VW 150-5 Workshop Manual - Zanshin

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Engine code letters ANH, BCV 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: ANH Engine code letters: BCV 175...225 170...215 35...45 mg/stroke 34...43 mg/stroke Throttle lever position 255 100 % Commencement of injection Engine code letters: ANH Engine code letters: BCV 194...255 162...213 18...12.5° bef. TDC 14...10° before TDC Engine speed 136...<strong>150</strong> 2,850...3,<strong>150</strong> rpm 01-65
Display group 004 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). Engine code letters ANG, BCU Display group 004 -Commencement of injection- Read measurement value block 4 → A Display xxxx rpm xx.x ° bef.(after) TDC xx.x ° bef.(after) TDC xxx % 1 2 3 4 A Display fields Setpoint value Evaluation Pulse duty factor from commencement of injection valve 20...95 % ⇒ page 01-68 Commencement of injection (actual) Commencement of injection (setpoint) Engine code letters: ANG Engine code letters: BCU approx. commencement of injection (setpoint) 9...5.5° bef. TDC 8.5...1.0° bef. TDC ⇒ page 01-68 --- Engine speed 2400...2800 rpm --- 01-66
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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
Page 11 and 12:
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
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 and 78: Evaluation: Display of injection qu
Page 79: Engine code letters ANG, BCU Displa
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
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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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Page 375 and 376:
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
Page 379 and 380:
- 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
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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
Page 407 and 408:
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-.
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
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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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