VW 150-5 Workshop Manual - Zanshin

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- Ensure that the supports in the cylinder head are correctly seated. - Insert the clamping collar. Tightening torques: Injection lines = 25 Nm Screw for clamping collar = 25 Nm - Install the console with the accelerator lever position sender: ⇒ page 20-11; Servicing throttle controls - Install the engine cover. Checking injectors V.A.G 1322 These engines are fitted with 2-spring injectors. Injection of the fuel quantity is in two stages. If these injectors are damaged or defective, it is only possible to replace them; neither a pressure adjustment nor servicing are possible. Special tools, workshop equipment, test and measuring equipment and accessories required W00--1049 ♦ Injector tester V.A.G 1322 with pressure line V.A.G 1322/2 Test condition Pressure gauge switched on 23-37
Checking injection pressure Important! When checking the injectors, ensure that the jet of fuel does not strike your hands as the high pressure means that the fuel could penetrate the skin and cause serious injury. V.A.G 1322 - Connect injector to the injector testing device. - Slowly press down the pump lever. At the beginning of the injection, read off the injection pressure. If the injection pressure deviates from the setpoint value, replace the injectors. Setpoint values: (overpressure) V02--0184 Engine code letters ANF, BCT New nozzles: 190 ... 200 bar Wear limit: 170 bar Engine code letters ANG, ANH, BCU, BCV New nozzles: 220 ... 230 bar Wear limit: 200 bar 23-38
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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
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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
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V.A.G 1342 Note: Operating test and
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Removing and installing parts of co
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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
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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
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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
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: Rapid data transfer Select function
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: Defective nozzles can be detected b
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 349 and 350: - If there is no realistic display
Page 351 and 352: 2 4 A - Check the wires between plu
Page 355 and 356: 7000 6000 5000 4000 3000 2000 A B 9
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 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 375 and 376: 10 8 6 4 2 - Measure resistance bet
Page 379 and 380: - 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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