vw150 5workshop

Service.
Workshop Manual
VW Marine Boat Engine
Engine BCT ANF BCU ANG BCV
code
ANH BTW
Booklet 5-Cyl. Diesel Engine

Edition 10.01
Service Department. Technical Information

Table of Contents
00 Technical data Page

Safety Precautions and Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1
- Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1
- Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-5
- Engine characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-6
01 Self-diagnosis Page
Self diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
- Properties of self diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
- Technical data of self diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2
- Connecting fault reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-4
Fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
- Interrogating fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
- Erasing fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12
Fault table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-14
Final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-33
- Carrying out final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-33
Measuring value blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-37
- Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-37
- Reading measuring value blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-37
- Evaluating measuring value blocks at idle speed with ignition on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-40
- Evaluating measuring value blocks at full load, engine code letters ANF, BCT . . . . . . . . . . . . . . . . . . . . . . 01-58
- Evaluating measuring value blocks at full load, engine code letters ANG, ANH, BCU, BCV . . . . . . . . . . . 01-64
10 Removing and installing engine Page
Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
- Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
- Mounting engine on repair stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
- Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
- Unit mounting and gearbox bells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
13 Crankshaft group Page

Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
- Removing and installing ribbed V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-18
Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-21
- Removing and installing two-part flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-24
- Renewing crankshaft oil seal -belt pulley end- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-26
- Renewing oil seal for crankshaft -flywheel end- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-28
Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-30
- Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-33
Dismantling and assembling piston and conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-34
- Checking piston height at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-42
- Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-44
15 Cylinder head, Valve gear Page

Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
- Removing and installing toothed belt for camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-9
- Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-20
- Checking compression pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-24
Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-27
- Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-34
- Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-36
- Renewing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-37
- Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-39
- Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-41
- Checking hydraulic bucket tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-43
17 Lubrication Page
Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1
- Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-18
- Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-22
19 Cooling system Page

Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1
- Parts of cooling system - seawater side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-3
- Dismantling and assembling seawater filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-10
- Parts of cooling system on engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-12
- Dismantling and assembling housing-radiator package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-16
- Connection diagram for coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-20
- Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-26
- Removing and installing seawater pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-30
- Dismantling and assembling seawater pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-34
20 Fuel supply system Page
Parts of fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
- Dismantling and assembling parts of fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2
- Servicing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-7
- Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-9
- Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-9
- Servicing throttle controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11
- Checking accelerator position sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13
- Adjusting accelerator position sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-19
21 Charging Page
Turbocharger with and without charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-1
- Removing and installing turbocharger with attached parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-1
- Removing and installing parts of intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-6
- Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-10
- Dismantling and assembling intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-17
Checking boost pressure system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-21
- Checking turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-21
23 Mixture preparation, Injection Page

Servicing diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1
- Fitting location overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-3
- Removing and installing toothed belt for injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-10
- Servicing injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-12
- Dismantling and assembling air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-17
- Removing and installing, tensioning toothed belt for injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-18
- Removing and installing injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-25
- Checking and adjusting commencement of injection dynamically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-31
- Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-35
- Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-37
- Renewing O-ring on cover of injection timing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-39
Checking components and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-41
- Checking power supply for diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-41
- Checking engine speed sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-47
- Checking intake manifold pressure sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-49
- Checking coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-54
- Checking intake manifold temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-58
- Checking fuel temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-64
- Checking modulating piston movement sender and quantity adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-69
- Checking needle lift sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-76
- Checking injection distributor control range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-79
Checking additional signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-84
- Checking clutch switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-84
- Checking engine speed signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-86
Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-88
- Renewing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-88
- Checking terminating resistor for data bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-90
26 Exhaust system Page

Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-1
- Exhaust system without turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-2
- Exhaust system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-3
27 Starter, Current supply Page
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-1
- Removing and installing starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-2
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-5
- Compact alternator with ribbed V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-5
- Check carbon brushes for alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-7
- Renewing ribbed V-belt pulley on alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-7
- Checking ribbed V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-9
- Alternator brackets and ribbed V-belt routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-10
- Overview of ribbed V-belt drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-14
- Removing and installing ribbed V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-17
- 230 V additional alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-22
- Exploded view of additional 230 V alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-23
- Removing and installing additional 230 V alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-25
- Fault displays on 230 V additional alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-29
28 Glow plug system Page

Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-1
- Checking glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-3
48 Steering Page
Exploded view: Power steering pump, reservoir, hydraulic lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-1
- Function overview: Power steering pump, oil cooler, hydraulic lines, reservoir . . . . . . . . . . . . . . . . . . . . . 48-2
- Exploded view: Power steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-4
- Checking feed pressure of power steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-7
- Removing and installing power steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-9
90 Gauges, Instruments Page
Instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
- Removing and installing instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
- Removing and installing individual instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-2
- Function overview of instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3
97 Wiring Page
Fuse box/relay plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97-1
- Removing and fuse box/relay plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97-1
- Connection assignment on fuse box/relay plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97-4
- Removing and installing earth switch-off relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97-11
- Wiring loom versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97-14
Wiring loom and connector repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97-16
Safety Precautions and Technical Data
Safety precautions
Introduction
This Workshop Manual contains technical data, descriptions and repair

instructions for the 5-cylinder Volkswagen marine boat engine with and
without turbocharger.
The individual repair groups of the Volkswagen marine boat engine are
listed in the contents.
General information
Spare parts for electrical systems and fuel systems are subject to legal
provisions. Genuine Volkswagen Marine parts comply with these
provisions. Injuries and damage caused from the use of non-genuine
spare parts is excluded from the guarantee.
Volkswagen marine boat engines are certified in accordance with

BSO 2 under the certificate numbers:
M 103 300 05, M 103 300 06 and M 103 300 07.
00-1
Important
Read the safety precautions carefully before beginning with the

repair instructions. The dangers and safety measures that should
always be observed when operating and preforming maintenance
on the engine are listed in the following:
Stop the engine by switching off the power supply to the engine at
the stop switch of the central electrics.
Always conduct maintenance work with the engine switched off.

However, certain adjustment work must be carried out with the
engine running.
When the engine is running, make sure loose clothing, long hair or
tools cannot get caught in rotating parts and cause serious injuries.
During maintenance work or test drives, be sure to wear appropriate

shoes (deck shoes) and work clothing.
Never start an engine equipped with a turbocharger without the air

filter mounted. The rotating compressor in the turbocharger can
cause serious injuries. Objects that get into the intake duct can
cause mechanical damage.
Stop the engine and close the seawater valve when working on the
cooling system.
00-2
Open the cap of the cooling system extremely carefully when the
engine is hot (danger of scalding) and do not remove the cap until the
pressure is completely released.
Connect and disconnect the cables of the glow plug and fuel injec-
tion system - including measurement device cables - only when the
ignition is switched off.
If the engine is to be run at starting speed without actually starting,

e.g. during a compression test, disconnect all connectors for the
injection pump.
Only use motor oils approved by Volkswagen Marine (⇒ Operating

Manual for Volkswagen Marine Boat Engine).
Only start the engine in a well-ventilated area. When operating the

engine in a closed room, make sure that the exhaust bases are
routed out of the working area with a suitable ventilation system.
Exercise extreme caution in case of leaks in the fuel system. Wear

protective goggles when testing the injectors. Fuel spraying down
can cause serious injuries due to the high injection pressure.
00-3
Incorrect connection of the battery can lead to sparks that cause an
explosion. Avoid open flame and welding work near the battery.
Hydrogen gas escapes when charging batteries that forms a highly

explosive mixture with oxygen. Therefore, wear protective goggles
and appropriate protective clothing. As the mixture is heavier than
air, it can collect in the bilge. Use only onboard charging units and
so-called gel batteries if possible.
Torques
The tighten torques for screw connections are tightened with a

torque spanner. All torques listed in this Workshop Manual refer to
the cleaned thread, screw/bolt head and contact surfaces.
When tightening to a specified torque setting and a rotating angle,

first apply the specified torque with a torque spanner. Then addition-
ally tighten to the specified angle using the protractor scale.
00-4
Technical Data
Engine number
The engine number (”engine code” and ”serial number”) is located on

the left-hand side next to the injection pump on the cylinder block.
The engine number consists of up to nine characters (alphanumeric).

The first part (maximum of 3 code characters) represents the ”engine
code”, the second part (six places) the ”serial number”. If more than
999,999 engines with the same code have been produced, the first of
the six places is renewed with a letter.
In addition, an information plate with ”engine code letters” and ”serial

N10--0052
number” is located on the upper section of the toothed belt guard.
00-5
Engine characteristics
Code letters BCT ANF

Manufactured 06.01 ➤ 06.01 ➤
Displacement l 2.5 2.5
Output kW at rpm 40/2500 55/3600
Torque Nm at rpm 155/2250 155/2250
Bore ∅ mm 81 81
Stroke mm 95.5 95.5
Compression ratio 19.0 19.0
CZ at least 49 49
Firing order 1-2-4-5-3 1-2-4-5-3
Turbocharging - -
Charge air cooling - -
Self-Diagnosis x x
Weight kg 260 260
(dry, with sub-assem-
blies, cooling system
and coupling flange)
Certificate No. as per M 103 300 05 M 103 300 05
BSO 2
00-6
Code letters BCU ANG BCV ANH
Manufactured 06.01 ➤ 06.01 ➤ 06.01 ➤ 06.01 ➤
Displacement l 2.5 2.5 2.5 2.5
Output kW at rpm 74/2600 88/3250 108/4000 111/4000
Torque Nm at rpm 270/2500 275/2500 310/1900 310/1900
Bore ∅ mm 81 81 81 81
Stroke mm 95.5 95.5 95.5 95.5
Compression ratio 19.0 19.0 19.0 19.0
CZ at least 49 49 49 49
Firing order 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3
Turbocharging x x x x
Intercooler - - x x
Self-Diagnosis x x x x
Weight kg 275 275 280 280
(dry, with sub-assem-
blies, cooling system
and coupling flange)
Certificate No. as per M 103 300 06 M 103 300 06 M 103 300 07 M 103 300 07
BSO 2
00-7
Self-Diagnosis
Properties of the Self-Diagnosis
The control unit for the diesel direct injection system is equipped with
a fault memory.
If faults occur in the sensors or components monitored, these are

stored in the fault memory together with details of the type of fault.
Faults that only occur temporarily (sporadically) are also printed out
with the supplement ”sporadically occurring fault”. These faults
appear on the display with the supplement ”/SP”.
The cause of sporadic faults can be, for example, a loose connection
or a brief break in the line. If a sporadic fault no longer occurs after
50 warm-up phases, it is deleted from the fault memory.
If faults that influence the vehicle handling are detected, the glow
period warning lamp flashes.
The stored faults can be read out with the fault output device
V.A.G 1552 or the new tester VAS 5052 ⇒ page 01-10.
After the fault(s) has (have) been eliminated, the fault memory must
be erased ⇒ page 01-12.
01-1
Note:
General information on self-diagnosis is contained in the operating
manual for the fault output device V.A.G 1552 (VAS 5052).
Technical Data for the Self-Diagnosis

Equipment
♦ The data is interchanged between the control unit and fault output
device V.A.G 1551 in the ”Rapid data transfer” operating mode.
♦ Fault memory: Permanent and temporary memory1)

1) Will
be deleted after the 50th warm-up phase if the fault has not
occurred again.
Reading out control unit version
The control unit version is displayed when the fault output device
V.A.G 1552 or the tester VAS 5052 is connected and the control unit for
the engine electronics is selected ⇒ page 01-4.
01-2
Selectable functions using the tester V.A.G 1552 or VAS 5052 under address word 01, engine electronics
Note:
Please consult the following table to see the requirements for selection of the desired functions.
Function Condition
Functions on V.A.G 1552/VAS 5052 Engine stopped, Engine runs at idle Boat in driving
ignition switched on mode
01 Reading out control unit version yes yes yes
02 Interrogate fault memory yes1) yes yes
03 Final control diagnosis yes yes no
04 Basic setting no yes no
05 Erase fault memory yes yes yes
06 End output yes yes yes
08 Read measurement value block yes yes yes
1) Only carry out with ignition switched on when engine fails to start.
01-3
Connecting fault reader
All functions possible with the fault output device V.A.G 1552 can also
be carried out with the tester VAS 5051, VAS 5052 or V.A.G 1551.
V.A.G 1552 Connect V.A.G 1552
Connecting VAS 5052 ⇒ page 01-7
Special tools, workshop equipment, test and measuring equip-

ment and accessories required
♦ Fault reader V.A.G 1552
W00--1188
V.A.G 1551/3 ♦ Cable V.A.G 1551/3
Testing Requirements
The battery voltage must be at least 11.5 V.
Fuse 33 OK.
W00--0047
01-4
Procedure
- Unscrew the cover of the diagnosis connection on the main panel.

V.A.G 1552
- Connect the fault output device V.A.G 1552 with the cable
V.A.G 1551/3.
Note:
You can also connect the V.A.G 1552 to the diagnosis plug in the
central electrics ⇒ Fitting location overview, page 23-3.
- Depending on the function desired, you must:

switch on the ignition
or
V.A.G 1551/3 Y01--0001
start the engine ⇒ page 01-3, ”Selectable Functions” table.
Notes:
♦ If the display remains dark, check the power supply for the diagnosis
plug using the CFD:
⇒ Current flow diagrams
♦ If the displays indicated in the work procedure are not achieved:
⇒ Operating instructions for the fault output device
01-5
♦ If input errors produce the message ”Fault in the data inter-
change!”, remove the cable from the fault output device, reconnect
it and repeat the work steps.
Vehicle system test HELP Display:
Enter address word XX
- Keep an eye on the information that appears on the display while
operating the fault output device:
- Press buttons 0 and 1 for ”Engine electronics” address word and

confirm entry with Q button.
065906018 T150-5 MDC 0000SG 3601 → The control unit identification appears on the display of the fault output
Coding 00001 WSC00000 device V.A.G 1552, e.g.:
♦ 065906018 = part no. of the control unit (for current control unit
version, see Spare Parts Catalogue)
♦ T150-5 = 5-cyl. TDI engine with 150 bhp
♦ MDC 0000SG = Injection system (Marine Diesel Electronic Control)
♦ 3601 = Software version of control unit
♦ Coding 00001 = Coding variant
♦ WSC xxxxx = Dealership identifier
- Press the → button.
01-6
Rapid data transfer HELP Display:
Select function XX
- See repair procedures for further procedure.
VAS 5052 Connecting VAS 5052

♦ Fault output device VAS 5052
The battery voltage must be at least 11.5 V.

W00--1206
Fuse 33 OK.
01-7
Procedure
- Unscrew the cover of the diagnosis connection on the main panel.

VAS 5052
- Connect the plug of the diagnosis cable to the diagnosis connection.
Note:
You can also connect the VAS 5052 to the diagnosis plug in the central
electrics ⇒ Fitting location overview, page 23-3.
Select operating mode:

Y01--0002
- Press the button for ”Vehicle Self-Diagnosis” on the display.
Select vehicle system:
- Press the button ”01 - engine electronics on the display.
The control-unit identification of the engine control unit appears on the

display.
Selecting diagnosis function:
All diagnosis functions that can be carried out are available on the
display.
- Press the button for the desired function on the display.
01-8
Notes:
The display fields in the functions 04 - Basic setting and 08 - Reading
measurement value block, are shown from top to bottom.
The following test procedures are described for the fault output device
V.A.G 1552.
01-9
Fault memory
Interrogate fault memory
V.A.G 1552 ♦ Fault output device V.A.G 1552 with cable V.A.G 1551/3 or fault
output device VAS 5052
Procedure
- Connect the fault output device V.A.G 1552 (VAS 5052) and select
the engine electronics control unit with the ”Address word” 01.
Here, the engine should be idling.
(Connecting fault output device and selecting engine control unit
⇒ page 01-4)
W00--1188
Only if the engine does not start:
- Switch on the ignition.

Select function XX
operating the vehicle system tester:
- Press the keys 0 and 2 for the function ”Query fault memory” and
confirm the input using the Q key.
X faults detected! The display shows the number of faults stored or ”No faults
detected!”.
01-10
If one or more faults are stored:
With the → key you can now display the individual fault numbers with
the related texts.
Rapid data transfer HELP - Press the → key repeatedly until all the previously stored faults have
Select function XX been displayed and the display is as follows:
- Eliminate the Faults using the fault table ⇒ page 01-14.
- Then erase the fault memory

⇒ page 01-12
If the memory contains no faults:
- Press the → -button.

Select function XX
- Press keys 0 and 6 for ”End data transfer” function and acknowledge
entry with Q key.
01-11
Erase fault memory
Test condition
Fault rectified
Note:
After the fault has been rectified, the fault memory must again be
W00--1188
queried as described below and then deleted.
Procedure
⇒ page 01-4)

Select function XX
- Press the keys 0 and 2 for the function ”Query fault memory” and
Rapid data transfer HELP - Press the → key repeatedly until all the previously stored faults have
Select function XX been displayed and the display is as follows:
01-12
- Press the keys 0 and 5 for the function ”Delete fault memory” and
Rapid data transfer → Display:
Fault memory has been erased!
- If the fault memory cannot be deleted, there is still a fault to be recti-
fied.

Select function XX
entry with Q key.
01-13
Fault table
Notes:
♦ The fault table is arranged according to the 5-digit fault code on the left-hand side.
♦ In addition, the so-called P-codes, e.g. P0118, are output. These P-codes can currently be ignored, as they will first be
used in future self-diagnosis systems.
♦ Explanations on the fault types (e.g. ”break/short circuit to earth”):
⇒ Operating instructions for the fault output device
♦ If components are output as defective:
First check the cables and connectors to these components and the earth cables of the system using the current flow
diagram. Only when no faults are found here should components be replaced. This especially applies when faults are
output as ”sporadic” (SP).
♦ Erase the fault memory after eliminating existing faults.
Output on V.A.G 1552/VAS 5052, e.g.:

16502 P0118 035
Coolant temperature sender -G62
Signal too large
Sporadic fault
Explanation:
♦ 16502 = Fault code
♦ P0118 = Additional fault code
♦ 035 = Fault type as number
♦ Coolant temperature sender -G62 = Defective current path or fault location
♦ Signal too large = Fault type as text
♦ Sporadic fault = Fault not always present, e.g. loose contact
01-14
Output on Possible Cause(s) of Possible effects Remedying the Fault
V.A.G 1552/VAS 5052 Fault(s)
16705 P0321
Engine speed sender
-G28
Implausible signal ♦ G28 defective ♦ Preheating warning lamp - Check G28
♦ Distance between speed flashes ⇒ page 23-47
sender and sender wheel ♦ Engine does not start
too large ♦ Engine dies
♦ Metal chips on G28 or ♦ No display on rev counter
retaining base loose
16706 P0322
Engine speed sender
-G28
No signal ♦ G28 defective ♦ Preheating warning lamp - Check G28
♦ Break in wiring or short flashes ⇒ page 23-47
circuit ♦ Engine does not start
♦ Engine dies
♦ No display on rev counter
01-15
16989 P0605
Control unit defective ♦ Internal defect in control ♦ Preheating warning lamp - Renew J248
unit may flash ⇒ page 23-88
♦ Poor driveability
♦ Engine stops
17563 P1155
Intake manifold
pressure sender -G71
Short to positive ♦ Short to positive ♦ Glow plug warning lamp - Check G71
♦ G71 defective flashes ⇒ page 23-49
♦ Reduced power - Check turbocharger
⇒ page 21-21; Checking
boost pressure system;
Checking turbocharger
01-16
17564 P1156
Intake manifold
Open circuit/ ♦ G71 defective ♦ Glow plug warning lamp - Check G71
Short to earth ♦ Break in wiring or short flashes ⇒ page 23-49
circuit to earth ♦ Reduced power
♦ Increased emissions
17565 P1157
Intake manifold
Supply voltage ♦ G71 defective ♦ Glow plug warning lamp - Check G71
circuit ♦ Reduced power
01-17
17568 P1160
Intake manifold tem-
perature sender -G72
Short circuit to earth ♦ G72 defective ♦ Switches to default value - Check G72
♦ Wiring has short circuit to 136.8°C ⇒ page 23-58
earth
♦ Intake manifold tempera-
ture or ambient tempera-
ture too high
17569 P1161
Intake manifold tem-
perature sender -G72
♦ G72 defective ♦ Switches to default value - Check G72
Short to positive ♦ Break in wiring or short 136.8 °C ⇒ page 23-58
circuit to positive
01-18
17570 P1162
Fuel temperature
sender -G81
Short circuit to earth ♦ G81 defective ♦ Goes to default value - Check G81
♦ Wiring has short circuit to - 5,34 °C ⇒ page 23-64
earth ♦ Increased emissions
17571 P1163
Fuel temperature
sender -G81
♦ G81 defective ♦ Goes to default value - Check G81
Short to positive ♦ Break in wiring or short - 5,34 °C ⇒ page 23-64
circuit to positive ♦ Increased emissions
01-19
17653 P1245
Needle lift sender -G80
Short circuit to earth ♦ G80 defective ♦ Glow plug warning lamp - Check G80 ⇒ page 23-76
♦ Wiring has short circuit to flashes
earth ♦ Engine runs roughly
♦ Reduced power
17654 P1246
Implausible signal ♦ G80 defective ♦ Glow plug warning lamp - Check G80 ⇒ page 23-76
♦ Injection line to injector flashes
with needle lift sender ♦ Engine runs roughly
not OK ♦ Reduced power
♦ Fuel shortage ♦ Increased emissions
♦ Air in fuel system
01-20
17655 P1247
♦ G80 defective ♦ Glow plug warning lamp - Check G80 ⇒ page 23-76
Short to positive ♦ Break in wiring or short flashes
circuit ♦ Engine runs roughly
♦ Reduced power
17656 P1248
Commencement of
injection control
Control difference ♦ Commencement of injec- ♦ Glow plug warning lamp - Check N108
tion valve (N108) defec- flashes ⇒ page 01-33, Final
tive ♦ Engine runs roughly control diagnosis
♦ Needle lift sender (G80) ♦ Reduced power - Check G80
defective ♦ Increased emissions ⇒ page 23-76
♦ Fuel tank empty ♦ Poor cold starting - Fuel filter or fuel line
♦ Fuel supply not OK, fuel behaviour clogged
shortage - Check and adjust com-
♦ Point of injection not OK mencement of injection
⇒ page 23-31
01-21
17659 P1251
Commencement of
injection valve -N108
Short to positive ♦ Short to positive ♦ Glow plug warning lamp - Check N108
flashes ⇒ page 01-33, Final
♦ Engine knocks in idle, control diagnosis
as commencement of
injection is constantly
set to ”advance”
♦ Reduced power
01-22
17660 P1252
Commencement of
injection valve -N108
Open circuit/ ♦ Break in wiring ♦ Glow plug warning lamp - Check N108
Short to earth ♦ Commencement of injec- flashes ⇒ page 01-33, Final
tion valve defective ♦ Engine knocks in idle, control diagnosis
as commencement of
injection is constantly
set to ”advance”
♦ Reduced power
♦ Short circuit to earth ♦ Glow plug warning lamp
flashes
♦ Lack of power, as com-
mencement of injection
is constantly set to
”retard”
♦ Reduced power
01-23
17663 P1255
Coolant temperature
sender -G62
Short circuit to earth ♦ G62 defective ♦ Glow plug warning lamp - Check G62
♦ Wiring has short circuit to flashes ⇒ page 23-54
earth ♦ Black smoke during
starting
♦ Preheating is always
carried out for approx.
20 sec.
17664 P1256
Coolant temperature
sender -G62
♦ G62 defective ♦ Glow plug warning lamp - Check G62
Short to positive ♦ Break in wiring or wiring flashes ⇒ page 23-54
has short circuit to posi- ♦ Black smoke during
tive starting
♦ Preheating is always
carried out for approx.
20 sec.
01-24
17762 P1354
Modulating piston
movement sender
-G149
Electrical fault in ♦ Injection pump defective ♦ Preheating warning lamp - Check G149
circuit ♦ Break in wiring or short flashes ⇒ page 23-69
circuit ♦ Engine stops
17945 P1537
Fuel cut-off valve -N109
Malfunction ♦ N109 defective, leaky or ♦ Preheating warning lamp - Check N109
sticking flashes ⇒ page 23-54,
⇒ page 01-33, Final
control diagnosis
01-25
17946 P1538
Open circuit/ ♦ N109 defective ♦ Preheating warning lamp - Check N109
Short to earth ♦ Break in wiring or short flashes ⇒ page 23-54,
circuit to earth ⇒ page 01-33, Final
control diagnosis
17969 P1561
Quantity adjuster -N146
Control difference ♦ Injection pump defective ♦ Glow plug warning lamp - Check N146
circuit ♦ Engine stops
01-26
17970 P1562
Upper stop value - Quantity adjuster (N146) ♦ Preheating warning lamp - Check N146
defective/blocked flashes ⇒ page 23-69
- Upper stop value reached ♦ Reduced power
17971 P1563
Lower stop value - Quantity adjuster (N146) ♦ Preheating warning lamp - Check N146
defective/blocked flashes ⇒ page 23-69
- Lower stop value reached ♦ Black smoke
♦ Rough idling
01-27
17978 P1570
Engine control unit ♦ Attempted tampering ♦ Preheating warning lamp - Renew J248
blocked ♦ Incorrect control unit flashes ⇒ page 23-88
♦ Engine starts briefly and
then dies again
18008 P1600
Voltage supply Ter.15
Voltage too low ♦ No voltage with ignition ♦ Poor driveability and - Check power supply of
switched on (Terminal 15) engine stops the control unit for diesel
direct injection system
⇒ page 23-41
01-28
18009 P1601
Voltage supply relay - ♦ Voltage supply relay ter- ♦ Engine does not start - Check power supply of
Terminal 30 -J317 minal 30 (J317) defective ♦ Poor driveability and en- the control unit for diesel
♦ Relay sticks (sporadic) gine stops direct injection system
⇒ page 23-41
18026 P1618
Glow plug relay -J52
Short to positive ♦ Wiring has short circuit to ♦ Preheating warning lamp - Check J52
positive flashes ⇒ page 01-33, Final
♦ J52 defective ♦ No preheating control diagnosis
♦ Poor cold starting
behaviour
01-29
18027 P1619
Open circuit/ ♦ Break in wiring or short ♦ Preheating warning lamp - Check J52
Short to earth circuit to earth flashes ⇒ page 01-33, Final con-
♦ J52 defective ♦ No preheating trol diagnosis
♦ Poor cold starting
behaviour
18039 P1631
Accelerator lever posi-
tion sender -G79
Signal too high ♦ G79 defective ♦ Preheating warning lamp - Check G79:
flashes ⇒ page 20-13; Checking
♦ Increased idling speed accelerator lever position
sender
01-30
18040 P1632
tion sender -G79
Supply voltage ♦ Operating voltage too ♦ Preheating warning lamp - Check G79:
high or too low flashes ⇒ page 20-13; Checking
♦ Break in wiring accelerator lever position
sender
01-31
18047 P1639
tion sender 1/2
G79+G1851)
Implausible signal ♦ G79 defective ♦ Preheating warning lamp - Check G79:
flashes ⇒ page 20-13; Checking
♦ Increased idling speed accelerator lever position
sender
18048 P1640
Control unit -J248 ♦ Internal defect in control ♦ Preheating warning lamp - Renew J248
defective unit flashes ⇒ page 23-88
♦ Poor driveability
1) Incorrect
fault text display. The correct display is:
Accelerator lever position sender -G79
Implausible signal
01-32
Final control diagnosis
Carry out diagnosis of actuators
With the diagnosis of actuators, the following components are acti-

vated in the order stated.
1. Commencement of injection valve (N108)
2. Fuel cut-off valve (N109)

W00--1188 3. Glow plug relay (J52)
4.Glow period warning lamp (K29)
Notes:
♦ The activation of the individual actuators is limited to 30 secs, but it
can be terminated at any time by pressing the ” key.
♦ Before the diagnosis of actuators is repeated, the ignition must be
switched off.
01-33
Procedure
⇒ page 01-4)

Select function XX
operating the vehicle system tester:
- Press the keys 0 and 3 for the function ”Diagnosis of actuators”.

Fast data interchange Q Display:
030303 diagnosis of actuators
- Confirm the input using the Q key.
Final control element diagnosis → Display:
Commencement of injection valve -N108
Activating the valve produces a clearly audible change in the sound
of combustion (knocking).
If a change in the sound of combustion is audible:
- Check injection timing device adjustment range

⇒ page 23-79
- Press the →-button.

The engine must come to a standstill.
01-34
If the engine does not come to a standstill.
- Switch off the ignition.
- Unscrew the fuel cut-off valve and clean it to remove swarf and dirt
that might have accumulated.
- Repeat the diagnosis of actuators. If the engine again does not come
to a standstill, replace the fuel cut-off valve ⇒ page 23-13, item 5.
- Continue the diagnosis of actuators with the engine off and the igni-
tion on.

The relay must click.
Note:
The glow plug relay is located in the central electrics.
If the relay does not click:
- Check the glow plug relay:

⇒ Current Flow Diagrams binder

Glow period warning lamp -K29
The warning lamp must flash.
If the warning lamp does not flash:
01-35
- Check the glow period warning lamp:

Select function XX
entry with Q key.
01-36
Measuring value blocks
Safety Measures
If test and measuring devices are required during test drives, the
following must be observed:
♦ The test and measuring devices must be secured in the boat and
must be operated by a second person.
Read measurement value block

Test conditions
The coolant temperature must be at least 70 °C.
All electrical consumers, e.g. hydraulic pumps or 230 V additional

alternators must be switched off.
W00--1188 No fault must be stored in the fault memory ⇒ page 01-10, retrieve
fault memory.
01-37
Procedure
⇒ page 01-4)

Select function XX
- Press keys 0 and 8 for ”Read measuring value block” function and
acknowledge entry with Q key.
Read measuring value block HELP Display:
Enter display group number XXX
Note:
The display group number 001 is an example for illustrating the
procedure.
- Press keys 0, 0 and 1 for ”Display group number 1” and acknow-

ledge entry with Q key.
Read measuring value block 1 → Display:
1 2 3 4 (1...4 = display fields)

Select function XX
- Press the keys 0 and 6 for the function ”quit output” and confirm the
input using the Q key.
01-38
Note:
To switch into another display group, proceed as follows:
Display group V.A.G 1552

Up Press ↑ key
Down Press the ↓ key
Skip Press C key
01-39
Evaluate measuring value blocks at idle speed with ignition on
Display group 000 at idling (warm engine, coolant temperature not below 70 °C)
Display group 000 (display values, decimal)

• Engine runs at idle
Read measurement value block 0 A Display
x x x x x x x x x x
1 2 3 4 5 6 7 8 9 10 A Display fields Setpoint value corresponds to
Air quantity do not observe ---
Coolant temperature 88...198 20...100 °C
Intake manifold temperature 0...182 10...135 °C
Atmospheric pressure do not observe ---
Intake manifold pressure do not observe ---
Injection quantity 11...45 2.2..9.0 mg/stroke
Throttle lever position 0 0%
Commencement of injection
Engine code letters: ANF, BCT 0...150 9° before TDC.3° after TDC
Engine code letters: ANH, ANG, BCU, BCV 0...73 2.8° before TDC.3° after TDC
Engine speed 36...39 750...820rpm
01-40
Display group 001 -Injection quantity-

Read measurement value block 1 → A Display
xxxx rpm xx.x mg/ x.xx V xxx.x °C
stroke
1 2 3 4 A Display fields Setpoint value Evaluation
Coolant temperature 70...110 °C ---
Voltage from modulating piston movement 1.25-2.00 V ⇒ page 01-42
sender
Injection quantity 2.2-9.0 mg/H ⇒ page 01-42
Engine speed 750...820rpm ---
01-41
Evaluation: Display of injection quantity
Display on V.A.G Possible Cause(s) of Fault(s) Remedying the Fault

1552
below 2.2 mg/stroke ♦ Injection pump too rich - Replace injection pump ⇒ page 23-25
over 9 mg/stroke ♦ Engine too cold - Allow engine to run with increased speed
and repeat the check
♦ Injection pump too lean - Replace injection pump ⇒ page 23-25
Evaluation: Display of voltage from modulating piston movement sender

1552
below 1.25 V ♦ Injection pump too rich - Replace injection pump ⇒ page 23-25
above 2.00 V ♦ Engine too cold - Allow engine to run with increased speed
and repeat the check
♦ Injection pump too lean - Replace injection pump ⇒ page 23-25
01-42
Display group 002 -Idle speed-

xxxx rpm xxx.x % xxx xxx.x °C
Coolant temperature 70...110 °C ---
Operating mode 010 ⇒ page 01-44
Throttle lever position 0% ⇒ page 01-44
01-43
Evaluation: Display of accelerator position

1552
1...100 % ♦ Accelerator lever position sender -G79 - Check G79
defective ⇒ page 20-13; Checking accelerator lever posi-
tion sender
♦ Cable brake to G79
Evaluation: Display of operating mode

Meaning of numbers in 3-digit numerical block for operating mode of engine:
Meaning when display digits = 1

x x x Operating mode of engine
0 Do not observe
1 Idle switch closed
0 Do not observe
01-44
Display group 004 -Commencement of injection-

xxxx rpm xx.x ° xx.x ° xxx %
bef.(after) bef.(after)
TDC TDC
Pulse duty factor from com- 20...95 % ---
mencement of injection valve
Commencement of injection (actual) ⇒ page 01-46
Engine code letters: ANF, BCT 9° before TDC...3°
Engine code letters: after TDC
ANH, ANG, BCU, BCV 2.8° before TDC...3°
after TDC
Commencement of injection (setpoint) ⇒ page 01-46
Engine code letters: ANF, BCT 9° before TDC...3°
Engine code letters: ANH, ANG, BCU, BCV after TDC
2.8° before TDC...3°
after TDC
01-45
Evaluation: Display of commencement of injection (setpoint)

1552
above 2.8° before ♦ Engine too cold - Allow engine to warm up with increased
TDC speed and repeat check.
or above 9° before
TDC
Evaluation: Display of commencement of injection (actual)

1552
above 2.8° before ♦ Engine too cold - Allow engine to warm up with increased
TDC speed and repeat check.
or above 9° before
TDC
♦ Injection pump stops too ”early” - Check commencement of injection dynami-
cally and adjust ⇒ page 23-31
♦ Commencement of injection valve -N108 - Check N108 ⇒ page 01-33, final control
defective diagnosis
later than 3° after ♦ Injection pump stops much too ”late” - Check commencement of injection dynami-
TDC cally and adjust ⇒ page 23-31
♦ Injection timing device blocked - Check N108 ⇒ page 01-33, final control
diagnosis
♦ Commencement of injection valve -N108
defective
01-46
Display group 006 with ignition on
Display group 006 -Switch positions-

xxx xxxxxx xxx
Cruise control system 255 ---
Cruise control system do not observe ---
Switch positions ⇒ page 01-47
No display
Evaluation: Display of switch positions

Meaning of numbers in 3-digit numerical block for switch positions:
Meaning when display digits = 1

x x x Switch positions
1 Decrease in idling speed (engaging and
disengaging
1 do not observe
0 do not observe
01-47
Display group 007 with ignition on (cold, stationary engine)
Display group 007 -Temperatures-

xxx.x °C xxx.x °C xxx.x °C
Coolant temperature approx. ambient ⇒ page 01-49
temperature1)
Intake manifold temperature approx. ambient ⇒ page 01-49
temperature1)
No display
Coolant temperature approx. ambient ⇒ page 01-49
temperature1)
1) It is not possible to specify setpoint values for temperatures. With the engine cold, the temperature values of the fuel,
intake air and coolant must naturally match the ambient temperature. If a value deviates to an obvious extent, the
relevant sender must be checked.
01-48
Evaluation: Display of fuel temperature

1552
- 5.4 °C ♦ Short circuit or fuel temperature sender - Check G81 ⇒ page 23-64
-G81 defective - In a fault situation, the measurement value
block shows a fuel temperature of -5.4 °C
Evaluation: Display of intake manifold temperature or intake air temperature

1552
approx. 136.8 °C ♦ Intake manifold temperature sender -G72 - Check G72 ⇒ page 23-58
defective - In a fault situation, the measurement value
block shows a constant intake manifold or
intake air temperature of approx. 136.8 °C
Evaluation: Display of coolant temperature

1552
Large deviation from ♦ Short circuit or coolant temperature sender - Check G62 ⇒ page 23-54
ambient temperature -G62 defective - In a fault situation, the fuel temperature is
displayed instead
01-49
Display group 013 -Idling rest control-

x.xx mg/ x.xx mg/ x.xx mg/ x.xx mg/
stroke stroke stroke stroke
Smooth-running controller injec- - 2.0...+ 2.0 mg/ ⇒ page 01-52
tion quantity cyl. 4 stroke
Smooth-running controller injection quantity - 2.0...+ 2.0 mg/ ⇒ page 01-52
cyl. 3 stroke
Smooth-running controller injection quantity cyl. 2 - 2.0...+ 2.0 mg/ ⇒ page 01-52
stroke
Smooth-running controller injection quantity cyl. 1 - 2.0...+ 2.0 mg/ ⇒ page 01-52
stroke
01-50
Display group 014 -idling rest control-

x.xx mg/
stroke
--- ---
--- ---
--- ---
Deviating injection quantity cyl. 5 differs from average quantity - 2.0...+ 2.0 mg/ ⇒ page 01-52
stroke
01-51
Evaluation: Display of idle running control
♦ The fuel injection system has an idle running control. Differences in performance between the individual cylinders (parts
tolerances, nozzle flow rate,compression etc.) can be detected and balanced out by selective distribution of the injection
quantity when idling.
♦ The detection takes place when the engine is idling via the signal from the engine speed sender, which supplies five
signals per crankshaft revolution to the control unit. If the signals come in the same rhythm, all the cylinders have the
same performance. If one cylinder has reduced performance, the crankshaft requires a longer interval for the next half
crankshaft revolution. On the other hand, a cylinder performing at a higher level accelerates the crankshaft to such an
extent that it requires a very short interval
♦ If the control unit has detected a deviation, the cylinder in question is immediately supplied with a greater or smaller
injection quantity, until the engine again runs ”smoothly”.
♦ In measurement value block 013 and 014 the injection quantity differences of the individual cylinders are displayed.
Display group 013 shows Cylinder 1 to Cylinder 4. The display for Cylinder 5 appears in display group 014.
♦ +... mg/stroke: The respective cylinder is more powerful and is therefore supplied with less fuel.
♦ -... mg/stroke: The respective cylinder is less powerful and is therefore supplied with more fuel.
01-52
Display group 015
The displayed values are of no significance for trouble-shooting in service.
Display group 015 -Fuel consumption-

xxxx rpm xx.x mg/ xx.xx l/h xx.x mg/
stroke stroke
Injection quantity required --- ---
(specified by driver via
accelerator)
Fuel consumption --- ---
Injection quantity (actual) --- ---
Engine speed --- ---
01-53
Display group 19 with ignition on
Display group 019 -quantity adjuster-

x.xxx V x.xxx V
No display ---
No display ---
Voltage from modulating piston movement sender 4.100...4.800 V ⇒ page 01-55
(start-limit)
Voltage from modulating piston movement sender (stop-limit) 0.540...0.880 V ⇒ page 01-55
01-54
Evaluation: Display of voltage from modulating piston movement sender (stop and start-limit)

1552
Setpoint outside ♦ Quantity adjuster of injection pump mis- - Replace injection pump ⇒ page 23-25
tolerance adjusted
01-55
Display group 125 at idle
Display group 125 -Communications data-bus messages-

Text
No display
Status instrument cluster (main panel) Instrument cluster 1 ---
No display
No display
Note:
If a 0 appears in the display, there is a fault in data bus operation.
01-56
Evaluating the measurement value blocks at full load, engine code letters ANF, BCT
Display group 000 at full load (test drive with warm engine, coolant temperature not below 70 °C)
Notes:
♦ For the tests, accelerate the boat at full throttle.
♦ When the specified engine speed is reached, the measurement values must be printed out or read off (2nd person
required).
01-57
x x x x x x x x x x
Intake manifold pressure do not observe ---
Injection quantity
Engine code letters: ANF 110...125 22...25 mg/stroke
Engine code letters: BCT 105...125 21...25 mg/stroke
Throttle lever position 255 100 %
Engine code letters: ANF 150...175 11...9° bef. TDC
Engine code letters: BCT 112...169 10.5...6° before TDC
Engine speed
Engine code letters: ANF 163...182 3400...3800 rpm
Engine code letters: BCT 110...130 2300...2700 rpm
01-58
Notes:
required).

TDC TDC
Pulse duty factor from com- 20...95 % ⇒ page 01-60
Commencement of injection (actual) approx. commence- ⇒ page 01-60
ment of injection
(setpoint)
Commencement of injection (setpoint) ---
Engine code letters: ANF 11...9° bef. TDC
Engine code letters: BCT 10.5...6° bef. TDC
Engine speed ---
Engine code letters: ANF 3400...3800 rpm
Engine code letters: BCT 2300...2700 rpm
01-59

1552
In the event of too ♦ Commencement of injection valve -N108 - Check N108 ⇒ page 01-33, final control
large a deviation defective diagnosis
from the setpoint
value (approx. 5°)
♦ Injection pump stops very incorrectly - Check commencement of injection dynami-
♦ Air in fuel system - Check fuel supply
Evaluation: Display of pulse duty factor from commencement of injection valve

1552
below 20 or ♦ Commencement of injection valve -N108 - Check N108 ⇒ page 01-33, final control
above 95 % defective diagnosis
- Check commencement of injection dynami-
- Check fuel supply
01-60
Notes:
required).
Display group 008 -Limitation quantities-

xxxx rpm xx.x mg/ xx.x mg/ xx.x mg/
stroke stroke stroke
Injection quantity limitation due 50...52 mg/stroke ---
to air mass intake (smoke avoid-
ance)
Injection quantity limitation by speed ⇒ page 01-62
(torque limitation)
Engine code letters: ANF 22...25 mg/stroke
Engine code letters: BCT 21...25 mg/stroke
Injection quantity (specified by driver) 25...30 mg/stroke ⇒ page 01-62
Engine speed ---
Engine code letters: ANF 3400...3800 rpm
Engine code letters: BCT 2300...2700 rpm
01-61
Evaluation: Display of injection quantity (specified by driver)

1552
below 25 mg/stroke ♦ No full throttle - Repeat test at full throttle.
♦ Accelerator lever position sender -G79 - Check G79
defective ⇒ page 20-13; Checking accelerator lever posi-
tion sender
Evaluation: Display of injection quantity limitation by speed (torque limitation)

1552
below 21 or 22 mg/ ♦ Engine speed too high or too low - Read off the setpoint at the specified
stroke engine speed
01-62
Evaluating the measurement value blocks at full load, engine code letters ANG, ANH,
BCU, BCV
Notes:
required).
01-63
Engine code letters ANG, BCU

x x x x x x x x x x
Intake manifold pressure 191...221 1950...2250 mbar
Injection quantity
Engine code letters: ANG 160...220 32...45 mg/stroke
Engine code letters: BCU 175...215 35...43 mg/stroke
Injection quantity 160...220 32...45 mg/stroke
Engine code letters: ANG 106...150 9...5.5° bef. TDC
Engine code letters: BCU 50...144 8.5...1.0° before
TDC
Engine speed 114...134 2400...2800 rpm
01-64
Engine code letters ANH, BCV

x x x x x x x x x x
Intake manifold pressure 191...221 1950...2250 mbar
Injection quantity
Engine code letters: ANH 175...225 35...45 mg/stroke
Engine code letters: BCV 170...215 34...43 mg/stroke
Engine code letters: ANH 194...255 18...12.5° bef. TDC
Engine code letters: BCV 162...213 14...10° before TDC
Engine speed 136...150 2,850...3,150 rpm
01-65
Notes:
required).

TDC TDC
ment of injection
(setpoint)
Engine code letters: ANG 9...5.5° bef. TDC
Engine code letters: BCU 8.5...1.0° bef. TDC
Engine speed 2400...2800 rpm ---
01-66

TDC TDC
ment of injection
(setpoint)
Engine code letters: ANH 18...12.5° bef. TDC
Engine code letters: BCV 14...10° bef. TDC
Engine speed 2,850...3,150 rpm ---
01-67

1552
In the event of too ♦ Commencement of injection valve -N108 - Check N108 ⇒ page 01-33, final control
large a deviation defective diagnosis
from the setpoint
value (approx. 5°)
♦ Injection pump stops very incorrectly - Check commencement of injection dynami-
♦ Air in fuel system - Check fuel supply
Evaluation: Display of pulse duty factor from commencement of injection valve

1552
below 20 or ♦ Commencement of injection valve -N108 - Check N108 ⇒ page 01-33, final control
above 95 % defective diagnosis
- Check commencement of injection dynami-
- Check fuel supply
01-68
Notes:
required).

ance)
(torque limitation)
Engine code letters: ANG 32...44 mg/stroke
Engine code letters: BCU 35...43 mg/stroke
01-69

ance)
(torque limitation)
Engine code letters: ANH 35...45 mg/stroke
Engine code letters: BCV 34...43 mg/stroke
Engine speed 2,850...3,150 rpm ---
01-70
Evaluation: Display of injection quantity (specified by driver)

1552
below 42 mg/stroke ♦ No full throttle - Repeat test at full throttle.
or 43 mg/stroke
♦ Accelerator lever position sender -G79 - Check G79 and adjust if necessary
incorrectly adjusted or defective ⇒ page 20-13; Checking accelerator lever posi-
tion sender
Evaluation: Display of injection quantity limitation by speed (torque limitation)

1552
below 32 mg/stroke ♦ Engine speed too high or too low - Read off the setpoint at the specified
or 34 mg/stroke engine speed
or 35 mg/stroke
01-71
Notes:
required).
Display group 010 -Air values-

xxxx/min xxxx mbr xxxx mbr xxx.x %
Accelerator pedal position 100 % ⇒ page 01-73
Intake manifold pressure (boost pressure) 1950...2250 mbar ⇒ page 01-73
Atmospheric pressure (air pressure) do not observe ---
Engine speed ---
Engine code letters: ANG, BCU 2400...2800 rpm
Engine code letters: ANH, BCV 2850...3150 rpm
01-72
Evaluation: Display of intake manifold pressure (boost pressure)

1552
below 1950 mbar ♦ Boost pressure system leaky - Check turbocharger
♦ Linkage on turbocharge does not move ⇒ page 21-21; Checking boost pressure
smoothly system; Checking turbocharger
♦ Turbocharger defective
above 2250 mbar ♦ Hose of boost pressure control has fallen
off or is plugged
♦ Linkage on turbocharge does not move
smoothly
♦ Pressure unit on turbocharger defective
Evaluation: Display of accelerator position

1552
below 100 % ♦ No full throttle - Repeat test at full throttle.
♦ Accelerator lever position sender -G79 - Check G79
defective ⇒ page 20-13; Servicing throttle controls
01-73
Removing and installing
VW 313 VW 540 engine
Special tools, workshop equipment, test
and measuring equipment and acces-
sories required
Note:
For conducting assembly work on the
removed engine, it is advisable to use the
clamp VW 313 and the engine and gearbox
support VW 540.
3033 V.A.G 1331
♦ VW 313 Clamp
♦ VW 540 Engine and gearbox support with

additional set VW 540/1A
♦ 3033 Lifting tackle with holder 3180 and

additional hook 10-222A/2
♦ V.A.G 1331 Torque spanner (5 - 50 Nm)

V.A.G 1332 VAS 5024
♦ VAS 5024 Fitting tool for spring clips
W10--0070
10-1
3094 ♦ 3094 Hose clamp or 3093 Hose clamp
♦ Cable ties
W00--0079
Removing engine
Note:
Depending on the type and equipment of the boat, the work described
here in the following for removing and installing the engine may differ
slightly.
- Remove the engine cover.
- All cable ties released or cut open when removing engine must be
remounted in same locations when installing engine.
1
- Depending on the boat design, the engine can be removed with or
without the gearbox.
- Pull off the central plug -arrow- of the battery connection.
Y10--0007
10-2
- Screw the central plug of the instrumentation off the connection of
the fuse box/relay plate in the direction of the arrow.
Note:
Y10--0009
Before removing the fuel supply line, clamp it off with the hose clamp
3094.
Important!
Lay a cleaning cloth around the connection point before dis-
connecting the fuel lines. Then catch the fuel running out by
carefully pulling off the hose.
Note:
Please observe the disposal regulations.
- Loosen the hose clip of the fuel supply line -2- on the fuel lift pump
1 -1- and pull off the hose in the direction of the arrow.
2
Y10--0015
10-3
1 Note:
Before removing the fuel return line, clamp it off with the hose clamp
3094.
- Also remove the fuel return line -1- on the combination radiator (for
fuel and hydraulic oil/gear oil) -2-.
2 Y10--0011
Note:
Before removing the connection lines, clamp them off with hose
clamps 3094 and mark.
- On boats with an external heater and hot water supply system, the
two connection lines -arrows- must be sealed off with clamps.
1 2
Y10--0008
10-4
- Unscrew the throttle linkage -1- at the bracket -2-.
- Unclip the throttle linkage -1- at the accelerator lever position sender
-arrow-.
2
- Close the seawater valve.
Y10--0013
- Drain off the seawater at the drain screw -2- on the combination
radiator (for fuel and hydraulic oil/gear oil) -1- ⇒ page 19-8, Fig. 2.
- Carefully clamp off the seawater supply hose -3- at the combination
radiator -1-.
Engine with additional alternator
- Disconnect the electrical connection lines from the additional alter-

nator.
1 2 3 Y10--0012
Engine with power steering pump
- Clamp off hydraulic lines of the power steering pump:

⇒ page 48-4; Assembly overview: Power steering pump
- Allow hydraulic fluid to drain off and catch.
10-5
Note:
Please observe the disposal regulations.
Engine with reversing gear
- Disconnect the connection lines from the reversing gear on the com-
bination radiator (for fuel and hydraulic oil/gear oil).
Further procedure for all engines
- Disconnect gearbox/Z-drive at flange.
- Unscrew unit mountings on the engine and gearbox side -arrows-.
- Remove exhaust system ⇒ page 26-1, Removing and installing

parts of exhaust system.
Y10--0010
10-6
- Hook in the lifting tackle 3033 as follows and lift the engine out of the
3033 boat with the workshop crane as follows.
Notes:
♦ If the engine is removed with the reversing gear, the gearbox must
also be supported.
♦ Lifting out with sling gear at a flat angle is not permissible.
Mounting engine on repair stand

Y10--0006 To conduct assembly work, the engine must be mounted on the clamp
VW 313 of the repair stand with the engine and gearbox support
VW 540.
Note:
VW540/1 A
Before mounting the engine and gearbox support VW 540, the gear-
box bell must be removed.
VW540
- Mount the engine on the clamp VW 313 with the engine and gearbox
support VW 540 and supplemental set VW 540/1 A.
VW313
N10--0051
10-7
Installing engine
Installation is carried out in the reverse order while observing the

following:
- Check whether dowel sleeves -arrows- for centring the engine/gear-

box bell are present in the cylinder block and insert if necessary.
- Screw the gearbox bell firmly onto the engine.
- Install and align the engine.
Y10--0014
Note:
When installing the gearbox, observe the manufacturer’s specifica-
tions for the respective gearbox.
Further procedure after installing the engine
- Screw the engine mounting onto the boat hull -arrows-.
Note:
Observe the manufacturer’s specifications for the tightening torque of
the mounting screws on the boat hull.
Y10--0010
Engine with additional alternator
- Connect the electrical lines to the additional alternator.

10-8
Engine with power steering pump
- Install the hydraulic line of the power steering pump.

⇒ page 48-4; Assembly overview: Power steering pump
Engine with reversing gear
- Connect the connection lines from the reversing gear on the com-
bination radiator (for fuel and hydraulic oil/gear oil).
Further procedure for all engines
- Attach the central plug to the fuse box/relay plate and to the battery
connection.
- Connect the connection lines -arrows- if a heater and hot water

supply is installed (do not interchange return line -1- and supply line
-2-).
1 2
- Connect the seawater line to the combination radiator (for fuel and
hydraulic oil/gear oil).
- Install exhaust system ⇒ page 26-1, Removing and installing parts

of exhaust system.
Y10--0008 - Fill with coolant ⇒ page 19-26.
- Top up the hydraulic oil with the engine running in the top-up tank.
Note:
If the engine is started without seawater cooling, the ribbed V-belt for
the seawater pump must be removed, as otherwise the impeller of
the seawater pump will be destroyed.
10-9
- Start engine and interrogate fault memory:
⇒ page 01-10; Fault memory; Interrogating fault memory
- Install the engine cover.
Unit mounting and gearbox bells

4
Unit mounting:
3
2 1 - Bearings
1 2 - Engine height adjustment
3 - Washer
4 - Mounting nut 60 Nm + 90°
(1/4 turn.)
Y10--0005
10-10
1
Gearbox bell for reversing gear (SAE-7):
1 - Mounting bolt 60 Nm
2
2 - Gearbox bell
Y10--0004
1
Gearbox bell for Mercruiser:
2 - Gearbox bell
Y10--0003
10-11
1
Gearbox bell for VOLVO SX/DP-S and OMC:
2 - Gearbox bell
Y10--0002
1
Gearbox bell for VOLVO SP-E/DP-E:
2
3
4 2 - Gearbox bell
3 - Bearings
5 4 - Circlip
5 6
5 - Circlip
7 Y10--0001
6 - Seal
7 - Input shaft
10-12
I II Dismantling and assembling
engine
Notes:
♦ If large quantities of metal chips and
abrasion caused by seizing, such as crank-
shaft and conrod bearing damage, is found
in the engine oil, the oil cooler must be
renewed and the oil channels thoroughly
cleaned to prevent subsequent damage.
♦ Defective injectors can lead to heavy
engine knocking and indicate bearing
damage. In the case of complaints, run the
engine at idle and loosen the union nuts on
the injection lines consecutively. If the
knocking disappears after loosening
III IV a union nut, this indicates a defective
injector.
Check injectors:
⇒ page 23-37; Checking injectors
Y13--0013
13-1
I II
I ⇒ page 13-3
II ⇒ page 13-6
III ⇒ page 13-9
IV ⇒ page 13-14
III IV
Y13--0013
13-2
Part I
1 2 3 4 5 6 7 8 9 10 1 - Dust cap
2 - 20 Nm
3 - Idler pulley
4 - 40 Nm
5 - Tensioner for ribbed V-belt

♦ To relax the ribbed V-belt, swivel with
16 mm open-end spanner
⇒ page 13-18
6 - Tensioner
7 - Retainer
♦ For power steering pump
♦ For 12 V alternator and 12V/24V/230V
1 13 12 11 additional alternator
♦ When installing an additional alterna-
tor, additional attachment parts are re-
quired:
⇒ page 27-10; Alternator brackets
and ribbed V-belt routing
18 17 16 15 14 Y13--0010
13-3
8 - 40 Nm
1 2 3 4 5 6 7 8 9 10 9 - Bearing bushes
♦ Renew if damaged
10 - 40 Nm
11 - Shim
12 - Idler pulley
♦ Watch position when installing
toothed belt
⇒ page 15-9, Removing and instal-
ling, tensioning toothed belt for cam-
shaft
13 - 20 Nm
14 - Ribbed V-belt
♦ Mark running direction before remov-
1 13 12 11 ing
♦ Check for wear
18 17 16 15 14 Y13--0010
13-4
15 - Washer
1 2 3 4 5 6 7 8 ♦ Diamond disc must be installed
9 10 ♦ Renew
♦ Must be diamond-coated
16 - Vibration damper with ribbed

V-belt pulley
♦ Watch securing when
mounting
17 - 20 Nm
18 - 160 Nm + 1/2 (180 °) additional turn

♦ Renew
♦ Use brace T 01900 to loosen and
tighten
♦ Removing and installing, tensioning
toothed belt for camshaft
⇒ page 15-9
1 13 12 11
18 17 16 15 14 Y13--0010
13-5
Part II
1 2 3 4 5 6 7
1 - Upper section of toothed belt guard
2 - Toothed belt for camshaft

♦ Check for wear
♦ Always renew after removal
♦ Do not kink
8 ♦ Removing and installing, tensioning
⇒ page 15-9
9
3 - Mounting bolt for camshaft sprocket
♦ Observe marking for bolt steel on bolt
6 head:
8.8 = 85 Nm
10.9 = 100 Nm
♦ Use brace 3036 to loosen and tighten
6
10
7 13 12 6 11 7
Y13--0004
13-6
4 - Camshaft sprocket
1 2 3 4 5 6 7 ♦ Remove from camshaft taper by strik-
ing with hammer using drift through
hole of toothed belt guard
toothed belt
8 shaft
9 5 - Rear toothed belt guard
6 - 20 Nm
6 ♦ Mount with sealing compound
7 - 10 Nm
♦ Mount with sealing compound
8 - Coolant pump
♦ Without oblong hole
♦ Check for smooth running
6 ♦ Renew completely if damaged or
leaky
10
7 13 12 6 11 7
Y13--0004
13-7
9 - O-ring
1 2 3 4 5 6 7 ♦ Renew if damaged or leaky
10 - Lower section of toothed belt guard
11 - Tensioner
12 - Toothed belt sprocket for crankshaft

8 ♦ Removing and installing
9 ling, tensioning toothed belt for cam-
shaft
13 - Toothed belt guard

6
6
10
7 13 12 6 11 7
Y13--0004
13-8
1 2 3 4 5 6 Part III
1 - Intake manifold
♦ Engine code letters BCV, ANH;
7 removing and installing with inte-
grated intercooler ⇒ page 21-17
8
26 9 2 - Gasket
♦ Renew
25 10
3 - 20 Nm
24 11 4 - Connecting piece
23 ♦ For crankcase ventilation
12
5 - Gasket
6 - To oil separator
7 - Cylinder head cover

♦ With gasket
♦ Before fitting, thoroughly clean seal-
13 14 15 ing surface of cylinder head with a
clean cloth
16
17
18
22 21 20 19 Y13--0009
13-9
1 2 3 4 5 6 8 - Cylinder head screw
♦ Renew
♦ Observe order when loosening and
tightening
7 ⇒ page 15-20, Installing cylinder
8 head
26 9 9 - Oil deflector
25 10 10 - Drive sprocket for injection pump

24 11 toothed belt for injection pump:
⇒ page 23-18: Removing and installing, ten-
23 sioning toothed belt for injection pump
12
11 - Mounting bolt for drive sprocket of
injection pump
♦ 160 Nm
♦ Oil thread and contact surface
13 14 15
16
17
18
22 21 20 19 Y13--0009
13-10
1 2 3 4 5 6 12 - Toothed belt for injection pump
♦ Check for wear
♦ Do not kink
8 toothed belt for injection pump:
26 9 sioning toothed belt for injection pump
25 10 13 - Idler pulley
♦ Ensure proper installation
24 11 position:
23
14 - 20 Nm
15 - Hydraulic oil reservoir

♦ With Z-drive
16 - Bracket
♦ For hydraulic oil reservoir
♦ With Z-drive
13 14 15
16
17
18
22 21 20 19 Y13--0009
13-11
1 2 3 4 5 6 17 - 10 Nm
18 - 20 Nm
7 19 - Flange cover
♦ Only on engines without power stee-
8 ring
26 9
20 - Gasket
25 10 ♦ Renew
24 11 21 - Cylinder head gasket

♦ Renew
23 ♦ Observe marking
12 ⇒ page13-43
♦ Renew all coolant after renewing
22 - Cylinder head
♦ Check for warping
⇒ page 15-8, Fig. 1
♦ Installing ⇒ page 15-20
♦ Removing and installing injectors:
13 14 15 ⇒ page 23-35; Removing and installing in-
16 jectors
17
18
22 21 20 19 Y13--0009
13-12
1 2 3 4 5 6 23 - Cup packing
24 - End cover
7 ♦ Replace seal if damaged
8 25 - Intake manifold pressure sender G 71
26 9 with intake manifold temperature
sender G 72
25 10 ♦ Check
⇒ page 23-49; Check intake manifold pres-
24 11 sure sender
23 26 - 20 Nm
12
13 14 15
16
17
18
22 21 20 19 Y13--0009
13-13
1 2 3 4 5 Part IV
1 - Cylinder block
♦ Removing and installing sealing
6 flange and flywheel ⇒ page 13-21
7 ♦ Removing and installing crankshaft
⇒ page 13-30
8 ♦ Dismantling and assembling piston
and conrod ⇒ page 13-34
9 ♦ Renew if damaged
10 2 - Guide sleeve
11 3 - Bracket
12 4 - Tensioner
13 ♦ Removing and installing:
5 - 15 Nm
15
19 16
18
17
Y13--0012
13-14
1 2 3 4 5 6 - Mounting nut for injection pump
sprocket
♦ 90 Nm
6
7 7 - Removing Injection Pump Sprocket
♦ Removing and installing:
8 ⇒ page 23-25; Removing and installing in-
jection pump
9
8 - 30 Nm
10
9 - Mounting bolt for bracket
11 ♦ 45 Nm
12 10 - O-ring
14
15
19 16
18
17
Y13--0012
13-15
1 2 3 4 5 11 - Engine speed sender (G28)
♦ Check:
⇒ page 01-10; Fault memory; Interrogating
fault memory
6
7 12 - 10 Nm
8 13 - Woodruff key
♦ check that securely seated
9
14 - Injection pump
⇒ page 23-25; Removing and installing in-
11 jection pump
12 15 - 25 Nm
13 ♦ With taper
14 16 - Oil sump
♦ Removing and installing
⇒ page 17-18
15 ♦ Clean sealing surface before assem-
bly
19 16
18
17
Y13--0012
13-16
1 2 3 4 5 17 - 20 Nm
♦ M8, install bolt with hexagon head on
gearbox side
6 18 - 15 Nm
7 ♦ M6, with flywheel installed:
Turn flywheel so that bolts are ac-
8 cessible
9 19 - Injection lines
♦ Tighten with 25 Nm
10 ♦ Remove with ring spanner 3035
♦ always remove complete set of lines
11 ♦ Do not change shape of bends
12
13
14
15
19 16
18
17
Y13--0012
13-17
Removing and installing ribbed V-belt
Notes:
♦ The ribbed V-belt for the seawater pump must be removed
⇒ page 19-30, Removing and installing seawater pump.
♦ Mark the running direction before removing the ribbed V-belt.
Ensure proper seating in the belt pulley when installing.
Removing ribbed V-belt
- Relax tensioner in direction of arrow with 16 mm open-end spanner

and remove ribbed V-belt from belt pulleys.
Installing ribbed V-belt
Note:
Before installing the ribbed V-belt, make sure that all units (alternator,
Y13--0011
additional alternator, power steering pump) are securely mounted.
- Lay ribbed V-belt on vibration damper with ribbed V-belt pulley.
- Lift tensioner with 16 mm open-end spanner in direction of arrow,

lay on ribbed V-belt and tension.
13-18
Belt drive without power steering pump and without additional alterna-
tor
- Start engine and check belt routing.
Y13--0008
Belt drive with power steering pump and without additional alternator
Y13--0007
13-19
Belt drive with additional alternator and without power steering pump
Note:
When mounting a 24 V/230 V additional alternator, it must be secured
with an additional bracket.
Y13--0006
Belt drive with power steering pump and additional alternator
Note:
When mounting a 24 V/230 V additional alternator, it must be secured
with an additional bracket.
Y13--0005
13-20
3 4 5 6 7 8 9 10 11 12
sealing flange and flywheel
1 - Seal
♦ Renew ⇒ page 13-26
2 - O-ring
♦ Renew
1 2 11 3 - 10 Nm
4 - Vacuum line
12 5 - Intake pipe
6 - Circlip
14 13
7 - Flywheel
♦ When removing and installing; lock
with brace 10-201
♦ Removing and installing two-part fly-
wheel ⇒ page 13-24
3
16 15
20 3 19 18 17
Y13--0017
13-21
8 - Drive plate
3 4 5 6 7 8 9 10 11 12 9 - 20 Nm
10 - Driver
♦ For VOLVO SX/DP-S Z-drive
♦ For Mercruiser Z-drive
11 - Washer
1 2 11
12 - 40 Nm
13 - Driver
12 ♦ For reversing gear
♦ For VOLVO SP-E/DP-E Z-drive
14 13 14 - 60 Nm + 1/4 (90 °) additional turn

♦ Renew
15 - Sealing flange
♦ With sealing ring, only renew com-
3 pletely
♦ Must be seated on dowel sleeves
16 15
20 3 19 18 17
Y13--0017
13-22
16 - Cylinder block
3 4 5 6 7 8 9 10 11 12 ♦ Removing and installing crankshaft
⇒ page 13-30
♦ Dismantling and assembling piston
and conrod
⇒ page 13-34
17 - Oil pump driver

1 2 ♦ With 4 drive journals
11 ♦ Burst open to pull off
♦ Heat new driver to max. 200 °C be-
fore fitting
12
18 - Gasket
♦ Renew
14 13 19 - Oil pump
♦ Watch driver on crankshaft when in-
stalling, Item 17
♦ Only renew entire unit
♦ Must be seated on dowel sleeves
♦ Dismantling and assembling
3 ⇒ page 17-1, Removing and instal-
ling parts of lubrication system
20 - 20 Nm
16 15
20 3 19 18 17
Y13--0017
13-23
10--201 Removing and installing two-part flywheel
♦ 10-201 Brace
W00--0254
V.A.G 1332 ♦ V.A.G 1332 Torque spanner (40 - 200 Nm)
Removing
Note:
W00--0428
To unscrew the mounting bolts from the drive plate and the two-part
flywheel, use the brace 10-201.
13-24
1 2 - Unscrew the bolts -arrows- from the drive plate -2- on the two-part
flywheel -1- and pull the drive plate of the dowel pins.
Y13--0014
- Now screw the mounting bolts -arrow- out of the two-part flywheel
-1-.
- Remove the two-part flywheel.
Fitting
Note:
To secure the mounting bolts of the drive plate and the two-part
1 flywheel, use the brace 10-201.
Y13--0015
- Position the two-part flywheel on the crankshaft.
- Insert new mounting bolts and tighten hand-tight diagonally.
- Tighten mounting bolts to 60 Nm and turn

90° (1/4 turn)
further (turning further can be carried out in several steps).
13-25
Renewing crankshaft oil seal -belt pulley end-
3203 Special tools, workshop equipment, test and measuring equip-

♦ 3203 Oil seal puller
W00--0062
2080 A ♦ 2080 A Mounting sleeve for oil seal
W00--0519
13-26
Removing
- Remove toothed belt for camshaft: ⇒ page 15-9 Removing and in-
stalling, tensioning toothed belt for camshaft
- Screw inner section of oil seal puller 3203 two turns (approx. 3 mm)
out of outer section and lock in place with knurled screw.
- Oil threaded head of oil seal puller, position and screw into oil seal
as far as possible using high pressure.
- Unscrew knurled screw and turn inner section against crankshaft

until oil seal is pulled out.
3203 N13--0108
Fitting
- Lightly oil sealing lips of oil seal.
- Push oil seal over guide sleeve from 2080 A.
- Press in oil seal as far as possible with pressure sleeve from 2080
A and central bolt of vibration damper.
- Installing and tensioning toothed belt:

⇒ page 15-9 Removing and installing, tensioning toothed belt for
camshaft.
2080 A N13--0110
13-27
Renewing oil seal for crankshaft -flywheel end-
V.A.G 1331 Special tools, workshop equipment, test and measuring equip-
W00--0427
Removing
- Remove flywheel ⇒ page 13-21, Item 7

1
- Remove sealing flange -1-.
Notes:
♦ Do not dismantle sealing flange further.
♦ Only renew entire unit.
N13--0235
13-28
Fitting
Note:
The oil seal of the sealing flange is provided with an mounting aid.
- Push sealing flange evenly onto crankshaft flange by hand and care-
fully remove mounting aid.
- Install flywheel and tighten new mounting bolts with

Tighten to 60 Nm and turn 90° (1/4 turn)
further.
13-29
1 2 3 4 5 6
crankshaft
1 - Oil pump driver
♦ With 4 drive journals
♦ Burst open to pull off
6 ♦ Heat new driver to max. 200 °C be-
5
4
2
3 fore fitting
1
7
2 - Bearing shell 1, 2, 3, 5 and 6
♦ For bearing cap without lubrication
groove
♦ For cylinder block with lubrication
8 groove
♦ Do not interchange used bearing
9 shells (mark)
2 8 3 - Bearing cap
♦ Bearing cap 1: Belt pulley end
10 ♦ Bearing cap 4 with recesses for thrust
washers
9 ♦ Retaining lugs of bearing shells of
cylinder block/bearing cap must be
10 positioned above each other
11
Y13--0018
13-30
1 2 3 4 5 6 4 - 65 Nm
5 - Crankshaft
♦ Axial clearance new: 0.07 - 0.18 mm
Wear limit: 0.25 mm
♦ Measure radial clearance with Plasti-
5
6 gage
4
2
3 new: 0.016 - 0.075 mm
1
7 Wear limit: 0.16 mm
♦ Do not turn crankshaft during radial
clearance measurement
♦ For crankshaft dimensions
⇒ page 13-33
8
6 - Sender wheel
9 ♦ For engine speed sender (G28)
2 8 7 - 25 Nm
♦ Renew
10
8 - Thrust washer
9 ♦ For bearing cap 4
♦ Watch fixing
10
11
Y13--0018
13-31
1 2 3 4 5 6 9 - Bearing shell 4
♦ For bearing cap without lubrication
groove
♦ For cylinder block with lubrication
groove
5
6 10 - Thrust washer
4
2
3 ♦ For cylinder block, bearing 4
1
7
11 - Cylinder block
♦ Dismantling and assembling piston
and conrod
⇒ page 13-34
8
9
2 8
10
9
10
11
Y13--0018
13-32
Crankshaft dimensions
(Dimensions in mm)
Grinding Crankshaft Conrod bearing

dimension bearing
journal dim. journal dim.
-0.022 -0.022
Basic 58.00 47.80
dimension -0.042 -0.042
-0.022 -0.022
Step I 57.75 47.55
-0.042 -0.042
-0.022 -0.022
Step II 57.50 47.30
-0.042 -0.042
-0.022 -0.022
Step III 57.25 47.05
-0.042 -0.042
13-33
Dismantling and assem-
bling piston and conrod
1 1 - Piston rings
♦ Offset seam by 120 °
2 ♦ Remove and install with piston ring
pliers
11 3 ♦ Marked ”TOP” on crown
♦ Check gap clearance ⇒ fig. 1
♦ Check height clearance ⇒ fig. 2
2 4
2 - Circlip
B A
10
9
5
8
6
7 N13--0201
13-34
3 - Piston
♦ Mark installation position and cylin-
der assignment
1 ♦ Arrow on piston crown points toward
belt pulley end
2 ♦ Install with piston-ring scuff band
♦ Renew piston in case of cracks on pis-
11 3 ton skirt
♦ With notch for oil spray nozzles
2 ♦ Checking piston height at TDC
4 ⇒ page 13-42
4 - Conrod
♦ Only renew as a set
♦ Mark assignment to cylinder -A-
♦ installation position:
B A Markings -B- face toward belt pulley
end
10
9
5
8
6
7 N13--0201
13-35
5 - Oil spray nozzle
♦ For piston cooling
1 6 - 10 Nm
♦ Fit with AMV 188 100 02
2
7 - Conrod bolt, 30 Nm + 1/4 (90 °) addi-
11 3 tional turn
♦ Renew
2 4 ♦ Use old bolt for measuring radial
clearance
8 - Conrod cover
♦ Mark assignment to cylinder -A-
♦ installation position:
B A Markings -B- face toward belt pulley
end
10
9
5
8
6
7 N13--0201
13-36
9 - Bearing shell
♦ Ensure proper installation position
♦ Do not interchange used bearing
1 shells
♦ Ensure firm seating in retaining lugs
2 ♦ Axial clearance
Wear limit: 0.40 mm
11 3 ♦ Measure radial clearance with Plasti-
gage:
2 Wear limit: 0.08 mm
4 Do not turn crankshaft during radial
clearance measurement
10 - Cylinder block
♦ Check cylinder bore
⇒ Fig. 3
B A ♦ For piston and cylinder dimensions
⇒ page 13-44
11 - Piston pin
♦ In case of binding, heat piston to
60 °C
10 ♦ Remove and install with drift
VW 222a
9
5
8
6
7 N13--0201
13-37
Fig. 1 Checking piston-ring gap clearance

♦ Feeler gauge
Test procedure
- Push in ring perpendicular from top into lower cylinder opening,

V13--0016 approx. 15 mm from cylinder rim.
Piston ring New Wear limit

Dimensions in mm
1st compression ring 0.25 - 0.45 1.0
2nd compression ring 0.20 - 0.40 1.0
Oil scraper ring 0.25 - 0.50 1.0
13-38
Fig. 2 Checking piston-ring height clearance

♦ Feeler gauge
Test procedure
Clean ring groove before the test.

V13 -- 0687
Piston ring New Wear limit

Dimensions in mm
1st compression ring 0.07 - 0.11 0.25
2nd compression ring 0.05 - 0.08 0.25
Oil scraper ring 0.03 - 0.06 0.15
13-39
Fig. 3 Checking cylinder bore
A
B
1 ment and accessories required
♦ Inside precision measuring device: 50 - 100 mm
2 Test procedure
- Measure at 3 points diagonally in lateral direction -A- and longitudinal

direction -B-. Differences compared to nominal dimension
3 max. 0.08 mm
Note:
The measurement of the cylinder bore may not be carried out when
the cylinder block is mounted on the repair stand with the engine
V13--0280 support VW 540, as incorrect measurements are possible.
13-40
Fig. 4 Piston installation position and piston/cylinder assign-
ment
4
4 Piston in cylinder 1 and 2:
4
Large valve pocket for inlet valve toward flywheel end -arrows-
Piston in cylinder 3, 4 and 5:
Large valve pocket for inlet valve toward belt pulley end -arrows-
N13--0105
Note:
With new pistons, the assignment to the cylinder is stamped on the
piston crown with paint.
♦ Piston for cylinder 1 and 2:
Marking 1/2
♦ Piston for cylinder 3, 4 and 5:
Marking 3/4/5
13-41
Checking piston height at TDC
VW 382/7 ♦ VW 382/7 Measuring bridge
W00--0511
VW 385/17 ♦ VW 385/17 End dimension plate
♦ Dial gauge
W00--0129
13-42
Test procedure
When installing new pistons or a short engine, the

piston height at TDC must be checked. Depending
VW382/7 on the piston overhang, the corresponding cylin-
der head gasket must be installed in accordance
VW385/17 with the following table:
Piston overhang Marking

Notches/holes
up to - 0.96 mm 0.96 mm 1
V13 -- 0353
0.97 mm ... 1.01 mm 2
above ... 1.01 mm 3
Marking of cylinder head gasket
♦ Part No. = arrow A
♦ Notches/holes = arrow B
046 103 383 S Note:

If different values are measured during overhang measurement of the
pistons, the greatest dimension applies for the assignment of the
A
gasket.
B N15--0106
13-43
For piston and cylinder dimensions
Grinding dimension Piston Cylinder

for cylinder bore dia. bore dia.
Basic mm 80.96 81.01
dimension
Step I mm 81.21 81.26
13-44
31 1 2 3 4 5
30 cylinder head
29 Checking compression pressure
⇒ page 15-24.
28 Notes:
♦ When installing a replacement cylinder
27 6 head with a mounted camshaft, the con-
tact surfaces between the bucket tappets
7 and the cam surface must be oiled after
the head is installed.
26 ♦ The plastic washers provided to protect
the open valves may not be removed until
directly prior to fitting the cylinder head.
25 ♦ When renewing the cylinder head, the
24 11 10 9 8 entire coolant must be renewed.
23
22 12
13
14
15
21 20 19 18 17 16
Y15--0002
15-1
31 1 2 3 4 5 1 - 20 Nm
30
2 - Connecting piece
3 - To oil separator
28
4 - Cylinder head screw
♦ Renew
27 6 ♦ Observe order when loosening and
7 tightening
⇒ page 15-20, Installing cylinder
head
26
5 - Toothed belt for injection pump
♦ Check for wear
25 ♦ Always renew after removal
24 11 10 9 8 ♦ Do not kink
22 12
sioning toothed belt for injection pump
13
14
15
21 20 19 18 17 16
Y15--0002
15-2
31 1 2 3 4 5 6 - Drive sprocket for injection pump
toothed belt for injection pump:
29 ⇒ page 23-18: Removing and installing, ten-
28 7 - Mounting bolt for drive sprocket of
injection pump
27 ♦ 160 Nm
6 ♦ Oil thread and contact surface
7 ♦ Use brace 3036 to loosen and tighten
8 - Cover for hydraulic oil reservoir

26
9 - 20 Nm
25 10 - Idler pulley
24 11 10 9 8 ♦ Ensure proper installation
position:
23 ⇒ page 23-18: Removing and installing, ten-
22 12
13
14
15
21 20 19 18 17 16
Y15--0002
15-3
31 1 2 3 4 5 11 - Hydraulic oil reservoir
30 ♦ With Z-drive
29 12 - Gasket
♦ Renew
28 13 - Retainer
♦ For hydraulic oil reservoir
27 ♦ With Z-drive
6
7 14 - 10 Nm
15 - Flange cover
26
16 - 20 Nm
25 17 - Rear toothed belt guard

24 11 10 9 8 18 - 10 Nm
23
19 - 20 Nm
22 12
13
14
15
21 20 19 18 17 16
Y15--0002
15-4
31 1 2 3 4 5 20 - Toothed belt for camshaft
30 ♦ Check for wear
29 ♦ Do not kink
28 ⇒ page 15-9
27 6 21 - Upper section of toothed belt guard
7 22 - Mounting bolt for camshaft sprocket

♦ Observe marking for bolt steel on bolt
head:
26 8.8 = 85 Nm
10.9 = 100 Nm
25
24 11 10 9 8
23
22 12
13
14
15
21 20 19 18 17 16
Y15--0002
15-5
31 1 2 3 4 5 23 - Camshaft sprocket
30 ♦ Remove from camshaft taper by strik-
ing with hammer using drift through
29 hole of toothed belt guard
toothed belt:
27 6 shaft
7 24 - Cylinder head gasket

♦ Renew
♦ Observe marking
26 ⇒ page 15-8, Fig. 2
25 25 - Retainer
24 11 10 9 8
23
22 12
13
14
15
21 20 19 18 17 16
Y15--0002
15-6
31 1 2 3 4 5 26 - Cylinder head
30 ♦ Check for warping
⇒ page 15-8, Fig. 1
29 ♦ Installing ⇒ page 15-20
♦ Removing and installing injectors:
28 ⇒ page 23-35; Removing and installing
injectors
27 6 27 - Oil deflector
7
28 - Cylinder head cover
♦ With gasket
26 ♦ Before fitting, thoroughly clean seal-
ing surface of cylinder head with a
clean cloth
25
24 11 10 9 8 29 - Gasket
23
22 12
30 - Cup packing
13 31 - End cover
♦ Replace seal if damaged
14
15
21 20 19 18 17 16
Y15--0002
15-7
Fig. 1 Checking cylinder head for warping

♦ Straight-edge
♦ Feeler gauge
Max. permissible warping: 0,2 mm

Y15--0005
Note:
It is not permissible to remachine Diesel cylinder heads.
Fig. 2 Cylinder head gasket marking
♦ Part No. = arrow A
♦ Notches/holes = arrow B
046 103 383 S Note:

Depending on the piston overhand, cylinder head gaskets of various
thicknesses are installed. When renewing the gasket, install a new
A
gasket with the same marking.
B N15--0106
15-8
2065 A 2068 A Removing and installing,
tensioning toothed belt for
camshaft
sories required
♦ 2065 A Adjustment ruler
♦ 2068 A Adjustment device for TDC point

3036 3355
♦ 3036 Brace
♦ 3355 Ring spanner
Not shown:
♦ T 01900 Brace
♦ T 01901 TDC sender

V.A.G 1332
W15--0158
15-9
V.A.G 1331 ♦ Torque wrench (5 - 50 Nm) V.A.G 1331
W00--0427
Removing
- Remove ribbed V-belt ⇒ page 13-18.

W00--0608
- Remove upper section of toothed belt guard.
15-10
- Remove the tensioner for the ribbed V-belt.
- Turn crankshaft in engine rotating direction to TDC position of cylin-

der 1:
T01900 - Remove toothed belt guard for toothed belts and cylinder head
cover.
- Tighten brace T 01900 on engine block -arrows- to

40 Nm
.
Y15--0008 - Unscrew vibration damper/toothed belt-crankshaft at central bolt.
- Unscrew the brace T 01900 from the engine block.
- Check the TDC position:
- The markings of the vibration damper and the lower section of the
toothed belt guard must be vertically aligned -arrow-.
Y13--0002
15-11
Engine installed:
A
- The marking -A- on the injection pump pulley is to be located in the
visible area of the injection pump marking -arrow-.
Notes:
♦ This state is only achieved in every 2nd TDC position and is used
exclusively to check the TDC position.
♦ The marking -A- indicates that the injection pump is positioned on
Y15--0009 Cylinder 1.
- Screw the TDC sender T 01901 into the opening of the clutch bell.
- The TDC sender must engage, otherwise the crankshaft must be

turned until the TDC sender is heard and felt to engage.
T01901
Y15--0007
15-12
A 2068 A
Engine removed:
- Set adjustment device for TDC 2068 A to 96.9 mm -arrow A-, left
notch of vernier gauge is reference point.
B - Screw in adjustment device as shown. Turn crankshaft until TDC
marking on flywheel aligns with edge of adjustment device
-arrow B-.
A - The marking -A- on the injection pump pulley is to be located in the

area of the injection pump marking -arrow-.
Notes:
- Remove toothed belt for injection pump ⇒ page 23-18; Removing

and installing, tensioning toothed belt for injection pump
- Unscrew 4 mounting bolts M8 of vibration damper/toothed belt

pulley-crankshaft.
- Unscrew central bolt for vibration damper.
- Remove vibration damper.
- Remove toothed belt guard at bottom ⇒ page 13-8, item 13.
- Relax tensioner for toothed belt with ring spanner 3355.
15-13
- Remove toothed belt.
Installing, tensioning
Engine installed:
- Check whether TDC sender T 01901 is screwed in and engaged.
Engine removed:
- Check whether TDC marking on flywheel and reference mark are

aligned.
2065A - Lock camshaft in place with adjustment ruler 2065 A.
N13--0198
15-14
- Centre adjustment ruler as follows:
Turn the locked camshaft until one end of the adjustment ruler
strikes the cylinder head. Measure the resulting clearance at the
other end of the adjustment ruler with a feeler gauge. Push a feeler
gauge with half the clearance dimension between the adjustment
ruler and the cylinder head. Now turn the camshaft until the adjust-
ment ruler contacts the feeler gauge. Insert a second feeler gauge
with the same dimension between the adjustment ruler and the
cylinder head at the other end.
- Loosen mounting bolt of camshaft sprocket 1/2 turn. Separate cam-

shaft sprocket from taper of camshaft by striking with a hammer
(with drift through hole of rear toothed belt guard).
Y13--0006
15-15
- Install tensioner -1- so that tab -2- of tensioner is seated in anti-twist
pin of lower section of toothed belt guard.
2
- Lay on new toothed belt for camshaftdrive.
- Tighten mounting bolt of tensioner hand-tight.

1
N13--0482
- To tension toothed belt, turn tensioner clockwise -direction of arrow-

with ring spanner 3355 until right edge of pointer -A- is aligned with
right edge of pointer -B-.
B Note:
The right edge of pointer -A- may not be turned past the right edge of
3355 A pointer -B-, as otherwise there is danger of pre-damage to the
tensioner.
N13--0483
15-16
However, if it is accidentally turned too far once, the tensioner must be
completely relaxed and retensioned. The eccentric may not be turned
back only by the dimension it was turned too far.
- Tighten mounting bolt of tensioner with

20 Nm
.
- Check whether crankshaft is still at TDC of cylinder 1 and correct if

necessary.
Engine installed:
Note:
Unscrew TDC sender T 01901 from gearbox bell.
2065A - Tighten mounting bolt for camshaft sprocket with brace 3036.
Observe marking for bolt steel on bolt head:
8.8 = 85 Nm
10.9 = 100 Nm
- Remove adjustment ruler 2065 A from camshaft.
- Install bottom toothed belt guard.
- Fit vibration damper with new central bolt.

N13--0198
15-17
- Screw brace T 01900 onto engine block with 40 Nm -arrows-, tighten
vibration damper/toothed belt pulley-crankshaft at central bolt to
160 Nm and turn
T01900 180° (1/2 turn)
further (turning further can be carried out in several steps).
- Unscrew the brace T 01900.
- Tighten 4 mounting bolts M8 of vibration damper/toothed belt

pulley-crankshaft with 20 Nm.
Y15--0008
- Turn crankshaft two rotations in engine rotating direction until crank-

shaft is positioned at TDC for cylinder 1 again.
- Check pointer position of tensioner again. If right edges of pointers

B -A- and -B- do not align, tensioning must be repeated.
3355 A
N13--0483
15-18
- Toothed belt for injection pump
⇒ page 23-18, Removing and installing, tensioning toothed belt for
injection pump
- Install toothed belt guard for toothed belt and cylinder head cover.
- Install tensioner for ribbed V-belt.
- Install ribbed V-belt ⇒ page 13-18.
15-19
V.A.G 1306 V.A.G 1331 Removing and installing
cylinder head
sories required
♦ V.A.G 1306 Catch pan
V.A.G 1332
W15--0159
15-20
Preconditions
The engine may be a maximum of hand-warm.
The pistons may not be at top dead centre.
Removing
- Drain the coolant ⇒ page 19-26.
- Remove ribbed V-belt ⇒ page 13-18.
- Remove upper toothed belt guard and cylinder head cover.
- Take toothed belt off camshaft pulley and remove camshaft pulley
⇒ page 15-9, Removing and installing toothed belt for camshaft.
- Loosen cylinder head bolts in specified order and unscrew.
- Carefully remove cylinder head.

1 7 9 11 5 3
4 6 12 10 8 2
N15--0148
15-21
Fitting
Notes:
♦ Always renew cylinder head bolts.
♦ Remove gasket residues from the cylinder head and cylinder block
when making repairs. Make sure that not long grooves or scratches
result. When using emery paper the grain may not be below 100.
♦ Thoroughly remove sanding and grinding residues.
♦ Do not remove the new cylinder head gasket from the package until
directly prior to installation.
♦ Handle the gasket with extreme care. Damage to the silicone layer
and in the bead area results in leaks.
- Set crankshaft to the TDC marking before fitting cylinder head.
- Turn crankshaft in direction opposite engine rotating direction until

no piston is at TDC.
- Check whether dowel sleeves for guiding cylinder head are located
in cylinder head and insert if necessary.
- Fit cylinder head gasket.
- Fit cylinder head, insert cylinder head bolts and tighten hand-tight.
15-22
9 5 3 1 7 11
- Tighten cylinder head in four steps in tightening order shown as
follows:
- 1. Pre-tighten with torque spanner:

Step I = 40 Nm
Step II = 60 Nm
- 2. Turn further with rigid spanner:

Step III = 1/4 turn (90 °)
12 8 2 4 6 10 Step IV = 1/4 turn (90 °)
N15--0058
Notes:
♦ Loosen cylinder head: Reverse order.
♦ It is not necessary to retighten the cylinder head bolts following
repairs.
- After mounting cylinder head, turn camshaft so that cams for cylin-
der 1 point upward evenly. Set crankshaft to TDC in engine rotating
direction before fitting toothed belt.
How to install toothed belt and adjust control times ⇒ page 15-9,
Removing and installing toothed belt for camshaft.
How to pour in new coolant ⇒ page 19-26.
15-23
V.A.G 1381 V.A.G 1763 Checking compression
pressure
sories required
♦ V.A.G 1381 Compression pressure tester
♦ V.A.G 1763 Compression pressure tester
♦ V.A.G 1381/12 Adapter

V.A.G 1381/12 3220
♦ 3220 Flexible-head spanner
V.A.G 1331
W15--0093
15-24
Test condition
Engine oil temperature at least 30 °C.
Test procedure
- Pull plug of injection pump off fuse box/relay plate.

V.A.G 1381/12
- Disconnect plugs from all glowplugs.
- Remove all glow plugs with flexible-head spanner 3220.
- Screw in adapter V.A.G 1381/12 in place of glow plugs.

Cyl bar
- Check compression pressure with compression pressure tester

Cylinder
V.A.G 1381 or V.A.G 1763.
Print
V.A.G 1763
C
Note:
V.A.G 1763 Y15--0001
For instructions on using the tester ⇒ Operating Manual.
- Actuate starter until no further pressure increase is indicated by

tester.
Compression pressure values:
New: 30 - 35 bar gauge pressure

Wear limit: 28 bar gauge pressure
Permissible difference between all cylinders: 5 bar
15-25
- Install glow plugs with flexible-head spanner 3220
Tightening torque: 15 Nm.
- Interrogate fault memory:

Note:
Faults are saved when the connectors to the injection pump are separ-
ated. Therefore, interrogate the fault memory and clear it if necessary.
15-26
Servicing valve gear
1 2 1 3
Note:
Cylinder heads with minor cracks (max.
0.5 mm wide) between the valve seats
4 can still be used without shortening the
service life.
5
1 - Bearing cap
6 ♦ Installation position ⇒ Fig. 2
♦ For installation sequence
ling camshaft
8
2 - 20 Nm
19 9
10 3 - Camshaft
♦ Check axial clearance ⇒ fig. 1
⇒ page 15-41
12 ♦ Check radial clearance with Plasti-
gage
Wear limit: 0.11 mm
♦ Run-out: max. 0.01 mm
♦ Marking, valve timing ⇒ fig. 4
13
14
18 17 16 15
N15--0110
15-27
4 - Bucket tappet
1 2 1 3 ♦ Do not interchange
♦ With hydraulic valve clearance com-
pensation
♦ Check ⇒ page 15-43
4 ♦ Lay down with running surface down-
ward
5 ♦ Check axial clearance of camshaft be-
fore installing
6 ⇒ Fig. 1
7 ♦ Oil running surface
8 5 - Valve cotters
19 9 6 - Upper valve spring retainer
10 7 - Valve spring
11 Cylinder head
removed: With valve spring com-
12 pressor 2037 installed: ⇒ page 15-39,
Renewing valve stem seals
13
14
18 17 16 15
N15--0110
15-28
8 - Valve stem seal
1 2 1 3 ♦ Renew ⇒ page 15-39
9 - Repair valve guide

♦ Repair guide with shoulder
4 ♦ Check ⇒ page 15-36
5
10 - Seal
6 ♦ Remove to remove and install bearing
cap
19 9 sioning toothed belt for injection pump
10 11 - Glow plug
♦ Removing and installing, checking
11 glow plug:
⇒ page 28-3; Checking glowplug
12
12 - 30 Nm
13 - Clamp
13
14
18 17 16 15
N15--0110
15-29
14 - Injector
1 2 1 3 ♦ Removing and installing
injectors:
⇒ page 23-35; Removing and installing in-
jectors
4
15 - Heat shield
5 ♦ Renew
6 16 - Cylinder head
♦ Observe note
7 ⇒ page 15-27
8 ♦ Reworking valve seats
⇒ page 15-34
19 9
17 - Valves
10 ♦ Valve dimensions ⇒ fig. 3
11 18 - Seal
♦ Remove to remove and install bearing
12 cap
⇒ page 15-9
13 19 - Valve guide
14 ♦ Renew ⇒ page 15-37
18 17 16 15
N15--0110
15-30
VW 387 Fig. 1 Checking camshaft, axial clearance

0
♦ VW 387 Universal dial gauge holder
90 10
80 20
70 30
♦ Dial gauge
60 40
50
Wear limit: max. 0.15 mm

V15--0740
Carry out measurement with bucket tappets removed and first and last
bearing cap mounted.
Fig. 2 Installation position of camshaft bearing cap
Observe centre offset. Before installing the camshaft, fit bearing cap
and determine installation position.
V15 -- 0098
15-31
c Fig. 3 Valve dimensions
Note:
Valves may not be reworked. Only grinding in is permitted.
a b
Dimension Inlet valve Exhaust valve
∅a mm 36.00 31.50
a ∅b mm 7.97 7.95
V15--0024
c mm 96.85 96.85
α ∠° 45 45
15-32
Fig. 4 Camshaft marking, valve timing
Marking
♦ Base circle of cams: a = 38 mm dia.
A B ♦ Marking with stamped-in numbers and letters on the camshaft:
Cylinder 1 -arrow A- WZO

Y15--0003 Cylinder 2 -arrow B- 046/074
Valve timing for 1 mm valve lift
Inlet opens after TDC 8.0 °

Inlet closes after BDC 28.0 °
Exhaust opens before BDC 37.0 °
Exhaust closes before TDC 10.0 °
15-33
Reworking valve seats
♦ Depth dimension
♦ Valve-seat machining device
Notes:
♦ When servicing engines with leaky valves, it is not sufficient to
machine or renew the valve seats and valves. Especially on engines
with higher kilometrage it is necessary to check the valve guides for
wear.
♦ Only rework valve seat so far that a proper surface condition is
achieved. Before reworking the maximum permissible reworking
dimension must be calculated. If the reworking dimension is
exceeded, the operation of the hydraulic valve clearance compensa-
tion is no longer ensured and the cylinder head must be renewed.
Calculate maximum permissible reworking dimension
- Insert valve and press firmly against valve seat.
Note:
If the valve is renewed as part of repair work, use a new valve for
measurement.
15-34
- Measure distance -a- between valve stem end and upper edge of
cylinder head.
a - Calculate maximum permissible reworking dimension from
measured distance -a- and minimum dimension.
Minimum dimension:
Inlet valve 35.8 mm
Exhaust valve 36.1 mm
V15 -- 0640 Measured distance minus minimum dimension
= maximum permissible reworking dimension.
Example:
Measured distance 36.5 mm

- Minimum dimension 35.8 mm
= Max. perm. reworking dimension 0.7 mm
15-35
a
b Reworking valve seats
Dimension Inlet valve seat Exhaust valve

15º seat
∅a mm 37.201) 33.201)
c ∅b mm 34.80 30.40
c mm 2.70 2.05
V15 -- 0806
45° Valve seat angle
15° Correction angle
1) Maximum outside diameter of correction cutter
Checking valve guides
VW 387 Special tools, workshop equipment, test and measuring equip-

♦ VW 387 Universal dial gauge holder
♦ Dial gauge
W00--0037
15-36
VW387
Test procedure
- Insert new valve in guide. Valve stem end must be flush with guide.
Due to different stem diameters, only inlet valve can be used in inlet
guide and exhaust valve in exhaust guide.
Rock: max. 1.3mm
V15--0133
Renewing valve guides

10--206 ♦ 10-206 Drift
W00--0259
15-37
10--215 ♦ 10-215 Hand reamer and cutting fluid
Removing
- Clean and check cylinder head. Heads with valve seal inserts that
W00--0256 cannot be reworked or cylinder heads which have already been
machined to the minimum dimension are not suitable for replacing
the valve guides.
- Press out worn guides with driver 10-206 from camshaft side (valve
guide with shoulder repair guides - from combustion chamber side).
Fitting
- Moisten new guides with oil and press into cold cylinder head up to
shoulder with driver 10-206 from camshaft side.
Note:
After the guide makes contact with the shoulder, the press-in pressure
may not be increased above 1.0 t, as otherwise the shoulder may
break off.
- Ream valve guide by hand with hand reamer 10-215. Be sure to use
cutting fluid when doing so.
- Rework valve seats ⇒ page 15-34.
15-38
2036 3047 A Renewing valve stem seals
sories required
♦ 2036 Service device
♦ 3047 A Puller
♦ 10-204 Press-on device

10--204 VW 541/1A ♦ VW 541/1A Service lever
♦ VW 541/5 Pressure piece
VW 541/5
W15--0045
15-39
Removing
2036 VW 541/1A
(with cylinder head installed)
- Remove camshaft ⇒ page 15-41.
- Remove bucket tappets (do not interchange) and lay down with
running surface facing downward.
VW 541/5
- Move piston of respective cylinder into top dead centre (TDC) posi-
tion.
N15--0311 - Fit service device 2036 and adjust mounting to stud height.
- Remove valve springs with valve lever VW 541/1A and pressure

piece.
Note:
The valves are supported on the piston crown in the process.
3047A
- Pull off valve stem seals with puller 3047A.
V15 -- 0610
15-40
Fitting
10 -- 204 - To prevent damage to new valve stem seals, push plastic sleeve -A-
A B onto valve stem.
- Oil valve stem seal -B- insert in press-on device 10-204 and carefully
push onto valve guide.
V15 -- 0072
Removing and installing camshaft
Removing
- Remove toothed belt for camshaft ⇒ page 15-9, Removing and

installing, tensioning toothed belt for camshaft
- Remove toothed belt for injection pump ⇒ page 23-18; Removing

and installing, tensioning toothed belt for injection pump
W00--0427 - First remove bearing cap 1 and 3. Loosen bearing cap 2 and 4 alter-
nately and diagonally.
15-41
Fitting
Notes:
♦ When installing the camshaft, the cams for cylinder 1 must face
upward.
♦ When installing the bearing caps, watch centre offset of hole by fit-
ting bearing cap and determining installation position prior to
installation.
- Oil camshaft running surfaces.
- Tighten bearing caps 2 and 4 alternately and diagonally with

20 Nm
.
V15 -- 0098
- Install bearing caps 1 and 3 and also tighten with
20 Nm
.
- Install and tension toothed belt for camshaft ⇒ page 15-9 Removing
and installing, tensioning toothed belt for camshaft.
- Toothed belt for injection pump ⇒ page 23-18, Removing and instal-
ling, tensioning toothed belt for injection pump
Note:
After installing new bucket tappets, the motor may not be started for
approx. 30 minutes. Hydraulic compensation elements must settle
(otherwise the valves set down on the pistons).
15-42
Checking hydraulic bucket tappets
♦ Feeler gauge
♦ Wood or plastic wedge
Notes:
♦ Only renew bucket tappets in complete sets (cannot be adjusted or
serviced).
♦ Irregular valve noises are normal during starting.
Test procedure
- Start engine and run until a coolant temperature of approx. 80°C is

reached.
- Increase speed to approx. 2500 rpm for 2 minutes.
If the hydraulic bucket tappets are still loud, determine the defective
tappet(s) as follows:
- Remove cylinder head cover.
- Turn crankshaft in engine rotating direction until cams of bucket

tappets to be checked are facing upward.
15-43
- Determine clearance between cam and bucket tappet.
- If clearance is greater then 0.1 mm, renew bucket tappet. If clear-

ance less than 0.1 mm or not clearance is determined, continue
check as follows:
- Press down bucket tappet with wood or plastic wedge. If travel is

greater than
0.1 mm until opening of valve is felt, renew tappet.
Note:
After installing new bucket tappets, the motor may not be started for
approx. 30 minutes. Hydraulic compensation elements must settle
(otherwise the valves set down on the pistons).
V15--0708
15-44
Removing and installing parts of lubrication
system
Note:
If large quantities of metal chips and abrasion caused by seizing, such
as crankshaft and conrod bearing damage, is found in the engine oil,
the oil cooler must be renewed and the oil channels thoroughly
cleaned to prevent subsequent damage.
Check oil pressure ⇒ page 17-22
Oil capacity:
with oil filter 6.5 l
Engine oil specifications:
Use only motor oil in accordance with TL 52173, VW Standard 50300.
Notes:
♦ The VW Marine Longlife Oil is recommended which, compared to
ordinary longlife oil for passenger cars, is provided with additives for
increased corrosion protection. The increased share of corrosion
protection is particularly important for longer standstill times and
winter storage.
♦ An annual oil change at the end of the season is generally specified.
17-1
I II
I ⇒ page 17-3
II ⇒ page 17-7
III ⇒ page 17-10
IV ⇒ page 17-14
III IV
Y17--0005
17-2
1 2 3 4 5 6 7 8 9 10 Part I
11
1 - 160 Nm + 1/2 (180 °) additional turn
♦ Renew
10 ♦ To loosen and tighten, use brace
T 01900
⇒ page 15-9
2 - 20 Nm
3 - Ribbed V-belt
10 ♦ Mark running direction before remov-
ing
11 ♦ Check for wear
19 11 20 13 10 21 ♦ Removing and installing
⇒ page 13-18
12
10
11
14
15
18 17 16 11 Y17--0001
17-3
1 2 3 4 5 6 7 8 9 10 4 - Vibration damper with ribbed
11 V-belt pulley
♦ Watch securing when
10 mounting
5 - Upper section of toothed belt guard
6 - Toothed belt for camshaft

♦ Check for wear
♦ Do not kink
⇒ page 15-9
10
7 - Mounting bolt for camshaft sprocket
11 ♦ Observe marking for bolt steel on bolt
19 11 20 13 10 21 head:
8.8 = 85 Nm
12 10.9 = 100 Nm
10 ♦ Use brace 3036 to loosen and tighten
11
14
15
18 17 16 11 Y17--0001
17-4
1 2 3 4 5 6 7 8 9 10 8 - Camshaft sprocket
11 ♦ Watch position when installing
toothed belt
shaft
9 - Rear toothed belt guard
10 - 20 Nm
♦ Mount with sealing compound
11 - 10 Nm
10 ♦ Mount with sealing compound
11 12 - Lower section of toothed belt guard

19 11 20 13 10 21
13 - Oil pump
♦ Watch driver on crankshaft when
12
10 installing ⇒ page 17-13, item 30
♦ Only renew entire unit
11 ♦ Must be seated on dowel sleeves
14 - Closing cover
14
15
18 17 16 11 Y17--0001
17-5
1 2 3 4 5 6 7 8 9 10 15 - Oil pump gears
11 ♦ Marking ”D” faces toward closing
cover
10 16 - Oil-pressure relief valve, 40 Nm
♦ Opening pressure: 5.3 - 6.3 bar gauge
pressure
17 - Seal
18 - Toothed belt sprocket for crankshaft
10 19 - Washer
♦ Renew
11 ♦ Must be diamond-coated
19 11 20 13 10 21
20 - Toothed belt guard
12
10 21 - Tensioner
11
14
15
18 17 16 11 Y17--0001
17-6
1 2 3 4 5 6 7 8 9 10 Part II
1 - Connection piece
♦ For crankcase ventilation
11 2 - Connecting hose
♦ Secured with clamps
13
3 - Retaining plate
14
4 - Washer
15
5 - 10 Nm
16
6 - 15 Nm
18 17
7 - Round bearing
8 - 10 Nm
21 20 19
Y17--0003
17-7
1 2 3 4 5 6 7 8 9 10 9 - Cover for pressure control valve
10 - O-ring
♦ Renew
11 11 - 5 Nm
12 12 - Retaining clip
13 13 - Oil separator
14
14 - Oil separator housing
15
15 - 25 Nm
16
16 - Gasket
18 17 ♦ Renew if damaged
17 - To oil return line

♦ ⇒ page 17-10, item 3
18 - Retainer
♦ For accelerator lever position sender
♦ For oil separator reservoir
21 20 19
Y17--0003
17-8
1 2 3 4 5 6 7 8 9 10 19 - Sealing plug
20 - Seal
♦ Renew
11 21 - Cylinder block
12
13
14
15
16
18 17
21 20 19
Y17--0003
17-9
1 2
Part III
32
1 - Cap
31 ♦ Replace seal if damaged
30
3 2 - Cup packing
3 - From oil separator reservoir

29 4 - Oil return line
4
5 - Oil spray nozzle
♦ For piston cooling
28
27 25 24 6 - 10 Nm
♦ Fit with AMV 188 100 02
13 23 9 8 7 6 5
26
13 22 7 - Adapter, 50 Nm
10 ♦ Pinch off and renew sealing ring in
11 case of leaks
21
20 8 - Spring for oil-pressure holding valve
9 - Oil-pressure holding valve

12
13
19 18 17 16 15 14
Y17--0004
17-10
1 2
10 - 10 Nm
32
11 - 20 Nm
31 ♦ M8, install bolt with hexagon head on
30 flywheel side
3
12 - From seawater filter
13 - 20 Nm
29 14 - Combination radiator
4 ♦ For fuel
♦ For hydraulic oil/gear oil
28 15 - To seawater pump
27 25 24
16 - 15 Nm
13 23 9 8 7 6 5
26 ♦ M6, with flywheel installed:
13 22 Turn flywheel so that notches align
10 with bolts
11
21
20
12
13
19 18 17 16 15 14
Y17--0004
17-11
1 2
17 - Seal
31 18 - Oil drain plug, 50 Nm
30
3 19 - Oil sump
⇒ page 17-18
♦ Clean sealing surface before assembly
29 20 - Vacuum line
4 ♦ Clean screen when dirty
28 21 - Gasket
♦ Renew
27 25 24
13 23 9 8 7 6 5
22 - O-ring
13 22
10 23 - Flange cover
11 ♦ Only on engines without turbo-
21 charger
20 ♦ Oil return-line connection on engines
with turbocharger
12
13
19 18 17 16 15 14
Y17--0004
17-12
1 2
24 - Hollow screw, 30 Nm
32
25 - Seal
30 ♦ Use only aluminium sealing rings
3
26 - Vacuum line
27 - Oil extraction pump

29 28 - Oil drain line
4
29 - Gasket
♦ Renew
28
27 25 24 30 - Driver
♦ For oil pump
13 23 9 8 7 6 5
26 ♦ With 4 drive journals
13 22 ♦ Heat new driver to max. 200 °C
10 before fitting
11
21 31 - Cylinder block
20
32 - Step
12
13
19 18 17 16 15 14
Y17--0004
17-13
1 2 3 Part IV
1 - Oil filter
♦ Observe installation instructions on
28 oil filter
4
2 - O-ring
♦ Renew
5
3 - Oil filter cover, 25 Nm
6 4 - 20 Nm
19
7 5 - Oil dip stick
♦ Oil level may not exceed max. mark-
27 ing!
♦ Measurement only applies for hori-
18 zontal engine installation
2 26 17 8 6 - Guide tube
♦ For oil dip stick
16 9 ♦ With connection piece for oil return
17 line
21 2 20 10 7 - Gasket
18 25 2 ♦ Renew if damaged
11
12
24 23 22 15 14 13
Y17--0008
17-14
1 2 3 8 - Retaining clip
9 - 20 Nm
10 - Sealing plug
28
4 ♦ On engines with turbocharger, con-
nection of oil supply line
5 11 - Gasket
♦ Renew
6 12 - Sealing plug, 40 Nm
19
7 13 - Seal
♦ Renew
27
14 - 0.9 bar oil pressure switch/sender
18 (F1), 25 Nm
2 26 17 8
15 - Oil cooler bracket
16 9 ♦ Installation position fixed with dowel
17 pins
21 2 20 10
18 25 2
11
12
24 23 22 15 14 13
Y17--0008
17-15
1 2 3 16 - Hollow screw, 70 Nm
17 - Retaining clip
18 - 20 Nm
28
4
19 - Hose clamp
5 20 - From engine block
21 - To housing-radiator package
6
19 22 - Oil cooler
7 ♦ Coat contract surfaces outside of
sealing ring with AMV 188 100 02
♦ Ensure clearance to surrounding
27 components
18 ♦ Observe note
⇒ page 17-1
2 26 17 8
23 - Gasket
16 9 ♦ Renew if damaged
17
24 - Oil cooler cap, 30 Nm
21 2 20 10
18 25 2
11
12
24 23 22 15 14 13
Y17--0008
17-16
1 2 3 25 - Oil return line
26 - Oil supply line
27 - 25 Nm
28
4
28 - Cup oil-filter bracket
♦ Mounted on housing-radiator
5 package
6
19
7
27
18
2 26 17 8
16 9
17
21 2 20 10
18 25 2
11
12
24 23 22 15 14 13
Y17--0008
17-17
Removing and installing oil sump
♦ Hand drill with plastic brush insert
♦ Silicone sealing compound with original part number D176404 A2
♦ Flat scraper
W00--0427
Removing
Note:
The oil sump can only be removed with the engine raised or removed.
- Actuate the switch of the electric oil change pump and suck all oil out
of the engine.
- Unscrew the mounting bolts from the gearbox bell to the oil sump.
17-18
- Unscrew the oil sump.
- If necessary, the oil pan must be separated by tapping lightly with

a rubber mallet.
- Remove the sealant residues on the cylinder block with a flat

scraper.
- Remove the sealant residues on the oil sump with a rotating brush,
e.g. a hand drill with a plastic brush insert (wear protective goggles).
- Clean the sealing surfaces. They must be oil and grease-free.

Y17--0006
Fitting
Notes:
♦ Observe the expiration date of the sealing compound.
♦ The oil sump must be installed within 5 minutes after applying the
silicone sealing compound.
- Cut off the tube nozzle at the front marking (∅ of the nozzle approx.
3 mm).
Y17--0007
17-19
- Apply the silicone sealing compound to the clean sealing surface of
the oil sump as shown. The sealing compound bead must:
♦ be 2 - 3 mm thick
♦ Run past the bolt holes on the inside -arrows-
Note:
The sealing compound bead may not be thicker, as otherwise excess
sealing compound can get into the oil sump and clog the screen in the
oil-pump suction line.
- Immediately position the oil sump and slightly tighten all oil sump
bolts.
Note:
The oil sump must align flush with the cylinder block and the gearbox
bell.
- Tighten the M6 oil sump bolts with

15 Nm
- Tighten the M8 oil sump bolts with

20 Nm
- Tighten the oil sump/gearbox bell bolts with

60 Nm
17-20
Note:
After fitting the oil sump, the sealing compound must dry for approx.
30 minutes. Do not pour in motor oil until after this time.
Further assembly is carried out in the opposite order of removal.
17-21
V.A.G 1342 V.A.G 1527 B Checking oil pressure and oil
pressure switch
sories required
♦ V.A.G 1342 Oil pressure tester
♦ V.A.G 1527 B Diode test lamp
V.A.G 1594 A
♦ V.A.G 1594 A Auxiliary test set
W17--0001
17-22
Note:
V.A.G 1342 Operating test and servicing of optical and acoustic oil pressure indicator:
⇒ Current flow diagrams
Test procedure
+ --
- Remove 0.9 bar oil pressure switch (F1) and carefully screw in tester.
- Screw hose connection from tester V.A.G 1342 into oil cooler bracket
in place of oil pressure switch.
Y17--0002
- Lay brown wire of tester to contact -M- (ground) of oil pressure
switch.
V.A.G 1342
- Connect diode test lamp V.A.G 1527 B to battery positive (+) and 0.9
bar oil pressure switch (F1) and to contact -WK- (warning contact) of
oil pressure switch with auxiliary wires from V.A.G 1594 A
LED must light up.
+ --
- Start engine and slowly increase speed.
At
0.75 - 1.05 bar gauge pressure
LED must go out, otherwise
Replace 0.9 bar oil pressure switch.
Y17--0002
- Increase speed further.

At 2000 rpm and 80 °C oil temperature, oil gauge pressure is to be
at least 2.0 bar.
17-23
At higher speed oil gauge pressure may not exceed
5.0 bar
- Renew oil-pressure relief valve (⇒ page 17-6, item 16) or oil-

pressure holding valve (⇒ page 17-10, item 9) if necessary.
17-24
Removing and installing parts of cooling
system
Notes:
♦ When the engine is hot, the cooling system is pressurised. Before
repairs, release pressure if necessary (carefully open cap of
housing-radiator package).
♦ Hose connections are secured with spring clips. Use only spring
clips when making repairs.
♦ The assembly tool VAS 5024 or the pliers V.A.G 1921 are recom-
mended for mounting the spring clips.
♦ Paint areas damaged on during removal and installation must be
touched up immediately (danger of corrosion).
Test the cooling system for leaks with the cooling system tester
V.A.G 1274.
Parts of cooling system on seawater side ⇒ page 19-3.
Parts of cooling system on engine ⇒ 19-12.
Dismantling and assembling housing-radiator package ⇒ page 19-16.
19-1
Connection diagram for coolant hoses ⇒ page 19-20.
Draining and filling coolant ⇒ page 19-26.
Coolant mixing specifications ⇒ page 19-26, Draining and filling coolant.
19-2
1 2 3
Parts of cooling system on sea-
4
water side
1 - 20 Nm
29 5 6 7 8 9
28 2 - Intake manifold
♦ Engine code letters BCV, ANH with
integrated intercooler
⇒ page 21-17
3 - From air filter

10
27 26 25 1
4 - 20 Nm
11
5 - Reactive anode
♦ Check and renew if necessary:
1 15 ⇒ Inspection service; Work Descriptions for
20 19 18 17 16 12 Service Work; Checking reactive anode
24 and replacing if necessary
4 ♦ Renew if worn by more than 50%
23 (10 mm)
22
21
14 13
22
Y19--0013
19-3
1 2 3 6 - Sealing plug
4 7 - Seal
♦ Renew
29 5 6 7 8 9 8 - Connecting piece
28 ♦ Mark installation position before
removing
9 - To exhaust-pipe connection piece
10 - Housing-radiator package
10
27 26 25 1 ⇒ page 19-16
♦ Install with assembly aid
11 T 01902 ⇒ Fig. 3
11 - Drain plug
1 15 ♦ Draining and filling coolant
20 19 18 17 16 12 ⇒ page 19-8, Fig. 1
24
4 12 - Seawater supply line
23
22 13 - Seawater filter
⇒ page 19-10
21
14 13
22
Y19--0013
19-4
1 2 3 14 - Connecting hose
4 15 - Gasket
♦ Renew
29 5 6 7 8 9 16 - Return line for power steering/
28 reversing gear
17 - To hydraulic oil reservoir
18 - Return line of injection pump
19 - Connection of fuel return line to tank

10
27 26 25 1
20 - Combination radiator
11 ♦ For fuel
♦ With seawater drain screw ⇒ Fig. 2
1 15
20 19 18 17 16 12 21 - Connecting hose
24
4
23
22
21
14 13
22
Y19--0013
19-5
1 2 3 22 - 25 Nm
4 23 - Belt pulley
♦ To remove, use water pump key
V.A.G 1590
29 5 6 7 8 9
28 24 - Seawater pump
⇒ page 19-30
25 - Washer
26 - Connecting hose
10
27 26 25 1 ♦ On engines without intercooling,
direct to seawater pump connection
11
♦ On engines without intercooling,
1 15 direct to housing-radiator package
20 19 18 17 16 12 connection
24
4 Note:
23
On engines without intercooling, instead of
22 Items 26 and 27 only a hose is installed that
connects the seawater pump to the housing-
radiator package.
21
14 13
22
Y19--0013
19-6
1 2 3 28 - 20 Nm
4 29 - End cover
♦ Test pressure 1.3 - 1.5 bar gauge pres-
sure
29 5 6 7 8 9
28
10
27 26 25 1
11
1 15
20 19 18 17 16 12
24
4
23
22
21
14 13
22
Y19--0013
19-7
Fig. 1 Seawater drain screw
Note:
Push a suitable hose onto the drain screw and then catch the seawater
flowing out.
Open the drain screw -arrow- 1 turn and drain off seawater.
Y19--0014
Fig. 2 Seawater drain screw on combination radiator for

hydraulic system/gearbox and fuel
Open the drain screw -2- approx. ½ turn and drain off seawater.
1 2 3 Y10--0012
19-8
Fig. 3 Installing housing-radiator package

♦ T 01902 Assembly aid
Fitting
T01902
- Screw the guide pin of the assembly aid T 01902 into the cylinder
Y19--0021 head.
- Assembly the housing-radiator package with the gaskets on the

guide pins and screw in the mounting bolts for the housing hand-
tight.
- Unscrew the guide pins with the assembly aid T 01902.
- Screw in the remaining mounting bolts hand-tight
- Screw housing-radiator package onto cylinder head

Tightening torque: 20 Nm
19-9
1 2 3 4 5 6 7 Dismantling and assembling
seawater filter
1 - Sight glass
2 - End cover
3 - Washer
4 - 10 Nm
5 - Seawater filter
♦ Filter must be checked and cleaned
regularly
6 - O-ring
♦ Renew if damaged or leaky
7 - Seawater supply line
13 8 ♦ Seal off with Teflon tape before
screwing in
12
11
10 8 9
Y19--0015
19-10
1 2 3 4 5 6 7 9 - Seawater filter housing
♦ Mounted in engine compartment
11 - To combination radiator
12 - Seal
♦ Renew
13 - Drain plug
13 8
12
11
10 8 9
Y19--0015
19-11
1 2 3 4 Parts of cooling system on
engine
♦ Supply line
3 5 ♦ Dismantling and assembling
⇒ page 19-16
6 ♦ Install with assembly aid
7 T 01902 ⇒ page 19-9, Fig. 3
♦ Connection diagram for coolant
8 hoses ⇒ page 19-20
15
19
3 ♦ Return line
15 7 18 ⇒ page 19-16
9 7 ♦ Install with assembly aid
15 17 T 01902 ⇒ page 19-9, Fig. 3
♦ Connection diagram for coolant
16 16 7
3 - Coolant hose
22 ♦ Connection diagram for coolant
21 4 - To connection piece
15 15 ♦ Hose connection
⇒ page 19-16, Item 6
20
14 13 3 8 12 11
Y19--0006
19-12
1 2 3 4 5 - Connection piece
6 - Coolant hose
♦ Engine code letters BCT, ANF to
exhaust-pipe connection piece
3 5
♦ Engine code letters BCU, ANG, BCV,
ANH to turbocharger
6 7 - 10 Nm
7
8 - Coolant pipe
8
15 9 - Coolant drain hose
♦ With drain screw
19
3 ♦ Draining and filling coolant
⇒ page 19-26
15 7 18
9 7 10 - Return line of external heater and hot
water supply
15 17
7 11 - Sealing plug
♦ Only when external heater and hot
16 16 7 water supply is not installed
22
10
21
15 15
20
14 13 3 8 12 11
Y19--0006
19-13
1 2 3 4 12 - Supply line of external heater and hot
water supply
13 - Coolant temperature sender (G2)

♦ blue
3 5
♦ 2-pin
♦ Check:
6 ⇒ page 01-10; Fault memory; Interrogating
fault memory
7
14 - Coolant temperature sender (G62)
8 ♦ with coolant temperature gauge
15 sender (G2)
19 ♦ Yellow
3 ♦ 4-pin
♦ Check:
15 7 18 ⇒ page 01-10; Fault memory; Interrogating
9 7 fault memory
15 17
15 - O-ring
7 ♦ Renew if damaged or leaky
16 16 7
22
10
21
15 15
20
14 13 3 8 12 11
Y19--0006
19-14
1 2 3 4 16 - Retaining clip
♦ check that securely seated
3 5
♦ For thermostat
6 19 - Thermostat
7 ♦ Check: Heat thermostat in water bath
♦ Start of opening approx. 80 °C
8 ♦ Opening stroke at least 7 mm
15
20 - 20 Nm
19
3
21 - Coolant pump
15 7 18 ♦ Check for smooth running
9 7 ♦ Only renew completely in case of
damage and leaks
15 17
7 22 - Toothed belt for camshaft
♦ Check for wear
16 16 7 ♦ Always renew after removal
22 ♦ Do not kink
⇒ page 15-9
21
15 15
20
14 13 3 8 12 11
Y19--0006
19-15
1 2 3 4 5
Dismantling and assembling
8 housing-radiator package
24 1 - Capl
♦ Test pressure 1.3 - 1.5 bar gauge pres-
6 sure
22 23 2 - 20 Nm
21 ♦ Install with assembly aid
20 7 T 01902 ⇒ page 19-9, Fig. 3
4 - O-ring
8 ♦ Renew if damaged or leaky
4
17 9
5 - Water level sender (G120)
19 10
16 8 ♦ Check
15 11 ⇒ Current Flow Diagrams binder
4 6 - Connection piece
♦ For coolant hose
⇒ page 19-12, item 4
12
14 13
18 12 10 4 Y19--0016
19-16
1 2 3 4 5
7 - Locking ball
8 8 - Seal
24 ♦ Use only aluminium sealing rings
6
9 - Sealing plug, 40 Nm
22 23 10 - Connecting piece
♦ Mark installation position before
removing
21
20 7 11 - To exhaust-pipe connection piece
12 - 20 Nm
8
4
17 9 13 - Drain plug
♦ Draining and filling coolant
19 10
16 8 ⇒ page 19-8, Fig. 1
15 11
14 - Intermediate plate
removing
12
14 13
18 12 10 4 Y19--0016
19-17
1 2 3 4 5
15 - Reactive anode
♦ Check and renew if necessary:
8 ⇒ Inspection service; Work Descriptions for
Service Work; Checking reactive anode
24 and replacing if necessary
6 ♦ Renew if worn by more than 50%
(10 mm)
22 23 16 - Sealing plug
21 17 - Gasket
♦ Renew
20 7
18 - Connection hose to intercooler
♦ On engines without intercooling,
8
4 direct to seawater pump connection
17 9
19 10 19 - Heat exchanger
16 8 ♦ Mark installation position before
15 11 removing
4 20 - Washer
12
14 13
18 12 10 4 Y19--0016
19-18
1 2 3 4 5
21 - 20 Nm
8 22 - Coolant vent hose

24 23 - To cylinder head
6 ♦ Connection diagram for coolant
hoses ⇒ page 19-20
22 23 24 - Banjo bolt, 20 Nm
21
20 7
8
4
17 9
19 10
16 8
15 11
4
12
14 13
18 12 10 4 Y19--0016
19-19
7 Connection diagram for coolant
hoses
Engine code letters BCT, ANF
Engine code letters BCU, ANG ⇒ page 19-22
Engine code letters BCV, ANH ⇒ page 19-24

6
1 - Seawater inlet
2 - Seawater filter
♦ For fuel
4 - Seawater pump
5 - Main heat exchanger
6 - Seawater outlet
4
13 12 11 10 9 8
3
2
1 Y19--0004
19-20
7 7 - Exhaust-pipe connection piece
8 - Thermostat
9 - Cylinder block
10 - Oil cooler
11 - Coolant expansion tank

6
12 - Exhaust plenum chamber
4
13 12 11 10 9 8
3
2
1 Y19--0004
19-21
7 8 Engine code letters BCU, ANG
1 - Seawater inlet
2 - Seawater filter
6 ♦ For fuel
4 - Seawater pump
6 - Exhaust-pipe connection piece
7 - Seawater outlet
8 - Turbocharger
9 - Thermostat
10 - Cylinder block
5
4
14 13 12 11 10 9
3
2
1
Y19--0020
19-22
7 8 11 - Oil cooler
13 - Exhaust plenum chamber
6
5
4
14 13 12 11 10 9
3
2
1
Y19--0020
19-23
7 8
Engine code letters BCV, ANH
1 - Seawater inlet
2 - Seawater filter
♦ For fuel
4 - Seawater pump
5 - Intake manifold
♦ With intercooler
6 - Exhaust-pipe connection piece
7 - Seawater outlet
8 - Turbocharger
9 - Thermostat
4 15 14 13 12 11 10 9
3
2
1 Y19--0019
19-24
7 8
10 - Cylinder block
11 - Oil cooler
6 13 - Exhaust plenum chamber
4 15 14 13 12 11 10 9
3
2
1 Y19--0019
19-25
T10007 V.A.G 1306 Draining and filling coolant
sories required
♦ T10007 Refractometer

VAS 5024
W19--0017
19-26
Draining
- Open cap of housing-radiator package.
- Drain coolant via drain screw -1- below thermostat housing.
Note:
1 Please observe the coolant disposal regulations!
Filling
Notes:
♦ Only G 12 - as per TL VW 774 D may be used as a coolant additive.
Y19--0012 Distinguishing characteristic: Red colour
♦ G 12 may never be mixed with other coolant additives!
Important!
The coolant additives -G 11- and -G 12- cannot be mixed. If they
are mixed, serious engine damage will result.
♦ If the liquid in the coolant system is brown, G 12 has been mixed
with another coolant. In this case the coolant must be renewed.
19-27
♦ G 12 and coolant additives with the reference ”as per TL VW 774 D
(C)” prevent frost and corrosion damage, scale deposits and
increase the boiling temperature. For these reasons the cooling sys-
tem must always be filled with radiator antifreeze and anti-corrosion
agent throughout the year.
♦ Especially in countries with a tropical climate, the coolant contrib-
utes to the operating safety due to the higher boiling point when the
engine is subjected to heavy loads.
♦ The frost protection must be ensured down to approximately -25 °C
(in countries with an arctic climate down to approximately -35 °C).
♦ The coolant concentration may not be reduced during the warmer
season or in warmer countries by adding water. The coolant additive
share must be at least 33 %.
♦ If stronger frost protection is required for climatic reasons, the per-
T10007 centage of G 12 can be increased, however only up to 60 % (frost
protection down to approximately -40 5C), as otherwise the frost
protection will be reduced again and the cooling efficiency wor-
sened.
♦ To determine the current frost protection density, the refractometer
T10007 is recommended.
♦ If the cylinder head or cylinder head gasket has been renewed, do
not reuse used coolant.
W00--0689
19-28
Recommended mixing ratio:
Antifreeze percentage1) G12 Water

33 % 4.0 l 8.0 l
1) Antifreeze percentage may not exceed 60 %; frost protection and
cooling efficiency decrease with higher percentage.
- Slowly pour in coolant (filling duration approx. 5 minutes).
Note:
If the engine is started without seawater cooling, the ribbed V-belt for
the seawater pump must be removed, as otherwise the impeller will
be damaged.
- Start engine and run at idle for a maximum of 2 minutes while adding
missing coolant.
- Close cap of housing exhaust manifold.
- Run engine until warm.
- Check coolant level and top up if necessary.
19-29
T10007 V.A.G 1306 Removing and installing
seawater pump
sories required
♦ T10007 Refractometer

V.A.G 1331 VAS 5024
W19--0019
19-30
Removing
Notes:
♦ Always renew gaskets and seals.
♦ Only use aluminium seals when renewing.
- Unscrew drain screw -2- approx. ½ turn on radiator for fuel and
hydraulic oil/gear oil -1- and drain off seawater.
1 2 3 Y10--0012
- Open drain screw -arrow- approx. 1 turn on housing-radiator package

and also drain off seawater.
Y19--0014
19-31
- Relax tensioner in direction of arrow with 16 mm open-end spanner
and remove ribbed V-belt from belt pulleys.
Y19--0011
2
- Disconnect hose connections -1- and -2- on quick-release coupling
1 of seawater pump.
- Unscrew mounting screws -arrows- through notches of belt pulley

and carefully take out seawater pump with belt pulley.
Y19--0005
19-32
Fitting
2
Installation is carried out in the reverse order while observing the
1 following:
- Insert seawater pump in bracket and tighten mounting bolts

-arrows-.
- Install ribbed V-belt.
Y19--0005
19-33
Dismantling and assembling seawater pump
♦ Torque wrench (5 - 50 Nm) V.A.G 1331
♦ T 01904 JABSCO puller
W00--0427
Removing
1
- Remove the seawater pump ⇒ page 19-30.
- Unscrew the cover -1- of the seawater pump -2-.
Y19--0007
19-34
- Lever the rubber protection cap -3- off the impeller -2- of the sea-
1 2 water pump -1- with a suitable screwdriver
Y19--0010
- Carefully pull the impeller -2- out of the seawater-pump drive shaft
T 01904 -1- with the puller T 01904.
2
1
Y19--0028
19-35
Fitting
- Thoroughly clean the inside housing of the seawater pump of dirt

and deposits.
Notes:
♦ Lightly grease the drive shaft before fitting the impeller.
1 2 3 4 5 6 ♦ Always renew seals after removal.
♦ If the impeller shows damage or traces of wear, it must always be
renewed.
- Press the impeller -2- flush onto the drive shaft of the seawater
pump -1- and seal off with the rubber protection cap -3-.
Note:
Install new round sealing ring when assembling the seawater pump.
Y19--0009
- Screw the cover -5- onto the seawater pump -1- with a new round
sealing ring -4- diagonally and hand-tight.
- Now tighten the screws -6- with

4 Nm
- Install the seawater pump ⇒ page 19-30.
19-36
Parts of fuel supply
Dismantling and assembling parts of fuel supply ⇒ page 20-2.
Servicing fuel filter ⇒ page 20-7.
Observe safety precautions ⇒ page 20-9.
Observe rules for cleanliness ⇒ page 20-9.
Notes:
♦ Hose connections are secured with spring clips.
♦ Fuel hoses on the engine may only be secured with spring clips. It
is not permissible to use clamps or screw clips.
20-1
33 1 2 3 4 5 Dismantling and assembling
parts of fuel supply
32
1 - 20 Nm
31
2 - Bracket with fuel filter
30 ♦ With vent screw
29 3 - Supply line
28 ♦ Ensure firm seating
27 4 - to the injection pump

25 15 5 - Fuse box/relay plate
26 ♦ With stud bolt for fuel filter bracket
6 6 - Rubber bush
7 ♦ Rubber bushes may not twist during
removal and installation
24 25 16 8 7 - 20 Nm
17
23 18 9
22
20
13 12 7
21
10
20 14
19 11
Y20--0010
20-2
33 1 2 3 4 5 8 - Retainer
♦ Mounted on engine block
♦ With mounting for fuse box/relay plate
32
31 9 - 10 Nm
♦ Rubber bushes may not twist when
30 tightening and loosening screws
29 10 - 10 Nm
28 11 - Fuel lift pump
27 12 - Mounting clip for fuel pump
25 15 13 - Electrical connection
26
14 - Supply line
6 ♦ Ensure firm seating
7
24 25 16 8
17
23 18 9
22
20
13 12 7
21
10
20 14
19 11
Y20--0010
20-3
33 1 2 3 4 5 15 - Water drain screw with water
warning device
♦ Function of water warning device:
32 an excessively high water level in the
31 filter is signalled via a warning lamp in
the instrument panel
30 ♦ To drain the filter, unscrew the screw
approx. 1 turn and allow approx.
29 100 cm3 of liquid to drain out
28 16 - Return line
♦ from the injection pump
27
25 15 17 - Hose connection
♦ For fuel
6 ♦ For hydraulic oil/gear oil
7
19 - to fuel tank
24 25 16 8
20 - Seal
17 ♦ Renew
23 18 9
22
20
13 12 7
21
10
20 14
19 11
Y20--0010
20-4
33 1 2 3 4 5 21 - Hose connection
32
23 - Drain valve
31 ♦ For draining circulation pre-filter with
30 water separator
♦ Press in yellow knob and turn
29
24 - From fuel tank
28
25 - Hose connection
27
25 15 26 - To fuel lift pump
26 27 - Circulation pre-filter with water

separator
6
7 28 - Filter insert
♦ Renew if soiled
24 25 16 8 ♦ Bleed fuel system after renewing
filter
17
23 18 9
22
20
13 12 7
21
10
20 14
19 11
Y20--0010
20-5
33 1 2 3 4 5 29 - Spring cartridge
30 - Filter cover
31 31 - Washer
30 32 - 10 Nm
29 ♦ Tighten screws diagonally
28 33 - Vent screw
27
25 15
26
6
7
24 25 16 8
17
23 18 9
22
20
13 12 7
21
10
20 14
19 11
Y20--0010
20-6
1 3 1 4 Servicing the Fuel Filter
1 - Banjo bolt, 30 Nm
2 2 - Seal
♦ Renew
5
3 - Supply line
♦ Ensure firm seating
2 4 - Fuse box/relay plate

♦ With mounting for fuel filter bracket
6
5 - To the injection pump
12 7
6 - Bracket for fuel supply filter
1 7 - 20 Nm
8 - Fuel supply filter

11
10
9 8 Y20--0017
20-7
1 3 1 4 9 - Water drain screw with water warn-
ing device
♦ Function of water warning device:
an excessively high water level in the
2 filter is signalled via a warning lamp in
the instrument panel
♦ To drain the filter, unscrew the screw
5 approx. 1 turn and allow approx.
100 cm3 of liquid to drain out
2 10 - From fuel lift pump
6 11 - Supply line
♦ Ensure firm seating
12 7
12 - Vent screw
2
1
11
10
9 8 Y20--0017
20-8
Safety precautions when working on fuel supply
system
Observe the following when working on the fuel supply:
♦ Avoid skin contact with fuel! Wear fuel-proof gloves!
Rules regarding cleanliness

When working on the fuel supply/injection system, the following
”rules” regarding cleanliness should be carefully observed:
♦ Thoroughly clean connection points and their surroundings before

loosening or removing them.
♦ Lay removed parts on a clean surface and cover. Use only lint-free
cloths!
♦ Carefully cover or close opened parts if repairs cannot be carried out

immediately.
♦ Only fit clean parts:

Do not remove spare parts from their packages until directly before
installation.
Do not use parts which have been stored unpacked (e.g. stored in
toolboxes etc.).
♦ When the system is opened:

Avoid working with compressed air.
20-9
♦ In addition, also make sure that no Diesel fuel gets onto the coolant
hoses. If necessary, the hoses must be cleaned again immediately.
Damaged hoses must be renewed.
20-10
1 2 1 3 4 Servicing throttle controls
Note:
Only remove and install console together
with retainer.
1 - 10 Nm
2 - Retainer
♦ Only remove and install together with
console
3 - Console
♦ Only remove and install together with
retainer
10 4 - 6 Nm
5 - 10 Nm
6 - Accelerator lever
♦ Installing ⇒ page 20-19, Adjusting
accelerator lever position sender
9
8 7 6 5
Y23--0004
20-11
1 2 1 3 4 7 - Connecting plug
♦ Black, 6-pin
8 - Accelerator lever position sender (G79)

♦ The accelerator lever position sender passes
the driver request on to the engine con-
trol unit
♦ To remove accelerator lever, unscrew
Item 6
♦ Adjust ⇒ page 20-19
9 - 10 Nm
10 - Rubber bush
♦ Rubber bushes may not twist during
10 removal and installation
8 7 6 5
Y23--0004
20-12
V.A.G 1526 A V.A.G 1594 A Checking accelerator lever position
sender
sories required
♦ V.A.G 1526 A Hand multimeter
♦ Fault output device V.A.G 1552 with cable

V.A.G 1552
V.A.G 1551/3 or fault output device VAS
5052
♦ Current flow diagram
W23--0031
20-13
Function
The two accelerator position senders -G79 and -G185 are located in a
housing and pass on the driver request to the engine completely inde-
pendently of each other. The sender is secured on the console above
the engine and can be mounted as desired (depending on the installa-
tion position of the throttle linkage).
Test procedure
Here, the ignition must be on.
⇒ page 01-4)

Select function XX
- Press keys 0, 0 and 2 for ”Display group number 2” and acknowl-
edge entry with Q key.
20-14
Read measuring value block 2 → - Check display of accelerator position in display field 2. Accelerator
rpm 0.0 % 0 0 1 18.4 °C must be in idling position.
Setpoint value: 0.0 %
- Also check the display for the idling switch in display field 3. The
middle position must be at 1.
Display: 010
Read measuring value block 2 → - Slowly depress the accelerator to the floor while watching the
rpm 0.0 % 0 0 1 18.4 °C display fields 2 and 3.
♦ Display field 2:
The value for the accelerator position must increase continuously.
Setpoint value in full-throttle position: 100 %
♦ Display field 3:
The middle position must jump to 0.
Display: 000
If the setpoint values are not reached:
- Check the adjustment of the throttle linkage.
- Adjust the accelerator position sender

⇒ page 20-19.
If the display does not change or only changes irregularly:
20-15
1
entry with Q key.
- Check the wires of the accelerator lever position sender as follows:
- Open the cover -1- of the fuse box/relay plate.
- To do this, unscrew the screws -arrows-.
Y20--0007
- Pull the relay -1- out of the relay socket of the fuse box/relay plate.
- Unlock the engine control unit -3- at socket -2- of the fuse box/relay
3 plate and pull out the engine control unit.
1 2
Y20--0008
20-16
- Separate the 6-pin connector for the accelerator position sender on
the back of the fuse box/relay plate.
- Connect the hand multimeter V.A.G 1526 A with auxiliary wires from
V.A.G 1594 A for resistance measurement:
1 2
- Check the wires at the contacts between the plug -A- and the socket
3 4 -B- of the engine control unit for open circuits using the CFD.
Plug -A- contact 2 + socket -B- contact 12
5 6 Plug -A- contact 4 + socket -B- contact 63
Wire resistance: max. 1.5 Ω
A
81 62 63 44 - Also check the wires for short circuits to each other, to the vehicle
earth and to the battery positive.
Setpoint value: ∞ Ω
If no faults are determined in the wiring:
24 43 6 25
B Y20--0009
20-17
1 - Measure the resistance of the sender between contacts 1+3 of the
connector.
3 Setpoint value:
Accelerator lever in idling position: 0.9 - 1.1 kΩ
5 Accelerator lever in full-throttle position: 1.6 - 1.8 kΩ
2 - Measure the resistance of the sender between contacts 2+3 of the
connector.
4 Setpoint value:
6 Accelerator lever in idling position: 0.7 - 0.9 kΩ
Y20--0004
- Check the idling switch (F60) in the accelerator position sender. To

do this, measure the resistance between the plug contacts 4+6.
Setpoint value:
Accelerator lever in idling position:0.9 - 1.1 kΩ
Accelerator lever in full-throttle position: ∞ Ω
- Renew the accelerator positionsender (G79)

⇒ page 20-12, item 8.
- Interrogate fault memory:

⇒ Repair group 01; Fault memory; Interrogating fault memory
20-18
Adjusting accelerator lever position sender
VAS 5024 Special tools, workshop equipment, test and measuring equip-
W00--0495
- Unscrew throttle linkage from brake accelerator lever.
- Unclip the mounting clip -arrow- from the air filter.
Y20--0006
20-19
- Unscrew the two upper mounting screws -1- of the fuse box/relay
1
plate.
- Pull off the fuse box/relay plate somewhat in -direction of arrow-.
Y20--0005
- Unscrew the accelerator lever -1- from the accelerator position

1 sender -2-.
- Position the accelerator lever -1- on the accelerator position sender

-2- so that there is a space of 3 mm between the console and the
accelerator lever -arrow- (idling stop).
2
Y23--0002
20-20
1
- Tighten the mounting screws -arrows-of the fuse box/relay plate
with
10 Nm
- Install throttle linkage.
- After installation check the sender with the engine system tester
V.A.G 1552 ⇒ page 20-13, Checking accelerator lever position sender.
Y20--0007
- Secure mounting clip -arrow- on air filter.
Y20--0006
20-21
Turbocharger with and without charge air
system
Removing and installing turbocharger with
attached parts
Parts of intercooling for engine code letters BCV, ANH ⇒ page 21-6
Observe rules for cleanliness ⇒ page 21-9.
Notes:
♦ All hose connections are secured with clips.
♦ Charge air system must be leak-free.
♦ Renew all self-locking nuts.
21-1
1 2 3 4 3 5 1 - To intake manifold
33 2 - Charge air hose
3 - 20 Nm
4 - 30 Nm
6 5 - Cover
6 - 40 Nm
7
7 - Bracket for engine suspension
8
8 - 20 Nm
23 14 9 - Mounted on engine block
24 9 10 - Wastegate
32 31 30 29 ♦ Part of turbocharger and cannot be
25 10
renewed
14 11
22 12
12 - Air hose
21 13 ♦ From air filter
20 14
15
19 16
28
27 26
18 17
Y21--0002
21-2
1 2 3 4 3 5 13 - Turbocharger
33 ⇒ page 21-10
♦ Check boost pressure
⇒ page 21-21, Checking turbocharger
14 - Seal
♦ Renew
6
15 - Connection piece
7
16 - Coolant hose
♦ To connection piece on
8 cylinder head ⇒ page 19-13, item 5
23 14 17 - 10 Nm
24 9 18 - Oil return line

32 31 30 29
25 10 19 - To oil sump
♦ To flange cover on oil sump
14 11 ⇒ page 17-12, Item 23
22 12 20 - Gasket
21 ♦ Renew
13
20 14
15
19 16
28
27 26
18 17
Y21--0002
21-3
1 2 3 4 3 5 21 - Gasket
♦ Renew
33 ♦ Ensure proper installation position
♦ Tabs face upward
22 - 40 Nm
♦ Do not interchange screws:
♦ Allen screws from above
6 ♦ Hexagon bolts from below
7 23 - Hollow screw, 30 Nm
8 ♦ To connection piece for housing-radi-
ator package ⇒ page 21-3, Item 15
23 14
24 9
32 31 30 29 26 - Oil supply line
25 10 ♦ Fill turbocharger with engine oil at fit-
ting of oil supply line before installing
14 11
22 12
21 13
20 14
15
19 16
28
27 26
18 17
Y21--0002
21-4
1 2 3 4 3 5 27 - 10 Nm
33 28 - To connection on oil cooler bracket
♦ Connection ⇒ page 17-15, item 10
29 - Gasket
♦ Renew
6
7 ♦ Dismantling and assembling
⇒ page 19-16
♦ Install with assembly aid T 01902
8 ⇒ page 19-9, Fig. 3
23 14 31 - Washer
24 9 32 - 20 Nm
32 31 30 29
25 10 33 - 20 Nm
14 11
22 12
21 13
20 14
15
19 16
28
27 26
18 17
Y21--0002
21-5
1 2 3 4 5
Removing and installing parts
6 of charge air cooling
7 Notes:
♦ All hose connections are secured with
2 clips.
9 ♦ Charge air system must be leak-free.
8
1 - Intake manifold
♦ With integrated intercooler
2
2 - O-ring
17 11 3 - Intake manifold pressure sender (G71)

with intake manifold temperature
sender (G72)
16 ♦ With vent hole
♦ Clean vent hole when dirty
2 ♦ Check:
2 ⇒ page 23-49;Check intake manifold pres-
6 sure sender
15
14
13
12 Y21--0001
21-6
1 2 3 4 5 4 - 10 Nm
6 5 - Sealing plug, 40 Nm
7 6 - 20 Nm
7 - Closing cover
9 removing
8
8 - Intermediate flange
removing
10 9 - Locking ball
17 11 10 - From hose connection of turbocharger
11 - Gasket
16 ♦ Renew
2
2 12 - To seawater pump
6
15
14
13
12 Y21--0001
21-7
1 2 3 4 5 13 - To housing-radiator package
6 14 - Hose clamp
7 15 - Connecting piece
♦ Mark installation position before
removing
2
9 16 - Intercooler
removing
2
17 - 20 Nm
10
17 11
16
2
2
6
15
14
13
12 Y21--0001
21-8
Always carefully observe the following ”5 rules” for cleanliness when
working on the fuel supply/injection system:

cloths!

immediately.

installation.
toolboxes etc.).

21-9
Removing and installing turbocharger
W00--0427

VAS 5024
W00--0495
21-10
Removing
- Unscrew the mounting bolts -arrows- for the cover -1-.
1 Y21--0014
2 - Disconnect the connection line -2- from the turbocharger -1-.
- Loosen the clamp -3- for the exhaust-pipe connection piece and
1 remove the exhaust-pipe connection piece.
Y21--0009
21-11
- Disconnect the air filter hose -arrow- from the turbocharger -1-.
1
Y21--0016
- Remove the connection hose -3- between the intake manifold -2-
and the turbocharger -1-.
2
3
Y21--0007
21-12
- Disconnect the oil return line -3- from the turbocharger -1-.
- Unclip the coolant hose -2- on the connection piece of the turbo-
charger -1-.
3 1
2
Y21--0008
- Unscrew the oil supply line -arrow- from the turbocharger -1-.
1
Y21--0013
21-13
- Unscrew the lower mounting bolts -arrows- on the turbocharger -1-.
Y21--0011
- Unscrew the upper mounting bolts -arrows- between the housing-

radiator package and the turbocharger -1-.
- Lift out the turbocharger with the gasket upward.
1 Y21--0012
21-14
Fitting
1 Installation is carried out in reverse sequence. Here the following must

be observed:
- Position a new gasket -2- on the turbocharger -1- (tabs face toward
turbocharger) and tighten the turbocharger with
40 Nm
2
Note:
Y21--0010
Do not interchange the mounting bolts of the turbocharger (the hexa-
gon bolts mount the turbocharger from below and the Allen screws
from above).
- Position the oil return line -3- with new sealing rings and tighten with
10 Nm
3 1
2
Y21--0008
21-15
- Position the oil supply line -arrow- with new sealing rings and tighten
the banjo bolt with
30 Nm
1
Y21--0013
2 - Position the connection line -2- with new sealing rings and tighten
the banjo bolt with
15 Nm
1
Y21--0009
21-16
Dismantling and assembling intercooler
V.A.G 1331 Engine code letters BCV, ANH

W00--0427
Removing
- Drain off the seawater at the drain screw -arrow-.
Y19--0014
21-17
1 - Disconnect the connection hoses between the seawater pump/
intercooler and the intercooler/housing-radiator package -arrows-.
Y21--0004
Note:
Before removing the intercooler, mark the installation position of the
connection piece and the end cover.
- Unscrew the mounting screws -arrows-from the flange -2- on the

intake manifold -1-.
1
- Also remove the flange on the opposite side of the intake manifold.
2
Y21--0015
21-18
1 - Unscrew the two locking screws -arrows- at the top on the intake
manifold -1- until the intercooler can be moved easily in the intake
manifold.
Y21--0005
1
Note:
The intercooler must not become jammed when pulling out.
- Now carefully pull the intercooler out of the intake manifold in the
-direction of the arrow-.
Note:
Clean the intercooler thoroughly before installing.
Pay particular attention to metal chips that may be located in the intake
Y21--0003
manifold and on the intercooler.
21-19
Fitting
Installation is carried out in reverse sequence. Here the following must

be observed:
1 - Always renew the sealing rings.
- Tough-up paint defects.
- Tighten the locking screws with

40 Nm

Y21--0005
21-20
Checking boost pressure system
V.A.G 1552 Checking turbocharger

♦ Fault output device V.A.G 1552 with cable V.A.G 1551/3 or fault out-
put device VAS 5052
Test conditions
W00--1188
No fault in fault memory
No leaks on intake and exhaust side.
No fault in engine/injection system, such as commencement of

injection, injectors or compression pressure.
Engine oil temperature at least 80 °C
Test procedure
If test and measuring devices are required during test drives, the
following must be observed:
♦ The test and measuring devices must be secured in the boat and
operated there by a second person.
21-21
Notes:
♦ The hoses must be connected absolutely leak-free.
- The boost pressure is measured using the fault output device

V.A.G 1552 or VAS 5052 during a test drive.
- Connect the fault output device V.A.G 1552 or VAS 5052 and use the
”Address word” 01 to select the control unit for engine electronics.
The engine must be running at idle:
⇒ page 01-4)
Select function XX
- Press keys 0,1 and 1 for ”Display group number 11” and acknow-
Read measuring value block 11 → - Display:
780 rpm XXX mbar 978 mbar X%
- Accelerate the boat out of idle at full throttle.
21-22
Engine code letters BCU, ANG
- Read off the value in display field 3 at approx. 2500 rpm on the
V.A.G 1552 or VAS 5052.
Read measuring value block 11 → Setpoint value on V.A.G 1552 or VAS 5052: 1950 - 2250 mbar
2500 rpm XXXX mbar 2150 mbar X % (in display field 3)
- Read off the value in display field 3 at approx. 3000 rpm on the
V.A.G 1552 or VAS 5052.
Read measuring value block 11 → Setpoint value on V.A.G 1551 or VAS 5052: 1950 - 2250 mbar
3030 rpm XXXX mbar 2150 mbar X % (in display field 3)
Note:
The fault output device V.A.G 1552 or VAS 5052 is used to check
whether the boost pressure is also detected in the control unit.
If the setpoint value is not reached:
- Check the function of the pressure unit for boost pressure control
⇒ page 21-24.
21-23
Check the function of the pressure unit for boost pressure control
The technical information on checking the pressure unit was not yet
available at the editorial deadline.
21-24
Servicing diesel direct injection system
The control unit for the diesel direct injection system is equipped with
a fault memory. Before repairs, adjustments and for trouble-shooting,
the fault memory should be retrieved and the diagnosis of actuators
carried out ⇒ page 01-10
Note:
During testing and adjustment, the control unit is able to detect and
store faults.
After all the testing and adjustments have been completed, it is there-
fore essential that the fault memory is deleted
⇒ page 01-12.
Safety measures:
⇒ page 00-1; Safety precautions
23-1
Always carefully observe the following ”6 rules” for cleanliness when
working on the fuel supply/injection system:

cloths!

immediately.

installation.
toolboxes etc.).

♦ In addition, also make sure that no Diesel fuel gets onto the coolant
hoses. If necessary, the hoses must be cleaned again immediately.
Damaged hoses must be renewed.
23-2
1 2 3 4 5 6 7 8
SUPERIOR MARINE TECHNOLOGY
Overview of Installation Points
1 - Glow period warning lamp (K29)
2 - Main panel
3 - Diagnosis connection
4 - Intake manifold temperature sender

9 (G72)
10 ♦ With intake manifold pressure sender
(G71), only on engines with turbo-
charger
11
5 - Sender for accelerator position
(G79)and idle switch (F60)
⇒ page 20-13; Checking accelerator lever
position sender
6 - Injector
12 ♦ Cylinder 5 with needle lift sender
(G80)
13
14
Y23--0026
23-3
1 2 3 4 5 6 7 8
7 - Glow plug
8 - Injection pump
♦ With quantity adjuster mechanism
♦ With quantity adjuster (N146)
♦ With modulating piston movement
sender (G149)
♦ With fuel temperature sender (G81)
♦ With fuel shut-off valve (N109)
9 ♦ With commencement of injection
10 valve (N108)
9 - Fuse box/relay plate

♦ Components and connectors
11 ⇒ page 23-6
10 - Air cleaner
11 - Clutch switch (F36)

♦ With Z-drive MercruiserTM
AlphaOneTM
12
13
14
Y23--0026
23-4
1 2 3 4 5 6 7 8
12 - 4-pin connector
♦ For clutch switch (F36) or gearbox

neutral switch (E352)
♦ With Z-drive (except Z-drive
TM TM
Mercruiser AlphaOne ) plug with
two jumpers
13 - Engine speed sender (G28)
9 14 - Coolant temperature sender (G62)

10
11
12
13
14
Y23--0026
23-5
1 2 3 4 5 6 Fuse box/relay plate
1 - Emergency-Stop button
2 - Control unit for diesel direct injection

system (J248)
3 - Fuse box/relay plate

⇒ page 97-1; Fuse box/relay plate; Remov-
ing and installing fuse box/relay plate
4 - 2-pin connector
♦ For needle lift sender (G80)
25 8 9 10 5 - 6-pin connector
♦ For accelerator lever position sender
(G79) and idling switch (F60)
24 11
12
13
23
22 21 20 19 18 17 16 15 14 Y23--0008
23-6
1 2 3 4 5 6 6 - 10-pin connector
♦ For fuel temperature sender (G81)
♦ For quantity adjuster (N146)
♦ For modulating piston movement
sender (G149)
♦ For fuel shut-off valve (N109)
♦ For commencement of injection
valve (N108)
7
7 - 5-pin connector
♦ For glow plugs
25 8 9 10
11 - Diagnosis connection
24 11 12 - Fuse S125
12 ♦ For glowplugs
13
23
22 21 20 19 18 17 16 15 14 Y23--0008
23-7
1 2 3 4 5 6 13 - Glow plug relay (J52)
14 - Water separator relay (J597)
15 - Fuel shut-off activation relay (J593)
16 - Coolant level relay (J597)
17 - Engine stop relay - fuse box/relay

7 plate (J594)
18 - Starter relay (J19)
19 - Fuel pump relay (J17)
25 8 9 10 20 - Fuse S190
♦ For power supply
Ter. 30
21 - Fuse S81
24 11 ♦ For fuel pump
12
13
23
22 21 20 19 18 17 16 15 14 Y23--0008
23-8
1 2 3 4 5 6 22 - Oil extraction pump relay (J597)
23 - Starting aid relay (J600)
24 - Diode group (J79)
25 - Voltage supply relay - Terminal 30
25 8 9 10
24 11
12
13
23
22 21 20 19 18 17 16 15 14 Y23--0008
23-9
1 2 3 4 5 Removing and installing
toothed belt for injection pump
1 - Drive sprocket for injection pump
♦ Ensure proper position when instal-
ling toothed belt
ling, tensioning toothed belt for injec-
tion pump
2 - Mounting bolt for drive sprocket of

injection pump
♦ 160 Nm
3 - Toothed belt for injection pump

♦ Mark running direction before remov-
ing
♦ Do not kink
⇒ page 23-18
9 8 7 6
Y23--0006
23-10
1 2 3 4 5 4 - Tensioner
5 - 15 Nm
6 - 20 Nm
7 - 45 Nm
8 - Injection pump sprocket

♦ Removing ⇒ page 23-25, Removing
injection pump
9 - Idler pulley
ling, tensioning toothed belt for injec-
tion pump
9 8 7 6
Y23--0006
23-11
5 6 7 3
Servicing injection pump
1 2 3 4 3 ♦ Observe rules regarding cleanliness
8 ⇒ page 23-2
3
♦ Removing and installing injection pump
9 ⇒ page 23-25
10
♦ Check commencement of injection
11 dynamically and adjust ⇒ page 23-31
1 - Injection lines
12 ♦ Tighten with 25 Nm
31 30 ♦ remove using 3035
16 13 ♦ always remove complete set of lines
♦ Do not change shape of bends
2 - 25 Nm
29
28 3 - Seal
♦ Renew
27 20 19 18 17 16 15 6 14 6
26
25
24 23 22 21 Y23--0005
23-12
5 6 7 3 4 - Return line
1 2 3 4 3 5 - Fuel shut-off valve(N109), 40 Nm

8 ♦ Checking ⇒ page 01-33, Final control
diagnosis
3
9 6 - O-ring
10
11 7 - Connecting piece
♦ For return line
12 8 - Hollow screw, 25 Nm
31 30
16 13 9 - Supply line
10 - Injection pump
♦ With quantity adjuster mechanism
29 ♦ With quantity adjuster (N146)
♦ With modulating piston movement
28 sender (G149)
27 ♦ With fuel temperature sender (G81)
20 19 18 17 16 15 6 14 6 ♦ With fuel shut-off valve (N109)
26 ♦ With commencement of injection
25 valve (N108)
24 23 22 21 Y23--0005
23-13
5 6 7 3 11 - Woodruff key
♦ Check that securely seated
1 2 3 4 3
8 12 - Intermediate plate
3 13 - Blocking bolt
9 ♦ 12 Nm with intermediate plate
30 Nm without intermediate plate
10 ♦ Blocking injection pump from deliv-
11 ery commencement
⇒ Removing and installing injection
pump, page 23-25
12
31 30 14 - Sieve
16 13
15 - Commencement of injection valve
(N108)
♦ Checking ⇒ page 01-33, Final control
29 diagnosis
28 16 - 10 Nm
27 20 19 18 17 16 15 6 14 6 17 - Retainer
26
18 - Sleeve
25
19 - 12 Nm
24 23 22 21 Y23--0005
23-14
5 6 7 3 20 - Ball washer
1 2 3 4 3 21 - 25 Nm
8 ♦ Renew
3 22 - Bracket
9
23 - 45 Nm
10
11 24 - 25 Nm
♦ tapered nut
12 25 - Mounting bracket
31 30
16 13 26 - Heat shield
♦ Renew
27 - Clamp
29 28 - Injector
28 ♦ for cylinder 5 with needle lift sender
27 20 19 18 17 16 15 6 14 6 ⇒ page 23-35
26 ♦ Check ⇒ page 23-37
25
24 23 22 21 Y23--0005
23-15
5 6 7 3 29 - 25 Nm
1 2 3 4 3 30 - 20 Nm
8
31 - Connecting tube, 45 Nm
3 ♦ with pressure valve
9
10
11
12
31 30
16 13
29
28
27 20 19 18 17 16 15 6 14 6
26
25
24 23 22 21 Y23--0005
23-16
Dismantling and assembling
1 2 3 4 5 6 7 air filter
1 - Spring clip
2 - Filter insert
♦ Maintenance intervals and cleaning:
⇒ Operating Manual
3 - Circlip
4 - 10 Nm
5 - Air filter housing
6 - Circlip
7 - 10 Nm
8 - 10 Nm
9 - Retainer
10 - Bolt
10 8 9 8
Y23--0025
23-17
2068 A 3036 Removing and installing,
tensioning toothed belt for
injection pump
sories required

(with engine removed)
3313 V.A.G 1331 ♦ 3036 Brace
♦ 3313 Dial gauge adapter
Not shown:
V.A.G 1332 ♦ Dial gauge (measuring range 0 - 3 mm)
W13--0046
23-18
Removing
- Remove the air filter and the intake manifold.
- Turn crankshaft in engine rotating direction to TDC position of cylin-

der 1:
- Check the TDC position:
- The markings of the vibration damper and the lower section of the
toothed belt guard must be vertically aligned -arrow- .
Y13--0002
Engine installed:
A
visible area of the injection pump marking -arrow-.
Notes:
23-19
- Screw the TDC sender T 01901 into the opening of the clutch bell.
- The TDC sender must engage, otherwise the crankshaft must be

turned until the TDC sender is heard and felt to engage.
T01901
Y15--0007
A 2068 A
Engine removed:
- Set adjustment device for TDC 2068 A to 96.9 mm -arrow A-, left
notch of vernier gauge is reference point.
B - Screw in adjustment device as shown. Turn crankshaft until TDC
marking on flywheel aligns with edge of adjustment device -arrow B-.

A area of the injection pump marking -arrow-.
Y15--0010
23-20
Notes:
Cylinder 1.
- Mark running direction of toothed belt.
- Hold injection-pump drive sprocket in place with brace 3036.

Unscrew mounting bolt and remove toothed belt.
- Remove tensioner for toothed belt.
Installing, tensioning
- Block the injection pump from delivery commencement

⇒ page 23-30.
Engine installed:
- Check whether TDC sender T 01901 is screwed in and engaged.
Engine removed:
- Check whether TDC marking on flywheel and reference mark are

aligned.
23-21
- Place the toothed belt on the injection pump sprocket.
- Watch running direction with used toothed belt.
- Insert the drive sprocket for the injection pump into the toothed belt
2 and secure the sprocket on the camshaft in such a way that it can still
1 be turned.
- Check installation position of idler pulley:
- Turn the deflection roller until the pointer is flush with the flange con-
tour of the cylinder head -arrow-.
- Tighten the securing nuts -2- with 20 Nm.

N23--0123
A
- Fit the tensioner -1- in such a way that the tab of the tensioner is
1 seated in the recess on the bracket -arrow B-.
- Tighten the securing screw by hand.
- To tension the toothed belt, turn the tensioning roller anti-clockwise

until the two pointers are facing one another -arrow A-.
B
- Tighten the securing screw with 15 Nm.
N23--0124 - Tighten the securing nuts of the drive sprocket for the injection
pump with 160 Nm. Use the retainer 3036.
23-22
Note:
Make sure when tightening the mounting bolt that no torque is trans-
mitted to the injection pump shaft blocked at the point of injection.
- Slacken the blocking screw -2- on the injection pump.
- Insert the intermediate plate -1- and tighten the blocking screw with
12 Nm.
2 Engine installed:
1 - Unscrew TDC sender T 01901 from gearbox bell.
N23--0119
A
- Turn crankshaft two rotations in engine rotating direction until crank-
1 shaft is positioned at TDC for cylinder 1 again.
- Check position of pointer -arrow A-. Pointers should be opposite

each other. If pointers are not opposite each other, however front
pointer is located within metal contour located behind it, then this
is permissible.
B
N23--0124
23-23
Note:
If the front pointer is outside the metal contour located behind it, then
the tensioning procedure must be repeated.
- Install the air filter and the intake manifold.
- Test the injection commencement dynamically and adjust if necess-

ary ⇒ page 23-31.
23-24
2068 A 3036 Removing and installing injec-
tion pump
sories required

(with engine removed)
♦ 3036 Brace
3313 V.A.G 1331
♦ 3313 Dial gauge adapter
♦ Extractor 3032
V.A.G 1332 3032
W23--0012
23-25
3035 ♦ 3035 Ring spanner
♦ Dial gauge (measuring range 0 - 3 mm)
Removing
W00--0269 - Remove the air filter and the intake manifold.
- Remove the fuse box/relay plate:

⇒ page 97-1; Fuse box/relay plate; Removing and installing fuse box/
relay plate
- Remove the console with the accelerator lever position sender:

⇒ page 20-11; Servicing throttle controls
- Remove the injection lines using the open ring spanner 3035.
Note:
Always remove complete set of lines. Do not change the original
shape
- Cover the openings with a clean cloth.
- Remove the toothed belt for the injection pump ⇒ page 23-18.
23-26
- Use retainer 3036 to slacken the securing nut for the injection pump
sprocket by approx. 1 revolution.
- Remove the tensioning roller and the deflection roller.
3036
N23--0120
- Use extractor 3032 to pre-tension the injection pump sprocket.

3032
Note:
In place of the extractor hook, screw two cheese head screws
1 3032/13 -1- into the threaded holes of the injection pump sprocket.
- Separate the injection pump sprocket from the taper of the injection
pump by lightly tapping the spindle of the extractor -arrow-.
1 - Remove the injection pump sprocket.
V23--0206
- Separate the 10-pin connector for the injection pump.

⇒ Overview of installation locations, page 23-3.
23-27
- Unscrew the securing screws -1- and the tapered nut -2- from the
console.
1 - Remove the injection pump.
Fitting
- Block the injection pump from delivery commencement

⇒ page 23-30.
2 N23--0122 Note:
New injection pumps are already blocked for delivery commence-
ment.
- Place the injection pump in the console.
- Tighten the securing screws -1- and the tapered nut -2- with 25 Nm.
Note:
1 The commencement of injection is adjusted dynamically with
V.A.G 1552/VAS 5052.
- Fit the injection pump sprocket. When aligning, ensure that the
Woodruff keys are correctly aligned.
Note:
2 N23--0122
When tightening the securing nuts, make sure that none of the torque
is transferred to the injection pump shaft which is blocked for delivery
commencement.
- Tighten the securing nut with 45 Nm. Use the retainer 3036.
23-28
- Install the idler pulley and the toothed belt for the injection pump
⇒ page 23-18.
- At the connection for the return line, fill the injection pump with clean
diesel fuel.
Filling capacity for new pump is at least 180 ml
- Connect the injection lines, fuel lines.
- Install the console with the accelerator lever position sender:

- Install the fuse box/relay plate:

relay plate
- Install the air filter and the intake manifold.
- Test the injection commencement dynamically and adjust if necess-

ary ⇒ page 23-31.
23-29
Blocking injection pump from delivery commencement
- In place of the sealing bolt, screw in adapter 3313.
- Insert the meter (measurement range 0...3.0 mm) with approx.

2.0 mm initial tension in the adapter.
3313 N23--0125
- Check whether the markings on the injection pump sprocket and the
injection pump -arrows- match up.
V23--0324
23-30
- Slacken the blocking screw -2- on the injection pump.
- Remove the underlying intermediate plate -1-.
- Set the meter to ”0”.
- To make sure that high-pressure piston of injection pump is at BDC,

slowly turn injection pump sprocket somewhat opposite engine
2 rotating direction (clockwise) with brace 3036. The pointer on the
1 dial gauge must stop at ”0”; if necessary, set the dial gauge to ”0”
N23--0119 after the BDC position has been reached.
- Use retainer 3036 to turn the injection pump sprocket slowly in the
direction of engine rotation (anti-clockwise) until the pointer of the
dial gauge shows 0.55 mm stroke.
V.A.G 1552 - Tighten blocking bolt with 30 Nm.
Testing and adjusting injection commencement

dynamically
♦ Fault output device V.A.G 1552 with cable V.A.G 1551/3 or fault
W00--1188 output device VAS 5052
23-31
Notes:
♦ The dynamic test and correction of the injection commencement is
only possible in function 04 ”Basic Setting of the Engine”.
♦ The injection commencement must always be checked and, if
necessary, adjusted after replacement of the toothed belt or after
removing the screwed connections on the injection pump or the
toothed belt sprockets.
Test and adjustment conditions
Basic mechanical setting of the engine OK
Toothed belt tension OK. (Toothed belt camshaft drive)

⇒ page 15-9; Removing and installing toothed belt for camshaft
The coolant temperature must be at least 70 °C.
Testing injection commencement
⇒ page 01-4)
23-32
Select function XX
- Press keys 0 and 4 for ”Initiate basic setting” function and acknow-
Basic setting HELP Display:
- Press keys 0 three times for ”Display group number 0” and acknow-
System in basic setting 0 → Display:
1 2 3 4 5 6 7 8 9 10 (1...10 = display fields)
To read off commencement of injection in display field 2, the fuel

temperature in display field 9 must be within the numerical range from
120 to 190.
80
A - Display field 2 ”Commencement of injection”
70
B - Display field 9 ”Fuel temperature
60
A C - Setpoint value range for commencement of injection
50 C
40 Readout example:
30
20 Numerical value 140 in display field 9 (B) corresponds to a numerical
10 value range of 38 - 67 in display field 2 (A).
0
100 120 140 160 180 200
N23--0277
B
23-33
Note:
♦ During the check, if the commencement of injection is within the
setpoint value range -C-, no new setting is required. After repairs
such as removing and fitting the injection pump, setting the control
times, etc., set the commencement of injection to the mean value
(dotted line) of the setpoint value range -C-.
Setting commencement of injection
- Loosen the securing nut -2- of the idler pulley -1-.
- Observe the value in display field 2 and, if necessary, repeat the

setting until the displayed value remains at the mean value of the
setpoint value range -C-.
- Tighten the securing nuts -2- with 20 Nm.

1 2
Y23--0007 - Press keys 0 and 6 for ”End data transfer” function and acknowledge
entry with Q key.
23-34
V.A.G 1331 Removing and installing injectors
W00--0427
3035 ♦ 3035 Ring spanner
Note:
Defective injectors cause the following faults:
♦ Ignition failure
♦ Knocking in one or more cylinders
♦ Engine overheats
♦ Drop in power/performance
W00--0269
♦ Excessive black exhaust smoke
♦ High fuel consumption
♦ Increased blue smoke at cold start
23-35
Defective nozzles can be detected by slackening the injection line
union nuts one after the other while the engine is idling. If the engine
speed remains constant after the union nut has been slackened, this
indicates a defective nozzle.
Removing
Note:
To remove the injectors on Cylinder 4 and 5 remove the console with
the accelerator lever position sender:
- Remove the injection lines using the open ring spanner 3035.
Note:
Always remove complete set of lines. Do not change the original
shape
- Slacken the securing screw, take off the clamping collar and remove
the injector.
Fitting
Note:
Always replace the heat protection gasket between the cylinder head
and the injectors.
- Insert the injectors.
23-36
- Ensure that the supports in the cylinder head are correctly seated.
- Insert the clamping collar.
Tightening torques:
Injection lines = 25 Nm
Screw for clamping collar = 25 Nm
- Install the console with the accelerator lever position sender:

Checking injectors
V.A.G 1322 These engines are fitted with 2-spring injectors. Injection of the fuel
quantity is in two stages.
If these injectors are damaged or defective, it is only possible to
replace them; neither a pressure adjustment nor servicing are
possible.

♦ Injector tester V.A.G 1322 with pressure line V.A.G 1322/2

W00--1049
Test condition
Pressure gauge switched on
23-37
Checking injection pressure
Important!
When checking the injectors, ensure that the jet of fuel does
not strike your hands as the high pressure means that the fuel
could penetrate the skin and cause serious injury.
- Connect injector to the injector testing device.

V.A.G 1322
- Slowly press down the pump lever. At the beginning of the injection,
read off the injection pressure. If the injection pressure deviates
from the setpoint value, replace the injectors.
Setpoint values: (overpressure)
Engine code letters ANF, BCT

New nozzles: 190 ... 200 bar
Wear limit: 170 bar
V02--0184
Engine code letters ANG, ANH, BCU, BCV

New nozzles: 220 ... 230 bar
Wear limit: 200 bar
23-38
Checking for Leaks
- Slowly press down the pump lever and maintain the pressure at
150 bar for 10 seconds. In the process, no fuel should seep out of
the nozzle opening.
- In the event of a leak, replace the injector.
Replacing O-ring on cover of injection timing

device
- Remove the fuse box/relay plate:

relay plate
- Place a clean cloth underneath the injection pump.
4 - Use a standard angle screwdriver for Torx screws, e.g. Hazet

5
4 2115-T30, to unscrew the cover screws -1-.
3
2
1 - Rake off the cover -2- and clean it.
- Replace the O-ring -3- and refit the cover with the existing shims -4-.
V23 -- 0218
23-39
- Install the fuse box/relay plate:
relay plate
23-40
Checking components and functions
Checking the Power Supply for the Diesel Direct
Injection System
V.A.G 1526 A Special tools, workshop equipment, test and measuring equip-
W00--0431
V.A.G 1594 A ♦ V.A.G 1594 A Auxiliary test set
Testing Requirement
Battery voltage OK (at least 11.5 V)
W00--0477
23-41
1
Test procedure
Y20--0007
Check voltage supply relay -Terminal 30 (J317)
- Switch on the ignition. The voltage supply relay -Terminal 30 -1- must
click once.
3 Note:
The relay can also be checked by touching.
1 2
Y20--0008
23-42
The relay clicks:
- Check the voltage supply to Terminal 30 ⇒ page 23-45.
If the relay does not click:
- Pull the voltage supply relay -Terminal 30 out of the fuse box/relay
plate.
- Measure the voltage with the multimeter between the contacts

87
86 85+86 of the fuse box/relay plate:
Setpoint value: at least 11.5 V
If the setpoint value is reached:

85
- Check the voltage supply relay -Terminal 30 (J317).
30 If the setpoint value is not reached:
Y23--0017 - Measure the voltage with the multimeter between contact 86 of the
fuse box/relay plate and the engine earth:
23-43
- Check the cable connections to the fuse box/relay plate contact 86
for breaks, short-circuits and transition resistance at the contact
points using the CFD.
- Measure the voltage with the multimeter between contact 85 of the

fuse box/relay plate and the battery (+):
87 86
A If the setpoint value is not reached:

85
- Remove the engine control unit ⇒ page 23-88.
30
- Check the control line from socket -B- of the engine control unit con-
tact 18 to the relay socket -A- contact 85 for breaks and short-circuits.
1 2 81 62 63 44
If no fault is detected in the cables and at the relay:
- Replace the control unit for diesel direct injection system (J248)
⇒ page 23-88.
4 5 24 43 6 25
B Y23--0016
23-44
Check voltage supply to Terminal 30

3
- Pull the voltage supply relay -Terminal 30 -1- out of the relay plate.
1 2
- Unlock the engine control unit t -3- at socket -2- of the fuse box/relay
plate and pull out the engine control unit.
Y20--0008
87 86
A - Bridge contacts 30+87 of the fuse box/relay plate -A- with auxiliary
wires from V.A.G 1594.
85 - Switch on the ignition.
30 - Measure the supply voltage with the multimeter between contacts

1+4 and 2+5 of the socket -B- for the engine control unit:
1 2 81 62 63 44
- Check the cable connections for breaks, short-circuits and transition

resistance at the contact points.
4 5 24 43 6 25
B Y23--0016
23-45
Check voltage supply to Terminal 15
4 81 62 63 44 - Measure the supply voltage with the multimeter between contacts

4+34, 4+37 and 5+70 of the socket for the engine control unit:
- Check the cable connections for breaks, short-circuits and transition

5 24 43 6 25 resistance at the contact points.
Y23--0024
23-46
Checking the Engine Speed Sender
The engine speed sender is the speed and reference mark sender. In
case of a failure, the engine will be switched off.
W00--0431
W00--0477
23-47
Test procedure
- Pull the plug off the engine speed sender (G28) -arrow-.
Y23--0009
1 2 - Measure the resistance between contacts 1+2 on the sender.

Setpoint value: 1,1 ... 1.6 kΩ
- Replace the engine speed sender (G28).

⇒ page 13-1; Dismantling and assembling engine

Y23--0010 - Remove the engine control unit ⇒ page 23-88.
23-48
1 2
- Check the wires between plug -A- and socket -B- of the engine
control unit for breaks using the CFD
A Wire resistance: max. 1.5 Ω
Plug for G28 Control unit socket

contact contact
1 102
98 105 2 110
- Check for short-circuits among the cables at the 2-pin connector in

accordance with the current flow diagram.

106 113
B Y23--0018 - Replace the control unit for diesel direct injection system (J248)
⇒ page 23-88.
Check intake manifold pressure sender

The intake manifold pressure sender is located together with the
intake manifold temperature sender in a common housing on the
intake manifold.
23-49
V.A.G 1594 A
V.A.G 1526 A
sories required

V.A.G 1551/3 or fault output device
VAS 5052
V.A.G 1552 ♦ Current flow diagram
W23--0031
23-50
Test procedure
⇒ page 01-4)

Select function XX
- Press keys 0,1 and 0 for ”Display group number 10” and acknow-
Read measuring value block 10 → - Compare the display in display field 3 (intake manifold pressure
780 rpm 1027 mbar1013 mbar 0.0 % sender -G71) with the following table:
Altitude Air pressure

0m 998 mbar
500 m 954 mbar
1000 m 902 mbar
1500 m 853 mbar
2000 m 805 mbar
23-51
Note:
Depending on the weather, the air pressure may differ from the value
specified in the table. Determine the actual air pressure if necessary
(e.g. with a barometer or the weather report).
Setpoint value:
The pressures must match up
(Tolerance ¦ 30 mbar)
If the value in display field 3 differs from the table value:
entry with Q key.
- Pull the plug off the intake manifold pressure sender (G71) -arrow-.
Y23--0011
23-52
A - Check the wires between plug -A- and socket -B- of the engine con-
trol unit for breaks using the CFD

contact contact
1 4
3 31
81 62 63 44 4 71
- Also check the wires for short circuits to each other, to the vehicle
If no fault is found in the wires:

24 43 6 25
B Y23--0019 - Replace the sender for intake manifold pressure with the sender for
intake manifold temperature.
23-53
V.A.G 1526 A V.A.G 1594 A Checking the Coolant
Temperature Sender
sories required

V.A.G 1552
VAS 5052
W23--0031
23-54
Test procedure
⇒ page 01-4)

Select function XX
Read measuring value block 7 → - Display:
15,4 °C 15.9 °C 16.7 °C
- Check the coolant temperature value in display field 4. The tempera-
ture value must
rise evenly without interruption.
- In the case of a fault, either the fuel temperature or the value - 5.4 °C
will be shown instead.
23-55
- If there is no realistic display in display field 4 or if the fuel tempera-
ture or - 5.4 °C is displayed instead, check the coolant temperature
sender and the cable connections to the sender as follows:
entry with Q key.
- Pull the 4-pin connector off the coolant temperature sender (G62)
-arrow-.
Y23--0012
- Carry out a resistance measurement on the coolant temperature

sender (G62) contact C (ground) and D (signal).
N24--1094
23-56
A B
900 Setpoint value, see diagram
800
7000 700 Area A shows you the resistance values for the temperature range 0
6000 600 - 50 °C; area B shows the values for the temperature range 50 - 100 °C.
5000 500
4000 400 Readout examples:
3000 300
2000 200 ♦ 30 °C corresponds to a resistance of 1500 - 2000Ω
1000 100
0 10 20 30 40 50 60 70 80 90 100ºC ♦ 80 °Corresponds to a resistance of 275 - 375 Ω

N24--0157
- Replace the coolant temperature sender (G62).
23-57
2 4 - Check the wires between plug -A- and socket -B- of the engine con-

1 3 contact contact
3 104
98 105 4 112

106 113
B Y23--0021 - Replace the control unit for diesel direct injection system (J248)
⇒ page 23-88.
Checking the Intake Manifold Temperature

Sender
The intake manifold temperature sender is located together with
the intake manifold pressure sender in a common housing.
23-58
V.A.G 1594 A
V.A.G 1526 A
sories required

VAS 5052
W23--0031
23-59
Test procedure
⇒ page 01-4)

Select function XX
15,4 °C % 15.9 °C 16.7 °C
- If there is no realistic display in display field 3 or if a replacement tem-
perature of 13 6.8 °C is displayed, check the intake manifold tem-
perature sender and the cable connections to the sender as follows:
entry with Q key.
23-60
- Pull the plug off the intake manifold temperature sender (G72)
-arrow-.
Y23--0011
- Carry out a resistance measurement on the intake manifold tem-

4 3 2 1 perature sender contact 1+2.
N23--0198
23-61
A B
800
7000 700 Area A shows you the resistance values for the temperature range 0
6000 600 - 50 °C; area B shows the values for the temperature range 50 - 100 °C.
5000 500
3000 300
1000 100
0 10 20 30 40 50 60 70 80 90 100ºC ♦ 80 °C corresponds to a resistance of 275 - 375 Ω

N24--0157
- Replace the intake manifold temperature sender (G72).
23-62
A - Check the wires between plug -A- and socket -B- of the engine con-
Plug for G72 contact Control unit socket contact

1 4 1 52
2 73
81 62 63 44

24 43 6 25 - Replace the control unit for diesel direct injection system (J248)
B Y23--0019 ⇒ page 23-88.
23-63
V.A.G 1526 A V.A.G 1594 A Checking the Fuel Temperature
Sender
sories required

V.A.G 1552
VAS 5052
W23--0031
23-64
Test procedure
⇒ page 01-4)

Select function XX
15,4 °C 15.9 °C 16.7 °C
- If there is no realistic display in display field 1 or if a replacement tem-
perature of -5.4 °C is displayed, check the fuel temperature sender
and the cable connections to the sender as follows:
- Press the → button.
entry with Q key.
23-65
- Separate the 10-pin connector for the injection pump -arrow-.
Y23--0013
10 8 6 4 2
- Measure the resistance of the sender at contacts 4+7 of the con-
nector.
9 7 5 3 1 A23--0027
23-66
A B
800
7000 700 Area A shows you the resistance values for the temperature range
6000 600 0 - 50 °C; area B shows the values for the temperature range
5000 500 50 - 100°C.
4000 400

2000 200

0 10 20 30 40 50 60 70 80 90 100ºC
N24--0157 ♦ 80 °Corresponds to a resistance of 275 - 375 Ω
- Renew the injection pump ⇒ page 23-25.
23-67
1 2
5 6
7 8
9 10 10-pin connector contact Control unit socket contact
A 4 103
7 111
12 98 105 114 116

B 106 113 121 - Replace the control unit for diesel direct injection system (J248)
Y23--0020 ⇒ page 23-88.
23-68
Checking the modulating piston movement
sender and quantity adjuster
The quantity adjuster is an electro-magnetic rotary switch which is
activated from the control unit by a targeted pulse duty factor. The
eccentric shaft of the quantity adjuster moves the control sleeve on the
high-pressure piston, thus determining the injection quantity.
The modulating piston movement sender supplies the control unit with
the position of the quantity adjuster -N146, i.e. determines the injec-
tion quantity.
23-69
V.A.G 1594 A
V.A.G 1526 A
sories required

VAS 5052
W23--0031
23-70
Test procedure
⇒ page 01-4)

Select function XX
840 rpm 6.5 mg/stroke 1,480 V 87.3 °C
- Check the coolant temperature in display field 4.
Setpoint value: at least 70 °C
Only continue the test when the coolant temperature has been
reached.
Read measuring value block 1 → - Check voltage from modulating piston movement sender in display
840 rpm6.5 mg/stroke 1,480 V 87.3 °C field 3.
- Setpoint value 1.25 - 2.0 V
- If the setpoint value is not reached, check the modulating piston

movement sender and the quantity adjuster in the following way:
23-71
Checking the Modulating Piston Movement Sender (G149)
entry with Q key.
Y23--0013
10 8 6 4 2
- Measure the resistance between contacts 1 + 2 and 2 + 3 of the con-
nector.
Setpoint value: 5 - 7 Ω
9 7 5 3 1 A23--0027
23-72
1 2
5 6
7 8
A 1 108
2 106
12 98 105 114 116
3 99
B 106 113 121 If no faults are determined in the wiring:

Y23--0020
⇒ page 23-88.
Checking the Quantity Adjuster (N146)
entry with Q key.
23-73
Y23--0013
10 8 6 4 2
- Measure the resistance between contacts 5+6 of the connector.
Setpoint value: 0.5 - 2.5 Ω

9 7 5 3 1 A23--0027
23-74
1 2
5 6
7 8
A 5 1, 2
6 116, 121
12 98 105 114 116

B 106 113 121 - Replace the control unit for diesel direct injection system (J248)
Y23--0020 ⇒ page 23-88.
23-75
Checking the Needle Lift Sender
V.A.G 1526 A The needle lift sender signal is required to determine the injection com-
mencement. In the event of a failure, the injection commencement is
controlled (dependent on engine-speed and load); in normal operation,
the injection commencement is regulated (dependent on engine-
speed load and temperature).


W00--0431
Test procedure
- Remove the air filter.
W00--0477
23-76
- Separate the connector for the needle lift sender -arrow-.
Y23--0015
- Measure the resistance between contacts of the connector.

- Replace the injector for cylinder 5 with the needle lift sender (G80)
⇒ page 23-35.

V96--1216 - Remove the engine control unit ⇒ page 23-88.
23-77
- Check the wires between plug -A- and socket -B- of the engine con-
2 trol unit for breaks using the CFD
1
2-pin connector contact Control unit socket contact
1 109
2 101
98 105

106 113 - Replace the control unit for diesel direct injection system (J248)
B Y23--0027 ⇒ page 23-88.
23-78
V.A.G 1526 A V.A.G 1594 A Check injection timing device
adjustment range
sories required

V.A.G 1552
VAS 5052
W23--0031
23-79
Test procedure
The injection timing-device control range is adjusted in Function 04

(basic setting). This procedure clocks the commencement of injection
valve so that in measured value block 004 the extreme values for the
advance and retard position of the injection timing device can be read
off in display field 3.
⇒ page 01-4)

Select function XX
- Press keys 0 and 4 for ”Initiate basic setting” function and acknow-
Basic setting HELP Display:
System in basic setting 4→ Display:

780 rpm advanced 7.4° bef. TDC 89%
Specified value in display field 3: 7.0...9.0° bef. TDC
After approx. 10 seconds the injection distributor is moved into its

retarded position.
23-80
System in basic setting 4→ Display:
780 rpm retarded 3.3° bef. TDC 30%
Specified value in display field 3: 3.0...5.0° bef. TDC
- Check commencement of injection valve as follows:
Checking commencement of injection valve (N108) electrically
entry with Q key.
Y23--0013
23-81
10 8 6 4 2
- Measure resistance between contacts 9+10 on connector.
- Renew commencement of injection valve (N108)

⇒ page 23-14.
9 7 5 3 1 A23--0027 - Remove the engine control unit ⇒ page 23-88.
1 2
5 6
7 8
A 9 114
10 1, 2
12 98 105 114 116
B 106 113 121

Y23--0020
23-82
⇒ page 23-88.
23-83
Checking additional signals
V.A.G 1526 A V.A.G 1594 A
Checking clutch switch

Boats with Z-drive MercruiserTM
AlphaOneTM
The clutch switch (F36) provides the control

unit with the information as to whether or
not the clutch is engaged.

V.A.G 1552 and measuring equipment and acces-
sories required

VAS 5052
W23--0031
23-84
Test procedure
⇒ page 01-4)

Select function XX
- Press keys 0, 0 and 6 for ”Display group number 6” and acknowl-
edge entry with Q key.
- Note the display in display field 2.

Read measuring value block 6 → Setpoint value: 0 1 0
0 km/h 0 1 0 000000 255
- Actuate the clutch switch on the “shifting bracket”. The right-hand
side must jump to 1.
Read measuring value block 6 → Setpoint value: 0 1 1
0 km/h 0 1 1 000000 255
23-85
entry with Q key.
- Check the switch or the cable connections to the switch for breaks
and short-circuits:
Checking speed signal
V.A.G 1526 A The signal from the engine speed sender cannot be used further in its
direct form, and is therefore prepared by the engine control unit for the
following devices. The signal is required for the rev. counter in the
panel.


W00--0431
23-86
Test procedure
W00--0477
4 81 62 63 44 - Check cable connection from contact 20 of engine control unit

socket to main panel breaks or short-circuits.
5 24 43 6 25
Y23--0024
23-87
Engine control unit
Renewing engine control unit
V.A.G 1552 ♦ Fault output device V.A.G 1552 with cable V.A.G 1551/3 or fault out-
put device VAS 5052
Procedure
- First specify the control unit identification of the previous control unit
as follows:
W00--1188 Here, the ignition must be on.
⇒ page 01-4)
065906018 T150-5 MDC 0000SG 3601 → The control unit identification appears on the display of the fault output
Coding 00001 WSC00000 device V.A.G 1552, e.g.:
- Note the control unit identification.
- Press → key.
- Press the keys 0 and 6 for the function ”Quit output” and confirm
the input using the Q key.
23-88
Select function XX
1
Y20--0007
23-89
- Pull the relay -1- out of the socket of the fuse box/relay plate.
- Unlock the connection plug on the fuse box/relay plate -2- and pull
3 out the control unit -3-.
1 2 - Before installing the replacement engine control unit, note its part
number.
- Finally, interrogate the fault memory of the new engine control unit
and erase the fault memory if necessary, Erase fault memory
Y20--0008 ⇒ page 01-12
- Install the cover of the fuse box/relay plate and tighten the mounting
screws with 10 Nm.
Checking terminating resistor for data bus

Function
The engine control unit communicates with other data-bus capable

components.
The control units are interconnected with two twisted data bus cables
(high and low) and exchange information (messages). Missing informa-
tion on the data bus is detected by the engine control unit as a fault.
So that the data bus can function fault-free, it requires a terminating

resistor. This central terminating resistor is located in the engine con-
trol unit.
23-90
Test condition
V.A.G 1526 A A data bus error has been detected by the self-diagnosis

W00--0431
W00--0477
23-91
Test procedure
- Check the central terminating resistor in the engine control unit:

7 6
- To do this, carry out a resistance measurement between contacts
6 + 7 of the engine control unit:
Setpoint value: 60...72 Ω
If the resistance value is outside the setpoint range:
- Renew the engine control unit ⇒ page 23-88.
If the resistance value is within the setpoint range:

Y23--0023 - Eliminate the fault:
23-92
Removing and installing parts of exhaust
system
Notes:
♦ Following assembly work on the exhaust system, make sure that
the exhaust system is not torqued and is a sufficient distance from
the boat hull. If necessary, loosen the retaining and clamping clips
and align the exhaust system so that it is a sufficient distance from
the boat hull at all points.
26-1
1 2 3 Exhaust system without turbo-
charger
1 - Exhaust pipe connection
2 - 40 Nm
♦ Allen screw
3 - To exhaust hose
4 - Gasket
♦ Renew
4
5 - 40 Nm
♦ Hexagon bolt
⇒ page 19-16
6 5 Y26--0001
26-2
1 2 3 Exhaust system with turbo-
charger
1 - Retaining clip
♦ For hose connection, Item2
2 - Hose connection
♦ Secure connection Verbindung with 2
retaining clips each
3 - Exhaust pipe connection

♦ With hose connection on boats with
10 reversing gear
4 4 - Hose clamp
5 - Turbocharger
⇒ page 21-10
5 ♦ Check boost pressure
⇒ page 21-21, Checking turbocharger
9 8 7 Y26--0002
26-3
1 2 3 6 - 40 Nm
♦ Allen screw
7 - Gasket
♦ Renew
⇒ page 19-16
9 - 40 Nm
10 ♦ Hexagon bolt
4 10 - Exhaust pipe
♦ For Z-drive
6
5
9 8 7 Y26--0002
26-4
Starter
Important!
Disconnect the high-voltage connector from the engine before
working on the electrical system.
Technical data of starter
♦ (12 V - 2.0 kW)
27-1
Removing and installing starter
W00--0427
V.A.G 1332 ♦ V.A.G 1332 Torque spanner (40 - 200 Nm)
W00--0428
27-2
Removing:
- Disconnect the high-voltage connector from the engine.
- Unlock and pull off the plug-in housing of Terminal 50 -arrow-.
Y90--0003
- Unscrew the hexagon nut (13 Nm) on the solenoid switch Terminal
30 -arrow- and pull off the wires.
Y90--0004
27-3
- Unscrew the mounting screws -arrows-.
- Remove the starter.
Y27--0003
Installing:
- Fit the starter.
- Tighten he mounting screws -arrows- with 60 Nm.
The further installation is carried out in the opposite order.
Y27--0003
27-4
Alternator
Important!
Compact alternator with ribbed V-belt drive
Mounting B+ cable on alternator
The tightening torque for the mounting nut of the B+ cable -arrow- is
15 Nm.
Notes:
The screw connection for the B+ cable on the compact alternator is
marked with B1+.
♦ Terminal designations on the connections
N27--0174 ⇒ also see current flow diagram
If the B+ cable is not mounted with the specified tightening torque,
the following dangers exist:
♦ The batters will not be completely charged.
♦ Complete failure of the boat electrical/electronic system (break-
downs).
♦ Danger of fire due to spark formation.
♦ Damage to electronic components and control units due to over-
voltages.
27-5
A Removing and installing voltage regulator
A
- Unscrew the mounting nuts -arrows A- and pull out the mounting
bolt -arrow B- of the protective cap.
- Remove the protective cap.

B
N27--0172
- Unscrew the mounting screws -arrows- of the voltage regulator and

take off the voltage regulator.
N27--0173
27-6
Checking carbon brushes for alternator
Length of carbon brushes when new = 12 mm
Wear limit = 5 mm
Tolerance of carbon brushes to each other = +1 mm
N27--0175
V.A.G 1332 Renewing ribbed V-belt pulley on alternator

W00--0428
27-7
3310 ♦ 3310 Socket head
W00--0299
Removing and installing ribbed V-belt pulley on alternator
- Loosen or tighten the mounting nut of the ribbed V-belt pulley with
the socket head 3310 while holding the alternator shaft in place with
an Allen socket head.
Tightening torque: 65 Nm ± 5 Nm
3310
N27--0029
27-8
Checking ribbed V-belt
Note:
If damage is determined, the ribbed V-belt must be renewed to pre-
vent failures or malfunctions.
- Turn the engine by hand while checking the ribbed V-belt:
♦ Base cracks (minor cracks, core breaks, cross-sectional breaks)
♦ Layer separation (top layer, tensile strands)
♦ Break-outs on base
♦ Fraying of tensile strands
♦ Side wear (material removal, frayed sides, side hardening -glassy

sides-, surface cracks)
♦ Traces of oil and grease
27-9
Alternator brackets and ribbed V-belt routing
W00--0427
W00--0428
27-10
Note:
Test alternator:
⇒ Current Flow Diagrams, Electrical Fault
14 Finding
1 1 - Alternator
2 - Hexagon bolt (M8 x 45)

12 ♦ 40 Nm
2
13
3 3 - Retainer
12 ♦ When installing the alternators, the
plastic sleeves must always be in-
serted in the alternator bracket.
Check sleeves for damage and wear,
and renew if necessary.
4 4 - Hexagon bolts (M10 x 120)

♦ 40 Nm
5 ♦ With washer
11 6
7
10 9 8 Y27--0004
27-11
5 - Hexagon bolts (M10 x 45)
♦ 40 Nm
♦ With washer
14
6 - Cheese head bolt (M8 x 35)
♦ 20 Nm
1
7 - Power steering pump
12
2 8 - Cheese head bolts (M80 x 30)
13 ♦ 20 Nm
3
12 9 - Belt pulley for vane pump
10 - Cheese head bolts (M8 x 12)

♦ 20 Nm
4
5
11 6
7
10 9 8 Y27--0004
27-12
11 - Washers
12 - Hexagon bolt (M8x85)

14 ♦ 25 Nm
13 - Combi-bolt (M10 x 38)

1 ♦ 40 Nm
12 14 - Ribbed V-belt
13 ⇒ page 27-17
3 ♦ Ribbed V-belt drive
12 ⇒ page 27-14
4
5
11 6
7
10 9 8 Y27--0004
27-13
Overview of ribbed V-belt drives
1 2
Fig. 4
3
9 1 - Ribbed V-belt for seawater coolant pump
4
2 - Tensioner
5 3 - Belt pulley - alternator
6 4 - Idler pulley
5 - Idler pulley
7
8 6 - Ribbed V-belt for alternator
Y27--0005 7 - Belt pulley - crankshaft
8 - Tensioner for belt drive with seawater coolant pump
9 - Belt pulley - seawater coolant pump
1
2 Fig. 5
10
3 1 - Tensioner
2 - Belt pulley - alternator
4
3 - Idler pulley
5 4 - Idler pulley
9
5 - Belt pulley - power steering pump
8
6 - Ribbed V-belt for alternator and power steering pump
7 6 Y27--0006
27-14
7 - Belt pulley - crankshaft
9 - Ribbed V-belt for seawater coolant pump
1 2 3
Fig. 6
1 - Tensioner
10 4
2 - Idler pulley
5
3 - Belt pulley - alternator
4 - Idler pulley
6 5 - Belt pulley - second alternator
7 6 - Ribbed V-belt for alternator and additional second alternator
9 8 Y27--0007 7 - Belt pulley - crankshaft
27-15
Fig. 7
1 2 3
1 - Tensioner
2 - Idler pulley
11 4 3 - Belt pulley - alternator
5 4 - Idler pulley
5 - Belt pulley - second alternator
6 - Ribbed V-belt for alternator, power steering pump and additional
6 second alternator
7 7 - Belt pulley - power steering pump
Y27--0008
10 9 8 8 - Belt pulley - crankshaft
27-16
Removing and installing ribbed V-belt
Notes:
♦ Mark the running direction of the ribbed V-belt before removing and
observe when installing. The opposite running direction lead to the
belt being destroyed!
♦ If damage is determined, the ribbed V-belt must be renewed to pre-
vent failures or malfunctions.
♦ It is not necessary to adjust the ribbed V-belt tension, as the best
possible belt tension is ensured by a spring-loaded tensioning
device.
Notes:
♦ When installing used ribbed V-belts, watch the previous running
direction marked during removal.
♦ Ensure proper seating of the ribbed V-belt in the belt pulley when
installing.
27-17
Removing ribbed V-belt of alternator
Note:
Mark the running direction before removing the ribbed V-belt. Ensure
proper seating in the belt pulley when installing.
- Remove the ribbed V-belt for the seawater coolant pump,

⇒ page 27-21.
- Lift the tensioner with a 16 mm open-end spanner and remove the

ribbed V-belt from the alternator belt pulley.
- Remove ribbed V-belt.

Y27--0009
Note:
Before installing the ribbed V-belt, make sure that all units (alternator
and, if installed, additional alternator or power steering pump) are
securely mounted.
- Lift the tensioner with a 16 mm open-end spanner and lay on the

ribbed V-belt and tension.
27-18
Belt drive with alternator
Y27--0010
Belt drive with alternator and power steering pump
Y27--0011
27-19
Belt drive with alternator and additional 24 V or 230 V alternator
Y27--0012
Belt drive with alternator, power steering pump and additional 24 V or

230 V alternator
- Reinstall the ribbed V-belt of the seawater cooling pump.
Y27--0013
27-20
Remove the ribbed V-belt of the seawater coolant pump
Note:
Mark the running direction before removing the ribbed V-belt. Ensure
proper seating in the belt pulley when installing.
- Lift the tensioner with a 16 mm open-end spanner and remove the

ribbed V-belt from the pump belt pulley.
- Remove ribbed V-belt.
Y27--0014
Note:
Before installing the ribbed V-belt, make sure that the seawater
coolant pump is securely mounted.
- Lift the tensioner with a 16 mm open-end spanner and lay on the

ribbed V-belt and tension.
Belt pulley with seawater coolant pump
Y27--0015
27-21
Additional 230 V alternator
Important!
High voltage!
Work on the additional alternator and the related components
and wiring connections may only be carried out by specially
trained personnel.
The additional alternator supplies 230 V of alternating current with a

sine wave of 50 Hertz.
The maximum current draw of 16 amperes (equivalent to 3.5 kVA) is

possible at an engine speed of 1700 rpm. With the engine at idle,
approx. 4 amperes (equivalent to 0.9kVA) are available.
In addition to the alternator, an On/Off switch with warning lamps and

a control unit (power box) and the required wiring connections and
components of the 230 V current circuit are also part of the system.
When the green LED in the switch lights up, 230 V alternating current
is available and the system is ready for operation.
27-22
Exploded view of additional
1 2 3 4 5 6 7 2 8 230 V alternator
1 - Hexagon bolt (M8 x 100)
♦ Tightening torque 24 Nm
2 - Lock washer (8 mm)
3 - Washers (8.4 mm x 16 mm)
4 - Retainer
♦ When installing the alternators, the
plastic sleeves must always be in-
serted in the alternator bracket. Check
sleeves for damage and wear, and
renew if necessary.
8 5 - Spacer sleeve (20 mm x 10 mm)
6 - Idler pulley (80 mm diameter)

9
10
11
8
3
Y27--0020
27-23
7 - Washers (8 mm x 25 mm)
1 2 3 4 5 6 7 2 8 8 - Hexagon bolt (M10 x 100)

♦ Tightening torque 47 Nm
9 - Spacer sleeve (20 mm x 8mm)
10 - Alternator fan impeller
11 - Belt pulley
♦ Tightening torque of mounting nut:
50 Nm
10
11
8
3
Y27--0020
27-24
Removing and installing additional 230 V alterna-
tor
W00--0427
Removing:
- Remove ribbed V-belt, ⇒ page 27-18.
- Unscrew the two mounting screws -arrows-.
- Disconnect the electrical connections and remove the alternator.
Y27--0017
27-25
Installing:
Installation is carried out in the reverse order.
When installing, do not forget the spacer sleeves -arrow-.
When installing, the plastic sleeves must always be inserted in the

alternator bracket. Check sleeves for damage and wear, and renew if
necessary.
Y27--0016
27-26
Removing bracket from additional alternator
W00--0427
Removing:
- Remove the belt pulley of the power steering pump -arrow- and the
idler pulley -arrow-.
Y27--0018
27-27
- Unscrew the two mounting screws -arrows-.
- Disconnect the electrical connections and remove the alternator

together with the bracket.
Installing:
Y27--0019
27-28
Fault displays on 230 V additional alternator
For safety reasons, the system is equipped with internal safety
mechanisms. As soon as a fault occurs, the internal safety device is
triggered and the red LED in the On/Off switch lights up.
If this is the case, the system should be switched off and not returned
to operation until the cause has been found and the fault eliminated.
Important!
High voltage!
Work on the additional alternator and the related components
and wiring connections may only be carried out by specially
trained personnel.
The green LED lights up:
♦ The system is operating properly
The green LED does not light up:
♦ The alternator voltage is too low
♦ The alternator load is too high
♦ The alternator speed is too low
27-29
The red LED lights up:
♦ Undervoltage or overvoltage comes from the battery
♦ Overloading, e.g. due to switching the alternator on and off quickly

with a load connected
♦ Too great a load is connected
♦ The switch connections are incorrectly mounted
♦ There is damage in the 230 V current circuit
♦ The temperature in the control unit (power box) is too high
Fault finding on 230 V additional alternator:

⇒ Chapter on fault finding, fault finding programme “Fault finding on
230 V additional alternator”
27-30
Checking glow plug system
W00--0431
Test conditions
Battery voltage at least 11.5 V
Ignition switched off
Control unit for diesel direct injection system (J248) OK
W00--0477 Fuse for glow plugs (S125) OK.
28-1
Test procedure
- Remove the connector from the coolant temperature sender

⇒ Installation Point Overview, page 23-3.
Note:
Removing the connector from the sender simulates a ”cold” engine
state and when the ignition is switched on the corresponding pre-
heating process takes place.
- Remove the plug connector from the glow plugs.
- Connect the multimeter for voltage measurement between a glow

plug connector and the vehicle earth.
- Switch on the ignition. For approx. 20 seconds, the

approx. battery voltage
is displayed.
- If there is no voltage:
28-2
Checking glow plugs
W00--0477
3220 ♦ 3220 Flexible-head spanner
♦ Diode testing lamp V.A.G 1527
Test conditions
Battery voltage at least 11.5 V
Ignition switched off
W00--0329
28-3
Test procedure
Note:
To check the glow plugs on Cylinder 4 and 5, remove the console with
the accelerator lever position sender:
- Remove the plug connector from the glow plugs.
- Connect the cable of the diode testing lamp to the battery positive
(+) terminal using clips from the measuring aids set.
- Place the testing tip of the diode testing lamp at one glow plug after
another.
Diode lights up: Glow plug OK
Diode does not light up: Replace glow plug
- Use the flexible-head wrench 3220 to remove and refit the glow
plugs
V28--0857
Tightening torque: 15 Nm.
28-4
Exploded view: Power steering pump,
reservoir, hydraulic lines
It is not possible to service the power steering pump. In case of com-
plaints, determine the cause using the pressure test. If the component
is defective, the power steering pump must be renewed.
♦ Pumps from the parts warehouse are not filled with oil. Therefore,
be sure to fill the pump with hydraulic oil G 000 200 and rotate it by
hand before installing, as otherwise noises or pump damage may
occur during driving.
♦ Oil type: Hydraulic oil G 002 000
♦ Oil quantity in system: approx. 1 l
♦ Do not reuse drained hydraulic oil.
♦ Renew seals.
48-1
1 2 Function overview: Power
steering pump, oil cooler,
hydraulic lines, reservoir
⇒ page 48-9
♦ Check feed pressure
⇒ page 48-7
♦ Fill with oil before installing
⇒ note on page 48-1
2 - Z-drive
5 ♦ For fuel
6 4 - Reservoir
♦ Oil level: Between Min. and Max.
8 marking
4 7 ♦ Thick connection is for supply line to
power steering pump
♦ Thin connection is for return line from
oil cooler
3
Y48--0008
48-2
1 2 5 - Pressure line
♦ With non-return valve
6 - Pressure line between Z-drive and oil

cooler
7 - Return line
♦ Make sure hose is laid kink-free
8 - Suction hose
♦ Make sure hose is laid kink-free
5
6
8
4 7
3
Y48--0008
48-3
1 2 Exploded view: Power steering
pump
Notes: ⇒ Page 48-1
1 - Allen screw, 40 Nm
2 - Hexagon bolt, 40 Nm
3 - Hexagon bolt, 40 Nm
3
4 - Bracket
14 5
12 4
6
13 7
11 10 9 8
Y48--0007
48-4
1 2 6 - Hexagon bolt, 40 Nm
♦ Dowel screw
7 - Ribbed V-belt
⇒ Electrical System; ⇒ page 27-17;
Removing and installing alternator with
ribbed V-belt; Removing and installing
ribbed V-belt
♦ Checking condition
3 ⇒ Inspection service
♦ Loosening and tightening
⇒ page 48-9
9 - Belt pulley
14 5
12 4 10 - Hollow screw, 30 Nm
6
13 7
11 10 9 8
Y48--0007
48-5
1 2 11 - Seal
♦ Renew
12 - Screw clip
♦ 4 Nm

♦ Check feed pressure
⇒ page 48-7
⇒ page 48-9
♦ Fill with oil before installing
⇒ note on page 48-1
14 5
12 4
6
13 7
11 10 9 8
Y48--0007
48-6
Checking feed pressure of power steering pump
♦ V.A.G 1402 Power steering tester

The adapter V.A.G 1402/6 is required for the feed pressure test.
V-belt/ribbed V-belt OK.

W00--0117
System free of leaks
Hoses/lines not kinked or constricted
- Unscrew pressure line from power steering gear (Z-drive).
- Connect pressure gauge V.A.G 1402 between power steering gear

(Z-drive) and pressure line. Shut-off valve on pressure gauge open.
- Fill with hydraulic oil Part No. G 002 000.
48-7
- Start engine and top up oil level in reservoir if necessary. Check hose
connections for leaks.
- With engine at idling speed, close shut-off valve (not longer than
5 seconds) and read off pressure.
- Setpoint value 95 - 110 bar gauge pressure

♦ If setpoint value is dropped below or exceeded by more than 5 bar,
renew pump.
♦ Exploded view: Power steering pump ⇒ page 48-4.
♦ In case of leaks on the Z-drive, first check the lines/line connections
for leaks, tighten if necessary and wipe dry.
48-8
Removing and installing power steering pump
♦ V.A.G 1590 Water pump spanner
Removing
- Remove suction and pressure line and drain off hydraulic oil.
W00--0444
- Remove belt pulley.
V.A.G 1590
V48--1042
48-9
- Unscrew bolts -1- and -2-.
1
Fitting
1 Installation is carried out in reverse sequence.

2
V48--1043
Assembly instructions for pressure line

The stop angle (arrow) must contact the power steering pump when
tightening the banjo bolt on the housing.
The tightening torque for the banjo bolt of the hydraulic line is 30 Nm.
The tightening torque for the screw clip of the supply line from the
reservoir is 4 Nm.
V48--1035
48-10
Instrument panel
Removing and installing instrument panel
Important!
Before working on the electrical system, disconnect high-
voltage connector from the engine.
Removing instrument panel
- Unscrew mounting nuts -arrows- from instrument panel.
- Take out instrument panel.
Installing instrument panel
Installation is carried out in reverse sequence.
Y90--0001
90-1
Removing and installing individual instruments
The individual instruments can be installed in the instrument panel or
also in the individual cockpit of the boat as individual instruments.
To remove the instruments, remove the instrument panel (if installed).

To remove the individual instruments, unscrew the nuts of the retain-
ing tabs and take out the instrument.
The ignition/starter switch is screwed to the instrument panel from the

outside.
90-2
1 2
Function overview
of instrumentation
1 - Instrument panel
2 - Instrument panel of 2nd control

stand
♦ If installed
3 3 - 2nd Accelerator-lever neutral switch
4 - Switch-on unit/electrical box

♦ If installed
7 5 - Fuse box/relay plate
6 - Switch-on unit/electrical box
6 7 - 1. Accelerator-lever neutral switch

♦ If installed
Y90--0002
90-3
Fuse box/relay plate
Removing and installing fuse box/relay plate
V.A.G 1331 Important!



W00--0427
Note:
♦ The fuse box/relay plate with fuse holder is located on the left-hand
side of the engine.
Removing:
- Unlock and pull off the 3 multi-pin connectors below the fuse box/
relay plate.
- Unscrew the fuel filter -arrows- and lay it aside with the lines con-
nected.
Y97--0001
97-1
- Unscrew the two screws from the air filter -arrows-.
Y97--0002
- Unscrew the air filter bracket from the housing of the fuse box/relay
plate -arrows-.
Y97--0003
97-2
- Unscrew the upper mounting screws -arrows-.
Y97--0004
- Unscrew the lower mounting screws -arrows-.
Y97--0005
97-3
- Pull the fuse box/relay plate forward somewhat.
- Unlock and pull off the connectors attached on the back of the fuse
box/relay plate.
- Remove the fuse box/relay plate from the engine.
Installing:
Connection assignment of fuse box/relay plate

Three multi-pin connectors are located on the underside of the fuse
box/relay plate. They are named after the number of their contacts. The
designations are T16, T35 and T 37. The individual contacts in the multi-
pin connectors have letter designations. Here a distinction is also made
between uppercase and lowercase letters.
Multi-pin connectors for the engine electrical system are located on

the back of the fuse box/relay plate.
97-4
A
B M Multi-pin connection T16 on underside of fuse box/relay plate
N P
C L A - K-wire
B - PWG 6
D K C - Earth Ter. 31
D - PWG 4
E J
O R E - PWG 3
F H F - PWG 2
G Y97--0012 G - PWG 1
H - Start
J - Positive Ter. 30
K - Stop
L - D+ direct
M - Positive Ter. 15
N - Supply voltage for glow plugs Ter. 30
O - Supply voltage for glow plugs Ter. 30
P - Supply voltage for glow plugs Ter. 30
R - Supply voltage for glow plugs Ter. 30
97-5
J A
K B
x a b Multi-pin connection T35 on underside of fuse box/relay plate
w c
d L A - Sender earth
P v
H u e C B - Starter Ter. 50
t f C - EKP +
s g D - Switching positive Ter. 15
r h D
E - Raw water temperature
p j M
G n m l k F - Positive Ter. 30
N Y97--0010 G - Positive Ter. 30
F E
H - Earth Ter. 31
J - Earth Ter. 31
K - Oil temperature
L - D+ direct
M - Water separator
N - Water level
P - Water temperature switch
a - Water temperature sender
b - Oil pressure switch
c - Neutral from gearbox
d - Oil pressure sender
e - Water temperature 1
97-6
J A
K B f - Water temperature 3
x a b
w c g - Charge air 4
P v d L h - Charge air 2
H u e C
j - Charge air 3
t f
s g k - Engine speed 1
r h D l - Engine speed 3
p j M m - Engine speed 2
G n m l k
N Y97--0010
n - not in use
F E p - not in use
r - Boost pressure controller
s - Air filter switch
t - Charge air 1
u - Oil extraction pump
v - not in use
w - Clutch switch
x - Earth relay
97-7
DCBA Multi-pin connection T37 on underside of fuse box/relay plate
J HGFE A - Positive Ter. 30
R PN MLK
Z XWV B - Starter control Ter. 50a
C - CAN screen
UTS D - Switching positive Ter. 15
f ed c ba
m k j hg E - Earth Ter. 31
F - Actuation EKP
s rpn Y97--0011 G - Consumer signal
H - not in use
J - not in use
K - K-wire
L - D+ for split charge relay
M - Oil pressure sender
N - CAN High
P - Stop button
R - CAN Low
S - Buzzer
T - Acknowledgement
U - Oil temperature
V - PWG 2
97-8
DCBA W - not in use
J HGFE X - PWG 4
R PN MLK Z - PWG 6
Z XWV
a - D+ charge monitoring
UTS b - PWG 1
f ed c ba c - Neutral from gearbox
m k j hg
d - Neutral to diode group
e - Raw water temperature
s rpn Y97--0011
f - System lamp
g - Air filter lamp
h - Water separator lamp
j - Water level lamp
k - Engine speed signal
m - Oil pressure switch
n - Water temperature sender
p - Water temperature switch
r - Sender earth
s - PWG 3
97-9
Multi-pin connections on back of fuse box/relay plate
1 2 3 1 - Connection plug for needle movement sensor
2 - Connection plug for pedal value sender (if installed)
3 - Connection plug for distributor injection pump
4 - Connection plug for glow plugs
4 Y97--0013
97-10
Removing and installing earth switch-off relay
Important!
Before working on the electrical system, disconnect the high-
voltage connector from the engine.
Note:
♦ The earth switch-off relay is located on the right-hand side of the
engine behind the support on which the connector for the battery
connection is mounted.
97-11
Removing:
- Separate the battery connection at the connector.
- Unscrew the positive cable from the starter.
- Unscrew the upper screws of the support -arrows-.
Y97--0006
- Unscrew the lower screw of the support -arrows-.
Y97--0017
97-12
B
- Remove the support -A- together with the earth switch-off relay -B-
A
and the cables.
- Unlock and pull the connector -1- off the earth switch-off relay -B-.
1
2
3
Y97--0016
B
- Unscrew the mounting screws -arrow- of the earth switch-off relay
A
-B- and remove the relay from the support.
- Unscrew the positive cable -2- and negative cable -3- from the con-
1 tacts on the relay -B- or on the support -A-.
2
3 Installing:

Y97--0016
97-13
Wiring loom versions
Wiring loom between engine/instrument panel and instrument
panel/2nd control stand
Various wiring loom lengths are available for installing the engine and
instrument panel electrical system.
The wiring looms are prefabricated and technically identical. However,

there are differences in the length.
♦ A wiring loom version with a length of 3 meters
These wiring looms are installed between the engine and the instru-
ment panel. The same wiring loom is also installed between the instru-
ment panel and the instrument panel of the 2nd control stand. The only
difference is the wiring loom length.
97-14
Wiring loom between instrument panel and connection unit (elec-
trical box)
This wiring loom is available in 2 versions:
♦ Prefabricated with connectors on both ends.
♦ Prefabricated with connectors on one end. The other end of the

wiring loom is open, and therefore enables connection to individual
instrumentation.
Note:
For connection to individual instrumentation:
⇒ Chapter on current flow diagrams, current flow diagram “Wiring
diagram for VW marine engines for individual instrumentation”
97-15
Wiring loom and connector
repair
Wiring-loom repair set
VAS 1978
Wiring loom and connector repairs on the

electrical system of the boat engine may
only be carried out with the Repair Set
VAS 1978.
Operating instructions are included with the

wiring-loom repair set
VAS 1978 in which the procedure for repairs
is described in detail.
For additional information, e.g. on installing

and removing components, please see the
respective Workshop Manual.
Please observe the following repair instruc-

tions.
N97--0027
97-16
Repair instructions for wiring loom and connector repair
Important!
Shielded cables may not be repaired. They must be completely
renewed if damaged.
Before repairs are begun, first the cause of the damage must be
eliminated, e.g. sharp-edged parts, defective electrical con-
sumers, corrosion etc.
Wiring repairs may only be carried out with yellow wires.
Yellow wires and points on the wiring loom wrapped with
yellow insulating tape mark previous repairs.
Following each repair, please conduct an operating test; if
necessary, fault memories must be erased or systems must be
brought into the basic setting.
97-17

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Service.

Booklet 5-Cyl. Diesel Engine

Service Department. Technical Information

00 Technical data Page

13 Crankshaft group Page

15 Cylinder head, Valve gear Page

19 Cooling system Page

23 Mixture preparation, Injection Page

26 Exhaust system Page

28 Glow plug system Page

This Workshop Manual contains technical data, descriptions and repair

Volkswagen marine boat engines are certified in accordance with

Read the safety precautions carefully before beginning with the

Always conduct maintenance work with the engine switched off.

During maintenance work or test drives, be sure to wear appropriate

Never start an engine equipped with a turbocharger without the air

If the engine is to be run at starting speed without actually starting,

Only use motor oils approved by Volkswagen Marine (⇒ Operating

Only start the engine in a well-ventilated area. When operating the

Exercise extreme caution in case of leaks in the fuel system. Wear

Hydrogen gas escapes when charging batteries that forms a highly

The tighten torques for screw connections are tightened with a

When tightening to a specified torque setting and a rotating angle,

The engine number (”engine code” and ”serial number”) is located on

The engine number consists of up to nine characters (alphanumeric).

In addition, an information plate with ”engine code letters” and ”serial

Code letters BCT ANF

If faults occur in the sensors or components monitored, these are

Technical Data for the Self-Diagnosis

♦ Fault memory: Permanent and temporary memory1)

Reading out control unit version

V.A.G 1552 Connect V.A.G 1552

Connecting VAS 5052 ⇒ page 01-7

Special tools, workshop equipment, test and measuring equip-

♦ Fault reader V.A.G 1552

V.A.G 1551/3 ♦ Cable V.A.G 1551/3

The battery voltage must be at least 11.5 V.

- Unscrew the cover of the diagnosis connection on the main panel.

- Depending on the function desired, you must:

- Press buttons 0 and 1 for ”Engine electronics” address word and

♦ T150-5 = 5-cyl. TDI engine with 150 bhp

♦ MDC 0000SG = Injection system (Marine Diesel Electronic Control)

♦ 3601 = Software version of control unit

♦ Coding 00001 = Coding variant

♦ WSC xxxxx = Dealership identifier

- Press the → button.

VAS 5052 Connecting VAS 5052

Special tools, workshop equipment, test and measuring equip-

♦ Fault output device VAS 5052

The battery voltage must be at least 11.5 V.

- Unscrew the cover of the diagnosis connection on the main panel.

Select operating mode:

Select vehicle system:

- Press the button ”01 - engine electronics on the display.

The control-unit identification of the engine control unit appears on the