Volkswagen CBDC Specifications
| Engine Model: Volkswagen CBDC |
| Engine Type: 4-cycle 4-cylinder DOHC 16-valve turbocharged liquid-cooled diesel |
| Total Displacement: 120.1 cu.in (1.96 L) |
| Rated Engine Power: 109 Hp (81 kW) at 4200 rpm |
| Fuel System Type: Common rail direct injection |
____________________________________________________________________________________
The Volkswagen CBDC is a 2.0-liter inline-four common
rail turbo diesel engine belonging to the EA189 family, produced between 2008
and 2010. Developed as an entry-level high-efficiency variant within the 2.0 TDI
range, this engine was positioned under the BlueMotion designation in the Golf
Mk6 and related models, prioritizing fuel economy and reduced emissions over
outright power output.
The CBDC utilizes a common rail direct injection system with solenoid-type
injectors managed by a Bosch EDC17 engine control unit, delivering precise fuel
metering across the operating range. A variable-geometry turbocharger and
intercooler provide forced induction while maintaining responsiveness at lower
engine speeds.
The engine shares its fundamental architecture with higher-output EA189
variants, including the robust 2.0-liter cast iron block and aluminum cylinder
head, but employs a smaller turbocharger and specific software calibration to
achieve its 81 kW output. This detuned configuration positioned the CBDC as a
replacement for the 1.9 TDI units in the Volkswagen lineup, offering improved
refinement, lower noise levels, and compliance with Euro 5 emissions standards
through the inclusion of a diesel particulate filter.
Configuration: Inline four-cylinder, transversely mounted
Valvetrain: DOHC, 16 valves with four valves per cylinder
Displacement: 1,968 cc (120.1 cu.in)
Bore: 81.0 mm (3.19 in)
Stroke: 95.5 mm (3.76 in)
Compression ratio: 16.5:1
Firing order: 1-3-4-2
Engine rotation: Clockwise when viewed from the crankshaft pulley end
Maximum power: 81 kW (110 PS, 109 hp) at 4,200 rpm
Maximum torque: 250 Nm (184 lb-ft) from 1,500 to 2,500 rpm
Engine idle speed: 800-850 rpm
Maximum engine speed: 5,000 rpm governed
Emissions standard: Euro 5 with diesel particulate filter
The cylinder block is constructed from cast iron using
high-pressure casting techniques, providing the structural rigidity required for
diesel engine combustion pressures. The closed-deck design incorporates fully
supported cylinder bores with extensive webbing between each bore to enhance
head gasket sealing and minimize bore distortion under the elevated cylinder
pressures characteristic of turbocharged diesel operation.
Five main bearings support the crankshaft, utilizing a bedplate construction
where a separate aluminum lower crankcase assembly bolts to the block to form
the main bearing structure, contributing to overall engine stiffness while
managing the high loads generated by the long-stroke configuration.
Cylinder bores are machined directly into the cast iron material without
separate liners, utilizing a plateau-honed finish to optimize piston ring
sealing. Integrated oil galleries are cast into the block to supply the main
bearings, connecting rod bearings, and piston cooling jets. The block
incorporates an integrated oil cooler mounting flange on the left side.
The cylinder head is manufactured from aluminum alloy
using precision sand-casting techniques to achieve complex coolant passages,
intake and exhaust ports, and injector mounting bores. The cross-flow design
positions the intake manifold on the rear side and the exhaust manifold mounting
flange on the front side for transverse engine installations. Combustion
chambers utilize a pent-roof configuration with four valves per cylinder
arranged around a centrally located direct injector.
Dual overhead camshafts are supported by five bearing journals machined directly
into the cylinder head casting. Valve actuation employs direct-acting bucket
tappets incorporating hydraulic lash adjusters within the tappet assemblies,
eliminating valve clearance adjustment requirements. The camshafts are driven by
a rubber timing belt with an automatic hydraulic tensioner. The cylinder head
incorporates integrated coolant passages surrounding the injector bores and
pre-chamber areas to manage thermal loads.
Valves: 16 (4 per cylinder).
Intake valve diameter: 29.5 mm (1.16 in).
Exhaust valve diameter: 26.0 mm (1.02 in).
Valve stem diameter: 5.0 mm (0.20 in).
Camshaft drive: Rubber timing belt with automatic hydraulic tensioner.
Valve lash adjustment: Hydraulic lash adjusters, no manual adjustment required.
The fuel system employs Bosch common rail direct
injection with solenoid-type injectors. A high-pressure fuel pump mounted on the
cylinder head and driven by the exhaust camshaft draws fuel from the tank
through an electric lift pump. The pump elevates fuel pressure to 160.0 MPa
(23,200 psi) maximum, delivering pressurized fuel to the common rail
accumulator.
The Bosch EDC17 engine control unit manages injection timing, duration, and the
number of injection events per combustion cycle, enabling up to five separate
injections including pilot, pre-injection, main injection, and post-injection
phases. Post-injection events are utilized for diesel particulate filter
regeneration.
Injector type: Bosch solenoid-type common rail injectors. Injector flow rate:
380 cc/min at 160.0 MPa (23,200 psi) system pressure. Fuel requirement: Diesel
fuel meeting EN 590 specification. High-pressure fuel pump: Bosch CP3
three-piston radial piston pump. Fuel rail construction: High-strength steel
with integrated pressure sensor and pressure relief valve.
The lubrication system operates as a fully pressurized
wet-sump configuration utilizing a rotor-type oil pump mounted at the front of
the engine and driven by the crankshaft through a chain drive. The pump
incorporates a pressure relief valve calibrated to maintain system pressure
under high-engine-speed conditions. Oil is drawn from the aluminum oil pan
through a baffled pickup tube with integrated oil level sensor.
A full-flow spin-on oil filter is mounted externally on the cylinder block. Oil
is distributed through main galleries cast into the cylinder block, supplying
the five main bearings, connecting rod bearings, camshaft bearings, hydraulic
lash adjusters, timing belt hydraulic tensioner, and piston cooling jets. Piston
cooling jets are integrated into the cylinder block, directing oil streams to
the underside of each piston crown to manage the high thermal loads of diesel
combustion.
Oil pump type: Rotor-type with chain drive from crankshaft
Oil pressure at idle (warm): 1.2-1.8 bar (17-26 psi)
Oil pressure at 3,000 rpm: 3.5-4.5 bar (51-65 psi)
Oil capacity with filter change: 4.3 liters (4.5 US qt)
Oil viscosity specification: 5W-30 meeting VW 507.00 specification
Oil pan construction: Aluminum with integrated baffling and windage tray
Oil filter thread: M20x1.5
Cooling system circulation is managed by a belt-driven
centrifugal water pump mounted on the front of the cylinder block. Coolant flows
from the pump into the cylinder block water jacket, circulating around the
cylinder bores before passing upward through the cylinder head gasket into the
cylinder head. A separate coolant circuit serves the exhaust gas recirculation
cooler and the turbocharger bearing housing. The cooling system includes an
electric auxiliary coolant pump to maintain circulation after engine shutdown
for turbocharger cooling.
Coolant capacity: 7.5 liters (7.9 US qt) including heater core and radiator.
Thermostat opening temperature: 87°C (189°F). Water pump drive: Serpentine
accessory belt. Radiator fan control: Dual electric fans with ECM-controlled
operation based on coolant temperature sensor input, charge air temperature, and
diesel particulate filter regeneration requirements. Coolant specification:
Phosphate-free, silicate-free ethylene glycol blend with corrosion inhibitors,
50 percent concentration recommended.
| Intake and Exhaust Systems |
Intake System: A composite plastic intake manifold with
integrated charge air cooler is mounted on the rear of the cylinder head. The
intake system incorporates a variable-geometry turbocharger with electronically
actuated vane control to optimize boost pressure across the engine speed range.
An air-to-air intercooler reduces charge air temperature before entry into the
intake manifold. An electronically controlled throttle valve manages airflow
during diesel particulate filter regeneration and engine shutdown.
Exhaust System: A stainless steel exhaust manifold is integrated into the
cylinder head casting. The exhaust system incorporates a close-coupled diesel
oxidation catalyst, a diesel particulate filter, and a selective catalytic
reduction system is not employed on this Euro 5 variant. The diesel particulate
filter utilizes passive and active regeneration strategies, with active
regeneration initiated by the engine control unit through post-injection fuel
events.
The engine is equipped with a variable-geometry
turbocharger (VGT) manufactured by BorgWarner or Garrett. The variable turbine
geometry utilizes movable vanes surrounding the turbine wheel, allowing the
turbocharger to maintain efficient operation across a wide range of engine
speeds and loads. A vacuum-actuated control mechanism adjusts vane position
based on engine control unit commands. Turbocharger model: BorgWarner BV43 or
Garrett GTB1446VZ. Maximum boost pressure: 2.2 bar absolute (1.2 bar gauge).
Length: 610 mm (24.0 in)
Width: 630 mm (24.8 in)
Height: 690 mm (27.2 in)
Engine dry weight (complete assembly without fluids): 150 kg (331 lb)
Valve clearance adjustment: Not required due to
hydraulic lash adjusters. Timing belt replacement interval: 120,000 km (75,000
miles) or 5 years recommended; official interval of 210,000 km (130,000 miles)
considered with strict adherence to condition-based inspection. Engine oil
change interval: 15,000 km (9,300 miles) or 12 months under normal conditions
with VW 507.00 specification oil; 10,000 km (6,200 miles) under severe service.
Oil filter replacement interval: Every oil change.
Fuel filter replacement interval: 30,000 km (18,600 miles). Air filter
replacement interval: 60,000 km (37,500 miles) under normal conditions.
Accessory belt inspection interval: 30,000 km (18,600 miles); replace if
cracking, glazing, or fraying is evident. Diesel particulate filter:
Regeneration occurs automatically; forced regeneration required if filter
reaches 85 percent soot load. Glow plug inspection: 120,000 km (75,000 miles);
replace as required based on cold-start performance.
Cylinder head bolts (11 mm x 1.5 thread), Step 1: 30 Nm
(22 lb-ft)
Cylinder head bolts (11 mm x 1.5 thread), Step 2: 60 Nm (44 lb-ft)
Main bearing bedplate bolts, Step 1: 30 Nm (22 lb-ft)
Main bearing bedplate bolts, Step 2: 70 Nm (52 lb-ft)
Connecting rod cap bolts: 30 Nm (22 lb-ft)
Camshaft bearing cap bolts: 12 Nm (9 lb-ft)
Camshaft sprocket bolts: 80 Nm (59 lb-ft)
Crankshaft pulley bolt: 250 Nm (184 lb-ft)
Flywheel bolts: 80 Nm (59 lb-ft)
Intake manifold bolts: 22 Nm (16 lb-ft)
Turbocharger mounting bolts: 28 Nm (21 lb-ft)
Glow plugs: 15 Nm (11 lb-ft)
Valve cover bolts: 10 Nm (7 lb-ft)
Oil pan bolts: 12 Nm (9 lb-ft)
Water pump bolts: 12 Nm (9 lb-ft)
Timing belt tensioner bolt: 25 Nm (18 lb-ft)
Engine mount through-bolts: 60 Nm (44 lb-ft)
The Volkswagen CBDC engine was produced for a
relatively short production window between 2008 and 2010, primarily serving as
the entry-level 2.0 TDI BlueMotion variant in the Volkswagen passenger car
range.
Volkswagen Golf Mk6 (2008-2010): The primary application for the CBDC engine in
the sixth-generation Golf, offered in BlueMotion and base TDI trim levels. The
engine was paired with a five-speed manual transmission in front-wheel-drive
configuration.
Volkswagen Golf Plus (2008-2010): The higher-roof variant of the Golf received
the CBDC engine in entry-level diesel configurations, providing increased
interior space while maintaining the fuel economy characteristics of the 2.0 TDI
BlueMotion powertrain.
Volkswagen Jetta Mk5 (2009-2010): Late-production fifth-generation Jetta models
received the CBDC engine as a replacement for the earlier 1.9 TDI units,
offering improved refinement and meeting Euro 5 emissions standards.
Volkswagen Touran (2008-2010): The compact multi-purpose vehicle based on the
Golf platform utilized the CBDC engine in base diesel variants, offering
seven-seat capacity with the fuel efficiency benefits of the 2.0 TDI BlueMotion
powertrain.
____________________________________________________________________________________
| Car Engines Technical Specifications |
| Small Engines Technical Specifications |
| Industrial Engines Technical Specifications |
| Outboard Engines Technical Specifications |
