VW 150-5 Workshop Manual - Zanshin

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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
Page 1: Service. Workshop Manual VW Marine
Page 5 and 6: 20 Fuel supply system Page Parts of
Page 7 and 8: 27 Starter, Current supply Page Sta
Page 9 and 10: Safety Precautions and Technical Da
Page 11 and 12: Open the cap of the cooling system
Page 13 and 14: Technical Data Engine number The en
Page 15 and 16: Code letters BCU ANG BCV ANH Manufa
Page 17 and 18: Note: General information on self-d
Page 19 and 20: Connecting fault reader All functio
Page 21 and 22: Vehicle system test Enter address w
Page 23 and 24: Procedure VAS 5052 - Unscrew the co
Page 25 and 26: Fault memory Interrogate fault memo
Page 27 and 28: Erase fault memory Special tools, w
Page 29 and 30: Fault table Notes: ♦ The fault ta
Page 31 and 32: Output on V.A.G 1552/VAS 5052 16989
Page 49 and 50: Rapid data transfer Select function
Page 51 and 52: Rapid data transfer Select function
Page 53 and 54:
Rapid data transfer Select function
Page 55 and 56:
Evaluate measuring value blocks at
Page 57 and 58:
Evaluation: Display of injection qu
Page 59 and 60:
Evaluation: Display of accelerator
Page 61 and 62:
Evaluation: Display of commencement
Page 63 and 64:
Display group 007 with ignition on
Page 65 and 66:
Display group 013 at idling (warm e
Page 67 and 68:
Evaluation: Display of idle running
Page 69 and 70:
Display group 19 with ignition on D
Page 71 and 72:
Display group 125 at idle Display g
Page 73 and 74:
Display group 000 (display values,
Page 75 and 76:
Page 77 and 78:
Evaluation: Display of injection qu
Page 79 and 80:
Engine code letters ANG, BCU Displa
Page 81 and 82:
Display group 004 at full load (tes
Page 83 and 84:
Page 85 and 86:
Engine code letters ANH, BCV Displa
Page 87 and 88:
Display group 010 at full load (tes
Page 89 and 90:
VW 313 3033 V.A.G 1332 VW 540 V.A.G
Page 91 and 92:
- Screw the central plug of the ins
Page 93 and 94:
- Unscrew the throttle linkage -1-
Page 95 and 96:
3033 - Hook in the lifting tackle 3
Page 97 and 98:
Engine with power steering pump - I
Page 99 and 100:
1 2 Gearbox bell for reversing gear
Page 101 and 102:
I III II IV Dismantling and assembl
Page 103 and 104:
1 2 3 4 5 6 7 8 9 10 Part I 1 - Dus
Page 105 and 106:
1 2 3 4 5 6 7 8 9 10 15 - Washer
Page 107 and 108:
1 2 3 4 5 6 7 8 9 4-Camshaftsprocke
Page 109 and 110:
1 2 3 4 5 6 Part III 26 25 24 23 7
Page 111 and 112:
26 25 24 23 1 2 3 4 5 6 7 8 9 10 11
Page 113 and 114:
1 2 3 4 5 6 23 - Cup packing ♦ Re
Page 115 and 116:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 6
Page 117 and 118:
1 2 3 4 5 6 7 8 17 - 20 Nm ♦ M8,
Page 119 and 120:
Belt drive without power steering p
Page 121 and 122:
3 4 5 6 7 8 9 10 11 12 Removing and
Page 123 and 124:
3 4 5 6 7 8 9 10 11 12 16 - Cylinde
Page 125 and 126:
1 2 - Unscrew the bolts -arrows- fr
Page 127 and 128:
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
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 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
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
Page 249 and 250:
Parts of fuel supply Dismantling an
Page 251 and 252:
33 32 31 30 29 28 27 26 24 23 22 20
Page 253 and 254:
33 32 31 30 29 28 27 26 24 23 22 20
Page 255 and 256:
1 3 1 4 2 5 Servicing the Fuel Filt
Page 257 and 258:
Safety precautions when working on
Page 259 and 260:
1 10 9 2 1 3 4 Servicing throttle c
Page 261 and 262:
V.A.G 1526 A V.A.G 1552 V.A.G 1594
Page 263 and 264:
Read measuring value block 2 → rp
Page 265 and 266:
- Separate the 6-pin connector for
Page 267 and 268:
Adjusting accelerator lever positio
Page 269 and 270:
1 - Tighten the mounting screws -ar
Page 271 and 272:
33 1 2 3 4 3 5 6 1 - To intake mani
Page 273 and 274:
33 1 2 3 4 3 5 6 7 21 - Gasket ♦
Page 275 and 276:
1 2 3 4 5 6 Removing and installing
Page 277 and 278:
1 2 3 4 5 6 13 - To housing-radiato
Page 279 and 280:
Removing and installing turbocharge
Page 281 and 282:
- Disconnect the air filter hose -a
Page 283 and 284:
- Unscrew the lower mounting bolts
Page 285 and 286:
- Position the oil supply line -arr
Page 287 and 288:
1 - Disconnect the connection hoses
Page 289 and 290:
Fitting Installation is carried out
Page 291 and 292:
Page 293 and 294:
Check the function of the pressure
Page 295 and 296:
Rules regarding cleanliness Always
Page 297 and 298:
1 2 3 4 5 6 7 8 SUPERIOR MARINE TEC
Page 299 and 300:
1 2 3 4 5 6 Fuse box/relay plate 1
Page 301 and 302:
1 2 3 4 5 6 13 - Glow plug relay (J
Page 303 and 304:
1 2 3 4 5 Removing and installing t
Page 305 and 306:
1 2 3 4 3 5 6 7 3 8 3 9 10 11 Servi
Page 307 and 308:
16 29 28 27 26 25 5 6 7 3 1 2 3 4 3
Page 309 and 310:
5 6 7 3 29 - 25 Nm 1 2 3 4 3 8 3 9
Page 311 and 312:
2068 A 3313 V.A.G 1332 3036 V.A.G 1
Page 313 and 314:
- Screw the TDC sender T 01901 into
Page 315 and 316:
- Place the toothed belt on the inj
Page 317 and 318:
Note: If the front pointer is outsi
Page 319 and 320:
3035 ♦ 3035 Ring spanner ♦ T 01
Page 321 and 322:
- Unscrew the securing screws -1- a
Page 323 and 324:
Blocking injection pump from delive
Page 325 and 326:
Notes: ♦ The dynamic test and cor
Page 327 and 328:
Note: ♦ During the check, if the
Page 329 and 330:
Defective nozzles can be detected b
Page 331 and 332:
Checking injection pressure Importa
Page 333 and 334:
- Install the fuse box/relay plate:
Page 335 and 336:
1 Test procedure - Open the cover -
Page 337 and 338:
- Check the cable connections to th
Page 339 and 340:
4 5 81 62 63 44 24 43 6 25 Check vo
Page 341 and 342:
Test procedure - Pull the plug off
Page 343 and 344:
V.A.G 1526 A V.A.G 1552 V.A.G 1594
Page 345 and 346:
Note: Depending on the weather, the
Page 347 and 348:
V.A.G 1526 A V.A.G 1552 V.A.G 1594
Page 349 and 350:
- If there is no realistic display
Page 351 and 352:
2 4 A - Check the wires between plu
Page 353 and 354:
Page 355 and 356:
7000 6000 5000 4000 3000 2000 A B 9
Page 357 and 358:
V.A.G 1526 A V.A.G 1552 V.A.G 1594
Page 359 and 360:
- Switch off the ignition. - Separa
Page 361 and 362:
1 3 5 7 9 A 2 4 6 8 10 1 2 98 105 1
Page 363 and 364:
V.A.G 1526 A V.A.G 1552 V.A.G 1594
Page 365 and 366:
Checking the Modulating Piston Move
Page 367 and 368:
- Separate the 10-pin connector for
Page 369 and 370:
Checking the Needle Lift Sender V.A
Page 371 and 372:
A 98 105 2 1 - Check the wires betw
Page 373 and 374:
Page 375 and 376:
10 8 6 4 2 - Measure resistance bet
Page 377 and 378:
V.A.G 1526 A V.A.G 1552 V.A.G 1594
Page 379 and 380:
- 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
Page 385 and 386:
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
Page 391 and 392:
Removing and installing starter V.A
Page 393 and 394:
- Unscrew the mounting screws -arro
Page 395 and 396:
A A Removing and installing voltage
Page 397 and 398:
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
Page 403 and 404:
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
Page 413 and 414:
7 - Washers (8 mm x 25 mm) 1 2 3 4
Page 415 and 416:
Installing: Installation is carried
Page 417 and 418:
- Unscrew the two mounting screws -
Page 419 and 420:
The red LED lights up: ♦ Undervol
Page 421 and 422:
Test procedure - Remove the connect
Page 423 and 424:
Test procedure - Remove the engine
Page 425 and 426:
1 2 Function overview: Power steeri
Page 427 and 428:
1 2 Exploded view: Power steering p
Page 429 and 430:
1 2 11 - Seal ♦ Renew 12 - Screw
Page 431 and 432:
- Start engine and top up oil level
Page 433 and 434:
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
Page 441 and 442:
A B C D E F G N O M P L K J R H Y97
Page 443 and 444:
J H G F P N K v u t s r p n m a b c
Page 445 and 446:
J H G F E Z X W V f e d c b a s r p
Page 447 and 448:
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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