VW 150-5 Workshop Manual - Zanshin

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Evaluating the measurement value blocks at full load, engine code letters ANG, ANH, BCU, BCV Display group 000 at full load (test drive with warm engine, coolant temperature not below 70 °C) Notes: ♦ For the tests, accelerate the boat at full throttle. ♦ When the specified engine speed is reached, the measurement values must be printed out or read off (2nd person required). 01-63
Engine code letters ANG, BCU Display group 000 (display values, decimal) Read measurement value block 0 x x x x x x x x x x A Display 1 2 3 4 5 6 7 8 9 10 A Display fields Setpoint value corresponds to Air quantity do not observe --- Coolant temperature 88...198 20...100 °C Intake manifold temperature 0...182 10...135 °C Coolant temperature 37...95 70...110 °C Atmospheric pressure do not observe --- Intake manifold pressure 191...221 1950...2250 mbar Injection quantity Engine code letters: ANG Engine code letters: BCU 160...220 175...215 32...45 mg/stroke 35...43 mg/stroke Injection quantity 160...220 32...45 mg/stroke Throttle lever position 255 100 % Commencement of injection Engine code letters: ANG Engine code letters: BCU 106...<strong>150</strong> 50...144 9...5.5° bef. TDC 8.5...1.0° before TDC Engine speed 114...134 2400...2800 rpm 01-64
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Service. Workshop Manual VW Marine
Page 3 and 4:
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
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
Page 73 and 74: Display group 000 (display values,
Page 77: Evaluation: Display of injection qu
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,
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
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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
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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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Rapid data transfer Select function
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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
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- 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
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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
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- 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
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Checking the Needle Lift Sender V.A
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A 98 105 2 1 - Check the wires betw
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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
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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
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
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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
Page 409 and 410:
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
Page 431 and 432:
- 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
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
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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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