Volkswagen Service Training Tdi Diesel

Full download: http://manualplace.com/download/volkswagen-service-training-tdi-diesel/

Service Training

Self-Study Program 821603

TDI Diesel

This is the cut pages sample. Download all 64 page(s) at: ManualPlace.com
Volkswagen of America, Inc.
Volkswagen Academy
Printed in U.S.A.
Printed 12/2006
Course Number 821603

©2006 Volkswagen of America, Inc.

All rights reserved. All information contained in this

manual is based on the latest information available
at the time of printing and is subject to the copyright
and other intellectual property rights of Volkswagen
of America, Inc., its affiliated companies and its
licensors. All rights are reserved to make changes at
any time without notice. No part of this document
may be reproduced, stored 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 the prior expressed written permission
of the publisher.

All requests for permission to copy and redistribute

information should be referred to Volkswagen of
America, Inc.

Always check Technical Bulletins and the latest

electronic repair information for information that may
supersede any information included in this booklet.

Trademarks: All brand names and product names

used in this manual are trade names, service marks,
trademarks, or registered trademarks; and are the
property of their respective owners.
 Contents

Introduction ................................................................................................................ 1

Fuel Supply .................................................................................................................. 8

Pump Injection System..........................................................................................15

Engine Management ..............................................................................................28

Glow Plug System ....................................................................................................52

Functional Diagram ................................................................................................53

Service .........................................................................................................................55

Knowledge Assessment ........................................................................................59

Note Important!

This Self-Study Program covers information on For testing, adjustment and repair
Volkswagen TDI Technology. procedures, always refer to the latest
This Self-Study Program is not a Repair Manual. electronic service information.
This information will not be updated.

i
 Page intentionally left blank

ii
 Introduction

Introduction

History and Theory of the 1890

Rudolph Diesel "blows
up" engine attempting
Diesel Engine to run it on coal dust
and compressed air

History Rudolph Diesel

1900
successfully runs "air-
The diesel engine was developed as an alternative blast" engine on heavy oil
means of power other than steam. Similar to the
Diesel obtains U.S.
gasoline engine, the operation is based on the Otto 1910 patents for compression-
cycle. ignition engine

Diesel engines in wide

The diesel engine is a compression-ignition engine. practical use in Europe
This means that tightly compressed air and injected 1920
Mercedes-Benz develops
fuel are used to power the engine; no spark plugs are
first production diesel
used in this type of engine. passenger car
1930
Rudolph Diesel is given the credit for the First Rabbit diesel
introduced in USA
compression-ignition engine. His first attempts used and Canada
coal dust as the fuel. These attempts resulted in the
engines exploding. After continuous failed attempts, 1940
Introduction of 1.6 liter
Diesel switched to a liquid fuel. The liquid fuel turbo-diesel with charge-air
cooling producing 59 kW
worked, and in 1895, the compression ignition engine
was patented in the U.S. and became known as the
1950
diesel engine. Introduction of the variable-
vane turbo-charger

Traditionally, diesels have been considered reliable,

Introduction of the TDI in
but massive and noisy engines. They lacked power 1960 the U.S. in the Passat
and were difficult to start in cold weather. Diesel
engines seemed to be best suited for industrial use, Introduction of the
DFI ECM J248
where they have succeeded as universal workhorses.
1970
Introduction of the
In an effort to explore all possibilities for cleaner, TDI Jetta
more efficient engines, Volkswagen has developed
Introduction of the
diesel engines that are practical for passenger car 1980 TDI Golf
use.
Introduction of the
TDI Beetle
Presently, the diesel is the only alternative engine
1990
capable of extraordinary fuel economy with a simple Introduction of Pumpe
design devoid of complex emission controls. Duse technology in the
1.9 Liter

Apply Pumpe Duse

2000 techology to the 2.0L and
5.0L V-10

90016728.ai

1
Volkswagen Service Training Tdi Diesel
Full download: http://manualplace.com/download/volkswagen-service-training-tdi-diesel/
Introduction

Theory

Diesel vs. Gasoline

The gasoline engine was being developed at the
same time as the diesel engine. The gasoline engine
quickly became more popular in automobiles because
of its major characteristics:
• Wide revolutions per minute (rpm) range
• Ease of starting
• Smooth and quiet operation
• Good acceleration
Even though the gasoline engine is more popular
for automobile applications, diesel has some
advantages:
Low fuel consumption is the most noticeable
advantage. This is a result of a high air-to-fuel ratio,
high compression ratio, and low pumping losses.
Air-to-Fuel Ratio
The air-to-fuel ratio is the amount of air and fuel
needed for combustion. Gasoline engines need more
fuel in comparison to air than diesel engines. Diesel
engines can have ratios between 20 parts air to one
part fuel, up to 100 parts air to one part fuel. This
contributes to low fuel consumption.

• Low fuel consumption

• Less fire hazard
• Lower emission levels

Gasoline Engine Diesel Engine

Gasoline Diesel Injector

Injector Spark
Plug Glow Plug

Pre-Combustion
Chamber

Combustion
Chamber

This is the cut pages sample. Download all 64 page(s) at: ManualPlace.com