VW 150-5 Workshop Manual - Zanshin

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Final control diagnosis Carry out diagnosis of actuators Special tools, workshop equipment, test and measuring equipment and accessories required V.A.G 1552 ♦ Fault output device V.A.G 1552 with cable V.A.G 1551/3 or fault output device VAS 5052 With the diagnosis of actuators, the following components are activated in the order stated. 1. Commencement of injection valve (N108) 2. Fuel cut-off valve (N109) W00--1188 3. Glow plug relay (J52) 4.Glow period warning lamp (K29) Notes: ♦ The activation of the individual actuators is limited to 30 secs, but it can be terminated at any time by pressing the ” key. ♦ Before the diagnosis of actuators is repeated, the ignition must be switched off. 01-33
Rapid data transfer Select function XX Fast data interchange 030303 diagnosis of actuators HELP Q Procedure - Connect the fault output device V.A.G 1552 (VAS 5052) and select the engine electronics control unit with the ”Address word” 01. Here, the engine should be idling. (Connecting fault output device and selecting engine control unit ⇒ page 01-4) Display: - Keep an eye on the information that appears on the display while operating the vehicle system tester: - Press the keys 0 and 3 for the function ”Diagnosis of actuators”. Display: - Confirm the input using the Q key. Final control element diagnosis → Commencement of injection valve -N108 Display: Activating the valve produces a clearly audible change in the sound of combustion (knocking). If a change in the sound of combustion is audible: - Check injection timing device adjustment range ⇒ page 23-79 - Press the →-button. Final control element diagnosis Fuel cut-off valve -N109 → Display: The engine must come to a standstill. 01-34
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 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 47: Output on V.A.G 1552/VAS 5052 18047
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 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 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,
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Belt drive without power steering p
Page 121 and 122:
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
Page 153 and 154:
2065 A 2068 A Removing and installi
Page 155 and 156:
- Remove the tensioner for the ribb
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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
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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
Page 191 and 192:
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
Page 197 and 198:
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
Page 201 and 202:
32 31 30 1 2 3 24 - Hollow screw, 3
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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
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Note: After fitting the oil sump, t
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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
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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
Page 255 and 256:
1 3 1 4 2 5 Servicing the Fuel Filt
Page 257 and 258:
Safety precautions when working on
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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
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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
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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:
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
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
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4 5 81 62 63 44 24 43 6 25 Check vo
Page 341 and 342:
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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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
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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
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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 -
Page 419 and 420:
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
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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