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

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ServiceRepair notesAfter installing the pump injector, the minimumclearance between the base of the high-pressurechamber and the pump piston must be adjustedin the lowest position at the adjusting screw ofthe pump injector.This adjustment prevents the pump pistonknocking against the base of the high-pressurechamber due to heat expansion.Adjusting screwPump pistonMinimum clearanceHigh-pressurechamber209_98You will find a description of the adjustment procedure in the Workshop Manual.56
Test your knowledge1.Identify the components209_232.Which of the following statements is true?a.An engine with a pump injection system is more efficient andcleaner than an engine with a distributor injection pump.b.The high combustion efficiency of the pump injector engine isthe result of the high injection pressure.c.Each cylinder in the engine has a single pump injector.57
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 and 24: Without a distributor pipe, the fue
Page 25 and 26: The fuel cooling circuitThe fuel re
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: Special toolsDesignation Tool UseT
Page 59 and 60: NotesSolutions:1. For a list of com
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1.9-ltr. TDI Engine with Pump Injection System - Volkswagen ...

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