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Pump-Jet Unit with Piezo Valve

Train the Trainer 2005 / 01 Up-to-date technology by Volkswagen

Service Training

Contents
General information Components Injection process Removal and installation Diagnostics
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Service Training

General information
PPD 1.0 and PPD 1.1

Service Training, VK-21, AH, 03.2005

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Service Training

General information
Differences to the pump-jet unit with solenoid valve

with solenoid valve

with piezo valve

Service Training, VK-21, AH, 03.2005

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Service Training

General information
Improvements

Injection pressure

Injection phases

max. 2200 bar

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Service Training, VK-21, AH, 03.2005

min. 130 bar

variable injection intervals

Service Training

General information
Improvements (efficiency)
(Diagrams of the pump-jet unit with solenoid valve) Pump piston

High pressure chambers

Service Training, VK-21, AH, 03.2005

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Alternative piston

Service Training

Design
New technical features

Check valve

Service Training, VK-21, AH, 03.2005

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Piezo valve

Closing piston

Service Training

Design
Inverse piezoelectric effect

Piezo element without voltage U

Service Training, VK-21, AH, 03.2005

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Piezo element with voltage U

Service Training

Design
Piezo actuator

Change in length of a piezo element

Service Training, VK-21, AH, 03.2005

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Voltage U

Change in length

Piezo actuator (schematic)

Service Training

Design
Transformer (row lever mechanism)

Service Training, VK-21, AH, 03.2005

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- Rest position

- Piezo actuator activated - Valve needle closed

- Valve needle open

Service Training

Design
Check valve for the jet spring space
e.g. end of pre-injection

The jet spring space is filled.

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Service Training, VK-21, AH, 03.2005

Start of the main or post-injection

The fuel pressure is maintained in the jet spring space.

Service Training

Design
Closing piston
Delay on opening the nozzle needle

Leakage gap at the closing piston


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Acceleration on closing the nozzle needle

Service Training

Injection process
Pre-injection

Jet spring space without pressure

Nozzle needle opens above approx. 130 bar.


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Nozzle needle damping restricts opening path of the nozzle needle.

Service Training, VK-21, AH, 03.2005

Service Training

Injection process
Main and post-injection

Jet spring space filled high fuel pressure Nozzle needle opens above approx. 400-600 bar.
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Nozzle needle is opened completely.

Service Training, VK-21, AH, 03.2005

Service Training

Removal and installation

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Fastening clamps on the precabling

Assembly sleeves T10308

Service Training, VK-21, AH, 03.2005

Hammer T10133 Extractor T10163

Service Training

Diagnosis
BIP (beginning of injection period)

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Simos PPD 1
Test impulse for the BIP reading of all 5 injection cycles in the injection pause Time

Service Training, VK-21, AH, 03.2005

Voltage U

BIP (beginning of injection period)

BIP = voltage kink when the valve needle closes.

Service Training

Diagnosis
VAS 5051

Guided Troubleshooting for the 2.0l-103kW-4V-TDI engine (BKP) with PPD1.0 German: from software version 59.01
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Other languages: from software version 60.00

Service Training, VK-21, AH, 03.2005

Service Training

Service Training