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Volkswagen 1.9 tdi, Owner'S Manual, Page: 1 / 67

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1.9-Liter TDI Engine
with Pump Injection
(Pumpe Düse)
Design and Function

Self-Study Program
Course Number 841303

Summary of Contents for 1.9 tdi

Page 1: ...1 9 Liter TDI Engine with Pump Injection Pumpe D se Design and Function Self Study Program Course Number 841303...

Page 2: ...tored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise nor may these materials be modified or reposted to other sites without...

Page 3: ...Pump Injection System Technical Data 1 9 Liter TDI Engine with Pump Injection System Trapezoidal Piston and Connecting Rod Toothed Belt Drive Fuel Supply 8 Fuel Supply System Overview Fuel Pump Distr...

Page 4: ......

Page 5: ...a pump injector combining the injection pump and injector in one unit in order to dispense with high pressure lines and achieve high injection pressures At the time however he did not have the techni...

Page 6: ...Study Program concerns the design and function of the new pump injection system and the modifications to the fuel system engine management system and engine mechanical components to accommodate the sy...

Page 7: ...in 95 5 mm Compression ratio 19 0 1 Maximum power output 100 bhp 74 kW 4000 rpm Maximum torque 177 lbs ft 240 Nm 1800 to 2400 rpm Engine management EDC 16 Firing sequence 1 3 4 2 Emission Control Bin...

Page 8: ...and Connecting Rod To accommodate the higher combustion pressures in the 1 9 liter TDI engine with pump injection system than are encountered in the base engine the piston hub and the connecting rod e...

Page 9: ...ed link between the piston and connecting rod the trapezoidal connecting rod eye and piston hub have a larger contact surface area at the piston pin owing to their shape SSP209 008 Combustion Force Co...

Page 10: ...e The toothed belt is about 0 20 inch 5 mm wider than the toothed belt used in the base engine Higher forces can be transmitted by the larger surface area A hydraulic tensioner keeps the toothed belt...

Page 11: ...as a result Because of the engine firing order this stretching process occurs at regular intervals and the same teeth on the timing belt gear are in mesh with the toothed belt every time Non uniform t...

Page 12: ...to the fuel tank via the return line in the cylinder head a fuel temperature sensor and a fuel cooler Non Return Valve Prevents fuel from the fuel pump flowing back into the fuel tank while the engine...

Page 13: ...when the fuel pressure exceeds 109 psi 750 kPa 7 5 bar Fuel is routed back to the suction side of the fuel pump Fuel Pump Rotor Pumps the fuel from the fuel tank through the fuel filter and the fuel s...

Page 14: ...ructions Fuel Supply 10 Fuel Pump The fuel pump is located directly behind the vacuum pump at the cylinder head It moves the fuel from the fuel tank to the pump injectors Both pumps are driven jointly...

Page 15: ...tem within the pump is designed so that the rotor always remains wetted with fuel even if the tank has been run dry This makes automatic priming possible SSP209 050 Blocking Vanes Restrictor Connectio...

Page 16: ...hed out at chamber 2 Fuel drawn into chamber 3 is pushed out at chamber 4 The rotation of the rotor increases the volume of chamber 1 while the volume of chamber 4 is simultaneously reduced Fuel is pu...

Page 17: ...the annular gap between the distributor pipe and the cylinder head wall This fuel mixes with the hot unused fuel that has been forced back into the supply line by the pump injectors This results in a...

Page 18: ...in the engine cooling circuit is too high to cool down the fuel when the engine is at operating temperature The fuel cooling circuit is connected to the engine cooling circuit near the expansion tank...

Page 19: ...ine has its own pump injector This means that there is no longer any need for a high pressure line or a distributor injection pump SSP209 012 Just like a conventional system with a distributor injecti...

Page 20: ...dividual clamping blocks It is important to ensure that the pump injectors are positioned correctly when they are installed Refer to the Repair Manual for instructions If the pump injectors are not in...

Page 21: ...O Ring Heat Insulating Seal Cylinder Head Injector Needle Injector Needle Damping Element Injector Spring Fuel Supply Line Retraction Piston Fuel Return Line High Pressure Chamber Pump Injector Soleno...

Page 22: ...anism The camshaft has four additional cams for driving the pump injectors They activate the pump injector pump pistons with roller type rocker arms Valve Cam SSP209 015 Injection Cam Hidden by Rocker...

Page 23: ...ressure chamber free of air bubbles The injection cam has a steep leading edge and a gradual slope to the trailing edge As a result of the steep leading edge the pump piston is pushed down at high vel...

Page 24: ...ection interval between the pre injection phase and the main injection phase produce a gradual rise in pressure within the combustion chamber not a sudden pressure buildup The effects of this are low...

Page 25: ...noid valve is not activated The solenoid valve needle is in its resting position The path is open from the fuel supply line to the high pressure chamber The fuel pressure in the supply line causes the...

Page 26: ...eedle is pressed into the valve seat and closes the path from the high pressure chamber to the fuel supply line This initiates a pressure build up in the high pressure chamber At 2 611 psi 18 000 kPa...

Page 27: ...n only be displaced into the injector spring chamber through a leakage gap This creates a hydraulic cushion which limits the injector needle stroke during the pre injection phase Function In the first...

Page 28: ...closes SSP209 026 This ends the pre injection phase The downward movement of the retraction piston pre loads the injector spring to a greater extent To re open the injector needle during the subsequen...

Page 29: ...d the main injection quantity is injected The pressure rises to between 27 121 psi 187 000 kPa 1 870 bar and 27 846 psi 192 000 kPa 1 920 bar because more fuel is displaced in the high pressure chambe...

Page 30: ...e fuel displaced by the pump piston can enter the fuel supply line The pressure drops The injector needle closes and the injector spring presses the bypass piston into its starting position This ends...

Page 31: ...rom the fuel supply line through the pump injector ducts into the fuel return line Discharge leaking fuel at the pump piston Separate vapor bubbles from the pump injector fuel supply line through the...

Page 32: ...ls Road Speed Signal Air Conditioner Compressor Ready CCS Switch Three Phase AC Generator Terminal DF Fuel Temperature Sensor G81 Brake Light Switch F Brake Pedal Switch F47 Clutch Vacuum Vent Valve S...

Page 33: ...Pump for Fuel Cooler V166 Change Over Valve for Intake Manifold Flap N239 Wastegate Bypass Regulator Valve N75 EGR Vacuum Regulator Solenoid Valve N18 Glow Plug Indicator Light K29 Valve for Pump Inj...

Page 34: ...nsor G40 generates to determine the relative positions of the pistons in the cylinders when starting the engine Effects of signal failure In the event of Camshaft Position Sensor G40 signal failure th...

Page 35: ...d by the Camshaft Position Sensor G40 which scans the teeth of the camshaft sensor wheel to determine the camshaft position Camshaft sensor wheel Since the camshaft executes one 360 degree revolution...

Page 36: ...ferent distances apart the induced voltage occurs at different time intervals From this the Diesel Direct Fuel Injection Engine Control Module J248 determines the relative positions of the cylinders a...

Page 37: ...circumference These gaps are 180 degrees apart and serve as reference points for determining the crankshaft position Signal application The signal generated by the Engine Speed Sensor G28 provides bo...

Page 38: ...fter only half a turn of the crankshaft Cylinder 1 Cylinder 3 Cylinder 4 Cylinder 2 By interpreting the signals from these two sensors the Diesel Direct Fuel Injection Engine Control Module J248 deter...

Page 39: ...rol Module J248 to determine the fuel temperature This signal is needed to calculate the start of injection point and the injection quantity so that allowance can be made for the density of the fuel a...

Page 40: ...r mass in the signal it sends to the Diesel Direct Fuel Injection Engine Control Module J248 The air mass is accurately measured Signal application The Diesel Direct Fuel Injection Engine Control Modu...

Page 41: ...Injection Engine Control Module J248 Signal application The Diesel Direct Fuel Injection Engine Control Module J248 uses the coolant temperature as a correction value for calculating the injection qu...

Page 42: ...cognize the position of the accelerator pedal from this signal In vehicles with an automatic transmission the Kick Down Switch F8 indicates to the Diesel Direct Fuel Injection Engine Control Module J2...

Page 43: ...Direct Fuel Injection Engine Control Module J248 adjusts the charge pressure via the Wastegate Bypass Regulator Valve N75 Effects of signal failure The charge pressure can no longer be regulated Engi...

Page 44: ...rge pressure control and exhaust gas recirculation Effects of signal failure Black smoke occurs at altitude Clutch Vacuum Vent Valve Switch F36 The Clutch Vacuum Vent Valve Switch F36 is located at th...

Page 45: ...ches supply the Diesel Direct Fuel Injection Engine Control Module J248 with the brake activated signal The engine speed is regulated when the brake is activated for safety reasons since the Throttle...

Page 46: ...ntrol Module J248 the ABS Control Module with EDL ASR ESP J104 and the Transmission Control Module J217 interchange information along a CAN data bus Additional Input Signals Road speed signal The Dies...

Page 47: ...ection points and injection quantities of the pump injectors by activating their solenoid valves at the appropriate times Start of injection point As soon as the Diesel Direct Fuel Injection Engine Co...

Page 48: ...injector If the valve stays closed the high pressure chamber of the pump injector can no longer be filled In either case no fuel is injected into the cylinders Electrical circuit J248 Diesel Direct Fu...

Page 49: ...njection period begins As the solenoid valve needle contacts its valve seat the distinctive signature of an alternately dropping and rising current flow is detected by the Diesel Direct Fuel Injection...

Page 50: ...the Diesel Direct Fuel Injection Engine Control Module J248 evaluates the BIP position from the current flow pattern If there are no faults BIP will be within the control limit If this is not the cas...

Page 51: ...high compression ratio The engine shudders when the ignition is turned off because of the high compression pressure of the induced air The intake manifold flap interrupts the air supply when the engi...

Page 52: ...s the intake manifold flap stays open The tendency of the engine to shudder when switched off will increase Electrical circuit J217 Transmission Control Module J248 Diesel Direct Fuel Injection Engine...

Page 53: ...fails the heated fuel flowing back from the pump injectors to the fuel tank will not be cooled The fuel tank and the Sender for Fuel Gage G can be damaged Electrical circuit J248 Diesel Direct Fuel In...

Page 54: ...cuum in the vacuum unit for turbocharger vane adjustment is set depending on the pulse duty factor The Wastegate Bypass Regulator Valve N75 is activated by the Diesel Direct Fuel Injection Engine Cont...

Page 55: ...ctivates the EGR Vacuum Regulator Solenoid Valve N18 with duty cycles based on internal control maps Effects of failure Engine performance is lower and exhaust gas recirculation is not assured Glow Pl...

Page 56: ...ng rapid acceleration from low engine speeds At coolant temperatures in excess of 248 F 120 C In the emergency running program Fuel consumption signal This signal provides information on fuel consumpt...

Page 57: ...tched on and outside temperature is below 48 F 9 C The Glow Plug Indicator Light K29 will light up Once the glow plug period has elapsed the Glow Plug Indicator Light K29 will go out and the engine ca...

Page 58: ...High Heat Output J445 Relay for Pump Fuel Cooling N18 EGR Vacuum Regulator Solenoid Valve N75 Wastegate Bypass Regulator Valve N239 Change Over Valve for Intake Manifold Flap N240 Valve for Pump Inje...

Page 59: ...ram SSP209 080 30 15 31 31 3 1 B D G J 317 S S S S N239 N75 N18 Q7 Q7 J360 A G70 F60 F8 G79 G28 G81 F F47 E45 G62 F36 J52 A Q6 G72 C S G71 S S S N240 N241 N242 N243 S G40 E F V166 J445 J359 A in out J...

Page 60: ...Actuator diagnosis 04 Basic adjustment 05 Erase fault memory 06 End of output 07 Encode control unit 08 Read measured value block Function 02 Interrogate fault memory The color coded components are s...

Page 61: ...ed at the pump injector adjusting screw This adjustment prevents the pump piston from knocking against the base of the high pressure chamber due to heat expansion For a complete description of this ad...

Page 62: ...ide sleeve and compression sleeve for installing the crankshaft sealing ring Camshaft Gear Puller T 10052 Camshaft gear removal from the tapered end of the camshaft Camshaft Gear Counter Holder T 1005...

Page 63: ...9 This shackle is used to remove and install the engine in the Passat The engine is moved into position using this shackle in combination with lifting gear 2024A Pump Injector Puller T 10055 Pump inje...

Page 64: ...60 Notes...

Page 65: ...ge Assessment at www vwwebsource com From the vwwebsource com Homepage do the following Click on the Certification tab Type the course number in the Search box Click Go and wait until the screen refre...

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Page 67: ...Volkswagen of America Inc 3800 Hamlin Road Auburn Hills MI 48326 Printed in U S A October 2003...

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