Service Training

Self-study Programme 352

Unit Injectors with Piezo Valves

Design and Function

 Giảm nhiên liệu hoạt động chính xác
Low consumption and excellent performance have The introduction and ongoing development of unit
made the rise of the diesel engine unstoppable. injectors has created considerable competitive
mục đích suự phát nổ
Nevertheless the targets for diesel engines in terms of advantages in the areas of injection pressure,
cảm giác lái
emissions, driving comfort and engine performance injection precision and efficiency. In collaboration with
liên tục
are also being raised constantly. Customer Siemens VDO Automotive AG, we have developed a
satisfaction, environmental protection and the unit injector with the same or even greater
fulfilment of legal requirements are always at the advantages. It also allows new flexibility in the
forefront and can only be achieved through continued configuration of the pilot, main and secondary
development. injection phases.
Improved mixture, higher efficiency and lower noise
emissions are the innovative results.

S352_002

NEW Important
Note

The self-study programme shows the design and For current testing, adjustment and repair
function of new developments. instructions, refer to the relevant service literature.
The contents will not be updated.

2
Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Improvements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
The Piezo Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Nozzle Spring Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Injection Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pilot Injection Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Main Injection Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Secondary Injection Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Test Yourself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3
 Introduction

General Information

The unit injector with piezo valve (version: This new type uses the same fitting as the unit injector
PPD 1.1) is a further development of the solenoid-type with solenoid valve (PDE-P2) and is also secured with
unit injector. As the name says, the solenoid valve has 2 screws to avoid additional engine assembly costs.
been replaced by a faster and more controllable In future, the new unit injectors will be used in the new
piezo 2.0l-125kW 4V TDI engine and later in other
valve. Furthermore the mechanical control of the 4-valve TDI engines.
varying injection pressures within the unit injector has
been improved so that there is no need for a
retraction piston. It has therefore been possible to
reduce the high-pressure volume in favour of
efficiency.

S352_005

Volkswagen Mechatronic GmbH & Co. KG has been 200 employees are currently working on the
founded for production of the unit injector with piezo production of the new unit injector.
valve in collaboration with Siemens VDO Automotive
AG. The new production site is located in Stollberg in
Saxony.

4
Improvements
Control of the injection phases
Pilot injection
Main injection As the new piezo valve switches approximately four
Secondary injection times faster than the previous solenoid valve, it is now
(if required) possible to close the switching valve and open it
again for each injection phase. This allows more
chính xác
precise control of the injection phases and flexible
Injection
quantity

control of the injection quantities.

Time
S352_007

Variable
injection intervals
Injection pressure
Pilot injection
Each injection phase has different requirements in
Main injection
terms of injection pressure. For example, the pilot
Secondary injection
injection phase requires a lower injection pressure
(if required)
and the main injection phase a very high injection
pressure. The extended injection pressure range (130-
Injection
pressure

2200bar) has allowed a further change in this area.

mức độ phun
As a result, the emission tơi are improved and
levels
greater performance is possible.
Time hoạt động tốt hơn
S352_008
Minimum
injection pressure
Maximum
injection pressure

Noise emissions
The typical noise emissions occur when TDI engines The mechanical noises transferred by the drive are
are idling above all due to the noise generated by the reduced by the smaller pump plunger diameter. The
quá trinh cháy
unit injectors, not due to the combustion. These noises power required to drive the unit injector is therefore
are caused by rapid, large-scale pressure changes also lower.
within the unit injector that are transmitted to the
engine via the unit injector drive.

The pressure changes can now be influenced with the

aid of the faster and more precise piezo valve to
chính xác
reduce the noise.
The piezo valve can be controlled so precisely that the
pressure build-up and pressure reduction of the
individual injection phases can be influenced.
độc lập

5
 Introduction

Efficiency
giảm công suất
In this case, higher efficiency means lower driving This reduces the high-pressure volume and therefore
power and also lower fuel consumption. giảm nhiên liệu a pump plunger diameter of just 6.35mm is required
The higher degree of efficiency has been achieved by to generate the required injection quantities.
saving on the high-pressure chambers and the tạo ra

retraction piston.

Unit injector with solenoid valve

Pump plunger diameter

Valve needle

High-pressure chambers, no longer required

Retraction piston

Nozzle needle

S352_009

6
Technical data at a glance

Unit injector with piezo valve (PPD 1.1) Unit injector with solenoid valve (PDE-
P2)
Pump plunger diameter [mm] 6.35 8.0

Minimum injection pressure [bar] 130 160

Maximum injection pressure [bar] 2200 2050

Possible number of 0-2 (variable) 1 (fixed)

pilot injections

Possible number of 0-2 (variable) 0 or 2

secondary injections

Distance between pilot, main and > 6 (variable) approx. 6-10 (fixed)
secondary injection
[° crank angle]

Pilot-injection quantity [mm³] Any (> approx. 0.5) approx. 1-3

Control of pilot injection Piezo valve (electronic) Retraction piston (mechanical/hydraulic)

Pressure raise for Closing plunger, check valve Retraction piston

main injection

7
 Design

Overview

Cam rocker arm

Return spring

Pump plunger

Valve for pump/nozzle

(piezo valve)

Injection cam

Valve needle

High-pressure chamber

Check valve Converter

Seals

Nozzle spring in
nozzle spring chamber
Fuel return line

Closing plunger
Fuel supply line

Nozzle needle
S352_010

Cylinder head

8
Piezo Valve
The most important new feature on the new unit injector is the piezo valve that replaces the previously used
solenoid valve. The piezo valve has higher switching rates and its actuator travel can be controlled via the voltage
supply. It comprises a piezo actuator with housing and connector, the converter and valve needle in the pump
barrel. bao gồm vỏ bộ nối van chuyển đổi van kim phun
thùng bơm

Piezo actuator
Inverse piezo-electrical effect Piezo (Greek) = pressure
(simplified crystal structure of a piezo element)
A well-known application area for piezo elements is
yếu tố sensors. Pressure is applied to a piezo element and a
Piezo element without voltage U measurable voltage is generated. This behaviour of a
crystal structure is called a piezo-electrical effect.
Starting length

bộ truyền động dảo ngược

When a piezo actuator is used, this effect is reversed.
The inverse piezo-electrical effect is used.
S352_018 That means a voltage is applied to the piezo element
and the crystal structure of the piezo element reacts
by changing in length.
Piezo element with voltage U
Starting length +
change in length

S352_019

Simple crystal structure

Metal contact with voltage supply

Change in length of a piezo element The change in length of a piezo element is

tỉ lệ proportional to the voltage applied. That means that
S352_020 the change in length of a piezo element, or the piezo
actuator, can be controlled with the voltage.
Voltage U

The control voltage of the piezo actuator is between

100V and 200V.

Path (change in length)

9
 Design

A piezo element is approx. 0.08mm thick and the Piezo actuator (schematics)
change when the voltage is applied is only 0.15%.
Metal contact plate
To achieve a maximum actuator travel of approx.
0.04mm, several piezo elements need to be stacked. xếp chồng Piezo element
In this piezo stack, the individual piezo elements are
Pressure plate
separated by metal contact plates (voltage supply).
phân biệt với nhau bởi những tấm kim loại

The piezo stack forms the piezo actuator together with

the pressure plate.

S352_021

Housing with connector

Converter
The piezo actuator has an actuator travel of approx. Converter in rest position
0.04mm. The valve needle requires an actuator travel
of approx. 0.1mm. To balance out this difference, a
converter in the form of a lever is used.
đòn bẫy
Lever
If the piezo actuator is not activated, the converter will
be in the rest position. The valve needle is opened by
the valve needle spring.

S352_022

Valve needle (open)

If the piezo actuator is activated, the pressure plate Converter operated

will press against the converter. The actuator travel is
extended to approx. 0.1mm due to the ratio of the
tỉ lệ
lever assembly. lắp ráp
The valve needle is closed and the injection pressure
is built up.

Valve needle
(closed)

S352_023

10
Nozzle Spring Chamber
The nozzle spring chamber contains the nozzle spring that is responsible for closing the nozzle needle and also
prevents early opening when an injection phase begins. The requirements for the nozzle spring force (nozzle
needle closing force) are very different, however. For example, the nozzle needle needs to open even with a low
fuel pressure for a pilot injection while it can only open at a high fuel pressure during the main injection phase.
In addition, the nozzle needle should close very quickly after an injection phase. To meet the requirements for
nozzle spring force, the nozzle spring needs to be supported for the main injection and for closing of the nozzle
needle by high fuel pressure in the nozzle spring chamber. This support is provided by the check valve and the
closing plunger.

Check valve
S352_024 At the end of each injection phase, the nozzle spring
chamber is filled with high-pressure fuel. The pressure
is released via the valve needle back into the fuel
Valve needle supply line and is then held by the supply throttle.
The check valve is opened by the high pressure of the
fuel thus opening the path to the nozzle spring
Nozzle spring chamber
chamber.

Nozzle spring

Supply throttle

Closing plunger

S352_024

Nozzle needle Check valve (open)

Fuel supply line

S352_025

The fuel pressure is reduced in the fuel supply line.

The check valve closes as the fuel pressure falls.
The pressure that is built up is thus held in the nozzle
spring chamber.
Check valve
(closed)

S352_026

11
 Design

Closing plunger
Close nozzle needle Nozzle spring

When an injection phase is completed, the nozzle spring

chamber is filled with high-pressure fuel. This high-pressure fuel
pushes against the closing plunger helping the nozzle spring to Closing plunger
close the nozzle needle. Closing the nozzle needle fast has a
positive effect on the exhaust emissions and means the
retraction piston used in the solenoid-type unit injectors is not
required. Close nozzle needle

S352_027

Injection pressure is reduced

Open nozzle needle

The fuel pressure held back in the nozzle spring chamber after
completion of the injection phase has an effect on the next
injection phase.
The high fuel pressure also supports the nozzle spring and thus
prevents the nozzle needle opening too early.
The injection phase starts with a high injection pressure.
This high injection pressure is particularly important for Nozzle needle open
quá trình cháyand the development of exhaust emissions in the
combustion
main injection phase.
S352_028

Injection pressure is built up

Pressure reduction

The pilot injection phase needs a low injection pressure, Leakage gap on closing plunger
however. Therefore, after an injection cycle (pilot, main and
secondary injection phases), it is important that the fuel pressure
can be reduced in the nozzle spring chamber. This is achieved
with a khe hở rò rỉgap on the closing plunger. The fuel pressure is
leakage
reduced between the injection cycles, the nozzle spring is no
longer supported and the pilot injection phase can begin at a
low injection pressure.
S352_029

12
 Injection Process

Pilot Injection Phase

Fill high-pressure chamber
The injection cam movement and the subsequent The piezo valve is not actuated and the valve needle
upwards movement of the cam rocker arm allow the is therefore open. The high-pressure chamber is filled
return spring to push the pump plunger upwards. via the fuel supply line.
The special shape of the injection cam causes a slow
upwards movement.
The high-pressure chamber is enlarged. mở rộng

Cam rocker arm

Return spring

Valve for pump/nozzle

Injection cam (piezo valve)

Pump plunger

Valve needle

High-pressure chamber

Fuel supply line

S352_011

13
 Injection Process

Pilot injection starts

The injection cam presses the pump plunger The nozzle needle is raised and the pilot injection
downwards at high speed via the cam roller arm. phase begins.
The fuel is pushed back into the fuel supply line until
the piezo valve is actuated and thus closed. Once the The nozzle needle damping works in exactly the same
piezo valve has been closed, the fuel is compressed way as in the unit injector with solenoid valve.
and the pressure build-up begins. From 130 bar, the The nozzle needle displacement is limited by a
fuel pressure on the nozzle needle is greater than the hydraulic cushion between the nozzle needle and
nozzle spring force. nozzle barrel during the pilot injection phase. This
limited opening stroke of the nozzle needle allows
Cam rocker arm precise dosage of small injection quantities during the
pilot injection phase.

Valve for pump/nozzle

Injection cam (piezo valve)

Pump plunger

Valve needle

High-pressure chamber

Nozzle spring

Fuel supply line

Nozzle needle damping

Nozzle needle

S352_012

14
Pilot injection phase ends
The pilot injection phase ends with the piezo valve The high-pressure fuel pushes the closing plunger and
opening the valve needle. The fuel pressure is thus speeds up the closing of the nozzle needle.
reduced in the fuel supply line and the nozzle needle
is closed by the nozzle spring. Depending on the engine operating mode, the engine
The nozzle spring is supported by the decreasing fuel control unit can trigger one or two pilot injection
pressure that is held back by the supply throttle and phases per injection cycle.
reaches the nozzle spring chamber via the open
check valve.

Valve for pump/nozzle

(piezo valve)

Valve needle
Check valve

Nozzle spring chamber with nozzle spring

Supply throttle

Fuel supply line

Closing plunger

Nozzle needle

S352_013

15
 Injection Process

Main Injection Phase

Main injection phase begins
The pump plunger is still being moved downwards. pilot injection is maintained by the check valve in the
Once the valve needle has been closed, the fuel nozzle chamber closing and presses against the
pressure is built up again and the main injection closing plunger.
phase can begin. To ensure that the nozzle needle
only opens at a higher pressure, the nozzle spring is The injection pressure rises to up to 2,200 bar during
supported by the fuel pressure in the nozzle chamber. maximum engine output.
The high fuel pressure that was built up after the

Valve for pump/nozzle

(piezo valve)

Pump plunger

Valve needle
Check valve

Nozzle spring chamber with nozzle spring

Closing plunger

Nozzle needle

S352_014

16
End of main injection phase
The main injection phase ends when the valve needle
is opened. The high fuel pressure is reduced in the
fuel supply line and nozzle spring chamber.
The nozzle needle is closed by the nozzle spring and
closing plunger.

It is cooled in the same way as the unit injector with

solenoid valve. The fuel is throttled as it flows through
the injector into the fuel return line and also allows the
fuel that leaked into the pump barrel to flow out.

Valve for pump/nozzle

(piezo valve)

Pump plunger

Valve needle
Cooling channel

Check valve

Nozzle spring chamber with nozzle spring

Fuel return line

Fuel supply line

Closing plunger

Nozzle needle

S352_015

17
 Injection Process

Secondary Injection Phase

Secondary injection phase starts
The secondary injection process will be explained The pump plunger continues to move downwards and
using a secondary injection phase. In practice, at least the secondary injection phase begins once the valve
two secondary injections are triggered that are needle closes and the nozzle opening pressure is
identical in principle. reached.đẩy ra
Secondary fuel injections are only triggered when The secondary injection phase works like the main
they are required to regenerate a diesel particulate injection phase. The only difference is that the injected
filter. quantity may be lower as the injection duration is
shorter.

Valve for pump/nozzle

(piezo valve)

Pump plunger

Valve needle
Check valve

Nozzle spring chamber with nozzle spring

Closing plunger

Nozzle needle

S352_016

18
Secondary injection phase ends
The secondary injection phase ends when the valve The time between the individual injection cycles is
needle opens. The high pressure of the fuel is reduced sufficient to allow the fuel to flow away into the fuel
and the nozzle needle closes. supply line via a leakage gap on the closing plunger.

At this point, high fuel pressure is built up again in the

nozzle spring chamber as the check valve is open.
To ensure that the next injection can be carried out
again at a low fuel pressure, the high-pressure fuel
needs to escape from the nozzle spring chamber.

Valve for pump/nozzle

(piezo valve)

Valve needle

Check valve

Nozzle spring chamber with nozzle spring

Fuel return line

Fuel supply line

Closing plunger with leakage gap

Nozzle needle

S352_017

19
 Service
chẩn đoán

Diagnosis
Sự định lượng, định phân
Monitoring the unit injector valve Simos PPD 1
(piezo valve)

A new engine control unit called Simos PPD 1 is

being introduced together with the new unit injector
with piezo valve.
The Simos PPD 1 diagnostics work in a similar way to
the Motronic with the solenoid-type unit injector. S352_031

The actual closing time of the valve needle is

measured by means of a turn in the voltage curve (BIP
= Beginning of Injection Period).
This voltage change is created by the valve needle Piezo valve voltage curve
hitting the valve seat and the resulting force
counteracting the piezo actuator movement. BIP

Voltage
A test pulse is triggered for all 5 injection phases
between the injection cycles to close the valve needle
without interfering influences (e.g. high fuel pressure).

S352_030
Time

Exceeding or falling below the control limit

If the BIP is not within a specific control limit, a fault entry will be written to the fault memory. Depending on the type
of fault found, the unit injector involved will be triggered or switched off. If it is switched off, this will prevent further
damage to the unit injector and the engine.

20
Removal and installation
Wiring harness for unit injectors and glow plugs

Connector for
unit injector

Connector for glow plug

Mounting bracket

S352_032

When you remove the wiring harness for the unit injectors and glow plugs, the wiring duct may not be
separated from the mounting brackets. Bending back the mounting brackets and removing the wiring
duct may break wires.
ELSA provides detailed information on the procedure.

Size and screw mounting

Piezo valve The unit injector with solenoid valve (PDE-P2/

2 mounting screws) and the unit injector with piezo valve are
the same size and have the same thread size for the cylinder
head. However, solenoid-type unit injectors cannot be
replaced with piezo-type unit injectors due to the different
connections and control units.

S352_004

Solenoid valve

21
 Service

Versions of piezo-type unit injector

There are two versions of the piezo-type unit injector, the first model (PPD 1.0) and the model described
in this self-study programme (PPD 1.1). The first version is already being used in the 2.0l, 103kW, 4V TDI engine for
the Passat from model year 2006 and will be gradually replaced by the latest version (PPD 1.1). These two types can
only be distinguished by the parts numbers stamped on them and are not interchangeable. If a combination of the
two is fitted, the engine will run poorly.

Check the outside appearance and the parts numbers of the different unit injectors so you do not
mix them up when replacing them.

Information on special tools

The T10163 puller together with the T10133 slide

hammer is not just used to remove the piezo unit
injector, but also to fit it.

S352_033
T10163 puller
T10133 slide hammer

The new T10308 assembly sleeves are used to fit the

seals for the unit injector with piezo valve.

S352_034
T10308 assembly sleeves

ELSA provides detailed information on the procedure.

22
 Test Yourself

Which answers are correct?

One, several or all answers could be correct.

1. Which statements on the unit injector with piezo valve are correct?

a) A connection to the engine control unit is not needed as a solenoid valve is not used.
The injection pressures are controlled purely mechanically with the aid of the closing plunger.

b) The piezo valve is so fast that it can be opened and closed for each injection phase (pilot, main,
secondary).

c) Due to the smaller pump plunger diameter, the unit injector with piezo valve has a lower high-pressure
volume and is therefore only suitable for diesel engines with a small capacity.

d) It has been possible to reduce the noise emissions due to lower drive forces and better configuration of the
pressure change inside the unit injector.

2. Complete the following statements.

a) Inverse piezoelectrical effect means that a piezo element .............................................................. when voltage is
applied.

b) To ensure that the main injection phase starts with a higher injection pressure than the pilot injection phase,
the nozzle spring is supported by the ...................................................................................... .

3. When removing or installing the unit injectors with piezo valve, make sure that ...

a) they are removed together with the wiring harness.

b) the fitting size and mounting (fastening with two screws) are the same as the unit injector with solenoid
valve.

c) the wiring harness can only be removed as a complete unit (wiring duct and mounting brackets).

3. b), c)
2. b) Closing plunger/high-pressure fuel
2. a) enlarged (also: expanded)
1. b), d)

Answers

23
 352

© VOLKSWAGEN AG, Wolfsburg

All rights and rights to make technical alterations reserved.
000.2811.66.20 Technical status 03/2005

Volkswagen AG
Service Training VK-21
Brieffach 1995
38436 Wolfsburg

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