227

227
Service.

3,3 l V8 TDI Common Rail Injection System

Construction Features and Functions

Self-Study Programme 227

All rights reserved. Subject to

technical modifications.
AUDI AG
Abteilung I/VK-5
D-85045 Ingolstadt
Fax 0841/89-36367
940.2810.46.20
Technical status 07/99
Printed in Germany

For internal use only

 With its TDI engines, Audi AG has been a leader in diesel development since 1989.
Its latest technological innovation, the unique V8 TDI bears testimony to this fact.

Common Rail

A new injection system for the V8 engine

Given that it can be integrated in existing engine concepts relatively easily, the
common rail system is a new alternative injection system for modern diesel engines.

As with any injection system, the common rail serves the following tasks:

– Supplying the diesel engine with fuel

– Generating a high pressure for the injection cycle and distributing fuel to the
cylinders
– Injecting a precisely calculated quantity of fuel into the cylinders at the right point
in time.

2
 Contents

Page
Introduction
Common Rail System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Components of the common rail

Overview of the fuel feed process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Low-pressure fuel feed
Roller cell pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Gear type pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
High-pressure fuel feed
High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Valve for fuel dosing N290 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Fuel rail with high-pressure control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Regulating valve for fuel pressure N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
High-pressure circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Valve-controlled injection unit (injector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Function of injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Engine management
Mixture formation
Commencement of fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
End of fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pre-injection cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Vacuum control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Double flow throttle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Function diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Actuators and sensors
Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Engine speed sender G28
Engine control unit J248/J494 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Fuel temperature sender G81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Intake manifold pressure sender G71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Fuel bypass valve N312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Valve for fuel dosing N290 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Important!
Note!
The Self-Study Programme informs you about designs and
functions.

The Self-Study Programme is not a Workshop Manual!

Please refer to the relevant Technical Literature for all maintenance

and repair instructions.
3
 Introduction

Common Rail System

The common rail system comprises:

– The pre-supply pump

– The high-pressure pump
– The fuel rail with high-pressure control
circuit and
– One rail element with 4 injectors
per cylinder bank.

Gear type pre-supply pump

Fuel rail with Fuel cooling

high-pressure control circuit

Rail elements

SSP227_001

High-pressure pump

Injectors

4
The Common Rail System is a
pressure accumulator-type injection system.

In the Common Rail System, pressure

generation and fuel injection take place
separately.

A separate high-pressure pump housed in the

inner V of the cylinder block generates
pressure continuously.
This pressure is accumulated inside a rail and
supplied to the injectors of a cylinder bank
along short injection pipes.

The engine control unit controls the quantity

of fuel injected into the cylinders and the
injection timing by means of solenoid valves
on the injectors.

Advantages:

– The fuel injection pressure can be 1800

selected almost at random from a range
1600
of values within the characteristic zone
bar
– High injection pressures are available at
Injection pressure

1200
low revs and in the part-throttle range
1000
– Flexible commencement of fuel
injection with pre-injection cycle, main 800
injection cycle and post-injection cycle
600
– There is much potential for development 400
for future dieselcombustion processes
given the total flexibility with regard to 200
injection
1000 2000 3000 U/min 5000
– Exhaust-gas aftertreatment systems
Engine speed
can be integrated optimally
SSP227_026

The common rail accumulator type

injection system
Pump injector element

Other cam-driven systems

5
 Components of the common rail

Fuel feed
Overview
High-pressure pump

Fuel rail with

high-pressure control
circuit

Regulating valve for

fuel pressure N276

Valve for fuel dosing N290

Sender for
fuel pressure
G247

Fuel cooler
(low-temperature circuit water)

Gear type pump

Fuel filter

Bimetallic
fuel pre-heating valve

6
 Rail element, cylinder bank II

Rail element, cylinder bank I

Injector 5 … 8

Mechanical
Injector 1 … 4 crash valve

Fuel cooler (air)

on the vehicle underbody
Fuel pump G23

Baffle housing

Solenoid valve for

fuel bypass N312

Fuel pump
(pre-supply pump) G6
SSP227_002
7
 Components of the common rail

Low-pressure feed
Roller cell pump (fuel pump G23)

The roller cell pump (an electric pre-supply

pump) is attached to the tank exterior at the
right.

The pump runs when the starter is operated,

drawing fuel out of the baffle housing.
Two suction jet pumps (entrainment pumps)
driven by a pump located inside the fuel tank
(pre-supply pump G6) fill the baffle housing
with fuel.

The task of the roller cell pump is to supply

fuel with a pilot pressure of approx. 3 bar to
the gear-type pump whenever the engine is
started.

This enables the engine to be started quickly

at any fuel temperature.

The roller cell pump is shut down after the

engine has been started.

Armature

Suction side Pressure side

SSP227_004

Grooved disc
Loose roller

Suction side Pressure side

SSP227_005
Eccentric
chamber
8
Gear type pump

The gear type pump is a mechanical, self-

priming pre-supply pump.
It is driven directly by the inlet camshaft of
the right cylinder bank.

The gear type pump draws fuel out of the

baffle housing and pumps it into the tank
along a bypass duct (bypassing the roller cell
pump) after the engine starts running.

The gear type pump, in turn, delivers fuel to

the high-pressure pump.

Advantages of the mechanical gear type

pump:
– Lower sensitivity to soiling (particle
barrier)
– Reliability
– Service life
– Vibration resistance

Delivery rate 3.1 cm3 /U

Delivery rate 40 l/h at 300 rpm

120 l/h at 2500 rpm

Drive gear

Pump housing

Suction side Pressure side

SSP227_006

9
 Components of the common rail
High-pressure feed
High-pressure pump

A 3-piston pump with a controlled intake Three feed strokes per revolution result in low
restrictor in the inner V serves as a high- peak torque and a even loading of the pump
pressure pump. drive.

The high pressure is generated by the radial Max. torque demand is 17 Nm at 1300 bar.
piston pump with three This is approx. 9 times less than that of
pump pistons arranged at an angle of 120o. comparable distributor pumps which utilise
The radial piston pump is driven by means of conventional injection technology.
a toothed belt.

Pump piston

Eccentric
Pressure spring

Pump housing
(section)
Input shaft

Return line to the gear type pump

Return line
from the fuel rail

Nozzle chamber

from the gear type pump

Valve for fuel dosing N290 to the fuel rail

SSP227_007

Specifications

Max. pressure 1350 bar

Rev range: 75 … 3000 rpm
Delivery rate: 0.6 … 0.7 cm3/U
Power consumption: 3.5 kW at rated engine speed and
at a rail pressure of 1350 bar

10
 Intake stroke Feed stroke

Fuel supply from the

gear type pump Exhaust valve

Intake valve
High-pressure connection

Corrugated disc

Pressure spring

SSP227_025

Pump piston

The input shaft, with its eccentric cam, moves If a piston overshoots bottom dead centre, the
the pistons of the three pump elements up intake valve closes due to the pressure drop.
and down in a sine-wave pattern.
The gear type pump forces fuel into the The fuel in the pump element can no longer
nozzle chamber or the lubricating and cooling escape.
circuit of the high-pressure pump through the The fuel can now be compressed beyond the feed
restrictor bore of solenoid valve for fuel pressure of the gear type pump.
dosing N290.
The pressure which now builds up causes the
If the fuel feed pressure exceeds the opening exhaust valve to open once it exceeds the pressure
pressure of the safety valve (0.5 - 1.5 bar), the present in the rail. The compressed fuel now enters
gear type pump can force fuel through the the high-pressure circuit.
intake valves in the pump element thus
causing the piston to move down (intake The pump element delivers fuel until top dead
stroke). centre is reached (feed stroke).

11
 Components of the common rail

Valve for fuel dosing N290

Pump piston

High-pressure Exhaust valve

pump

to rail

Lubricating
Regulating oil hole Intake valve
piston Return line, gear type pump

Safety valve

Supply line, gear type pump

Restrictor bore

Valve for fuel dosing

N290 SSP227_009

The high-pressure pump is driven by the Operated condition

toothed belt of the camshaft drive whose of de-energised solenoid valve N 290
gear ratio in relation to engine speed is i=2/3. When it is de-energised, the solenoid valve is
In the part-throttle range and at high engine open. The control piston is pushed to the left
speeds, the high-pressure pump can feed and by spring force and releases the minimum
compress more fuel than is injected into the cross section to the high-pressure pump.
cylinders. The solenoid valve is more or less closed
depending on load and engine speed.
To reduce the power consumption of the
high-pressure pump and avoid unnecessary Operated condition
fuel heating at these operating points, fuel of activated solenoid valve N290
can be redirected to the fuel return line (inner When it is activated, the solenoid valve is
circuit) by means of the solenoid valve N290. closed. The control pressure drops and the
control piston restricts the feed to the high-
pressure pump.
The control pressure and therefore the piston
position are changed by varying the pulse
duty ratio. The fuel cut off by the solenoid
valve returns to the gear pump.

12
Fuel rail with high-pressure control circuit

Supply line to rail

Cylinder bank 1 Return line
High-pressure pump
Sender for fuel
pressure G247 Fuel rail

Regulating valve for

fuel pressure N276

SSP227_010

Supply line to rail

Cylinder bank 2
Supply line from
high-pressure pump Return line
Fuel cooler

The fuel rail accommodates the fuel pressure

sender and the electric control valve for fuel
pressure, and distributes the fuel evenly to
the two rails under a pressure of up to
1350 bar.

13
 Components of the common rail
Regulating valve for fuel pressure N276

The regulating valve is located in the fuel rail

and generates a defined pressure in the high-
pressure circuit in dependence upon
operating point.

Engine – "OFF“
In the resting position (valve de-energised),
the force of the pressure spring counteracts
the high pressure from the high-pressure
pump. In the process, a rail pressure of
approx. 100 bar builds up.
Return line to high-pressure pump

Pressure spring

Solenoid connection
High pressure

Return line to tank SSP227_028

Engine – "ON" Magnetic coil

To increase the rail pressure, a magnetic force
is opposed to the high pressure of the high-
pressure pump by applying an electric
current to the magnetic coil.

The flow cross-section and the redirected

quantity are reduced as a result. This allows
the rail pressure to be set optimally by the
control unit and pressure fluctuation in the
rail to be compensated.

The fuel quantity redirected at the pressure

regulating valve returns to the tank along the
return line.

SSP227_013

14
Sender for fuel pressure G247

The fuel pressure sender measures the

current pressure in the high pressure system.
0
V 5
The sensor element records this pressure and
sends a corresponding voltage signal to the
engine control unit through the evaluation
electronics. +5 V
Evaluation
The supply voltage to the evaluation electronics
electronics is 5 V.

The resistance drops as the pressure

increases, causing the signal voltage to rise. Sensor element
SSP227_012
The high-precision sender for fuel pressure is
the chief component in the system. High-pressure connection

Fuel pressure
1500 bar

0
V 5

If the fuel pressure sender fails, a

fixed value is utilised for activating
the regulating valve for fuel pressure, +5 V
i.e. the system enters the emergency
running mode.

SSP227_011
Output voltage U

5,00 V
4,75 V Sensor defective

4,65 V
4,50 V Maximum pressure

0,50 V
0,30 V Minimum pressure

0,25 V Sensor defective

1500 bar Pressure

SSP227_027
15
 Components of the common rail

High-pressure circuit

The high-pressure circuit comprises the high-

pressure pump, the fuel rail with regulating
valve for fuel pressure, the two rails for
cylinder banks I+II, as well as the individual
high-pressure pipes to the injectors.

The accumulated volume of fuel acts as a

damper on pressure oscillation caused by the
high-pressure pump and simultaneous short-
time withdrawal of fuel during the injection
cycle.

Fuel rail
Rail, cylinder bank I

Return line to tank

Injector SSP227_014

16
Valve-controlled injection unit (injector)

6
Components of the injector: 5

– six-hole nozzle with injector needle

– hydraulic timing system
7
– solenoid valve
– and fuel ducts
8
Very narrow injectors with a diameter of
17 mm are used in view of the limited space
available in the cylinder head. 4
3
The fuel is conveyed from the high-pressure
connection along a duct to the nozzle and
into the valve timing space through the feed 9
restrictor.
2
The valve timing space is connected to the
fuel return line via the return restrictor. The 10
return restrictor can be opened by means of
a solenoid valve.

Specifications

Pick-up current > 20 A max. 300 µs

Activation up to 80 volts 11
Pressure range1 20 … 1350 bar
Dia. of injection holes
in nozzle 6 x 0.15 mm
12

13
High pressure
14
Return pressure
SSP227_030

1– Injector spring 8 – Fuel supply - high pressure from rail

2– Valve timing space 9 – Valve ball
3– Return restrictor 10 – Feed restrictor
4– Solenoid valve armature 11 – Valve timing piston
5– Fuel return line (to tank) 12 – Nozzle intake duct
6– Electrical connection, solenoid valve 13 – Chamber volume
7– Solenoid valve 14 – Injector needle

17
 Components of the common rail

Function injector

Resting position - engine "OFF“

The fuel from the rail is constantly present at

the high-pressure connection of the injector.
The fuel floods the chamber volume and the
valve timing space through the feed restrictor. High-pressure
connection
– There is a constant pressure between the
chamber volume and the valve timing
space.

– The solenoid valve of the injector is closed.

Feed restrictor

Valve timing space

A pressure of 1.5 times the area of the control Valve control piston
piston facing towards the injector is
generated in order to make sure that the
injector is leak-tight.

This means that the force exerted by the

hydraulic control piston is approx. 50% higher
than the nozzle opening force; in addition to
the injector spring, the valve control piston
presses the injector needle into its seat. Injector
spring
The injector spring keeps the injector closed
up to a pressure difference of approx. 40 bar Chamber volume
between the chamber volume and the valve
timing space.

SSP227_015

Injector
needle

18
Start of fuel injection - engine "ON"

If an electric current is applied to the solenoid

valve, the magnetic force will be greater than
the closing force of the solenoid valve spring.
Magnetic
The solenoid valve opens the return restrictor, valve spring
relieving the fuel pressure in the valve timing
space and reducing the closing force above
the nozzle.

As a result, the excess fuel and/or rail

pressure below the nozzle increases as from Return
an excess pressure of approx. 160 bar on the restrictor
nozzle side, causing the nozzle to open.

The opening velocity of the injector needle is Feed restrictor

dependent upon the application of a high
current for a short time and the return to feed Valve timing space
restrictor cross-section ratio.

The return restrictor cross-section

must be greater than the feed
restrictor cross-section before
injector needle can open at all.

Injector
needle

SSP227_016

19
 Engine management

Mixture formation
Commencement of fuel injection End of injection

If current is applied to the solenoid valve for If the solenoid valve is de-energised, the valve
longer, the valve control piston and injector spring again presses the solenoid valve
needle will rise up to the control piston stop. armature or the valve ball down onto the
valve seat.
The nozzle is now open as far as it will go, and
fuel is injected into the cylinders under The return restrictor is closed and the
approximately the same pressure as in the pressure in the control space rises to system
rail. pressure. The closing force acting upon the
nozzle above the control piston is greater
than the opening force of the nozzle applied
to the seat. This causes the injector to close.
The solenoid valve opens completely
during each injection cycle, even if
only a very small quantity of fuel is to
be injected.
In contrast to previous injection
systems, injector closure is controlled
even if the system pressure is very
To inject a small quantity of fuel, the solenoid high (sharp end of injection drop).
valve is only energised (clocked) for a short
period to time. The injector needle is not
opened as far as it will go, it is only raised
slightly.

The quantity of fuel injected into the cylinders

is defined by:

– solenoid valve activation time

– needle opening and closing velocity
– needle lift
– hydraulic flow rate of nozzle
– rail pressure

20
Pre-injection cycle

250

200
Needle lift [µm]

150
Injection pattern

100

50

0
0.00 1.00 2.00 3.00 4.00

Pre-injection cycle Time [µs]

Main injection SSP227_017
cycle

The object of the pre-injection cycle is to

reduce combustion noise, exhaust emissions
and fuel consumption.
Combustion pressure

The pre-injected quantity of fuel prepares the

combustion chamber for the main quantity to
be injected with respect to pressure and
temperature for the main injection quantity.

The main injection quantity is injected into

the prechamber.

Advantage:

– The spark lag for the main injection cycle is SSP227_029

Top dead centre
shortened.
– This system produces less noise than
conventional diesel engines thanks to the Pressure curve with pre-injection cycle
reduced combustion pressure peaks.
– Optimal combustion of the fuel mixture
Pressure curve without pre-injection
takes place.
cycle
Needle lift curve
The pre-injection cycle controls the
combustion pressure curve by means of the
following variable: The figure shows the difference between the
pressure curves of a combustion process with
– Pre-injection quantity and without a pre-injection cycle.
– Distance to main injection cycle at increa-
sing engine rpm

21
 Engine management
Vacuum control

J248

G70 G246

N213 G2/G62 G28 G40

N18 N

G71

22
 A Vacuum pump
B Brake servo
C Throttle valve
G2/G60 Coolant temperature sender
G28 Engine speed sender
G40 Hall sender
G70 Air-mass flow meter
G71 Intake manifold pressure sender
G246 Air-mass flow meter 2
J248 Diesel direct injection system
Control unit
N18 EGR valve
Cylinder bank 1
N75 Charge pressure control solenoid valve
N213 Exhaust gas recirculation valve -2-
B
N274 Solenoid valve 2 for charge pressure
control
N239 Intake manifold flap change-over valve

In the V8 TDI engine, an engine-driven vacuum

pump (A) supplies a sufficient quantity of medium
required for vacuum control.

In addition to the brake servo (B), the vacuum

controls the exhaust gas turbocharger, the EGR
valve and the two throttle valves (C) in the intake
module.

N75 Charge pressure data is acquired via the intake

N239 manifold pressure sender (G71). The signals from
the two hot-film air mass meters (G70/G246) are
utilised for controlling the turbocharger via the
charge pressure limiting valves (N75, N274).
N274
The throttle valves (C), activated by intake manifold
flap change-over valve N239, are in operation when
the engine is shut down for a short time.

SSP226_027

23
 Engine management

Double-flow throttle valve

The double-flow throttle valve is closed when

the engine is shut down for a short time.

Advantages:

The engine does not run on after it has been

shut down and no unburned fuel enters the
cylinders (when the engine is restarted, fewer
unburned particles are emitted).

Charge pressure
Throttle valve
intake manifold pressure G71

SSP226_026

Vacuum box for

throttle valve positioning

The two throttle valves are fully open

in the rest and full-throttle positions.

24
Notes

25
 Engine management
System overview
Sensors

Hot-film air mass meter

G70/G246

Automatic gearbox
Engine speed sender G28 control unit J217

Coolant temperature sender

G2 and G62

Combination processor
Sender for oil temperature G8 in the dash panel insert
J218
Fuel temperature
sender G81

Sender for fuel pressure G247

Operating and display
unit for air conditioning
Intake manifold pressure sender G71 system E82

Accelerator pedal sender with

accelerator position sender G79
and idling speed switch F60
ESP control
unit J104
Brake light switch F and
Brake pedal switch F47

Kick-down switch F8 Diesel direct injection

system control unit J248

Hall sender G40

Auxiliary signals:
Cruise control system
Coolant temperature sender Control unit 2 for diesel direct
DF signal injection system J494
Terminal 50
Speed sensor signal
Crash signal from airbag control unit
High pressure sensor G65
A/C ready
Auxiliary heater coolant

26
 Actuators

Solenoid valve for injector, cylinders 5-8;

N83 – N86

Glow plug relay J52

Glow plugs 1-4; Q6

Relay 2 for glow plugs J495

Glow plugs 5-8; Q6

Intake manifold flap change-over valve N239

Regulating valve for fuel pressure N276

EGR valves 1 + 2; N18 + N213

Solenoid valve for fan control N313

Electro/hydraulic engine mounting left/

Auxiliary signals: right, solenoid; N14427/N145

Air conditioner
compressor Charge pressure control solenoid valves 1+ 2;
Auxiliary heater, N75/N274
coolant

Relay for pump charge air cooling J536

Pump for charge air cooling V188

Electric fuel pump II relay J49

Diagnostic connection Fuel pump G23

Solenoid valve for injector, cylinders 1-4;

N30 – N33

Fuel bypass valve N312

Valve for fuel dosing N290

Auxiliary signals:

Fuel pump relay J17

Fan speeds 1+2
Fuel pump (pre-supply pump) G6

Pump relay, fuel cooling J445

Pump for cooling fuel V166

Alternator cut-in relay J442

SSP227_018 27
 Engine management
Function diagram
Code codes
= Input signal = Positive = Bidirectional

= Output signal = Earth = CAN-BUS

Components

A Battery N213 Exhaust gas recirculation valve -2-

E45 Cruise control system switch N239 Intake manifold flap change-over valve
D Ignition switch N274 Solenoid valve 2 for charge pressure
F Brake light switch control
F8 Kick-down switch N276 Regulating valve for fuel pressure
F47 Brake pedal switch for N290 Valve for fuel dosing
cruise control system N312 Fuel bypass valve
F60 Idling speed switch N313 Solenoid valve for fan control
G2 Coolant temperature sender Q6 Glow plug
G6 Fuel pump (pre-supply pump) S Fuse
G8 Oil temperature sender ST Fuse carrier
G23 Fuel pump S204 Fuse, terminal 30
G28 Engine speed sender V166 Pump for cooling fuel
G40 Hall sender V188 Pump for charge air cooling
G62 Coolant temperature sender
G70 Air-mass flow meter 1 Fan speed
G71 Intake manifold pressure sender
G79 Accelerator position sender 2 2nd fan speed
G81 Fuel temperature sender
G246 Air-mass flow meter 3 Terminal 61, alternator
G247 Fuel pressure sender
J17 Fuel pump relay 4 Coolant temperature
J49 Electric fuel pump II relay
5 Sensor earth
J52 Glow plug relay
J248 Diesel direct injection 6 Speed sensor signal
system control unit
J317 Voltage supply relay 7 Terminal 50
Terminal 30
J442 Alternator cut-in relay 8 DF signal
J445 Pump relay, fuel cooling
J494 Diesel direct injection 9 Crash signal from airbag control unit
system control unit
J495 Glow plug 2 relay 10 Additional heater, coolant
J536 Pump relay, charge air cooling
11 Additional heater, coolant
M9 Brake light bulb, left
M10 Brake light bulb, right 12 High pressure sensor G65
N18 EGR valve
N30 Solenoid valve for injector, cylinder 1 13 A/C ready
N31 Solenoid valve for injector, cylinder 2
N32 Solenoid valve for injector, cylinder 3 14 Air-conditioner compressor signal
N33 Solenoid valve for injector, cylinder 4
N75 Solenoid valve for charge pressure 15 Terminal 30a
control
N83 Solenoid valve for injector, cylinder 5
CAN-BUS L
N84
N85
Solenoid valve for injector, cylinder 6
Solenoid valve for injector, cylinder 7 CAN-BUS H } Connection to databus
N86 Solenoid valve for injector, cylinder 8
N144 Electro/hydraulic engine mounting X Y Z ... Terminals within the
left, solenoid function diagram
N145 Electro/hydraulic engine mounting
right, solenoid Diagnostic connection (K-wire)

28
29
 Engine management
Actuators and sensors
Hall sender G40

The inlet camshaft of the second cylinder

bank has a ferro-magnetic tooth.

When the tooth passes by the phase sensor, a

voltage signal (Hall voltage) is generated for a
short time.

The camshaft signal is generated once per

revolution of the camshaft and indicates the
position of the 1st cylinder to the master
control unit in the compression phase.

SSP227_021
Ferro-magnetic tooth

Engine speed sender G28

Engine speed sender G28

The engine speed sender is an inductive
sender. It acquires engine speed data and the
exact angular position of the crankshaft.

If the engine speed sender fails,

engine operation will not be
possible.

Segment gap

Sender wheel
SSP227_032

30
Signal pattern from engine speed sender G28 and Hall sender G40 as
generated by the oscilloscope function of the VAS 5051 Auto mode

10 V/div. 20 ms/div.

G40

5 V/div. 20 ms/div.
1 5 4 8 6 3 7 2

G28
T

SSP227_022

Indication of the software reference mark Auto mode

5 V/div. 10 ms/div.

G40

G28

SSP227_023
Sender wheel
Reference mark 108o TDC, 1st cylinder
before TDC, 1st cylinder

The reference mark is the point at which This reference mark is located approx. 108o
the control unit sets the crank angle to 0 crank angle before ignition TDC of the 1st
(initialisation). cylinder.

31
 Engine management

Engine control unit J248/J494

In the V8 TDI, two engine control units, one Diesel direct injection
master control unit and one slave (auxiliary) system control unit J248
control unit are responsible for engine
management.

The master control unit performs all the

functions which are required to calculate and
control parameters, e.g. injection point and
injection period.

80 volts are required in order to activate the

injectors for a short time. This calls for more Diesel direct injection
highly rated output stages and capacitors. system control unit 2 J494
Therefore, the injectors of bank 2 can only by
operated from the master control unit and the
injectors of bank 1 can only be operated from
the slave control unit.

The slave control unit controls the following SSP227_031

electrical components:

– Fuel bypass valve N312

– Valve for fuel dosing N290 Self-diagnosis Address word
– Fuel pump relay J17 and fuel pump (pre-
supply pump) G6 master control unit 01
– Pump relay, fuel cooling J445 and pump
for cooling fuel V166 slave control unit 11
– Alternator cut-in relay J442 (option)
– Fan (stage 1+2).

The control units intercommunicate

by CAN-BUS.
The master control unit indicates to the slave
control unit what functions it has to execute.

SSP186 describes how the CAN-BUS

works.

32
Fuel temperature sender G81

The fuel temperature is acquired in the return

line of the injectors. The temperature signal
influences the following:

– The valve for fuel dosing N290 (the quantity

of fuel to be compressed is regulated in
order to reduce the temperature)
– The rail pressure
– The injection quantity for fuel temperatures
over 118°C.

The sensor is of NTC type (negative

temperature co-efficient).

SSP227_003

If the sender fails, no substitute

signal is utilised.

Intake manifold pressure sender G71

is a piezo-electric pressure sensor and is

linked to the induction module by a hose
pipe.

The signal is used for:

– charge pressure control

If the sensor fails, the charge pressure

control is switched off.

Result:
Loss of engine power SSP227_008

33
 Engine management

Fuel bypass valve N312

The valve is integrated in the bypass of the

electric pre-supply pump.
It opens for 40 seconds when the ignition is
turned "ON" (terminal 15) and closes during
the starting cycle (terminal 50).

When the engine speed signal is input, the

solenoid valve opens and allows fuel to be
withdrawn directly from the baffle housing,
bypassing the electric pre-supply pump.

Valve for fuel dosing N290

High-pressure pump
The valve for fuel dosing (intake restrictor)
returns the fuel in accordance with power
demand.

As a result, the quantity of fuel pumped and

compressed is only slightly more than the
quantity of fuel injected.

The power demand of the pump and fuel

heating are reduced in this way.

If a malfunction occurs, the following

happens:

– The exhaust gas recirculation is switched

off
– The charge pressure control is switched off
– Full-throttle limitation

SSP227_020
Valve for fuel dosing
To protect the engine when a fault N290
in the system is registered, the
engine is forcibly shut down via
the intake restrictor.

34
Notes

35