivan T5; Volkswagen Caravelle T5; Volkswagen Transporter T5 | |
EA288 | 1.6 | DCXA | in-line 4 | 16 | 120 | 250 | Common rail | 2014 | Škoda Superb 3; Volkswagen Passat B8 |
2.0 | DBGC | in-line 4 | 16 | 150 | 340 | Common rail | 2016 | Škoda Kodiaq 1; Volkswagen Tiguan 2 | |
EA330 | 2.5 | BDH | V6 | 24 | 180 | 370 | Direct injection | 2004 | Audi A6 C5; Volkswagen Passat B5; Audi A4 B6 Cabrio |
EA381 | 2.5 | BJK | in-line 5 | 10 | 109 | 285 | Common rail | 2006 | Volkswagen Crafter 1 |
EA896 | 3.0 | CASA | V6 | 24 | 240 | 550 | Common rail | 2007 | Volkswagen Touareg 1; Audi Q7 4L |
EA897 | 3.0 | CRCA | V6 | 24 | 245 | 550 | Common rail | 2010 | Volkswagen Touareg 2; Audi Q7 4L |
EA898 | 4.2 | CKDA | V8 | 32 | 340 | 800 | Common rail | 2010 | Volkswagen Touareg 2 |
Common malfunctions of TDI engines
Malfunctions | Engines |
Adjustment of the electronically controlled high-pressure pump is often required. | 1T; BDH |
The cylinder head can get deformed due to overheating of the engine caused by malfunctioning of the cooling system. | 1T |
The intake manifold is prone to cracking. | BAC |
The seals of the unit injectors and the tandem pump lose tightness over time. | AJS; AWX; BAC |
The valve timing mechanism gears break down quickly. | AJS |
The valve seats burn out after a high mileage, leading to engine compression loss. | AFN |
The turbine blades or EGR valve sometimes get jammed. | AFN; AWX; CAAC; BDH; BMM |
Use of poor-quality oil causes the camshaft cams or hydraulic lifters to wear out quickly. | AWX;BJK |
The piezo injectors break down frequently. | BMM; CAYC; BJK; CKDA; CRCA; CASA; CAAC |
The fasteners of the unit injectors become loose, resulting in leaks | BMM |
Leaks from under the valve cover often appear. | BDH; CAYC |
The diesel particulate filter gets clogged relatively fast. | CAAC; DBGC; CKDA; CRCA; CASA; CAYC |
The heat exchanger gasket dries out frequently, leading to coolant leaks. | DCXA |
The intake manifold swirl flaps can get jammed over time. | CASA |
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