VW 150-5 Workshop Manual - Zanshin

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1 2 3 4 5 6 7 8 9 10 18 11 12 13 14 15 16 17 9 - Cover for pressure control valve 10 - O-ring ♦ Renew 11 - 5 Nm 12 - Retaining clip 13 - Oil separator 14 - Oil separator housing 15 - 25 Nm 16 - Gasket ♦ 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 18 11 12 13 14 15 16 17 19 - Sealing plug 20 - Seal ♦ Renew 21 - Cylinder block 21 20 19 Y17--0003 17-9
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Service. Workshop Manual VW Marine
Page 3 and 4:
10 Removing and installing engine P
Page 5 and 6:
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
Page 11 and 12:
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
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Fitting Note: The oil seal of the s
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1 2 3 4 5 6 4-65Nm 2 1 2 3 4 5 6 7
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Crankshaft dimensions (Dimensions i
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11 2 1 2 3 4 3 - Piston ♦ Mark in
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11 2 1 2 3 4 9 - Bearing shell ♦
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Fig. 2 Checking piston-ring height
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Fig. 4 Piston installation position
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Test procedure VW382/7 VW385/17 Whe
Page 145 and 146: 31 30 29 28 27 26 25 24 23 22 1 2 3
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 and 180: - Measure distance -a- between valv
Page 181 and 182: VW387 Test procedure - Insert new v
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: 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
Page 231 and 232: 1 2 3 4 5 21 - 20 Nm 8 24 22 23 6 2
Page 233 and 234: 7 7 - Exhaust-pipe connection piece
Page 235 and 236: 7 6 8 11 - Oil cooler 12 - Coolant
Page 237 and 238: 7 6 8 10 - Cylinder block 11 - Oil
Page 239 and 240: Draining - Open cap of housing-radi
Page 241 and 242: Recommended mixing ratio: Antifreez
Page 243 and 244: Removing Notes: ♦ Always renew ga
Page 245 and 246: 1 2 Fitting Installation is carried
Page 247 and 248:
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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Page 293 and 294:
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
Page 321 and 322:
- 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
Page 347 and 348:
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
Page 359 and 360:
- 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
Page 369 and 370:
Checking the Needle Lift Sender V.A
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A 98 105 2 1 - Check the wires betw
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Page 375 and 376:
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
Page 381 and 382:
Engine control unit Renewing engine
Page 383 and 384:
- Pull the relay -1- out of the soc
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Test procedure - Remove the engine
Page 387 and 388:
1 2 3 4 Exhaust system without turb
Page 389 and 390:
1 2 3 6-40Nm ♦ Allen screw 7-Gask
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Removing and installing starter V.A
Page 393 and 394:
- 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
Page 399 and 400:
Alternator brackets and ribbed V-be
Page 401 and 402:
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-
Page 405 and 406:
11 10 1 2 3 9 8 Y27--0008 4 5 6 7 F
Page 407 and 408:
Removing ribbed V-belt of alternato
Page 409 and 410:
Belt drive with alternator and addi
Page 411 and 412:
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
Page 417 and 418:
- 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
Page 431 and 432:
- Start engine and top up oil level
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1 1 2 - Unscrew bolts -1- and -2-.
Page 435 and 436:
Removing and installing individual
Page 437 and 438:
Fuse box/relay plate Removing and i
Page 439 and 440:
- 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
Page 449 and 450:
A B - Remove the support -A- togeth
Page 451 and 452:
Wiring loom between instrument pane
Page 453:
Repair instructions for wiring loom
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VW 150-5 Workshop Manual - Zanshin

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