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In this booklet we explain to you the design and function of the 2.0l 125 kW four valve TDI engine, focussing on the differences between it and the 103 kW version. 412 009 Reference For information about the 2.0l 103 kW four valve TDI engine, please refer to SSP 316 The 2.0l TDI Engine . Contents Introduction 2.0l 125 kW TDI engine with pump injection system .4 Engine mechanicals Crank train 6 Valve train . 8 Cylinder head 9 Intake manifold . 14 Exhaust system Exhaust gas recirculation 16 Exhaust gas turbocharger with positional feedback . 21 Diesel particulate filter . 23 Engine management System overview 24 Sensors 26 Actuators 30 Service Special tools . 38 The Self Study Programme explains the design and function of new vehicle models, new automotive components or new technologies. Reference Note The Self Study Programme is not a Repair Manual Please note that all data and values given are for purposes of easier comprehension only and refer to the software version valid at the time of publication of the SSP. For information about maintenance and repair work, always refer to the current technical literature. Introduction 2.0l 125 kW TDI engine with pump injection system The 2.0l 125 kW TDI engine is based on the 2.0l 103 kW TDI engine. In terms of power output, the 125 kW TDI engine is the market leader in the 2 litre diesel engine class. This gain in power was accomplished whilst reducing fuel consumption and pollutant exhaust emissions through systematic development of proven TDI technology. 412 002 4 2.0l TDI Technical features New pump injector unit with piezo valve and injection pressures up to 2200 bar Balancer shaft module Pistons without valve pockets Ceramic or steel glow plugs depending on engine code CTC toothed belt sprocket on the crankshaft Improved oil separation Exhaust gas turbocharger with positional feedback Mai