VW 150-5 Workshop Manual - Zanshin

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Procedure V.A.G 1552 - Unscrew the cover of the diagnosis connection on the main panel. - 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 start the engine ⇒ page 01-3, ”Selectable Functions” table. If the display remains dark, check the power supply for the using the Current flow ♦ the displays indicated in the work procedure are not Operating instructions for the fault output V.A.G 1551/3 Y01--0001 Notes: ♦ diagnosis plug CFD: ⇒ diagrams If achieved: ⇒ device 01-5
Vehicle system test Enter address word XX HELP ♦ If input errors produce the message ”Fault in the data interchange!”, remove the cable from the fault output device, reconnect it and repeat the work steps. Display: - 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 → Coding 00001 WSC00000 The control unit identification appears on the display of the fault output 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
Page 1 and 2: 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
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: Connecting fault reader All functio
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 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
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Display group 000 (display values,
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Evaluation: Display of commencement
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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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Evaluation: Display of commencement
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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
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
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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
Page 105 and 106:
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
Page 113 and 114:
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
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31 30 29 28 27 26 25 24 23 22 1 2 3
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31 30 29 28 27 1 2 3 4 5 6 7 6 - Dr
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31 30 29 28 1 2 3 4 5 20 - Toothed
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31 30 29 28 27 26 25 24 23 22 1 2 3
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2065 A 2068 A Removing and installi
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- Remove the tensioner for the ribb
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A 2068 A Engine removed: - Set adju
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- Centre adjustment ruler as follow
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However, if it is accidentally turn
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- Toothed belt for injection pump
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Preconditions The engine may be a m
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9 5 3 1 7 11 - Tighten cylinder hea
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Test condition Engine oil temperatu
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19 1 2 1 3 4 5 6 7 8 9 10 11 12 13
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1 2 1 3 8 - Valve stem seal ♦ Ren
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VW 387 Fig. 1 Checking camshaft, ax
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Fig. 4 Camshaft marking, valve timi
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- Measure distance -a- between valv
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VW387 Test procedure - Insert new v
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2036 10 -204 3047 A VW 541/1A Renew
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A B 10 - 204 Fitting - To prevent d
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Checking hydraulic bucket tappets S
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Removing and installing parts of lu
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1 2 3 4 5 6 7 8 9 10 11 10 Part I 1
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1 2 3 4 5 6 7 8 9 10 11 10 8-Camsha
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1 2 3 4 5 6 7 8 9 10 18 11 12 13 14
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1 2 3 4 5 6 7 8 9 10 18 11 12 13 14
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32 31 30 1 2 3 10 - 10 Nm 11 - 20 N
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32 31 30 1 2 3 24 - Hollow screw, 3
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1 2 3 8 - Retaining clip 9-20Nm 28
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1 2 3 25 - Oil return line 28 4 5 2
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- Unscrew the oil sump. - If necess
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Note: After fitting the oil sump, t
Page 211 and 212:
V.A.G 1342 Note: Operating test and
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Removing and installing parts of co
Page 215 and 216:
29 28 1 2 3 4 5 6 7 8 9 Parts of co
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1 2 3 14 - Connecting hose 29 28 4
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1 2 3 28 - 20 Nm 29 28 4 5 6 7 8 9
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Fig. 3 Installing housing-radiator
Page 223 and 224:
1 2 3 4 5 6 7 9 - Seawater filter h
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1 2 3 4 5 - Connection piece 22 21
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1 2 3 4 16 - Retaining clip ♦ che
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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
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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
Page 239 and 240:
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
Page 263 and 264:
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
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
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Fitting Installation is carried out
Page 291 and 292:
Rapid data transfer Select function
Page 293 and 294:
Check the function of the pressure
Page 295 and 296:
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
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
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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
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
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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
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
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
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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
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- Press the → -button. - Press ke
Page 381 and 382:
Engine control unit Renewing engine
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- 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
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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
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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
Page 413 and 414:
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 -
Page 419 and 420:
The red LED lights up: ♦ Undervol
Page 421 and 422:
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
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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