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Volkswagen 1.9-Liter TDI User Manual

Volkswagen 1.9-Liter TDI
67 pages
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1.9-Liter TDI Engine
with Pump Injection
(Pumpe Düse)
Design and Function
Self-Study Program
Course Number 841303

Table of Contents

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Volkswagen 1.9-Liter TDI Specifications

General IconGeneral
Fuel SystemDirect Injection
Fuel TypeDiesel
Bore79.5 mm
Stroke95.5 mm
AspirationTurbocharged
Displacement1.9 L / 1896 cm3
Power Output90-150 hp (67-112 kW)
Engine CodeALH, etc.
InjectionDirect Injection
ValvetrainSOHC

Summary

Introduction

Engine – Mechanics

1.9-Liter TDI Engine Development

Evolution of the 1.9-liter TDI engine and comparison with previous versions.

Technical Data and Specifications

Key technical data for the 1.9-liter TDI engine including bore, stroke, and power output.

Trapezoidal Piston and Connecting Rod Design

Design features of the piston and connecting rod for higher combustion pressures.

Toothed Belt Drive Modifications

Adaptations to the toothed belt drive to handle increased injection forces.

Fuel Supply

Fuel Supply System Overview

General layout and function of the fuel supply system from tank to pump/injectors.

Fuel Pump Operation and Design

Detailed explanation of the tandem pump's design and fuel delivery mechanism.

Distributor Pipe and Fuel Distribution

How the distributor pipe ensures uniform fuel distribution to all injectors.

Fuel Cooling System Function

Description of the circuit and components used to cool the fuel.

Pump Injection System

Pump/Injectors: Concept and Design

Concept of combined pump and injector units for each cylinder.

Pump/Injector Internal Components

Detailed breakdown of the pump/injector unit's internal parts and their functions.

Pump/Injector Drive Mechanism

How the camshaft drives the pump/injectors via roller-type rocker arms.

Injection Cycle Phases

Explanation of pre-injection, main injection, and end of injection phases.

Engine Management

EDC 16 System Overview

Introduction to the Engine Control Module (EDC 16) and its primary functions.

Sensors for Engine Management

Overview of critical sensors and their role in engine control.

Actuators Controlled by Engine Management

Explanation of primary actuators regulated by the engine management system.

Solenoid Valve Operation and Monitoring

Details on pump/injector solenoid valve operation, control, and monitoring.

Functional Diagram

EDC 16 System Components

List of components and their connections within the EDC 16 system.

Additional Signals and Data Bus

Overview of additional input signals and CAN data bus communication.

System Wiring and Signal Flow

Visual representation of electrical connections and signal flow in the EDC 16 system.

Service

Self-Diagnosis Functions

Available diagnostic functions using the Vehicle Diagnosis tool.

Pump/Injector Adjustment Procedure

Steps for adjusting the minimum clearance of the pump/injector.

Special Service Tools

List and description of specialized tools required for service tasks.

Knowledge Assessment

Online Assessment Information

Details on how to access and complete the online knowledge assessment.

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