Self-Study Programme 22 1.9L 50kw SDI 1.9L 81kw TDI.pdf

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1.9 l SDI 50 kW
1.9 l TDI 81 kW
SP22-23
Two new diesel engines from the proven group engine series
supplement the range of engines available from SKODA.
This publication will help you to become familiar with the new technical
details of these engines, the operation and design of the new
components and their most important features.
Function components with are identical to those of the other familiar
engines, can be found in SSP 16/1.9-ltr. 66 kW TDI engine.
2
Contents
Part I - 1.9-ltr. 50 kW SDI Engine
Technical Data
Engine Characteristics
Diesel Control Flap
Exhaust Gas Recirculation Valve
4
5
6
8
Part II - 1.9-ltr. 81 kW TDI Engine
Technical Data
Engine Characteristics
Intake Manifold Flap
System Overview
Turbocharger
Actuators
Self-Diagnosis
Function Diagram
Two-Mass Flywheel
Oil Filter
9
10
11
12
14
19
21
22
23
26
Service
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Service Service
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Service Service
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You can find information regarding inspection
and maintenance, setting and repair instructions
in the Workshop Manual.
3
Technical Data
Part I - 1.9-ltr. 50 kW SDI engine
SP22-6
Engine code:
Engine type:
Displacement:
Bore:
Stroke:
Compression ratio:
Mixture formation:
Firing order:
Fuel:
Emission control:
Power output:
Torque:
AGP
4-cylinder in-line engine
1896 cm
3
79.5 mm
95.5 mm
19.5 : 1
Distributor injection
pump, direct injection
1-3-4-2
Diesel, min. 45 CN
Exhaust gas recirculation
and oxidation catalytic
converter
50 kW (68
HP)
at 4200 rpm
130 Nm
at 2000 - 2600 rpm
Technical highlights:
–
–
Two-stage exhaust gas recirculation valve.
Electrically controlled intake manifold flap
(diesel control flap).
Preset injection pump with variable toothed
belt sprocket.
The engine can also be operated with biodie-
sel (VOME - vegetable oil methyl ester).
–
–
–
Upright oil filter with replaceable filter cartridge
(similar to 1.9-ltr. TDI).
4
Engine Characteristics
70
60
50
140
40
P (kW)
130
M (Nm)
30
120
20
110
10
0
0
1000
2000
3000
n (1/min)
4000
5000
P = Power
M = Torque
n = Engine speed
SP22-5
In what ways does the 1.9-ltr. SDI differ from
the 1.9-ltr. TDI?
While the engine employs the same fuel injection
method - direct injection - it operates without a
turbocharger and without intercooler.
Engine timing and fuel injection have been modi-
fied in order to achieve the performance parame-
ters while maintaining the exhaust limits:
–
New camshaft offers greater overlap of valve
opening times.
Valves with 7 mm stem diameter.
Flat design of piston bowl.
–
The injectors (5-hole injectors) feature smaller
injection holes which permit a reduction of
about 5 % in flow.
–
The diesel direct injection system control unit
is matched to the parameters of the naturally-
aspirated diesel.
Intake manifold and exhaust manifold are
new.
An additional flap (diesel control flap) in the
intake manifold modifies the pressure ratios of
the inducted air in the part load range in order
to create balanced pressure ratios for the
exhaust gas recirculation.
The exhaust gas recirculation (EGR) valve is
integrated in the intake manifold.
It operates in two stages. The opening is map-
controlled.
–
–
–
–
–
–
Injection pump operates at higher injection
pressure.
5
Diesel Control Flap
Exhaust gas recirculation is the most effective
measure at present for reducing the oxides of
nitrogen (NO
x
) in the exhaust. The recirculation
rates have to be very exactly metered to ensure
that an adequate level of oxygen nevertheless
remains for combusting the fuel injected.
Excessively high rates of exhaust gas recircula-
tion allow an increase in the emissions of soot,
carbon monoxide and hydrocarbon as a result of
the air deficiency.
The difference between inlet pressure and
exhaust pressure on diesel engines not fitted with
a turbocharger, is relatively slight.
Consequently, it is a complicated exercise to spe-
cifically feed exhaust gas into the inducted air
when the engine is operating at part load,
although this is essential, particularly at part load,
in order to reduce the oxides of nitrogen.
That is why the inducted air in the intake manifold
is controlled at certain engine speeds in order to
match the inlet pressure to the conditions of the
exhaust pressure and to thus achieve thorough
intermixing of exhaust gas and fresh air.
A two-stage exhaust gas recirculation valve is
used to set the exhaust recirculation rates as they
are required in the lower engine speed operating
range.
New!
G70
G72
Diesel control flap
(intake manifold flap)
AGR
V60
N18
VP
G28
J248
SP22-7
RGE
G28
G70
G72
=
=
=
=
Exhaust gas recirculation valve
Engine speed sensor
Air mass meter
Intake manifold temperature sender
J248
N18
V60
VP
=
=
=
=
Diesel direct injection system control unit
EGR valve
Intake manifold flap motor
Vacuum pump
6

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