VW 150-5 Workshop Manual - Zanshin

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a b Reworking valve seats 15º c V15 -- 0806 Dimension Inlet valve seat Exhaust valve seat ∅ a mm 37.20 1) 33.20 1) ∅ b mm 34.80 30.40 c mm 2.70 2.05 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 equipment and accessories required ♦ 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 Special tools, workshop equipment, test and measuring equipment and accessories required 10 -206 ♦ 10-206 Drift W00--0259 15-37
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Service. Workshop Manual VW Marine
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10 Removing and installing engine P
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20 Fuel supply system Page Parts of
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27 Starter, Current supply Page Sta
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Safety Precautions and Technical Da
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Open the cap of the cooling system
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Technical Data Engine number The en
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Code letters BCU ANG BCV ANH Manufa
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Note: General information on self-d
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Connecting fault reader All functio
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Vehicle system test Enter address w
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Procedure VAS 5052 - Unscrew the co
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Fault memory Interrogate fault memo
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Erase fault memory Special tools, w
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Fault table Notes: ♦ The fault ta
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Output on V.A.G 1552/VAS 5052 16989
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Rapid data transfer Select function
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Evaluate measuring value blocks at
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Evaluation: Display of injection qu
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Evaluation: Display of accelerator
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Evaluation: Display of commencement
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Display group 007 with ignition on
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Display group 013 at idling (warm e
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Evaluation: Display of idle running
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Display group 19 with ignition on D
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Display group 125 at idle Display g
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Display group 000 (display values,
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Evaluation: Display of injection qu
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Engine code letters ANG, BCU Displa
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Display group 004 at full load (tes
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Engine code letters ANH, BCV Displa
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Display group 010 at full load (tes
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VW 313 3033 V.A.G 1332 VW 540 V.A.G
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- Screw the central plug of the ins
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- Unscrew the throttle linkage -1-
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3033 - Hook in the lifting tackle 3
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Engine with power steering pump - I
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1 2 Gearbox bell for reversing gear
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I III II IV Dismantling and assembl
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1 2 3 4 5 6 7 8 9 10 Part I 1 - Dus
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1 2 3 4 5 6 7 8 9 10 15 - Washer
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1 2 3 4 5 6 7 8 9 4-Camshaftsprocke
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1 2 3 4 5 6 Part III 26 25 24 23 7
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26 25 24 23 1 2 3 4 5 6 7 8 9 10 11
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1 2 3 4 5 6 23 - Cup packing ♦ Re
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1 2 3 4 5 6 7 8 9 10 11 12 13 14 6
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1 2 3 4 5 6 7 8 17 - 20 Nm ♦ M8,
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Belt drive without power steering p
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3 4 5 6 7 8 9 10 11 12 Removing and
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3 4 5 6 7 8 9 10 11 12 16 - Cylinde
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1 2 - Unscrew the bolts -arrows- fr
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Removing - Remove toothed belt for
Page 129 and 130: Fitting Note: The oil seal of the s
Page 131 and 132: 1 2 3 4 5 6 4-65Nm 2 1 2 3 4 5 6 7
Page 133 and 134: Crankshaft dimensions (Dimensions i
Page 135 and 136: 11 2 1 2 3 4 3 - Piston ♦ Mark in
Page 137 and 138: 11 2 1 2 3 4 9 - Bearing shell ♦
Page 139 and 140: Fig. 2 Checking piston-ring height
Page 141 and 142: Fig. 4 Piston installation position
Page 143 and 144: Test procedure VW382/7 VW385/17 Whe
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Page 147 and 148: 31 30 29 28 27 1 2 3 4 5 6 7 6 - Dr
Page 149 and 150: 31 30 29 28 1 2 3 4 5 20 - Toothed
Page 151 and 152: 31 30 29 28 27 26 25 24 23 22 1 2 3
Page 153 and 154: 2065 A 2068 A Removing and installi
Page 155 and 156: - Remove the tensioner for the ribb
Page 157 and 158: A 2068 A Engine removed: - Set adju
Page 159 and 160: - Centre adjustment ruler as follow
Page 161 and 162: However, if it is accidentally turn
Page 163 and 164: - Toothed belt for injection pump
Page 165 and 166: Preconditions The engine may be a m
Page 167 and 168: 9 5 3 1 7 11 - Tighten cylinder hea
Page 169 and 170: Test condition Engine oil temperatu
Page 171 and 172: 19 1 2 1 3 4 5 6 7 8 9 10 11 12 13
Page 173 and 174: 1 2 1 3 8 - Valve stem seal ♦ Ren
Page 175 and 176: VW 387 Fig. 1 Checking camshaft, ax
Page 177 and 178: Fig. 4 Camshaft marking, valve timi
Page 179: - Measure distance -a- between valv
Page 183 and 184: 2036 10 -204 3047 A VW 541/1A Renew
Page 185 and 186: A B 10 - 204 Fitting - To prevent d
Page 187 and 188: Checking hydraulic bucket tappets S
Page 189 and 190: Removing and installing parts of lu
Page 191 and 192: 1 2 3 4 5 6 7 8 9 10 11 10 Part I 1
Page 193 and 194: 1 2 3 4 5 6 7 8 9 10 11 10 8-Camsha
Page 195 and 196: 1 2 3 4 5 6 7 8 9 10 18 11 12 13 14
Page 197 and 198: 1 2 3 4 5 6 7 8 9 10 18 11 12 13 14
Page 199 and 200: 32 31 30 1 2 3 10 - 10 Nm 11 - 20 N
Page 201 and 202: 32 31 30 1 2 3 24 - Hollow screw, 3
Page 203 and 204: 1 2 3 8 - Retaining clip 9-20Nm 28
Page 205 and 206: 1 2 3 25 - Oil return line 28 4 5 2
Page 207 and 208: - Unscrew the oil sump. - If necess
Page 209 and 210: Note: After fitting the oil sump, t
Page 211 and 212: V.A.G 1342 Note: Operating test and
Page 213 and 214: Removing and installing parts of co
Page 215 and 216: 29 28 1 2 3 4 5 6 7 8 9 Parts of co
Page 217 and 218: 1 2 3 14 - Connecting hose 29 28 4
Page 219 and 220: 1 2 3 28 - 20 Nm 29 28 4 5 6 7 8 9
Page 221 and 222: Fig. 3 Installing housing-radiator
Page 223 and 224: 1 2 3 4 5 6 7 9 - Seawater filter h
Page 225 and 226: 1 2 3 4 5 - Connection piece 22 21
Page 227 and 228: 1 2 3 4 16 - Retaining clip ♦ che
Page 229 and 230: 1 2 3 4 5 7 - Locking ball 8 24 22
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1 2 3 4 5 21 - 20 Nm 8 24 22 23 6 2
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7 7 - Exhaust-pipe connection piece
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7 6 8 11 - Oil cooler 12 - Coolant
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7 6 8 10 - Cylinder block 11 - Oil
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Draining - Open cap of housing-radi
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Recommended mixing ratio: Antifreez
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Removing Notes: ♦ Always renew ga
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1 2 Fitting Installation is carried
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1 2 - Lever the rubber protection c
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Parts of fuel supply Dismantling an
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33 32 31 30 29 28 27 26 24 23 22 20
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33 32 31 30 29 28 27 26 24 23 22 20
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1 3 1 4 2 5 Servicing the Fuel Filt
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Safety precautions when working on
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1 10 9 2 1 3 4 Servicing throttle c
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V.A.G 1526 A V.A.G 1552 V.A.G 1594
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Read measuring value block 2 → rp
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- Separate the 6-pin connector for
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Adjusting accelerator lever positio
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1 - Tighten the mounting screws -ar
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33 1 2 3 4 3 5 6 1 - To intake mani
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33 1 2 3 4 3 5 6 7 21 - Gasket ♦
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1 2 3 4 5 6 Removing and installing
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1 2 3 4 5 6 13 - To housing-radiato
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Removing and installing turbocharge
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- Disconnect the air filter hose -a
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- Unscrew the lower mounting bolts
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- Position the oil supply line -arr
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1 - Disconnect the connection hoses
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Fitting Installation is carried out
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Check the function of the pressure
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Rules regarding cleanliness Always
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1 2 3 4 5 6 7 8 SUPERIOR MARINE TEC
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1 2 3 4 5 6 Fuse box/relay plate 1
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1 2 3 4 5 6 13 - Glow plug relay (J
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1 2 3 4 5 Removing and installing t
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1 2 3 4 3 5 6 7 3 8 3 9 10 11 Servi
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16 29 28 27 26 25 5 6 7 3 1 2 3 4 3
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5 6 7 3 29 - 25 Nm 1 2 3 4 3 8 3 9
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2068 A 3313 V.A.G 1332 3036 V.A.G 1
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- Screw the TDC sender T 01901 into
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- Place the toothed belt on the inj
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Note: If the front pointer is outsi
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3035 ♦ 3035 Ring spanner ♦ T 01
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- Unscrew the securing screws -1- a
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Blocking injection pump from delive
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Notes: ♦ The dynamic test and cor
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Note: ♦ During the check, if the
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Defective nozzles can be detected b
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Checking injection pressure Importa
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- Install the fuse box/relay plate:
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1 Test procedure - Open the cover -
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- Check the cable connections to th
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4 5 81 62 63 44 24 43 6 25 Check vo
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Test procedure - Pull the plug off
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V.A.G 1526 A V.A.G 1552 V.A.G 1594
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Note: Depending on the weather, the
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V.A.G 1526 A V.A.G 1552 V.A.G 1594
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- If there is no realistic display
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2 4 A - Check the wires between plu
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7000 6000 5000 4000 3000 2000 A B 9
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V.A.G 1526 A V.A.G 1552 V.A.G 1594
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- Switch off the ignition. - Separa
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1 3 5 7 9 A 2 4 6 8 10 1 2 98 105 1
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V.A.G 1526 A V.A.G 1552 V.A.G 1594
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Checking the Modulating Piston Move
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- Separate the 10-pin connector for
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Checking the Needle Lift Sender V.A
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A 98 105 2 1 - Check the wires betw
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10 8 6 4 2 - Measure resistance bet
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V.A.G 1526 A V.A.G 1552 V.A.G 1594
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- Press the → -button. - Press ke
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Engine control unit Renewing engine
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- Pull the relay -1- out of the soc
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Test procedure - Remove the engine
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1 2 3 4 Exhaust system without turb
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1 2 3 6-40Nm ♦ Allen screw 7-Gask
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Removing and installing starter V.A
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- Unscrew the mounting screws -arro
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A A Removing and installing voltage
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3310 ♦ 3310 Socket head W00--0299
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Alternator brackets and ribbed V-be
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14 12 13 12 1 2 3 5 - Hexagon bolts
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1 2 9 8 1 10 9 8 7 6 Y27--0005 Y27-
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11 10 1 2 3 9 8 Y27--0008 4 5 6 7 F
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Removing ribbed V-belt of alternato
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Belt drive with alternator and addi
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Additional 230 V alternator Importa
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7 - Washers (8 mm x 25 mm) 1 2 3 4
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Installing: Installation is carried
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- Unscrew the two mounting screws -
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The red LED lights up: ♦ Undervol
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Test procedure - Remove the connect
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Test procedure - Remove the engine
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1 2 Function overview: Power steeri
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1 2 Exploded view: Power steering p
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1 2 11 - Seal ♦ Renew 12 - Screw
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- Start engine and top up oil level
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1 1 2 - Unscrew bolts -1- and -2-.
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Removing and installing individual
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Fuse box/relay plate Removing and i
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- Unscrew the upper mounting screws
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A B C D E F G N O M P L K J R H Y97
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J H G F P N K v u t s r p n m a b c
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J H G F E Z X W V f e d c b a s r p
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Removing and installing earth switc
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A B - Remove the support -A- togeth
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Wiring loom between instrument pane
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Repair instructions for wiring loom
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VW 150-5 Workshop Manual - Zanshin

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