1.9-ltr. TDI Engine with Pump Injection System - Volkswagen ...

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Fuel supplyThe fuel cooling systemThe high pressure in the pump injector heats upthe fuel so intensively that it has to be cooleddown before it flows back into the fuel tank.A fuel cooler is located on the fuel filter.It cools the returning fuel and thus protects thefuel tank and the fuel level sender againstexcessively hot fuel.Fuel coolerFuel pumpCoolant senderExpansion tank209_42Auxiliary water coolerFuel cooling pump24
The fuel cooling circuitThe fuel returning from the pump injector flowsthrough the fuel cooler and transfers its hightemperature to the coolant in the fuel coolingcircuit.The fuel cooling circuit is separate from theengine cooling circuit. This is necessary since thetemperature of the coolant is too high to cooldown the fuel when the engine is at operatingtemperature engine.The fuel cooling circuit is connected to the enginecooling circuit in the vicinity of the expansiontank. The fuel cooling circuit can thus be filledand changes in volume due to temperaturefluctuation can be compensated. The fuel coolingcircuit is connected so that the hotter enginecooling circuit does not have a detrimental effecton the fuel cooling circuit.Fueltemperature senderThe fuel coolerThe fuel and coolant flows through the fuelcooler. The temperature of the fuel istransferred to the coolant.Fuel tankFuel pumpExpansion tank209_48The auxiliary water coolerreduces the temperature of the coolantin the coolant circuit. It dissipates theheat of the coolant to the ambient air.The fuel cooling pumpis an electrical recirculation pump which circulates thecoolant in the fuel cooling circuit. It is switched on bythe engine control unit via the fuel cooling pump relayat a fuel temperature of 70°C.<strong>Engine</strong> coolingcircuit25
Page 3 and 4: Table of contentsIntroduction .....
Page 5 and 6: SpecificationsEngine code:Type:Stro
Page 7 and 8: Fitting locationThe pump injector i
Page 9 and 10: Drive mechanismThe camshaft has fou
Page 11 and 12: The injection cycleThe high-pressur
Page 13 and 14: The pre-injection cycle commencesIn
Page 15 and 16: The injection cycleThe main injecti
Page 17 and 18: Fuel return in the pump injectorThe
Page 19 and 20: The bypassThe pressure limiting val
Page 21 and 22: This is how it works:The fuel pump
Page 23: Without a distributor pipe, the fue
Page 27 and 28: Glow plugs Q6Control unitfor diesel
Page 29 and 30: Cylinder recognition when starting
Page 31 and 32: FunctionQuick start recognitionTo a
Page 33 and 34: The following sensors have previous
Page 35 and 36: Intake manifold pressure sender G71
Page 37 and 38: Brake light switch F andbrake pedal
Page 39 and 40: ActuatorsInjector solenoid valvesN2
Page 41 and 42: When the valve is closed, the curre
Page 43 and 44: Fuel cooling relay J445The fuel coo
Page 45 and 46: Warning lamp for glow period K29The
Page 47 and 48: Glow plug systemGlow plug systemThe
Page 49 and 50: 3015J52SSSSE45A/+B D F GFF47F36CESG
Page 51 and 52: Engine mechanicalsTo make allowance
Page 53 and 54: This is how it works:During the inj
Page 55 and 56: Special toolsDesignation Tool UseT
Page 57 and 58: Test your knowledge1.Identify the c
Page 59 and 60: NotesSolutions:1. For a list of com

1.9-ltr. TDI Engine with Pump Injection System - Volkswagen ...

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