Self Study Program 209 – 1.9L TDI Engine with Pump Injection System

VAG SSP 209. Something new has happened to the diesel engine. The demands on the modern diesel engine with regard to performance, fuel economy, exhaust emissions and noise levels are growing constantly. Good mixture preparation is a key factor for meeting these requirements. This calls for efficient injection systems which produce high injection pressures to ensure that fuel is atomised very finely. Also, it is necessary to precisely control the commencement of fuel injection and injection quantity.

The pump injection system meets these tough requirements. Even Rudolf Diesel thought about combining the injection pump and injector in one unit in order to dispense with high-pressure lines and  thereby achieve high injection pressures. However, he did not have the technical means to put this idea into practice.

Diesel engines with mechanically controlled pump injection systems have been in use in ships and trucks since the 1950s. For the first time, Volkswagen, in association with Robert Bosch AG, has succeeded in developing a diesel engine with a solenoid valve controlled pump injection system suitable for use in passenger cars.

A step into the future, this engine meets the tough demands on performance and clean emissions. At this rate, Rudolf Diesel’s vision of “smoke an dodour-free exhaust gases” will one day become reality.


  • Introduction
    • Specifications
  • Pump injection system
    • General
    • Structural design
    • Driving mechanism
    • Injection cycle
  • Fuel supply
    • Diagram of fuel circuit
    • Fuel pump
    • Distributor pipe
    • Fuel cooling system
  • Engine management
    • System overview
    • Sensors
    • Actuators
    • Glow plug system
    • Function diagram
    • Self-diagnosis
  • Engine mechanicals
    • Trapezoidal piston and conrod
    • Toothed belt drive
  • Service
    • Special tools

The Self-Study Programme is not a Workshop Manual.
Please always refer to the relevant Service Literature for all inspection, adjustment and repair instructions.

Language: English
Format: PDF
Pages: 60

Self Study Program 209 – 1.9-ltr. TDI Engine with Pump Injection System Design and Function PDF free online