Volkswagen 5-Cyl. Diesel Marine Engine Service & Repair Manual

Booklet Service. Service Department.Technical Information Workshop Manual Edition Engine code VW Marine Boat Engine BCT ANF BCU ANG BCV ANH BTW 5-Cyl. Diesel Engine 10.01

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 ................................................... - Rules for cleanliness 21-9 ....................................................................... - 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 ..................................................... - Rules for cleanliness 23-2 ....................................................................... - 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 ...........................................................

00-1 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.

00-2 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.

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Volkswagen 5-Cyl. Diesel Marine Engine Service & Repair Manual

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